Workshop manual E

ASC 70 / ASC 90 / ASC 110 / ASC 150 / ASC 200 / ASC 250
Cummins Tier II © 7 / 2004
 Verdichtung AG, CH-4900 Langenthal
 0041 (0)62 916 63 56 FAX: 0041 (0)62 916 64 03

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 CONTENTS

INTRODUCTION ............................................................................................................................. 4
SAFETY PRECAUTIONS .................................................................................................................. 5
REPAIR SAFETY INSTRUCTIONS .................................................................................................. 38
ENVIRONMENTAL MEASURES AND HEALTH PRECAUTIONS .......................................................... 42
1 - A SUMMARY OF APPLICATIONS ............................................................................................. 45
2 - DESCRIPTION OF THE MACHINE ............................................................................................. 46
3 - REMOVING THE ENGINE ......................................................................................................... 68
4 - DRUM REMOVAL .................................................................................................................... 92
5 - ARTICULATED JOINT ............................................................................................................133
6 - REMOVAL OF PUMPS, CENTO CLUTCH .................................................................................149
7 - STEERING CYLINDERS .........................................................................................................159
8 - CONTROLS ........................................................................................................................... 163
9 - THE DRIVER‘S STATION ASSEMBLY ...................................................................................... 167
10 - DISASSEMBLY OF HEATER .................................................................................................. 173
11 - ELECTRICAL INSTALLATION................................................................................................181
12 - REMOVAL OF ROPS FRAME ................................................................................................197
13 - ASSEMBLY OF SEGMENTS .................................................................................................. 199
14 - DISASSEMBLY OF WHEEL................................................................................................... 207
15 - REMOVAL OF HYDRAULIC MOTORS ...................................................................................209
16 - REPLACING PRESSURE FILTER OF HYDRAULICS ................................................................ 215
17 - FILLING HYDRAULIC OIL .................................................................................................... 218
18 - DISASSEMBLY OF LEVEL GAUGE ........................................................................................ 219
19 - DISASSEMBLY OF THE FLOATER ......................................................................................... 221
20 - ELECTRIC SCHEMATA ........................................................................................................223
21 - HYDRAULIC .......................................................................................................................256
22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS ............................................................... 268
23 - TROUBLESHOOTING ...........................................................................................................281
24 - TIGHTENING TORQUES ...................................................................................................... 310

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INTRODUCTION

INTRODUCTION
Vibration roller ASC 70/250 series is suitable for compaction of all kinds of ground and for large- and mid-scale groundwork
in highway construction (construction of motorways, railways, airports), in hydro-engineering (construction of dams), in building
construction (industrial areas, ports), and the like.
The roller should be used under conditions defined in the Czech Standard (CSN) IEC 721-2-1 (038900): WT, WDr, MWDr, i. e.
in mild, dry warm and dry hot weather in the range of temperatures from -15 °C (5 °F) to 45 °C (113 °F).
This STA machine is manufactured to the latest developments and standards, which secure its safe function.
If the machine is used incorrectly, by untrained operators or for other purpose than stipulated above, there is a danger of an
accident or damage to the equipment.
The main purpose of this manual is to give information necessary for carrying out assembly and disassembly of the machine as
well as service repairs of main assemblies of the equipment. It contains technical and installation data, instructions how to adjust
the machine and how to use special tools, fixtures and aids.
The manufacturer continuously improves the products on the basis of experience and latest developments in the field.
For this reason, the manufacturer may make some changes in drawings, descriptions and designs in this manual.
Some expressions are used in the manual for better orientation, i. e. right, left, forward, backward – in the sense of the machine
moving forward.

Data and figures from this manual must not be copied or distributed in any way, since they are protected by copyright.

4
 SAFETY PRECAUTIONS
GENERALITIES
Read the Operation and Maintenance Instruction Ma-
nual carefully before starting, operating, maintaining,
fuelling or servicing the machine.
Carefully read the explanation to each and all safety
signs in the special section of this Manual before star-
ting, operating, maintaining, fuelling or servicing the
machine.
Machine-mounted safety plates are colour coded
yellow with black borders when they refer to points
where special ATTENTION must be paid and failure
to observe them may cause a serious DANGER to
the integrity of machine operators. They are white
with red borders and black lettering when they refer
to a FORBIDDEN practice.
It is fundamental that all machine operators know very
well the meaning of each safety plate as this conside-
rably decreases operating hazards and accidents.
Do not allow unauthorised personnel to operate or
service this machine.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing, scarves,
unbuttoned or unzipped jackets that can get caught in
moving parts. Wear certified safety clothes such as:
hard hat, no-slip footwear, heavy gloves, ear protecti-
on, safety glasses , reflector vests, respirators every
time the job requires it. Ask your employer about safety
regulations in force and protective equipment. Always
keep the operator’s compartment, step plates, grab-
rails and handles clean and clear of foreign objects, oil,
grease, mud or snow to minimise the danger of slipping
or stumbling. Remove mud or grease from your shoes
before operating the machine.
Do not jump on or off the machine. Always keep both
hands and one foot, or both feet and one hand in contact
with steps and/or grab rails.
Do not use controls or hoses as hand holds. Hoses and
controls are movable parts and do not provide solid
support. Besides, controls may be inadvertently moved
and cause unexpected movement of the machine or its
attachments.
Never operate the machine or its attachments from any
position other than sitting in the driver’s seat. Keep
head, body, limbs, hands and feet inside the operator’s
compartment at all times to reduce exposure to external
hazards.
Be careful of possible slippery conditions of the steps
and hand rails as well as of the ground around the
machine. Wear protective boots or shoes with the soles
made of highly no-slip rubber.
Do not leave the machine until it has come to a complete
stop.
Always check height, width and weight limitations which
may be encountered in the working site and ensure the
machine does not exceed them.
Assess exact paths of gas ducts, water mains, telepho-
ne lines, sewers, overhead and underground electric
lines and all other possible obstacles.
Such paths should be opportunely defined by
competent Authorities. If necessary, require that the
service is interrupted or said installations are moved
prior to starting the work.
You must know the working capacity of the machine.
Define the rear upperstructure swing area and provide
for opportune barriers to prevent access into it.
STARTING
Never start or operate a failed machine. Walk all
around the machine before mounting.
Before operating the machine, make sure that any possi-
ble dangerous condition has been properly removed.
Before starting machine, check that steering and at-
tachment controls are in the neutral position and the
safety lever is in the LOCK position. Immediately report
any malfunction of parts or systems to the maintenance
managers for proper action.
Prior to starting the engine, check, adjust and lock the
driver’s seat for maximum riding comfort and control
accessibility. Prior to operating the machine and/or its
attachments, check that bystanders are outside the
machine operating range. Sound the horn.
Obey all hand signals, safety indications and signs. Due
to the presence of flammable fluids, never check fuel
level, refuel, charge the batteries or use the starting fluid
in the presence of smoking materials, open flames or
sparks.
Ensure that nobody is within operating area before
starting the machine or moving in any direction.
Adjust all rear-view mirrors for maximum visibility of the
area behind the machine.
Ensure that engine speed is appropriate to the job to be
carried out.
If any hydraulic control or system exhibits erratic perfor-
mance or responds abnormally, have the machine chec-
ked for air in the system.
Air in these circuits may cause incorrect movements with
consequent accident hazard. Refer to the Operation and
Maintenance Instruction Manual about corrective action
to be taken.
OPERATING
Do not run the engine of this machine in closed buildings
without proper ventilation capable to remove harmful
exhaust gases which concentrate in the air. Keep the
operator’s compartment free of foreign objects, especi-
ally if not firmly secured. Never use the machine to
transport objects, unless proper securing points are
provided.
Do not carry riders on the machine.
Study and familiarise with escape routes alternative to
normal exit routes.
For your personal safety, do not climb on or off the
machine while it is in motion.
Make sure that bystanders are clear of the machine
operating range before starting the engine and opera-
ting the attachment. Sound the horn.
5
 SAFETY PRECAUTIONS
Obey all hand signals, safety indications and signs.
When backing, always look to where the machine is to
be moved. Be alert of the position of bystanders. Should
someone enter the work area, stop the machine.
Maintain a safe distance from other machines or obsta-
cles to ensure required visibility conditions. Always
give way to loaded machines.
Maintain a clear vision of the surroundings of the travel
or work area at all times.
Keep cab windows clean and repaired.
When pulling loads or towing through a cable or chain,
do not start suddenly at full throttle. Take-up slack
carefully.
Avoid kinking or twisting chains or cables.
Carefully inspect cables or chains for flaws or problems
before proceeding.
Do not pull through a kinked chain or cable as the high
anomalous stresses existing in this condition may in-
duce failures in the kinked portion.
Always wear heavy gloves when handling chains or
cables.
Chains and cables should be securely anchored using
suitable hooks. Anchor points should be strong enou-
gh to withstand the expected load.
Keep anyone clear of anchor points and cables or
chains.
Do not pull or tow unless the operator’s compart-
ments of the machines involved are properly protec-
ted against possible backlash in case of cable or
chain failure or detachment.
Be alert of soft ground conditions close to newly con-
structed walls. The fill material and machine weight
may cause the wall to collapse under the machine.
In darkness, check area of operation carefully before
moving in with the machine. Use all lights provided. Do
not move into low visibility areas.
If the engine tends to slow down and stall for whatever
reason under load or at idle, immediately report this
problem to the maintenance managers for proper ac-
tion. Do not operate the machine until this condition is
corrected.
Regularly check all exhaust system components, as
exhaust fumes are toxic for the operator.
Operators must know the performance of the machine
they are driving.
When working on slopes or near sudden level drops in
the terrain, pay attention not to lose adherence and
avoid loose soft ground since overturn or loss of machi-
ne control could result.
If noise level is high and exceeds 90 dB(A) over 8 hours
at the operator’s ear, wear approved ear protection in
compliance with local regulations.
Do not operate the machine if you are extremely tired
or feel ill.
Be especially careful towards the end of the working
shift. Where removable counterweights are provided,
do not operate the machine if they have been removed.
When operating the machine, keep in mind height
limits of overhead doors, arches, overhead cables and
lines as well as width limits of corridors, roads and
narrow passages. Also, get to know load limits of the
6
ground and paving type of the ramps you are to work on.
Beware of fog, smoke or dust that obscure visibility.
Always inspect the working area to identify potential
risks such as: inclines, overhangs, trees, demolition
rubble, fires, ravines, steep slopes, rough terrain, dit-
ches, crowns, ridge trenches, diggings in traffic areas,
crowded parking lots, crowded service areas, fenced
zones. In such conditions, proceed with extreme care.
Whenever possible, avoid crossing over obstacles such
as very rough terrain, rocks, logs, steps, ditches, railroad
tracks. When obstructions must be crossed, do so with
extreme care and at a square angle, if possible. Slow
down. Ease up to the break-over point, pass the balance
point slowly and ease down the other side also using the
attachment, if necessary.
To overcome deep trenches or sinking ground, place the
machine perpendicular to the obstacle, drastically redu-
ce ground speed and start crossing using also the
attachment if necessary, only after assessing that ground
conditions allow the traverse safely and without risks.
The gradient you may attempt to overcome is limited by
factors such as ground conditions, load being handled,
machine type and speed, and visibility.
There is no substitute for good judgement and experien-
ce when working on slopes.
Avoid operating the attachment too close to an overhang
or high wall, either above or below the machine. Beware
of caving edges, falling objects and landslides. Remem-
ber that such hazards are likely to be concealed by
bushes, undergrowth and such.
Avoid faggots, bushes, logs and rocks. Never drive over
them, nor over any other surface irregularities that dis-
continue adherence or traction with the ground, especi-
ally near slopes or drop-offs.
Be alert to avoid changes in adherence conditions that
could cause loss of control.
Work with extreme care on ice or frozen ground and on
stepped slopes or near drop-offs.
Never use the machine as a work platform or scaffolding.
The machine must not be improperly used for works not
consistent with its features (such as pushing railway
cars, trucks or other machines). Always pay attention to
people within the machine operating range.
Ground speed should be adequate to ground condi-
tions.
- Nobody should be allowed to stand within the machine
operating range for any reason whatever. Never exceed
specified loading capacity. Incorrect fastening of slings
or chains may cause boom/arm failure or failure of the
lifting means with consequent bodily injuries and even
death.
Always ensure that slings and chains used for lifting are
adequate to the load and in good condition.
All features capacities are referred to the machine on
a level surface and should be disregarded when wor-
king on a slope.
Avoid travelling across slopes. Proceed from uphill
downhill and vice-versa.
 SAFETY PRECAUTIONS
Working on slopes is dangerous. Grade the working
area if possible. Reduce work cycle time if it is not
possible to grade the working area.
We recommend to work on slopes after checking machi-
ne stability.
Properly judge ground conditions with particular atten-
tion to consistency of the area you are going to work on.
Keep the machine sufficiently far from the ditch edge.
Do not swing the upperstructure, raise the load or brake
abruptly if not required. This may cause accidents.
Prior to beginning the work near gas distribution mains
or other public utilities:
- Contact the company owner of the gas mains or its
nearest branch before starting the work. Look up the
number in the telephone directory.
- Define together which precautions should be taken to
guarantee work safety.
- Decrease work speed. Reaction time could be too slow
and distance evaluation wrong.
- When working near gas mains or other public utilities
installations, appoint a person in charge of signalling
duties. This person will have the responsibility of obser-
ving the machine, any part of it and/or the load appro-
aching the gas mains from a standpoint more favou-
rable than the Operator’s. This signal man (flagman)
must be in direct communication with the Operator and
the Operator must pay undivided attention to the sig-
nals supplied.
- The gas distributing Company, if previously advised
and involved in the work, as well as machine Operator,
Owner and/or any natural person or legal entity having
rent or leased the machine or being responsible at the
time by contract or by law, are liable for the adoption of
the necessary precautions.
Working near electric lines can be very dangerous,
therefore some special precautions must be observed.
Within this Manual, „work near electric lines“ means
when the attachment (in any position) may reach the
minimum safety distance established by local or inter-
national Safety Regulations.
To work without risks, keep maximum possible distance
from electric lines and never trespass minimum safety
distance. Ensure that local or national safety regulati-
ons concerning work near electric lines are observed.
Prior to beginning the work near electric lines:
- Contact the Company owner of the electric lines or its
nearest branch before starting the work.
Look up the in the telephone directory.
- Define together with the Company representative
which precautions should be taken to guarantee work
safety.
- All electric lines should be considered as operative
live lines even though it might be well known that the
line in question is out of work and visibly connected to
the ground.
- The Electric Power Company, if previously advised
and involved in the work, as well as machine Operator,
Owner and/or any natural person or legal entity having
rent or leased the machine or being responsible at the
time by contract or by law, are liable for the adoption of
the necessary precautions.
- Decrease work speed. Reaction time could be too slow
and distance evaluation wrong.
- Warn all ground personnel to keep clear of the machine
at all times.
- Appoint a person in charge of signalling duties.
This person will have the responsibility of observing II
the machine approaching the electric lines from a I
standpoint more favourable than the Operator’s. This
signal man (flag-man) must be in direct communication
with the Operator and the Operator must pay undivided
attention to the signals supplied.
When working in or near pits, in ditches or very high
walls, check that the walls are sufficiently propped up to
avoid cave-in hazards.
Pay the utmost attention when working near overhang
walls or where landslides may take place. Make sure
that the support surface is strong enough to prevent
landslides.
Always check ground conditions and conditions of the
material to be removed. Support everywhere it is requi-
red to prevent possible cave-ins or landslides:
- near previous trenches filled with material, - in bad
ground conditions,
- when working trenches subject to vibration from rail-
roads, working machines or highway traffic.
STOPPING
When the machine is to be stopped for whatever reason,
always check that all controls are in the neutral position
and that the safety lever is on the lock position to
guarantee risk-free start-up.
Never leave the machine unattended with the engine
running.
Prior to leaving the driver’s seat, and after making sure
that all people are clear of the machine, slowly lower the
attachment until resting it safely to the ground. Retract
possible auxiliary tools to the closed safety position.
Check that all controls are in the neutral position. Move
engine controls to the shut-down position. Switch off the
key-start switch. Consult the Operation and Maintenan-
ce Instruction Manual. ‚‘ Park the machine in a non-
operating and no-traffic area. Park on firm level ground.
If this is not possible, position the machine at a right
angle to the slope, making sure there is no danger of
uncontrolled sliding.
If parking in traffic lanes cannot be avoided, provide
appropriate flags, barriers, flares and other signals as
required to adequately warn the oncoming drivers.
Always switch off the key-start switch before cleaning,
repairing or servicing, or parking the machine to prevent
accidental unauthorised start-up.
Never lower the attachment or auxiliary tools other than
from sitting in the operator’s seat. Sound the horn. Make
sure that nobody is within the machine operating range.
Lower the attachment slowly.
7
 SAFETY PRECAUTIONS
Securely block and lock the machine every time you
leave it unattended. Return keys to the safe place
previously agreed upon. Perform all necessary opera-
tions for stopping as detailed in the Operation and
Maintenance Instruction Manual.
Drive the machine far from pits, trenches, rocky han-
ging walls, areas with overhead electric lines, and
slopes before stopping it at the end of the working day.
Move all controls to the position specified for machine
stopping. Refer the Operation and Maintenance In-
struction Manual.
Never park on an incline without accurately blocking
the machine to prevent unexpected movement.
Follow stopping instructions contained in the Operati-
on and Maintenance Instruction Manual.
MAINTENANCE
GENERALITIES
Carefully read the Operation and Maintenance Instruc-
tion Manual before starting, operating, maintaining,
fuelling or servicing the machine in any manner.
Read all safety plates mounted on the machine and
observe instructions they contain before starting, ope-
rating, repairing, fuelling or servicing the machine. Do
not allow unauthorised personnel to repair or service
the machine.
Follow all recommended maintenance and service
procedures.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing, scarves,
unbuttoned or unzipped jackets that can get caught in
moving parts. Wear certified safety clothes such as:
hard hat, no-slip footwear, heavy gloves, ear protecti-
on, safety glasses, reflector vests, respirators when
required. Ask your employer about safety regulations
in force and protective equipment.
Do not use controls or hoses as hand holds. Hoses and
controls are movable parts and do not provide solid
support. Besides, controls may be inadvertently moved
and cause unexpected movement of the machine or its
attachments.
Do not jump on or off the machine. Always keep both
hands and one foot, or both feet and one hand in
contact with steps and/or grab rails.
Never service the machine with someone sitting in the
driver’s seat, unless this person is an authorised oper-
ator assisting in the maintenance being carried out.
Keep the operator’s compartment, step plates, grab
rails and handles clear of foreign objects, oil, grease,
mud or snow to minimise the danger of slipping or
stumbling.
Clean mud or grease from your shoes before climbing
on the machine or driving it.
Never attempt to operate the machine or its attachments
from any position other than sitting in the operator’s
seat.
Keep the driver’s seat free from foreign objects, espe-
cially if these are not secured.
8
Should it be necessary to move the attachment for
maintenance purposes, do not raise or lower the at-
tachment from any other position than sitting in the
operator’s seat. Before starting the machine or moving
its attachment, sound the horn and require that nobody
remains near the machine.
Raise the attachment slowly.
Always lock all moving components or parts of the
machine that must be lifted for maintenance purposes
using adequate external means as required by local and
national regulations. Do not allow anyone to pass or stay
near or below a raised attachment. If you are not abso-
lutely sure about your safety, do not stay or walk under
a raised attachment.
Do not place head, body, limbs, hands, feet or fingers
near articulated cutting edges deprived of the necessa-
ry guards, unless they are suitably and safely locked.
Never lubricate, repair or adjust the machine with the
engine running, except when this is specifically requi-
red by the Operation and Maintenance Instruction Ma-
nual.
Do not wear loose clothing, jewellery near rotating parts.
When service or maintenance require access to areas
that cannot be reached from the ground, use a ladder or
step platform conforming to local or national regulations
to reach the working area. If such means are not avai-
lable, use machine grab rails and steps. Always perform
all service or maintenance work with the greatest care
and attention.
Shop and/or field service platforms or ladders should be
manufactured and maintained in accordance with local
or national safety regulations in force.
Disconnect batteries and label all controls to warn that
service work is in progress, according to local and
national safety regulation requirements.
Block the machine and all attachments to be raised
according to local and national safety regulation requi-
rements.
Do not check or fill fuel tanks or install batteries near
burning or smoking materials and open flames due to
the presence of flammable vapours.
The fuel filler pipe nozzle must be constantly kept in
contact with the filler neck and this even before fuel starts
flowing in. Keep this contact from the beginning to the
end of the fuelling operation to avoid possible genera-
tion of sparks due to static electricity.
Use a trailer to haul a failed machine. Should it be
necessary to tow it, provide for suitable danger signals
as required by the local norms and regulations and
observe recommendations given in the Operation and
Maintenance Instruction Manual. Load/unload the ma-
chine on firm level ground providing safe support. Use
strong access ramps, with adequate height and angle.
Keep the trailer flatbed free of mud, oil or slippery
materials. Tie the machine securely to the trailer.
Never align holes or slots using your fingers; always use
appropriate aligning tools.
Remove all sharp edges and burrs from re-worked parts.
Use only approved and effectively grounded auxiliary
power sources for heaters, battery chargers, pumps and
similar equipment to reduce electrical shock hazard.
 SAFETY PRECAUTIONS
Lift and handle heavy components using hoisting devi-
ces of appropriate capacity. Ensure the parts are sup-
ported by appropriate straps and hooks.
Use lifting eyes provided to this aim.
Pay attention to bystanders near the lifting area.
Never pour gasoline or diesel fuel into open containers.
Never use gasoline, solvents or other flammable fluids
to clean parts. Use proprietary certified non-flammable,
non-toxic solvents only.
When using compressed air to clean parts, wear safety
glasses with side shields. Limit pressure to max. 2 bars,
in accordance with local and national safety regulati-
ons in force.
Do not run the engine of this machine in closed buildings
without proper forced ventilation capable to remove
toxic exhaust gases concentrating in the air. Do not
smoke, nor allow open flames or sparks nearby while
refuelling the unit or handling highly flammable mate-
rials.
Do not use open flames as light sources to look for leaks
or inspect anywhere on the machine.
Make sure that all mechanical tools provided are in
good condition at all times. Never use tools with mu-
shroomed or damaged heads. Always wear eye prote-
ctions with side shields.
Move with extreme care when working under, on or
near the machine or its attachments.
In case of attachment tests during which the engine
should be kept running, a qualified operator must sit in
the driver’s seat at all times while the mechanic is at
work.
Keep hands and clothes far OFF moving parts.
Stop the engine and move the safety lever to the lock
position before starting adjusting or repairing an as-
sembly.
Do not carry out any work on the attachment without
prior authorisation. Observe recommended mainte-
nance and repair procedures.
In case of field service, move the machine to level
ground and block it. If work on an incline cannot be
avoided, securely block the machine and its at-
tachments. Move the machine to level ground as soon
as possible. Do not twist chains and cables. Never use
a twisted chain or cable for lifting or pulling. Always
wear safety gloves to handle chains or cables. Be sure
chains and cables are firmly fastened and that
the anchor point is strong enough to withstand the
expected load. Keep all bystanders clear of the anchor
point, cables or chains. Do not pull or tow unless the
operator’s compartments of the machines involved
are fitted with proper guards against cable or chain
backlash.
Keep the maintenance area clean and dry at all times.
Clean immediately all water and oil spillage.
Do not pile up oily or greasy rags as they represent a
major fire hazard. Always store them in closed metal
containers.
Before starting the machine or its attachment, check,
adjust and lock the operator’s seat. Also ensure that
nobody is within the machine or attachment operating
range before starting or operating the machine and/or
its attachments. Sound the horn.
Rust inhibitors are volatile and flammable. Prepare
parts in well ventilated areas. Keep open flames away.
Do not smoke. Store containers in a cool well ventilated
place where they could not be reached by unauthorised
people.
Do not carry loose objects in your pockets that might fall
unnoticed into open compartments.
Wear appropriate safety clothing such as hard hat,
safety shoes and gloves, safety glasses when splinters
or other particles may be ejected.
Wear the appropriate welder’s equipment such as dark
safety glasses or mask, hard hat, protective clothing,
safety gloves and footwear always while welding or arc-
cutting. Wear dark safety glasses when you are near a
welding in progress.
Do not look the welding arc without proper eye prote-
ction.
Become acquainted with all your jacking equipment and
their capacity. Ensure that the jacking point on the
machine is appropriate for the load applied. Also, be
sure the supports under the jack and between the jack
and the machine are appropriate and stable.
Any equipment supported by a jack represents a possi-
ble hazard. Always support the load onto appropriate
blocking means as a safety measure before proceeding
with service or maintenance work, in compliance with
local or national safety regulations. Metal cables produ-
ce steel splinters. Always wear certified protection clo-
thes such as safety gloves and glasses while handling
them.
Handle all parts carefully. Keep hands and fingers away
from gaps, gears, and similar. Always use and wear
certified safety clothes such as safety glasses, gloves
and footwear.
The attachment is kept constantly in position by an oil
column trapped into the high pressure circuit. Lower the
attachment to the ground and relieve pressure from all
circuits prior to carrying out any type of maintenance or
repair work.
Do not service or repair the machine if it is parked
downhill. Consult the Operation and Maintenance In-
struction Manual for correct maintenance procedure.
Areas near articulated cutting edges where mechanical
parts are in motion are where personal injuries are most
likely to occur. Pay attention to prevent possible you are
near a welding in progress. Do not look the welding arc
without proper eye protection.
Become acquainted with all your jacking equipment and
their capacity. Ensure that the jacking point on the
machine is appropriate for the load applied. Also, be
sure the supports under the jack and between the jack
and the machine are appropriate and stable.
Any equipment supported by a jack represents a possi-
ble hazard. Always support the load onto appropriate
blocking means as a safety measure before proceeding
with service or maintenance work, in compliance with
9
 SAFETY PRECAUTIONS
local or national safety regulations. Metal cables pro-
duce steel splinters. Always wear certified protection
clothes such as safety gloves and glasses while han-
dling them.
Handle all parts carefully. Keep hands and fingers
away from gaps, gears, and similar. Always use and
wear certified safety clothes such as safety glasses,
gloves and footwear.
The attachment is kept constantly in position by an oil
column trapped into the high pressure circuit. Lower
the attachment to the ground and relieve pressure from
all circuits prior to carrying out any type of maintenance
or repair work.
Do not service or repair the machine if it is parked
downhill. Consult the Operation and Maintenance In-
struction Manual for correct maintenance procedure.
Areas near articulated cutting edges where mechani-
cal parts are in motion are where personal injuries are
most likely to occur. Pay attention to prevent possible
part movements by means of blocks or by keeping clear
of such zones when motion may take place during
maintenance or repair.
Move the hydraulic system lock safety lever to the lock
position when stopping the machine for whatever rea-
son.
Always install the safety stays for the hood and other
hinged covers before performing any maintenance or
repair work in the engine compartment.
TRANSFERS AND TRANSPORTATION
Before moving or transporting the machine, block it to
prevent accidental movement.
Pay particular attention during transfer on inclines,
both uphill and downhill.
Do not travel across the slope.
Never transfer the machine in the working site, in a
crowded area, or near people without having at least
one person charged with hand-signals who could guide
the Operator.
Sound the horn to inform that you are about to move off.
It is necessary to know load limits of bridges and
dimensional limits of tunnels. Such limits must never be
exceeded. You should also know machine height,
width, and weight. Have a signal-man help you when
clearances are limited.
Check dimensional limits during transfer or
transportation. Rough terrain may cause the machine
to sway and roll. Cross obstacles at a right angle at low
speed. Pay attention to machine shaking when the
centre of gravity overcomes the obstacle.
Drive with the lights on and use appropriate signals and
flags.
Get to know and respect local and national regulations.
Consider machine dimensions while turning.
Use a ramp to load the machine on a trailer. If a ramp
is not available, fabricate one using blocks. The ramp
should be sufficiently strong to support machine weight.
Always load and unload on level surface.
10
Tow the machine following the instructions contained in
the Operation and Maintenance Instruction Manual.
ENGINE
Do not run the engine in closed buildings without proper
ventilation capable to remove harmful exhaust fumes.
Do not place head, body, limbs, feet, hands or fingers
near rotating fans or belts. Be especially careful near
blower fans.
Loosen the radiator cap very slowly to relieve system
pressure before removing it. Always top-up coolant
level with the engine off or idling if hot. See the Operation
and Maintenance Instruction Manual.
Keep the exhaust manifold and tube free from combus-
tible matters. Fit the machine with shields and guards
when working in the presence of combustible matter free
in the air.
Do not refuel with the engine running, especially if hot,
as this increases fire hazard in case of fuel spillage.
Never attempt to check or adjust fan belt tensions when
the engine is running.
Do not adjust the fuel injection pump when the machine
is operating.
Do not lubricate the machine with the engine running. Do
not run the engine with the air intakes open and not
protected. If this cannot be avoided for service reasons,
place protection meshes on all intakes before servicing
the engine.
ELECTRICAL SYSTEM
Pay attention to connect connecting cables to correct
poles (+ to +) and (- to -) at both ends. Do not short-circuit
terminals. Thoroughly follow instructions given in Ope-
ration and Maintenance Instruction Manual.
Always move the key-start switch in the lock position
before servicing or repairing the machine.
Batteries contain SULPHURIC ACID. Protect the eyes
when working near the batteries against possible sprays
of the acid solution. Should acid contact skin, eyes, or
clothes, RINSE IMMEDIATELY IN WATER FOR AT
LEAST 15 MINUTES. Immediately seek medical
attention.
Battery released gas is highly flammable. Leave the
battery compartment cover open during recharging to
improve ventilation. Never check battery charge by
placing metal objects across the posts. Keep sparks or
open flames away from batteries. Do not smoke near the
battery to prevent explosion hazard.
Before any maintenance or repair, make sure that there
are no fuel or electrolyte leaks from the batteries. If any,
correct prior to proceeding with further work. Do not
recharge batteries in confined spaces. Ensure proper
ventilation is provided to avoid accidental explosions
due to build-up of explosive gas released during char-
ging.
 SAFETY PRECAUTIONS

Disconnect batteries before working on the electrical
system or carrying out any other type of work.
HYDRAULIC SYSTEM
Pressure fluid escaping from a very small hole can be
almost invisible and still have sufficient force to pene-
trate the skin. Always check any suspected pressure
leaks using a piece of cardboard or wood. Do not use
hands. If injured by escaping fluid, obtain medical
attention immediately or serious infection or reaction
may develop.
Stop the engine and ensure pressure is relieved from
all systems before removing side panels, housings,
guards and covers. See the Operation and Maintenan-
ce Instruction Manual.
Always use gauges of adequate capacity for pressure
testing. Refer to the Operation and Maintenance In-
struction Manual or Repair Manual.
Spare tyres must be inflated only as far it is necessary
to keep the rim components assembled; remember that
when not installed on the disc, a tyre inflated to maximum
pressure can explode.
Before operating on tyres, block all wheels, front and
rear. After lifting the machine with the cylinders, block it
with stands according to current safety rules and regu-
lations.
Deflate the tyres before removing them.
Before removing objects from the tyre tread, deflate it.
Do not inflate tyres with flammable gas: they may cause
explosions and serious personal injuries.

TOOLS

Always keep head, body, limbs, feet, hands, and fingers

away from the bucket and attachments, when in the
raised position.
Prior to any maintenance or repair work, install all
supports necessary to this aim according to local and
national safety regulations.
In case the attachment is to be operated for maintenan-
ce or repair purposes, do so exclusively while sitting in
the driver’s seat. Sound the horn before starting the
machine or moving the attachment. Require that nobo-
dy remain near the machine. Raise the attachment
slowly.
Do not use the machine to transport loose objects,
unless proper securing devices are provided.

TYRES AND WHEELS

Make sure that the inflation pressure of the tyres is

according to the specifications issued by the Manu-
facturer and check it periodically.

Should the pressure be changed, stand on the side of

the tyre at a safe distance.

Pressure check operations must be performed with

unloaded machine and cold tyres.
Never use reconditioned tyre rims, since eventual wel-
dings, heat-treatments or repairs not performed cor-
rectly can weaken the wheel, thus causing subsequent
damages or dangers.

Do not perform torch cutting or welding operations on

rims with tyres installed.

11
 SAFETY PRECAUTIONS

RIRECOGNISE SAFETY INFORMATION

This is your SAFETY SYMBOL ALERT

When you see this symbol on your machine or in this

Manual, be alert of the potential for personal injury.
Follow recommended precautions and safe operating
practises.

UNDERSTAND SIGNAL WORDS

These words are always accompanied by the safety

alert symbol. DANGER
DANGER: indicates an imminent hazardous situation
which, if not avoided, will result in death or serious injury. WARNING
WARNING: indicated a potential hazardous situation
which, if not avoided, could result in death or serious CAUTION
injury.

CAUTION: indicates a potential hazardous situation IMPORTANT

which, if not avoided, may result in minor or moderate
injury.
NOTE
IMPORTANT: indicates a situation which, if not avoided,
may cause damage to the machine.

NOTE: indicates an additional explanation for

information purposes.

ENVIRONMENTAL PROTECTION

This Manual also contains this symbol accompanying

instructions for correct behaviour as regards
environmental protection.

12
 SAFETY PRECAUTIONS

FOLLOW SAFETY INSTRUCTION

Carefully read and follow all safety signs on the machine

and all safety messages in this manual.

Safety signs should be installed maintained and

replaced when necessary.

If a safety sign or this manual is damaged or missing,

order a replacement from your dealer in the same way
you order other replacement parts (be sure to state
machine model and serial number when ordering).

Learn how to operate the machine and its controls

correctly and safety.

Allow only trained, qualified, authorized personnel to

operate the machine.

Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair

the function and/or safety and affect machine life.

The safety messages in this SAFETY PRECAUTIONS

chapter are intended to illustrate basic safety procedures
of hydraulic excavators. However it is impossible for
these safety messages to cover every hazardous
situation you may encounter.
If you have any questions, you should first consult your
supervisor before operating and servicing the machine.

PREPARE FOR EMERGENCIES

Be prepared if a fire starts or an accident occurs.

Keep the first-aid kit and fire extinguisher on hand.

Thoroughly read and understand the label attached to
the fire extinguisher to use it properly.
Establish emergency priority procedures to cope with
fires and accidents.

Keep emergency numbers for doctors, ambulance

service, hospitals and fire department posted near the
telephone.

13
 SAFETY PRECAUTIONS

WEAR PROTECTIVE CLOTHING

Avoid wearing loose clothing, jewelry, or other items that

can catch on control levers or other parts of the machine.
Operating equipment safety requires the full attention
of one operator. Do not wear radio or music headphones
while operating machine. Wear close fitting clothing and
safety equipment appropriate for the job.
Standard safety equipment includes:
- A hard hat
- Safety shoes
- Safety glasses, goggles, or face shield
- Heavy gloves
- Hearing protection
- Reflective clothing
- Wet weather clothing
- Respirator or filter mask.
Do not take chances. Wear whatever is needed for the
job at hand.

PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause impairment

or loss of hearing.

Wear a suitable hearing protective device such as earmuffs

or earplugs to protect against constant or uncomfortably
loud noised.

FASTEN SEAT BELT

Should the machine overturn, the operator may become

injured and/or thrown from the cab. Not only, the operator
may be crushed by the overturning machine resulting in
serious injury or oven death.

Prior to operating the machine, thoroughly examine belt

webbing, buckle, and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating operating the machine.
Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to
minimise injury hazard in case of accident.
After a significant accident, replace the seat belts even
though they do not look damaged.

14
 SAFETY PRECAUTIONS

INSPECT THE MACHINE

Inspect the machine carefully every day or work-shift

by an attentive visual inspection of machine outside prior
to starting it to prevent damages and personal injuries.

In the walk-around inspection, be sure to cover all points

detailed in the Chapter “MAINTENANCE”, paragraph
“EXTERNAL VISUAL INSPECTION”.

USE HANDHOLDS AND STEPS

Falling is one of the major causes of personal injury.

When you get on and off the machine, always maintain
a three-point contact with the steps and handrails and
face the machine. Do not use any controls as handholds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms, steps,
and handrails when leaving the machine.

ADJUST THE SEAT

Adjust the seat whenever changing operators. Be sure

that the operator can fully depress the pedals with his
back against the seat back.
If not, move the seat forward and check again.

15
 SAFETY PRECAUTIONS

OPERATE ONLY FROM OPERATOR’S SEAT

Avoid possible injury or machine damage. Do not start

the engine by shorting across started terminals.
NEVER start the engine while standing on ground. Start
the engine only from operator’s seat.

KEEP RIDERS OFF MACHINE

Only allow the operator on the machine. Keep riders off.

Riders on machine are vulnerable to injury such as being

struck by foreign objects or being thrown off the machine.

Riders also obstruct the operator’s view, resulting in

unsafe operation.

16
 SAFETY PRECAUTIONS

AVOID INJURY FROM BACK-OVER AND

SWING ACCIDENTS

To avoid back-over and swing accidents:

Always look around before you back up and swing the
machine. Be sure that everyone is in the clear.
Keep travel alarm in working condition (if equipped).

Always be alert for bystanders moving into the work

area. Use horn or other signal to warm bystanders before
moving machine.

A person could stand behind the machine, in a dead

area, not visible from rearview mirrors. Before backing
up, make sure nobody is standing in that area.

Use a signal person when backing up if you view is

obstructed. Always keep signal person in view.

Use hand signals when work conditions require signal

person.

No excavator or backhoe motions shall be made unless

signals are clearly understood by both signalman and
operator.

Learn the meaning of all flags, signs, and markings used

on the job and confirm who has the responsibility for
signaling.

When operating in potential dangerous areas, or in

areas with low visibility, use a person for machine shifts.

Before starting machine shifting, warm people near the

working area by means of the horn.

Keep windows, mirrors, and lights clean and in good

condition.

Dust, heavy rain, fog etc., can reduce visibility. As

visibility decreases, reduce speed and use proper
lighting.

17
 SAFETY PRECAUTIONS

WORK WITH CAUTION

Accidental severing of underground cables or gas lines

may cause an explosion and/or fire, possibly resulting
in serious injury or death.

Before digging, check the location of cables, gas lines,

and water lines.
Keep the minimum distance required by law from
cables, gas lines, and water lines. If a fiber optic cable
should be accidentally severed, do not look into the
end. Doing so may result in serious eye injury.
Contact local authorities and/or the utility companies
directly (electric power, gas, telephone, water, sewers,
telecommunications, etc.) to obtain information about
underground utility lines.

MOVE AND OPERATE MACHINE SAFELY

Bystanders are in danger of being run over.

Confirm the location of bystanders before moving,
swinging, or operating the machine.

Always keep the travel alarm in good working condition.

(if equipped). It warns people when the machine starts
to move.

Use a signal person when moving, swinging, or

operating the machine in congested areas. Coordinate
hand signals before starting the machine.

RULES FOR ROAD TRANSFER

The machine is equipped with safety locks to be used

for road transfer.
When transferring the machine:

- Locate cylinders as shown in homologation confi-

guration.
- Lock cylinders (cocks, reference marks).
- Lift dozing blade (if equipped).
- Unlock equipment control levers shifting safety
device lever to lock position.

On the road follow the rules regulating traffic.

18
 SAFETY PRECAUTIONS

INVESTIGATE JOB SITE BEFORE HAND

Clear all persons from area of operation and machine
movement.
Make sure worksite footing has sufficient strength to
firmly support the machine.
When working close to an excavation, operate the
machine with che chassis frame positioned
perpendicular to the cliff face, so that the machine can
more easily evacuate if the cliff face collapses.
Confirm that your machine is equipped with a R.O.P.S.
(Roll Over Protective Structure) cab before working in
areas where there is the possibility of falling stones or
landslides.

WORKING ON SLOPES

Never go down on slopes with gearbox in neutral. You

might loose control and cause serious injuries or death.

When going down on slopes, use a low gear. In this

way the engine is used as brake and holds the machine
without overloading brakes.

When working on a slope and the warning light for fuel

insufficient level lights up, fill the tank immediately.

Due to machine inclination, the engine can suct air and

stop suddenly, causing a serious danger to the
operator and the persons behind the machine.

If the engine stops suddenly, apply brakes and lower

immediately the blade to the ground.

19
 SAFETY PRECAUTIONS

AVOID TIPPING

When operating on a slope, keep blade low to ground

and close to machine.

To avoid tipping:

- Be extra careful before operating on a grade.

- Prepare machine operating area flat by grading.
- Keep the blade low to the ground and close to
the machine.
- Reduce machine operating speed to avoid tipping
or slipping.
- Never attempt to travel across a grade steeper
than 15 degrees.

Be careful when working on frozen ground.

- Temperature increases will cause the ground to

become soft and make ground travel unstable.

DRIVE MACHINE SAFELY

Before starting the machine, read carefully the “use and

instructions manual” to get familiar with levers.

Before moving the machine, confirm which way to move

pedals/levers for the corresponding direction you wish
to go.

When traveling up or down a grade, keep the blade in

the direction of travel, approximately 20 to 30 cm (A)
above the ground. A

BEWARE OF EXHAUST FUMES

Engine exhaust fumes can cause sickness or death.

If you must operate in a building, be sure there is

adequate ventilation.

Either use an exhaust pipe extension to remove the

exhaust fumes or open doors and windows to bring
enough outside air into the area.

20
 SAFETY PRECAUTIONS

PROTECTION OF CAB

In case of operation under conditions where land slides

with falling rocks or any conditions where there is a
potential falling of objects of different nature that could
endanger the operator, it is necessary to install a
FOPS (Falling Object Protective Structure) to protect
the cab.

OPERATE WITH CAUTION

If the front attachment or any other part of the machine

hits against an overhead obstacle, such as a bridge,
both the machine and the overhead obstacle will be
damaged, and personal injury may results as well.

AVOID INJURY FROM RUNAWAY

ACCIDENTS

Death or serious injury may result if you attempt to

stop a moving machine.

To avoid runaways:

Select level ground when possible to park machine.

Lower dozing blade (blade) to the ground.

Lock articulation.
Stop the engine and remove the key from the key switch.
Pull pilot control shut-off lever to LOCK position.

Block both tyres if you must park on a slope.

Park a reasonable distance from other machine.

21
 SAFETY PRECAUTIONS

PARK MACHINE SAFELY

Before working on the machine:

- Park machine on a level surface.
- Lower bucket to the ground.
- Move turret swing lever to lock position.
- Run engine at slow idle speed without load for
3 minutes.
- Turn key switch to OFF to stop engine. Remove
key from switch.
- Pull pilot control shut-off lever to LOCK position.
- Allow engine to cool.
- Close windows, roof window, and cab door.
- Lock all access doors and compartments.

NEVER WORK UNDER PROJECTING

BANKS

The edges could collapse o a land slide could occur

causing serious injury or death.

PROVIDE SIGNALS FOR JOBS INVOLVING

A NUMBER OF MACHINES

For jobs involving several machines, provide signals

commonly known by all personnel involved.

Also, appoint a signal person to co-ordinate the job

site.

Make sure that all personnel obey the signal person’s

directions.

22
 SAFETY PRECAUTIONS

KEEP PERSONNEL CLEAR FROM

WORKING AREA

A person may be hit severely by the swinging front

attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.

Keep all persons clear from the area of operation and

machine movement.

Before operating the machine, set up barriers to the

sides and rear area of the bucket swing radius to prevent
anyone from entering the work area.

SAFETY TRANSPORTING

The danger of tipping is present when loading/unloading

the machine onto/from a truck or trailer bed.

- Be sure to observe local regulations when

transporting the machine on public roads.

- Provide an appropriate truck or trailer for

transporting the machine.

Take the following precautions when loading/unloading

the machine:

- Select firm level ground.

- Be sure t use a loading dock or ramp.

- Be sure to have a signal person when loading/

unloading the machine.

- Always select the slow speed mode with the travel

speed selector.

- Avoid steering while driving up or down the ramp

as it is extremely dangerous.

If steering is unavoidable, first move back to the

ground or flatbed, modify travelling direction, and
begin to drive again.

23
 SAFETY PRECAUTIONS

- Operate the safety lever but do not operate

any other control except travel control when
driving up or down the ramp.

- The top end of the ramp where it meets the

flatbed is a sudden bump. Take care when
traveling over it.

- Securely fasten machine frame using chains

or cables.

Refer to “Transport” chapter in this manual for details.

24
 SAFETY PRECAUTIONS

PRACTICE SAFE MAINTENANCE

Understand service procedures before doing work.

Keep work area clean and dry.

Never lubricate or service the machine while it is

moving.

Keep hands, feet and clothing from power-driven

parts.

Before performing the machine maintenance:

- Park on a flat surface.

- Lower the blade to the ground.
- Operate the engine at low idle with no load for 3
minutes to cool it off.
- Move the key into position OFF to cut-off the
engine and remove it from the switch.
- Move the control safety cut-off lever into position
LOCK.
- Let the engine to cool-off.

Place a “maintenance in progress” sign (seen in the

SAFETY DECALS chapter). This sign can be located
on the cab door.

In the event maintenance operations require

operating the engine, do not leave the machine
unattended.
In the event the machine must be lifted, block with
appropriate supports the elements of the machine
during maintenance/repair operations.

Inspect certain parts periodically and repair or

replace as necessary.

Keep all parts in good condition and properly

installed.
Fix any damage immediately. Replace worn or broken
parts.

Remove any building of grease, oil, or debris.

Disconnect the ground cable (-) from the batteries
before servicing electrical systems or welding on
the machine

25
 SAFETY PRECAUTIONS

CLEAN TRASH FROM MACHINE

Keep engine compartment, radiator, batteries, hydraulic

lines, fuel tank, and operator’s station clean.
Temperature in engine compartment may go up
immediately after engine is stopped.
BE ON GUARD FOR FIRES DURING THIS PERIOD.
Open access door (s) to cool the engine faster, and
clean engine compartment.

WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious

injury.

Before performing any work on the machine, apply the

“Maintenance in progress” tag (see SAFETY PLATES
in this Chapter). This tag can be applied to the left-
hand control lever, safety lever or cab door

CLEAN THE MACHINE REGULARLY

Remove any grease, oil or debris build-up to avoid

possible injury or machine damage.

Do not spray water or steam inside the cab.

STORE ATTACHMENTS SAFELY

Stored attachments as blades can fall and cause serious

injury or death.

Securely store attachments and implements to prevent

them from falling. Keep playing children and bystanders
away from storage area.

26
 SAFETY PRECAUTIONS

SUPPORT MACHINE PROPERLY

Never attempt to work on the machine without securing

the machine first.

Always lower the attachment or tool to the ground before

working on the machine.
If you must work on a lifted machine or attachment,
securely support the machine or attachment.

Do not support the machine on cinder blocks, bollow

tires, or props that may crumble under continuous load.
Do not work under a machine that is supported solely
by a jack.

PREVENT PARTS FROM FLYING OFF

Tyres are pressurized.

Tyre and/or rim parts burst may result in serious injury

or death.

Only skilled staff can replace tyres.

Always keep the correct tyre pressure.

Never exceed the recommended pressure when inflating

tyres.

Slow down or stop and let tyres get cool.

When adjusting tyre pressure, keep at a certain distance

and protect yourself. Use an extension equipped with a
quick connection for the valve handling.

Always stay behind the tyre when adjusting pressure.

27
 SAFETY PRECAUTIONS

STARTING THE ENGINE WITH BOOSTER

BATTERIES

Battery gas may explode causing serious damages and

injuries.

If the engine ids to be started using booster batteries,

ensure to comply with all procedures detailed in the
chapter “OPERATING INSTRUCTIONS”.

The operator should be sitting in the driver’s seat to

keep the machine under control when the engine starts.
Starting the engine with booster batteries is a two man
operation.

Do not recharge batteries that have been stored in the

cold for a long time as they might explode. Heat them
at 15 °C.

Mistakes in following procedures detailed for starting

the engine with slave batteries may cause the batteries
to explode or machine to move unexpectedly.

28
 SAFETY PRECAUTIONS

PROTECT AGAINST FLYING DEBRIS

Guard against injury from flying pieces of metal or debris;

wear goggles or safety glasses.

Keep bystanders away from the working area before

striking any object, to avoid personal injury.

STAY CLEAR OF MOVING PARTS

Entanglements in moving parts can cause serious injury.

To prevent accidents, care should be taken to ensure

that hands, feet, clothing, jewelry and hair do not
become entangled when working around rotating parts.

SUPPORT MACHINE PROPERLY

Always lower the attachment or implement to the ground

before you work on the machine. If you must work on a
lifted machine or attachment, securely support the
machine or attachment.

Do not support the machine on cinder blocks, hollow

tiles, or props that may crumble under ontinuous load.

Do not work under a machine that is supported solely

by a jack. Follow the procedures in this manual.

29
 SAFETY PRECAUTIONS

PREVENT BURNS

After operation, the engine coolant is hot and is under

pressure. Hot water or steam are contained in the engine,
radiator and heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
Be sure to stop the engine, and let engine and radiator
cool.
Slowly loosen the cap to release pressure after
the system has cooled, then remove it.

Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot
as well.
Wait for the oil and components to cool before starting
any maintenance or inspection work. The hydraulic oil
tank is pressurized. Again, be sure to release all
pressure before removing the cap.

REMOVE PAINT BEFORE WELDING OR

HEATING

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch.

Do all such work outside or in a well-ventilated area.

Dispose of paint and solvent properly.

If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

If you use solvent or paint stripper, remove stripper with

soap and water before welding. Remove solvent or paint
stripper containers and other flammable material from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.

30
 SAFETY PRECAUTIONS

AVOID HEATING NEAR PRESSURIZED

FLUID LINES

Flammable spray can be generated by applying heat

near pressurized fluid lines, resulting in severe burns
to yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lined
or other flammable materials.

Pressurized lines can be accidentally cut when heat

goes beyond the immediate flame area. Install
temporary fire resistant guards to protect hoses or other
materials when engaging in welding, soldering, etc.

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS

Do not weld or flame cut pipes or tubes that contain

flammable fluids. Clean them thoroughly with
nonflammable solvent before welding or flame cutting
them.

AVOID HIGH PRESSURE FLUIDS

Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.

Relieve the pressure by moving the control levers

several times.
Tighten all connections before applying pressure.
Wear a shield or protection glasses to protect your eyes.

Search for leaks with a piece of cardboard; take care

to protect hands and body from high-pressure fluids.

If an accident occurs, see a doctor familiar with this

type of injury immediately

Any fluid injected into the shin must be surgically

removed within a few hours or gangrene may result.

31
 SAFETY PRECAUTIONS

PREVENT FIRES

1. Check for oil leaks:

Fuel, hydraulic oil and lubricant leaks can lead to

fires that may result in serious injury.

Check for missing or loose clamps, kinked hoses,

lines or hoses that rub against each other, damaged
oil-cooler, and loose oil-cooper flange bolts, for oil
leaks.

Search for leaks with a piece of cardboard.

Escaping fluid under pressure can penetrate the skin
causing serious injury.
Do not use your bare hand to check for oil leaks.

Tighten, repair or replace any missing, loose or

damaged clamps, lines, hoses, oil-cooler and oil
cooler flange bolts.

Do not bend or strike high-pressure lines.

Never install bent or damaged lines, pipes or hoses.

2. Check for shorts:

Short circuits can cause fires that may result in

serious injury.

Clean and tighten all electrical connections.

Check before each shift or after eight (8) hours of

operation for loose, kinked, hardened or frayed
electrical cables and wires.

Check before each shift or after eight (8) hours of

operation for missing or damaged terminal caps.

DO NOT OPERATE MACHINE if cable or wires are

loose, kinked, etc.

Tighten, repair or replace any loose or damaged

electrical cables, wires, and terminal caps before
operating the machine.

3. Clean flammables:

Spilled fuel and oils, and accumulated coal dust and

other flammables may cause fires and
serious personal injury.

Prevent fires by keeping machine clean every day.

32
 SAFETY PRECAUTIONS

4. Check key-start switch:

If a fire breaks out, failure to stop the engine will

escalate the fire, hampering fire fighting.
Always check key/start switch function before
operating the machine every day:
- Start the engine and run it at slow idle.
- Turn the key/start switch to the OFF position to
confirm that the engine stops.

If any abnormalities are found, be sure to repair them

before operating the machine.

5. Check heat shields:

Damaged or missing heat shields may lead to fires.

Damaged or missing heat shields must be repaired
or replaced before operating the machine.

HANDLE CHEMICAL PRODUCTS SAFETY

Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used
with you machine include such items as lubricants,
coolants, paints, and adhesives.

Check the local safety before you start any job using
a hazardous chemical. That way you will know exactly
what the risks are and how to do the job safety. Then
follow procedures and use recommended equipment.

33
 SAFETY PRECAUTIONS

DISPOSE OF WASTE PROPERLY

Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste on
includes such items as oil, fuel, coolant, brake fluid,
filters, and batteries.

Use leakproof containers when draining fluids. Do not

use food or beverage containers that may mislead
someone into drinking from them.

Do not pour waste onto the ground, down a drain, or

into any water source.

Air conditioning refrigerants escaping into the air can

damage the Earth’s atmosphere. Government
regulations may require a certified air conditioning
service center to recover and recycle used air
conditioning refrigerants.

Obtain information on the proper way to recycle or

dispose of waste from your local environmental or
recycling center, or from your authorized dealer.

PREVENT ACID BURNS

Sulfuric acid in battery electrolyte is poisonous. It is

strong enough to burn skin, eat holes in clothing, and
cause blindness if splashed into eyes.

Avoid the hazard by:

Filing batteries in a well-ventilated area.
Wearing eye protection and rubber gloves.
Avoiding breathing fumes when electrolyte is added
Avoiding spilling or dripping electrolyte.
Use proper jump start procedure.

If you spill acid on yourself:

Flush your skin with water.
Apply baking soda or lime to help neutralize the
acid.
Flush your eyes with water for 10-15 minutes.
Get medical attention immediately.

If acid is swallowed:
Drink large amounts of water of milk.
Then drink milk of magnesia, beaten eggs, or
vegetable oil.
Get medical attention immediately.

34
 SAFETY PRECAUTIONS

HANDLE FLUIDS - AVOID FIRES

Handle fuel with care; it is highly flammable.

Do not refuel the machine while smoking or near open
flame or sparks.
Always stop engine before refueling machine. Fill fuel
tank outdoors.

Store flammable fluids away from fire hazards.

Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and

debris.

Do not store oily rags; they can ignite and burn

spontaneously.

SERVICE COOLING SYSTEM SAFELY

Explosive release of fluids from pressurized cooling

system can cause serious burns.

Shut off engine. Only remove filler cap when cool

enough to touch with bare hands.

SERVICE COOLING SYSTEM SAFELY

Explosive release of fluids from pressurized cooling

system can cause serious burns.

Shut off engine. Only remove filler cap when cool

enough to touch with bare hands.

35
 SAFETY PRECAUTIONS

DISPOSE OF FLUIDS PROPERLY

Improperly disposing of fluids can harm the environment

and ecology. Before draining any fluids, find out the
proper way to dispose of waste from your local
environmental agency.

Use proper containers when draining fluids. Do not use

food or beverage containers that may mislead someone
into drinking from them.

DO NOT POUR oil into the ground, down a drain, or

into a stream, pond, or lake. Observe relevant
environmental protection regulations when disposing
of oil, fuel, coolant, brake fluid, filters, batteries, and
other harmful waste.

WORK IN A CLEAN AREA

Before starting a job, clean the work area. Remove

objects that may be a safety hazard to the mechanic or
bystanders.

ILLUMINATE WORK AREA SAFELY

Illuminate your work area adequately but safely. Use a

portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can
ignite spilled fuel or oil.

36
 SAFETY PRECAUTIONS

USE TOOLS PROPERLY

Use tools appropriate to the work. Makeshift tools, parts,

and precedures cam create safety hazard.
Usare soltanto attrezzi appropriati per allentare elementi
filettati e di fissaggio.

Use power tolls onlyto losen threaded tools and

fasteners.

For loosening and tightening hardware, use the correct

size tools. Do not use U.S. measurementt tools on metric
fasteners. Avoid bodily injury caused by slipping
wrenches.

Use only recommended replacement parts. (See Parts

Catalog).

EVACUATING IN CASE OF FIRE

If a fire breaks out, evacuate the machine in the following

way:

Stop the engine by turning the key-start switch to the

OFF position if there is time.
Use a fire extinguisher if there is time.
Exit the machine

37
REPAIR SAFETY INSTRUCTIONS

REPAIR SAFETY INSTRUCTIONS

THE FOLLOWING SAFETY INSTRUCTIONS MUST BE OBSERVED BY ALL REPAIRING THE MACHINE!

• Repairs may be carried out by skilled, trained and experienced personnel only and/or by Ammann SERVICE.
• When performing repairs, always use our shop manual. Special instructions for the assembly work are given in individual
chapters of the manual.
• Before putting the machine into operation acquaint yourselves with the machine control as given in the “Operator’s Manual“
and make sure that you understand well all outfit of the machine.
• Do not use the machine if you do not fully understand all controls and until you know how the machine works.
• Know the area where you will work.
• Do not make any redesign or modifications on the machine because you could decrease safety of the equipment.
• Original parts and accessories have been designed especially for this machine.
• Installation and usage of spare parts not supplied by the manufacturer of the machine or not authorized by him can have
negative effects on operational characteristics and safety operation of the machine.

SAFETY PRECAUTIONS WHEN REPAIRING AND INSPECTING THE EQUIPMENT

• Wear work clothe and boots.

• Use gloves when handling oils, fuel or coolant.
• Protect your eyes with goggles or a shield when handling the battery.
• Place the equipment on a flat and firm surface before starting repair. Secure the equipment against spontaneous movement.
• Secure the frame of the equipment and the drum against mutual rotation using a safety pin and a draw bar.
• Before starting work remove the ignition key, disconnect the batteries and let hot parts cool down.
• Attach a warning note “Equipment out of work“ to the steering wheel and leave it there for the duration of service work.
• Wash the equipment thoroughly. If you use steam, do not expose electrical components and insulation directly to stem jet,
or else cover them beforehand.
• Keep all parts absolutely clean when dismantling, mounting, and servicing each assembly. Protect removed parts from getting
soiled.
• Clean the surface of dismantled parts and provide for adequately dust-free working conditions and a needed lay-off area.
• Be careful when handling cleaning agents. Do not use petrol or other easy inflammable materials for cleaning.
• Dry the cleaned parts and immediately cover with anticorrosive protective oil- never install corroded parts!
• Tools, hoists, safety equipment of the supports, and other additional items must be serviceable and in good condition.
• Use hoists and fasteners (ropes, chains) that have sufficient carrying capacity and are in good condition.
• Make sure that there is enough fresh air supply when starting up the equipment in an enclosed area.
• Before placing the equipment into operation make sure there nobody on the equipment or close by. The start of the equipment
must always be announced with an audible alarm , also after any pause in operation before the equipment is restarted. Persons
present on the equipment and dangerously close by must leave the equipment after such alarm has been sounded. Sound
and hand signals and beacons must be also used as specified in the ČSN 27 7012 Standards, Appendix 1.
• Do not adjust moving equipment.

38
 REPAIR SAFETY INSTRUCTIONS

• When working (adjusting) on the running engine, avoid touching hot and rotating parts.. During work on the running engine,
another person must be present that can easily access the emergency switch and must be in contact at all times with the
person performing the adjustment, to be able to switch off the engine immediately when necessary.
• Use only prescribed makes of motor, gear and hydraulic oils and coolants.

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.
• Do not operate hydraulic generators and hydraulic motors without oil.
• There is danger of being scalded when handling hot oil.
• Do not warm oil to temperatures above 160 °C - oil or its fumes may ignite.
• For cleaning and wiping hydraulic parts use such textiles that do not leave lint.
• When reassembling parts use hydraulic oil - not grease - as lubricants.
• Clean screws and bolts carefully before installation, wash hoses and pipes and blow them off using compressed air.
• Always use new packing in seals.
• Fill new aggregates with hydraulic oil before installation.
• Rinse hydraulic circuit after replacing the hydraulic device, clean the hydraulic tank as well.
• Replace the oil filter cartridge.
• Fill the hydraulic circuit with pure oil of the prescribed viscosity, but only when the engine has been stopped!
• Wipe off overflow oil.
• Check connections for tightness, whether they leak oil, before applying pressure to the system.
• Do not adjust safety valves.
• After all work has been finished, recheck all connections and replace all safety elements
• After finishing the work install again all protective elements.

AFTER PUTTING THE MACHINE INTO OPERATION, CHECK

• Oil level in the hydraulic tank.

• Check up filling pressure in hydraulic generators in case they are replaced as well as pressure in safety valves. Carry out
the measurement at temperature of 40 °C (104 °F).

39
REPAIR SAFETY INSTRUCTIONS

SAFETY INSTRUCTION FOR WORK ON THE FUEL SYSTEM

Mixtures of petrol and diesel (winter fuel) are as inflammable as petrol.

- Do not refuel in closed areas.
- Wipe off overflowed fuel.
- Do not smoke when working on the fuel system and do not use naked light! There is a danger of fire!

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 (+).
• Do not disconnect batteries when the engine is running!
• Connect the “minus“ pole of the battery to the chassis and the “plus“ pole to lead “B+“ from the alternator. In case of the reverse
connection the whole semiconductor device could get destroyed.
• When starting with auxiliary external supply, do not disconnect such supply sooner than the battery of the machine is
connected. Watch out starting voltage of the auxiliary external supply (for 24 V).
• Do not put the alternator into no-load run, i. e. with the wire disconnected from the “+“ terminal and connected “D+“ terminal.
• Do not check the presence of voltage in the wire by sparking it on the chassis of the equipment.
• Do not do anything that produces sparks.
• When handling batteries, use protective rubber gloves and goggles.
• Protect your skin and clothes from stains by electrolyte or lead particles.
• When electrolyte gets into your eye, rinse it with a stream of water for a few minutes. Then see a doctor as soon as possible.
• When electrolyte stains your skin or clothes, take off your clothes, wash the stained area with soap water or with a solution
of baking soda and water and see a doctor.
• After taking electrolyte incidentally, drink as much milk or water as possible or a solution of magnesia and immediately see
a doctor.
• Never pour distilled water into the cells unless the operation of the machine or charging outside the equipment follows. In
such case the battery would self discharge increasingly.
• Never add sulfuric acid (H 2SO4)!
• Do not overturn the batteries because electrolyte could run out of the degassing holes of the battery.
• If acid (electrolyte) is spilled, rinse the place with water and neutralize it with lime.
• When the batteries are being charged, hydrogen is released and it makes mixed with air, an explosive, easily combustible
mixture. Do not use open flame and do not smoke.

40
 REPAIR SAFETY INSTRUCTIONS

WELDING ON THE MACHINE

Before starting arc welding, disconnect all parts with semiconductors from electrical wiring, inclusive of machine electronics:

• it is necessary to earth both the supply and the machine that is being repaired,
• secure the supply against moisture,
• place ground terminal close to the welded joint.
• when parts are welded or when the machine is in the suspended position, it is necessary to insulate the point of current transfer
to avoid current entering the hoist, or to use a non-conducting rope.

41
REPAIR SAFETY INSTRUCTIONS

SEALS

• Always use new packing.

• You will receive packing kits as spares.

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.
• Tightening torque is given in tables.
• Thread joints of hydraulic circuits are tightened according to tables.
• The given tightening torque is valid for not oiled bolt thread.
• Use new self-locking nuts only.

ENVIRONMENTAL MEASURES AND HEALTH PRECAUTIONS

When repairing the machine, keep general principles of health protection and environment protection as well, and observe laws,
regulations, and guidelines related to these problems as applicable to the territory where the equipment is used.

PRINCIPLES OF HYGIENE

• Oil products, coolants, battery acids, and paints including thinners can be harmful to your health and they can injure your
organs seriously.
• It is necessary to observe consistently safety and health instructions enclosed with the products and to use personal
protective aids when handling them.
• Personnel in contact with these products during servicing are obliged to observe general principles of their health protection
and keep in mind safety and health guidelines as given by manufacturers of such products, especially the following:
- protection of eyes and skin when working with batteries,
- protection of the skin when handling oil products, paint, and cooling liquids,
- workers should wash their hands properly after finishing their work and apply proper healing hand lotions,
- when working with the cooling system it is necessary to observe instruction manuals supplied with the machine.
• Oil products, coolants, batteries, and paint including organic thinners as well as cleaners and preservatives should be always
stored in their original packages properly labeled. Do not store such materials in unlabelled bottles and other vessels because
there is a danger of confusion. Confusion of food or drinks is especially dangerous.
• If the skin or eyes are by chance stained or fumes are breathed, apply immediately first aid. In case of incidental consumption
of such products see your doctor immediately.

42
 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,
- all removed filters and filter elements,
- all used and discarded hydraulic and fuel hoses, rubber - metals and the other elements stained with the above products.
• The above parts and materials must be handled, after they had been discarded, in accordance with valid national regulations
on environmental protection and according to directions concerning health protection.
• When hydraulic liquids, fuel, cooling systems and their aggregates are being removed it is necessary to prevent their
infiltration into the ground by using retaining vessels and by plugging the holes.
• After leaks the place must be immediately dried with sawdust, Vapex, and such.
• The contaminated earth must be removed to prevent further leakage. Then the soil and absorbing material must be disposed
of safely.

43
REPAIR SAFETY INSTRUCTIONS

FIRE PRECAUTIONS

• From the standpoint of fire danger, the inflammable liquids used are divided into the following risk classes
II. risk class
- oil
IV. risk class
- mineral oils
- lubricants
- antifreeze
• The place where oil is being changed must not situated in an area where there is danger of explosion or fire.
• Notices showing that smoking and open flame are not allowed must be installed there.
• The handling area must have sufficient dimensions to capture the amount of inflammable liquid equal to the volume of the
largest vessel or the transport package.
• Portable fire-extinguishers must be available.
• Oil and oil products should be handled in special vessels, e. g. metal barrels, cans, tin cans.
• Transport vessels must be properly closed when stored.
• The vessels should have one hole and should be always stored with the hole up and they must be secured against leakage.
• The vessels must be labeled with indelible inscriptions showing their contents and burning power class.

OTHER RELATED INSTRUCTIONS

Foreign documents:
Valid guidelines for safety of work and health protection in operation and maintenance of the equipment
Valid directions on fire protection
Valid directions on inflammable liquids
Valid directions and laws on the protection of health and environment related to these problems
Valid directions on handling dangerous substances and waste.

THE MACHINE IS SUPPLIED WITH THE FOLLOWING ITEMS:

Spare parts katalogue

Operations manual
Spare parts of engine
Operations manual of engine

44
 1 - SUMMARY OF APPLICATIONS

1 - A SUMMARY OF APPLICATIONS
Serial and type numbers are important for verification of the
machine identity and/or in case of claims. The name plate of the
machine containing basic data about the machine is attached
to the left side of the frame below the cab.

Plate with the serial number of Cummins engine is attached to

the box of the fuel injection pump drive and the steering
hydraulic generator of the drum.
Serial numbers and data of the aggregate purchased are
shown directly on each aggregate.

45
2 - DESCRIPTION OF THE MACHINE

2 - DESCRIPTION OF THE MACHINE VERSION:

Vibrating roller is a self-movable compaction machine consi- Vibrating roller ASC70/90 D, ASC110/150 D, ASC200/250 D
sting of two parts connected with a joint, i. e. drum and towing This kind of roller with a smooth drum is suitable for compacting
unit. all sorts of earth, rock-fill and aggravate materials.

Vibrating roller ASC70/90 PD, ASC110/150 PD, ASC200/250 PD

DRUM UNIT
- consists of the frame in which the drum with the travel drive
and vibration drive is placed. Owing to two amplitudes of
different size, which can be chosen together with the corre-
sponding frequency, it is possible to compact materials of
different characteristics. Two scrapers placed in the front side
on the beam and in the rear side on the cross bar of the drum
frame are used for removing the soil adhering to the drum.
This type of roller with a pad footed drum has a simultaneous
compacting and vibrating effect on clay and mixed soils.
Vibrating roller ASC70/90 PDB, ASC110/150 PDB,
ASC 200/250 PDB
This type of roller with a pad footed drum and the blade (earth-
board) is designed for compacting material as in the PD version
and is capable, moreover, of spreading made-up material.

TRAILING HINGE Sign the machine with index „H“

The machine is made for permanent operation on slopes over
- connects both units of the roller and enables mutual shift 30 % in extreme conditions.
of the parts in horizontal and vertical planes.

FRAME OF THE TOWING UNIT

- welding, in its front part there is a plate for gripping the joint,
holes where hydraulic motors of the travel are installed, in the
rear part there is a fuel tank with grips for batteries and a toolbox.
Holes for gripping the hydraulic tank, driver’s station and
protective ROPS frame are situated in the upper part of the
equipment.

46
 2 - DESCRIPTION OF THE MACHINE

ATTACHED EQUIPMENT

Pad-foot segments
The attached equipment installed on the smooth drum partially
substitutes the pad-footed drum.

Blade (earth-board)
The attached equipment serves for spreading bulk soil and for
its leveling in the area being compacted. The arms of the blade
are pendulum fixed to the frame of the drum. The blade is lifted
and lowered using two linear hydraulic motors fixed into brackets
on the right and left side beams of the drum.

The ROPS protective frame

It protects the driver in case of overthrow of the machine. The
data about the frame are shown in the plate.

ASC lock
It features the ability to pass well through a rough terrain
(gradient) at decreased adhesion, at running to the trailer, it
helps to free the machine, etc.

Filling of tires with liquid

47
2 - DESCRIPTION OF THE MACHINE

TECHNICAL DATA

ENGINES

VERSION ASC 70/90 - TIER I ASC 110/150 - TIER I ASC 200/250 - TIER I

Manufacturer CUMMINS-Diesel CUMMINS-Diesel CUMMINS-Diesel

Type B3.9-C99 B5.9-C148 B5.9-C200

Number of cylinders 4 6 6

Performance according to ISO

74 [99] 110 [148] 149 [200]
3046/1 kW [HP] (DIN 6271)

Specific speed - revolutions per

2200 2200 2500
minute [RPM]

VERSION ASC 70/ 90 - TIER II ASC 110/150 - TIER II ASC 200/250 - TIER II

Manufacturer CUMMINS-Diesel CUMMINS-Diesel CUMMINS-Diesel

Type B4.5-C99 QSB5.9-C155 QSB5.9-C205

Number of cylinders 4 6 6

Performance according to ISO

74 [99] 116 [155] 153 [205]
3046/1 kW [HP] (DIN 6271)

Specific speed - revolutions per

2200 2200 2500
minute [RPM]

48
 2 - DESCRIPTION OF THE MACHINE

WEIGHTS

Sign „D“ for machines with smooth drum.

Sign „PD“ for machines with taper foot drum.
Sign „PDB“ for taper foot drum with blade.

Operational weight of the machine ASC 70 in kg [lb] according to ISO 6016

MACHINE ASC 70 D ASC 70 PD ASC 70 PDB

Cab + ROPS frame * 7255 [15.994] 7200 [15.873] 7700 [16 976]

* - Smooth drum can be fitted with padfoots segments.

For machines with padfoots segments or liquid-filled tyres, weights specified in the following table must be added:

MACHINE ASC 70 D ASC 70 PD ASC 70 PDB

Weight of two tires with liquid filling in kg [lb] 420 [926] 420 [926] 420 [926]

Weight of three pad-foot segments in kg [lb] 1090 [2.403] - 1090 [2.403]**

** - If the smooth drum with padfoot segments is used for PDB version, weights of the segments, liquid-filled tyres and blade
must be added to „D“ version weight (7255 kg [15,994 lb]). Total weight of this heaviest version is 9265 kg [20,426 lb].

The value specified in the table shall be deducted for machines without the cab. For a machine with roof, deduct the weight of
the cab and add 140 kg.

MACHINE ASC 70 D ASC 70 PD ASC 70 PDB

Weight cabin kg [lb] 220 [485] 220 [485] 220 [485]

Weight dozing blade kg [lb] - - 500 [1,102]

For the mountain version of the machine (indicated by „H“ - e.g. ASC 70 HD; HDPD; PDBH), 480 kg (the weight of version H
accessories) must be added.

49
2 - DESCRIPTION OF THE MACHINE

Operational weight of the machine ASC 90 in kg [lb] according to ISO 6016

MACHINE ASC 90 D ASC 90 PD ASC 90 PDB

Cab + ROPS frame 8515 [18.772]* 8880 [19.577] 9380 [20.679]

* - Smooth drum can be fitted with padfoots segments.

For machines with padfoots segments or liquid-filled tyres, weights specified in the following table must be added:

MACHINE ASC 90 D ASC 90 PD ASC 90 PDB

Weight of two tires with liquid filling in kg [lb] 420 [926] 420 [926] 420 [926]

Weight of three pad-foot segments in kg [lb] 1090 [2.403] - 1090 [2.403] **

** - If the smooth drum with padfoot segments is used for PDB version, weights of the segments, liquid-filled tyres and blade
must be added to „D“ version weight (8515 kg [18,772 lb]). Total weight of this heaviest version is 10525 kg [23,204 lb].

The value specified in the table shall be deducted for machines without the cab. For a machine with roof, deduct the weight of
the cab and add 140 kg.

MACHINE ASC 90 D ASC 90 PD ASC 90 PDB

Weight cabin kg [lb] 220 [485] 220 [485] 220 [485]

Weight blade kg [lb] - - 500 [1,102]

For the mountain version of the machine (indicated by „H“ - e.g. ASC 90 HD; HDPD; PDBH), 480 kg (the weight of version H
accessories) must be added.

50
 2 - DESCRIPTION OF THE MACHINE

Operational weight of the machine ASC 110 in kg [lb] according to ISO 6016

MACHINE ASC 110 D ASC 110 PD ASC 110 PDB

Cab + ROPS frame * 11665 [25.716] 12095 [26.664] 13005 [28.670]

* - Smooth drum can be fitted with padfoots segments.

For machines with padfoots segments or liquid-filled tyres, weights specified in the following table must be added:

MACHINE ASC 110 D ASC 110 PD ASC 110 PDB

Weight of two tires with liquid filling in kg [lb] 1200 [2.645] 1200 [2.645] 1200 [2.645]

Weight of three pad-foot segments in kg [lb] 1680 [3.704] - 1680 [3.704] **

** - If the smooth drum with padfoot segments is used for PDB version, weights of the segments, liquid-filled tyres and blade
must be added to „D“ version weight (11665 kg [25,716 lb]). Total weight of this heaviest version is 15455 kg [34,426 lb].

The value specified in the table shall be deducted for machines without the cab. For a machine with roof, deduct the weight of
the cab and add 140 kg.

MACHINE ASC 110 D ASC 110 PD ASC 110 PDB

Weight cabin kg [lb] 220 [485] 220 [485] 220 [485]

Weight blade kg [lb] - - 910 [2,006]

For the mountain version of the machine (indicated by „H“ - e.g. ASC 110 HD; HDPD; PDBH), 480 kg (the weight of version H
accessories) must be added.

51
2 - DESCRIPTION OF THE MACHINE

Operational weight of the machine ASC 150 in kg [lb] according to ISO 6016

MACHINE ASC 150 D ASC 150 PD ASC 150 PDB

Cab + ROPS frame * 14550 [32.076] 14460 [31.878] 15370 [33.884]

* - Smooth drum can be fitted with padfoots segments.

For machines with padfoots segments or liquid-filled tyres, weights specified in the following table must be added:

MACHINE ASC 150 D ASC 150 PD ASC 150 PDB

Weight of two tires with liquid filling in kg [lb] 1200 [2.645] 1200 [2.645] 1200 [2.645]

Weight of three pad-foot segments in kg [lb] 1680 [3.704] - 1680 [3.704] **

** - If the smooth drum with padfoot segments is used for PDB version, weights of the segments, liquid-filled tyres and blade
must be added to „D“ version weight (14550 kg [32,076 lb]). Total weight of this heaviest version is 18340 kg [40,432 lb].

The value specified in the table shall be deducted for machines without the cab. For a machine with roof, deduct the weight of
the cab and add 140 kg.

MACHINE ASC 150 D ASC 150 PD ASC 150 PDB

Weight cabin kg [lb] 220 [485] 220 [485] 220 [485]

Weight blade kg [lb] - - 910 [2,006]

For the mountain version of the machine (indicated by „H“ - e.g. ASC 150 HD; HDPD; PDBH), 480 kg (the weight of version H
accessories) must be added.

52
 2 - DESCRIPTION OF THE MACHINE

Operational weight of the machine ASC 200 in kg [lb] according to ISO 6016

MACHINE ASC 200 D ASC 200 PD ASC 200 PDB

Cab + ROPS frame * 20875 [46.020] 20945 [46.175] 22025 [48.556]

* - Smooth drum can be fitted with padfoots segments.

For machines with padfoots segments or liquid-filled tyres, weights specified in the following table must be added:

MACHINE ASC 200 D ASC 200 PD ASC 200 PDB

Weight of two tires with liquid filling in kg [lb] 1200 [2.646] 1200 [2.646] 1200 [2.646]

Weight of three pad-foot segments in kg [lb] 2625 [5.787] - 2625 [5.787] **

** - If the smooth drum with padfoot segments is used for PDB version, weights of the segments, liquid-filled tyres and blade
must be added to „D“ version weight (20875 kg [46,020 lb]). Total weight of this heaviest version is 25780 kg [56,840 lb].

The value specified in the table shall be deducted for machines without the cab. For a machine with roof, deduct the weight of
the cab and add 140 kg.

MACHINE ASC 200 D ASC 200 PD ASC 200 PDB

Weight cabin kg [lb] 220 [485] 220 [485] 220 [485]

Weight blade kg [lb] - - 1080 [2,381]

For the mountain version of the machine (indicated by „H“ - e.g. ASC 200 HD; HDPD; PDBH), 1200 kg [2,646 lb] (the weight
of version H accessories) must be added.

53
2 - DESCRIPTION OF THE MACHINE

Operational weight of the machine ASC 250 in kg [lb] according to ISO 6016

MACHINE ASC 250 D ASC 250 PD ASC 250 PDB

Cab + ROPS frame * 25500 [53.217] 25685 [56.625] 26785 [59.049]

* - Smooth drum can be fitted with padfoots segments.

For machines with padfoots segments or liquid-filled tyres, weights specified in the following table must be added:

MACHINE ASC 250 D ASC 250 PD ASC 250 PDB

Weight of three pad-foot segments in kg [lb] 2625 [5.787] - 2625 [5.787] **

** - If the smooth drum with padfoot segments is used for PDB version, weights of the segments, liquid-filled tyres and blade
must be added to „D“ version weight (25500 kg [56,217 lb]). Total weight of this heaviest version is 29225 kg [64,429 lb].

The value specified in the table shall be deducted for machines without the cab. For a machine with roof, deduct the weight of
the cab and add 140 kg.

MACHINE ASC 250 D ASC 250 PD ASC 250 PDB

Weight cabin kg [lb] 220 [485] 220 [485] 220 [485]

Weight blade kg [lb] - - 1100 [2,425]

For the mountain version of the machine (indicated by „H“ - e.g. ASC 250 HD; HDPD; PDBH), 1200 kg [2,646 lb] (the weight
of version H accessories) must be added.

54
 2 - DESCRIPTION OF THE MACHINE

BASIC DIMENSIONS

BASIC DIMENSIONS OF MODEL ASC 70

ASC 70 D ASC 70 PD ASC 70 PDB

Total length in mm [in] 5195 [204.5] 5195 [204.5] 5555 [218.7]

Total width in mm [in] 1880 [74] 1880 [74] 2215 [87.2]

Wheel base in mm [in] 2560 [100.8] 2560 [100.8] 2560 [100.8]

Wheel spacing in mm [in] 1300 [51.2] 1300 [51.2] 1300 [51.2]

Height including the cab in mm [in] 2840 [111.8] 2870 [111.8] 2840 [111.8]

Height including the ROPS frame in mm [in] 2870 [113] 2870 [113] 2870 [113]

Ground clearance in mm [in] 385 [15.2] 385 [15.2] 385 [15.2]

Amplitude of the frame in the vertical plane (±°) 12 12 12

Outer contour turning radius in mm [in] 4685 [184.4] 4685 [184.4] 5242 [206.3]

Inner contour turning radius in mm [in] 2985 [117.5] 2985 [117.5] 2863 [112.7]

Number of tires 2 2 2

Dimensions of the tires 14.9-24" 14.9-24" 14.9-24"

Filling pressure in kPa [PSI] 150 [21.7] 150 [21.7] 150 [21.7]

BASIC DIMENSIONS OF MODEL ASC 90

ASC 90 D ASC 90 PD ASC 90 PDB

Total length in mm [in] 5195 [204.5] 5195 [204.5] 5555 [218.7]

Total width in mm [in] 1930 [76] 1930 [76] 2215 [87.2]

Wheel base in mm [in] 2560 [100.8] 2560 [100.8] 2560 [100.8]

Wheel spacing in mm [in] 1300 [51.2] 1300 [51.2] 1300 [51.2]

Height including the cab in mm [in] 2840 [111.8] 2840 [111.8] 2840 [111.8]

Height including the ROPS frame in mm [in] 2870 [113] 2870 [113] 2870 [113]

Ground clearance in mm [in] 385 [15.2] 385 [15.2] 385 [15.2]

Amplitude of the frame in the vertical plane (±°) 12 12 12

Outer contour turning radius in mm [in] 4795 [188.8] 4795 [188.8] 5242 [206.3]

Inner contour turning radius in mm [in] 2985 [117.5] 2985 [117.5] 2863 [112.7]

Number of tires 2 2 2

Dimensions of the tires 14.9-24" 14.9-24" 14.9-24"

Filling pressure in kPa [PSI] 150 [21.7] 150 [21.7] 150 [21.7]

55
2 - DESCRIPTION OF THE MACHINE

BASIC DIMENSIONS OF MODEL ASC 110

ASC 110 D ASC 110 PD ASC 110 PDB

Total length in mm [in] 5686 [223.8] 5686 [223.8] 6094 [240]

Total width in mm [in] 2436 [95.9] 2436 [95.9] 2950 [116.1]

Wheel base in mm [in] 2820 [111] 2820 [111] 2820 [111]

Wheel spacing in mm [in] 1580 [62.2] 1580 [62.2] 1580 [62.2]

Height including the cab in mm [in] 3000 [118.1] 3000 [118.1] 3000 [118.1]

Height including the ROPS frame in mm [in] 3030 [119.3] 3030 [119.3] 3030 [119.3]

Ground clearance in mm [in] 420 [16.5] 420 [16.5] 420 [16.5]

Amplitude of the frame in the vertical plane (±°) 10 10 10

Outer contour turning radius in mm [in] 5370 [211.4] 5370 [211.4] 5738 [225.9]

Inner contour turning radius in mm [in] 2920 [115] 2920 [115] 2920 [115]

Number of tires 2 2 2

Dimensions of the tires 23.1 - 26" 23.1 - 26" 23.1 - 26"

Filling pressure in kPa [PSI] 160 [23.2] 160 [23.2] 160 [23.2]

BASIC DIMENSIONS OF MODEL ASC 150

ASC 150 D ASC 150 PD ASC 150 PDB

Total length in mm [in] 5686 [223.8] 5686 [223.8] 6094 [240]

Total width in mm [in] 2500 [98.4] 2500 [98.4] 2950 [116.1]

Wheel base in mm [in] 2820 [111] 2820 [111] 2820 [111]

Wheel spacing in mm [in] 1580 [62.2] 1580 [62.2] 1580 [62.2]

Height including the cab in mm [in] 3000 [118.1] 3000 [118.1] 3000 [118.1]

Height including the ROPS frame in mm [in] 3030 [119.3] 3030 [119.3] 3030 [119.3]

Ground clearance in mm [in] 420 [16.5] 420 [16.5] 420 [16.5]

Amplitude of the frame in the vertical plane (±°) 10 10 10

Outer contour turning radius in mm [in] 5395 [212.4] 5395 [212.4] 5738 [225.9]

Inner contour turning radius in mm [in] 2920 [115] 2920 [115] 2920 [115]

Number of tires 2 2 2

Dimensions of the tires 23.1 - 26" 23.1 - 26" 23.1 - 26"

Filling pressure in kPa [PSI] 160 [23.2] 160 [23.2] 160 [23.2]

56
 2 - DESCRIPTION OF THE MACHINE

BASIC DIMENSIONS OF MODEL ASC 200

ASC 200 D ASC 200 PD ASC 200 PDB

Total length in mm [in] 6300 [248] 6300 [248] 6790 [267]

Total width in mm [in] 2500 [98.4] 2500 [98.4] 3000 [118.1]

Wheel base in mm [in] 3160 [124.4] 3160 [124.4] 3160 [124.4]

Wheel spacing in mm [in] 1590 [62.5] 1590 [62.5] 1590 [62.5]

Height including the cab in mm [in] 3210 [126.4] 3210 [126.4] 3210 [126.4]

Height including the ROPS frame in mm [in] 3265 [128.5] 3265 [128.5] 3265 [128.5]

Ground clearance in mm [in] 500 [19.7] 500 [19.7] 500 [19.7]

Amplitude of the frame in the vertical plane (±°) 10 10 10

Outer contour turning radius in mm [in] 6280 [247.2] 6280 [247.2] 6615 [260]

Inner contour turning radius in mm [in] 3780 [148.8] 3780 [148.8] 3780 [148.8]

Number of tires 2 2 2

Dimensions of the tires 23.5 - 25" 23.5 - 25" 23.5 - 25"

Filling pressure in kPa [PSI] 150 [22] 150 [22] 150 [22]

BASIC DIMENSIONS OF MODEL ASC 250

ASC 250 D ASC 250 PD ASC 250 PDB

Total length in mm [in] 6560 [258.2] 6560 [258.2] 6990 [275.2]

Total width in mm [in] 2500 [98.4] 2500 [98.4] 3000 [118.1]

Wheel base in mm [in] 3290 [129.5] 3290 [129.5] 3290 [129.5]

Wheel spacing in mm [in] 1590 [62.5] 1590 [62.2] 1590 [62.2]

Height including the cab in mm [in] 3210 [126.4] 3210 [126.4] 3210 [126.4]

Height including the ROPS frame in mm [in] 3265 [128.5] 3265 [128.5] 3265 [128.5]

Ground clearance in mm [in] 500 [19.7] 500 [19.7] 500 [19.7]

Amplitude of the frame in the vertical plane (±°) 10 10 10

Outer contour turning radius in mm [in] 6315 [248.6] 6315 [248.6] 6820 [268.5]

Inner contour turning radius in mm [in] 3815 [150.2] 3815 [150.2] 3815 [150.2]

Number of tires 2 2 2

Dimensions of the tires 23.5 - 25" 23.5 - 25" 23.5 - 25"

Filling pressure in kPa [PSI] 150 [21.7] 150 [21.7] 150 [21.7]

57
2 - DESCRIPTION OF THE MACHINE

RIDING CHARACTERISTICS

Travelling speed - continuously controlled in both directions

ASC 70 D ASC 70 PD ASC 70 PDB
st
1 gear
Position of the shifter for the working speed
1st position of the pre-selector km/h 0 - 2,5 0 - 2,5 0 - 2,5
MPH 0 - 1.55 0 - 1.55 0 - 1.55
nd
2 position of the pre-selectorkm/h 0 - 3,5 0 - 3,5 0 - 3,5
MPH 0 - 2.17 0 - 2.17 0 - 2.17
3 rd position of the pre-selector km/h 0 - 4,7 0 - 4,8 0 - 4,8
MPH 0 - 2.92 0 - 2.98 0 - 2.98

2nd gear
Position of the shifter for the transport speed (hare)
Pre-selective gear control disengaged
km/h 0 - 11 0 - 11,1 0 - 11,1
MPH 0 - 6.83 0 - 6.89 0 - 6.89

ASC 70 HD ASC 70 HDPD ASC 70 PDBH

st
1 gear
Position of the shifter for the working speed
1st position of the pre-selector km/h 0 - 2,5 0 - 2,5 0 - 2,5
MPH 0 - 1,55 0 - 1,55 0 - 1,55
nd
2 position of the pre-selector km/h 0 - 3,0 0 - 3,0 0 - 3,0
MPH 0 - 1,86 0 - 1,86 0 - 1,86
3 rd position of the pre-selector km/h 0 - 3,6 0 - 3,7 0 - 3,7
MPH 0 - 2,23 0 - 2,3 0 - 2,3

2nd gear
Position of the shifter for the transport speed (hare)
Pre-selective gear control disengaged
km/h 0 - 8,4 0 - 8,5 0 - 8,5
MPH 0 - 5,22 0 - 5,28 0 - 5,28

58
 2 - DESCRIPTION OF THE MACHINE

ASC 90 D ASC 90 PD ASC 90 PDB

1st gear
Position of the shifter for the working speed
1st position of the pre-selector km/h 0 - 2,5 0 - 2,5 0 - 2,5
MPH 0 - 1.55 0 - 1.55 0 - 1.55
2nd position of the pre-selector km/h 0 - 3,5 0 - 3,5 0 - 3,5
MPH 0 - 2.17 0 - 2.17 0 - 2.17
rd
3 position of the pre-selector km/h 0 - 4,7 0 - 4,8 0 - 4,8
MPH 0 - 2.92 0 - 2.98 0 - 2.98

2nd gear
Position of the shifter for the transport speed (hare)
Pre-selective gear control disengaged
km/h 0 - 11,0 0 - 11,1 0 - 11,1
MPH 0 - 6.83 0 - 6.89 0 - 6.89

ASC 90 HD ASC 90 HDPD ASC 90 PDBH

1st gear
Position of the shifter for the working speed
1st position of the pre-selector km/h 0 - 2,5 0 - 2,5 0 - 2,5
MPH 0 - 1,55 0 - 1,55 0 - 1,55
2nd position of the pre-selector km/h 0 - 3,0 0 - 3,0 0 - 3,0
MPH 0 - 1,86 0 - 1,86 0 - 1,86
rd
3 position of the pre-selector km/h 0 - 3,6 0 - 3,7 0 - 3,7
MPH 0 - 2,23 0 - 2,3 0 - 2,3

2nd gear
Position of the shifter for the transport speed (hare)
Pre-selective gear control disengaged
km/h 0 - 8,4 0 - 8,5 0 - 8,5
MPH 0 - 5,22 0 - 5,28 0 - 5,28

59
2 - DESCRIPTION OF THE MACHINE

ASC 110 D ASC 110 PD ASC 110 PDB

1st gear
Position of the shifter for the working speed
1st position of the pre-selector km/h 0 - 2,5 0 - 2,5 0-2,5
MPH 0 - 1.55 0 - 1.55 0 - 1.55
2nd position of the pre-selectorkm/h 0 - 3,5 0 - 3,5 0 - 3,5
MPH 0 - 2.17 0 - 2.17 0 - 2.17
rd
3 position of the pre-selector km/h 0 - 5,3 0 - 5,4 0 - 5,4
MPH 0 - 3.29 0 - 3.35 0 - 3.35

2nd gear
Position of the shifter for the transport speed (hare)
Pre-selective gear control disengaged
km/h 0 - 10,6 0 - 10,7 0 - 10,7
MPH 0 - 6.58 0 - 6.64 0 - 6.64

ASC 110 HD ASC 110 HDPD ASC 110 PDBH

1st gear
Position of the shifter for the working speed
1st position of the pre-selector km/h 0 - 2,4 0 - 2,4 0 - 2,4
MPH 0 - 1,49 0 - 1,49 0 - 1,49
2nd position of the pre-selector km/h 0 - 3,1 0 - 3,1 0 - 3,1
MPH 0 - 1,93 0 - 1,93 0 - 1,93
rd
3 position of the pre-selector km/h 0 - 3,8 0 - 3,8 0 - 3,8
MPH 0 - 2,36 0 - 2,36 0 - 2,36

2nd gear
Position of the shifter for the transport speed (hare)
Pre-selective gear control disengaged
km/h 0 - 8,0 0 - 8,0 0 - 8,0
MPH 0 - 4,97 0 - 4,97 0 - 4,97

60
 2 - DESCRIPTION OF THE MACHINE

ASC 150 D ASC 150 PD ASC 150 PDB

1st gear
Position of the shifter for the working speed
1st position of the pre-selector km/h 0 - 2,5 0 - 2,5 0 - 2,5
MPH 0 - 1.55 0 - 1.55 0 - 1.55
2nd position of the pre-selector km/h 0 - 3,5 0 - 3,5 0 - 3,5
MPH 0 - 2.17 0 - 2.17 0 - 2.17
rd
3 position of the pre-selector km/h 0 - 4,5 0 - 4,6 0 - 4,6
MPH 0 - 2.8 0 - 2.86 0 - 2.86

2nd gear
Position of the shifter for the transport speed (hare)
Pre-selective gear control disengaged
km/h 0 - 10 0 - 10,1 0 - 10,1
MPH 0 - 6.2 0 - 6.27 0 - 6.27

ASC 150 HD ASC 150 HDPD ASC 150 PDBH

1st gear
Position of the shifter for the working speed
1st position of the pre-selector km/h 0 - 2,4 0 - 2,4 0 - 2,4
MPH 0 - 1,49 0 - 1,49 0 - 1,49
2nd position of the pre-selector km/h 0 - 2,8 0 - 2,8 0 - 2,8
MPH 0 - 1,74 0 - 1,74 0 - 1,74
rd
3 position of the pre-selector km/h 0 - 3,15 0 - 3,15 0 - 3,15
MPH 0 - 1,96 0 - 1,96 0 - 1,96

2nd gear
Position of the shifter for the transport speed (hare)
Pre-selective gear control disengaged
km/h 0 - 7,0 0 - 7,0 0 - 7,0
(MPH) 0 - 4,35 0 - 4,35 0 - 4,35

61
2 - DESCRIPTION OF THE MACHINE

ASC 200 D ASC 200 PD ASC 200 PDB

1st gear
Position of the shifter for the working speed
1st position of the pre-selector km/h 0 - 2,5 0 - 2,5 0 - 2,5
MPH 0 - 1.55 0 - 1.55 0 - 1.55
2nd position of the pre-selector km/h 0 - 3,2 0 - 3,2 0 - 3,2
MPH 0 - 1.99 0 - 1.99 0 - 1.99
rd
3 position of the pre-selector km/h 0 - 3,8 0 - 3,9 0 - 3,9
MPH 0 - 2.42 0 - 2.42 0 - 2.42

2nd gear
Position of the shifter for the transport speed (hare)
Pre-selective gear control disengaged
km/h 0 - 10,5 0 - 10,6 0 - 10,6
MPH 0 - 6.52 0 - 6.58 0 - 6.58

ASC 200 HD ASC 200 HDPD ASC 200 PDBH

1st gear
Position of the shifter for the working speed
1st position of the pre-selector km/h 0 - 1,8 0 - 1,8 0 - 1,8
MPH 0 - 1,12 0 - 1,12 0 - 1,12
2nd position of the pre-selector km/h 0 - 2,5 0 - 2,5 0 - 2,5
MPH 0 - 1,55 0 - 1,55 0 - 1,55
rd
3 position of the pre-selector km/h 0 - 3,3 0 - 3,3 0 - 3,3
MPH 0 - 2,05 0 -2,05 0 - 2,05

2nd gear
Position of the shifter for the transport speed (hare)
Pre-selective gear control disengaged
km/h 0 - 7,5 0 - 7 ,6 0 - 7,6
MPH 0 - 4,66 0 - 4,66 0 - 4,66

62
 2 - DESCRIPTION OF THE MACHINE

ASC 250 D ASC 250 PD ASC 250 PDB

1st gear
Position of the shifter for the working speed
1st position of the pre-selector km/h 0 - 2,5 0 - 2,5 0 - 2,5
MPH 0 - 1.55 0 - 1.55 0 - 1.55
2nd position of the pre-selector km/h 0-3 0-3 0-3
MPH 0 - 1.86 0 - 1.86 0 - 1.86
rd
3 position of the pre-selector km/h 0 - 3,5 0 - 3,6 0 - 3,6
MPH 0 - 2.17 0 - 2.24 0 - 2.24

2nd gear
Position of the shifter for the transport speed (hare)
Pre-selective gear control disengaged
km/h 0 - 10 0 - 10 0 - 10,1
MPH 0 - 6.2 0 - 6.2 0 - 6.3

ASC 250 HD ASC 250 HDPD ASC 250 PDBH

1st gear
Position of the shifter for the working speed
1st position of the pre-selector km/h 0 - 1,8 0 - 1,8 0 - 1,8
MPH 0 - 1,12 0 - 1,12 0 - 1,12
2nd position of the pre-selector km/h 0 - 2,4 0 - 2,4 0 - 2,4
MPH 0 - 1,49 0 - 1,49 0 - 1,49
rd
3 position of the pre-selector km/h 0 - 3,0 0 - 3,0 0 - 3,0
MPH 0 - 1,86 0 - 1,86 0 - 1,86

2nd gear
Position of the shifter for the transport speed (hare)
Pre-selective gear control disengaged
km/h 0 - 8,7 0 - 8,7 0 - 8,7
MPH 0 - 5,4 0 - 5,4 0 - 5,4

63
2 - DESCRIPTION OF THE MACHINE

Practical climbing ability ASC 70 D ASC 70 PD

- without vibration % 45 45
- with vibration % 45 45
ASC 70 HD ASC 70 HDPD ASC 70 PDBH
- without vibration % 60 60 60
- with vibration % 60 60 60

ASC 90 D ASC 90 PD ASC 90 PDB

- without vibration % 45 45 45
- with vibration % 45 45 45
ASC 90 HD ASC 90 HDPD ASC 90 PDBH
- without vibration % 55 55 55
- with vibration % 55 55 55

ASC 110 D ASC 110 PD ASC 110 PDB

- without vibration % 45 45 45
- with vibration % 45 45 45
ASC 110 HD ASC 110 HDPD ASC 110 PDBH
- without vibration % 60 60 55
- with vibration % 60 60 55

ASC 150 D ASC 150 PD ASC 150 PDB

- without vibration % 45 45 45
- with vibration % 45 45 45
ASC 150 HD ASC 150 HDPD ASC 150 PDBH
- without vibration % 60 60 55
- with vibration % 60 60 55

ASC 200 D ASC 200 PD ASC 200 PDB

- without vibration % 50 55 55
- with vibration % 50 55 55
ASC 200 HD ASC 200 HDPD ASC 200 PDBH
- without vibration % 60 60 60
- with vibration % 60 60 60

ASC 250 D ASC 250 PD ASC 250 PDB

- without vibration % 45 50 50
- with vibration % 45 50 50
ASC 250 HD ASC 250 HDPD ASC 250 PDBH
- without vibration % 60 60 60
- with vibration % 60 60 60

64
 2 - DESCRIPTION OF THE MACHINE

Vibration frequency ASC 70 D;HD ASC 70 PD;HDPD ASC 70 PDB;PDBH

Hz 30/40 30/40 30/40
VPM [1800/2400] [1800/2400] [1800/2400]

ASC 90 D;HD ASC 90 PD;HDPD ASC90 PDB;PDBH

Hz 30/40 30/40 30/40
VPM [1800/2400] [1800/2400] [1800/2400]

ASC 110 D;HD ASC 110 PD;HDPD ASC 110 PDB;PDBH

Hz 32/35 32/35 32/35
VPM [1920/2100] [1920/2100] [1920/2100]

ASC 150 D;HD ASC 150 PD;HDPD ASC 150 PDB;PDBH

Hz 29/35 29/35 29/35
VPM [1740/2100] [1740/2100] [1740/2100]

ASC 200 D;HD ASC 200 PD;HDPD ASC 200 PDB;PDBH

Hz 28/34 28/34 28/34
VPM [1680/2040] [1680/2040] [1680/2040]

ASC 250 D;HD ASC 250 PD;HDPD ASC 250 PDB;PDBH

Hz 28/34 28/34 28/34
VPM [1680/2040] [1680/2040] [1680/2040]

Amplitude ASC 70 D;HD ASC 70 PD;HDPD ASC 70 PDB;PDBH

mm 1,7/0,86 1,7/0,86 1,7/0,86
in [0.069/0.0338] [0.069/0.0338] [0.069/0.0338]
ASC 90 D;HD ASC 90 PD;HDPD ASC90 PDB;PDBH
mm 1,85/0,96 1,85/0,96 1,85/0,96
in [0.073/0.0378] [0.073/0.0378] [0.073/0.0378]
ASC 110 D;HD ASC 110 PD;HDPD ASC 110 PDB;PDBH
mm 1,85/1,15 1,85/1,15 1,85/1,15
in [0.073/0.045] [0.073/0.045] [0.073/0.045]
ASC 150 D;HD ASC 150 PD;HDPD ASC 150 PDB;PDBH
mm 2,0/1,0 2,0/1,0 2,0/1,0
in [0.079/0.039] [0.079/0.039] [0.079/0.039]
ASC 200 D;HD ASC 200 PD;HDPD ASC 200 PDB;PDBH
mm 2,0/1,0 2,0/1,0 2,0/1,0
in [0.087/0.039] [0.087/0.039] [0.087/0.039]
ASC 250 D;HD ASC 250 PD;HDPD ASC 250 PDB;PDBH
mm 2,2/1,1 2,2/1,1 2,2/1,1
in [0.086/0.043] [0.086/0.043] [0.086/0.043]

65
2 - DESCRIPTION OF THE MACHINE

FLUID CONTENTS

ASC 70/90
Engine (oil filling) l [gal US] 11,2 [2.96]
Cooling system l [gal US] 19,0 [5.0]
Fuel l [gal US] 275,0 [72.7]
Hydraulic system l [gal US] 73,0 [19.3]
Drum gearbox l [gal US] 2,5 [0.66]
Wheel gears l [gal US] 2x2,5 [2x0.66]
Vibrating drum l [gal US] 6,7 [1.77]
Windshield washer bowl l [gal US] 2,75 [0.72]

ASC 110/150
Engine (oil filling) l [gal US] 16,3 [4.3]
Cooling system l [gal US] 25,0 [6.6]
Fuel l [gal US] 410,0 [108.3]
Hydraulic system l [gal US] 90,0 [23.8]
Drum gearbox l [gal US] 4,2 [1.11]
Wheel gears l [gal US] 2x2,8 [2x0.74]
Vibrating drum l [gal US] 8,0 [2.1]
Windshield washer bowl l [gal US] 2,75 [0.72]

ASC 200/250
Engine (oil filling) l [gal US] 14,3 [3.78]
Cooling system l [gal US] 30,0 [7.9]
Fuel l [gal US] 405,0 [107.0]
Hydraulic system l [gal US] 100,0 [26.4]
Drum gearbox l [gal US] 7,7 [2.0]
Wheel gears l [gal US] 2x4,4 [2x1.2]
Vibrating drum l [gal US] 7,5 [1.98]
Windshield washer bowl l [gal US] 2,7 [0.71]
Cooling system of the Drum l [gal US] 185[48.9]

66
 2 - DESCRIPTION OF THE MACHINE

ELECTRICAL INSTALLATION

ASC 70/90
Voltage V 24
Batteries Ah 2 x 61

ASC 110/150
Voltage V 24
Batteries Ah 2 x 100

ASC 200/250
Voltage V 24
Batteries Ah 2 x 100

67
3 - REMOVING THE ENGINE

3 - REMOVING THE ENGINE

TECHNICAL DATA

ASC 70/90 - TIER I

Manufacturer Cummins Diesel
Type of the engine B3.9-C99
Serial number ................
Number of cylinders 4
Cylinder bore mm [in] 102 [4.02]
Stroke mm [in] 120 [4.72]
Total stroke capacity cm3 [cu in] 3900 [239]
Output of the engine ISO 3046/1 (DIN 6271) kW [HP] 74 [99]
Specific speed - revolutions per minute min-1 [RPM] 2200
Maximum torque Nm [ft lb] 407 [300] / 1400 min-1 RPM
Specific fuel consumption at nominal output g/kWh 237
Fuel consumption at normal operation ASC 70 l/h [gal US/h] 9 [2.4]
Filters of Fleetguard fuel 1xFF 1280(3925274) and 1xFF 5052(3903640) *
Oil filter LF 3345 (Fleetguard)*
Air filter Donaldson FLG 08-0377
Air filter element Donaldson P77-2550
Safety air filter element Donaldson P11-9410
Cooling system of the engine water cooled engine with radiator 42420
Clutch CENTA CF-H-030-1 Sa 02

* Precise denomination of the parts is given in the specific supply from the engine manufacturer. If you want to order spare
parts, always give serial number of the engine.

ASC 70/90 - TIER II

Make Cummins Diesel
Type B4.5 C 99
Serial number ................
Number of cylinders 4
Bore mm (in) 102 (4,02)
Stroke mm (in) 138 (5,42)
Total displacement cm3 (cu in) 4500 (275)
Output according to ISO 3046/1 (DIN 6271) kW (HP) 74 (99)
Rated speed min-1 (RPM) 2200
Maximal torque Nm (ft lb) 414 (305) /1500 min-1 (RPM)
Specific fuel consumption at rated speed g/kWh 235
Fuel speed at normal operation l/h (gal US/h) 9 (2,4)
Fuel cleaners - Fleetguard Fleetguard 1x FS 1960800*
Oil cleaner - Fleetguard Fleetguard LF 0380500*
Air cleaner Donaldson FLG 08-0377
Air filter element P77-2550
Air filter safety element P11-9410
Cooling system liquid cooled engine with cooler 42420
Coupling CENTA CF-H-030-1 Sa 02

Engine fulfills requirements of DIR 97/68/EU STAGE 2

EPA/CARB 40 CFR Part 89 TIER 2

*/ The kind and marking can vary (delivery with the Cummins engine), when ordering the spare parts always indicate the own
engine number.

68
 3 - REMOVING THE ENGINE

ASC 110/150 - TIER I

Manufacturer Cummins Diesel
Type of the engine B5.9-C148
Serial number ................
Number of cylinders 6
Cylinder bore mm (in) 102 (4.02)
Stroke mm (in) 120 (4.72)
Total stroke capacity cm3 (cu in) 5880 (359)
Output of the engine ISO 3046/1 (DIN 6271) kW (HP) 110 (148)
-1
Specific speed - revolutions per minute min (RPM) 2200
Maximum torque Nm (ft lb) 597 (440) / 1600 min-1 RPM
Specific fuel consumption at nominal output g/kWh 234
Fuel consumption at normal operation ASC 110 l/h (gal US/h) 11,8 (3.12)
Fuel consumption at normal operation ASC 150 l/h (gal US/h) 12,5 (3.3)
Filters of Fleetguard fuel 1xFF 1280(3925274) and 1xFF 5052(3903640) *
Oil filter LF 3349 (Fleetguard)*
Air filter Donaldson FLG 10-0220
Air filter element Donaldson P77-2555
Safety air filter element Donaldson P13-3138
Cooling system of the engine water cooled engine with radiator 34299
Clutch CENTA CF-H-030-1 Sa 03
Engine fulfills requirements of 97/68/EC, EPA, CARB.
* Precise denomination of the parts is given in the specific supply from the engine manufacturer. If you want to order spare
parts, always give serial number of the engine.

ASC 110/150 - TIER II

Make Cummins Diesel
Type QSB5.9-C155
Serial number ................
Number of cylinders 6
Bore mm (in) 102 (4,02)
Stroke mm (in) 120 (4,72)
Total displacement cm3 (cu in) 5880 (359)
Output according to ISO 3046/1 (DIN 6271) kW (HP) 116 (155)
-1
Rated speed min (RPM) 2200
Maximal torque Nm (ft lb) 597 (440) /1500 min-1 (RPM)
Specific fuel consumption at rated speed g/kWh 234
Fuel speed at normal operation l/h (gal US/h) ASC 110 - 11,8 (3,12), ASC 150 - 12,5 (3,3)
Fuel cleaners - Fleetguard FS19616*
Oil cleaner - Fleetguard LF 3959*
Air cleaner Donaldson FLG 10-0220
Air filter element Donaldson P77-2555
Air filter safety element Donaldson P13-3138
Cooling system liquid cooled engine with cooler 34299
Coupling CENTA CF-H-030-1 Sa 03
Engine fulfills requirements of: Dir. 97/68/EU Stage 2
EPA/CARB 40 CFR Part 89 Tier 2
* Exact denomination of these parts is dependent on modification of the engine. For spare parts ordering always refer to the
serial number of your engine.

69
3 - REMOVING THE ENGINE

ASC 200/250 - TIER I

Manufacturer Cummins Diesel
Type B5.9-C148
Serial number ................
Number of cylinders 6
Bore mm [in] 102 [4.02]
Stroke mm (in) 120 [4.72]
Total displacement cm3 (cu in) 5880 [359]
Output according to ISO 3046/1 (DIN 6271) kW [HP] 110[148]
-1
Rated speed min [RPM] 2200
Maximal torque Nm [ft lb] 597 [440] /1600 min-1 [RPM]
Specific fuel consumption at rated speed g/kWh 234
Fuel consumption at normal operation ASC 200 l/h [gal US/h] 11,8 [3.12]
Fuel consumption at normal operation ASC 250 l/h [gal US/h] 12,5 [3.3]
Fuel cleaners - Fleetguard 1x FF 1280 (3925274) and 1x FF 5052 (3903640)*
Oil cleaner LF 3349 (Fleetguard)*
Air cleaner Donaldson FLG 10-0220
Air filter element Donaldson P77-2555
Air filter safety element Donaldson P13-3
Engine fulfills requirements of 97/68/EC, EPA, CARB.
* Precise denomination of the parts is given in the specific supply from the engine manufacturer. If you want to order spare
parts, always give serial number of the engine.

ASC 200/250 - TIER I

Make Cummins Diesel
Type QSB5.9-C205
Serial number ................
Number of cylinders 6
Bore mm (in) 102 (4,02)
Stroke mm (in) 120 (4,72)
Total displacement cm3 (cu in) 5900 (360)
Output according to ISO 3046/1 (DIN 6271) kW (HP) 153 (205)
Rated speed min-1 (RPM) 2500
Maximal torque Nm (ft lb) 847 (625) /1500 min-1 (RPM)
Specific fuel consumption at rated speed g/kWh (lb/hp-hr) 222 (0,365)
Fuel speed at normal operation l/h (gal US/h) ASC 200: 20,3 (5,36)
ASC 250: 21,1 (5,6)
Fuel cleaners - Fleetguard FS 19519*
Oil cleaner - Fleetguard LF 3970*
Air cleaner Donaldson FLG 12-0309
Air filter element Donaldson P77-2531
Air filter safety element Donaldson P77-0678
Cooling system liquid cooled engine with cooler 48910
Coupling CENTA CF-H-030-1 Sa 03
Engine fulfills requirements of Dir. 97/68/EU Stage 2
EPA/CARB 40 CFR Part 89 Tier 2
* Exact denomination of these parts is dependent on modification of the engine. For spare parts ordering always refer to the
serial number of your engine.

70
 3 - REMOVING THE ENGINE

MOTOR OILS AND LUBRICATING GREASE

Engine oil - API CE/SG, SAE 15W/40

Quantity l [gal US]

ASC 70/90 11,2 [2.96]

ASC 110/150 16,3 [3.4]

ASC 200/250 14,3 [3.78]

L u b r i c a t i n g g r e a s e - ma r k

Benzi na Mo b i l ES SO SHELL CASTROL

PM- L A- 2 Mo bi l gr e a s e SPECI AL Mu l t i - P u r po s e Ret i nax A Cast r ol ease LM

Mo bi l gr e a s e MP Gr eas e H Al vani a Spher ol

Mo b i l p l e x E P- 1 Gr eas e No 3 Gr eas e RBB 2

Coolant fluid in engine

Quantity l [gal US]

ASC 70/90 19 [5.5]

ASC 110/150 25 [6.6]

ASC 200/250 30 [7.9]

Coolant is a mixture consisting of treated demineralized or distilled water and antifreeze ethylene glycol. Coolant can be also
prepared from a propylene glycol antifreeze. Minimum portion of the ethylene glycol or propylene glycol antifreeze in the coolant
is 40 %. Temperature limits of coolant at different contents of ethylene glycol or propylene glycol in the liquids used are given
in the following table:

antifreeze with ethylene glycol antifreeze with propylene glycol

40 % = –23 °C [10 °F] 40 % = –21 °C [–6 °F]

50 % = –37 °C [–34 °F] 50 % = –33 °C [–27 °F]

60 % = –54 °C [-65 °F] 60 % = –49 °C [–56 °F]

68 % = –71 °C [–96 °F] 68 % = –63 °C [–82 °F]

71
3 - REMOVING THE ENGINE

Water for preparation of the coolant should be used according to the criteria given in the following table:
Liquids

Water quality Min. Max.

pH factor at 20 °C [68 °F] 6,5 8,5

Content of chlorides (mg/dm3) – 100

Content of sulfates (mg/dm3) – 100

Total hardness (°dGH) 3 12

The liquids used must contain anticorrosive additives protecting all materials in the cooling system including rubber and the
head gasket. Liquids should not be mixed together with those of other marks. They must correspond to testing criteria as given
in ASTM 4985 such as:
Fridex Stabil
BP - Antifreeze
SHELL - GLYCOSHELL - S
ÖMV - 5125 KÜHLER - frostschutz
SUNOCO ANTIFREEZE
CASTROL ANTI-FREEZE
Do not use a greater portion of the frost proof cooling agent in coolant than 50 % if it is not necessary.
Never use proportion greater than 68 %.

72
 3 - 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
chapter „Safety Instructions“. Ecological measures and HEAL-
TH principles must be kept as well.

73
3 - REMOVING THE ENGINE

DISMANTLING OF THE ENGINE

Lift the hood, support by fixture no.1 in lifted position

Disconnect electrical wiring

1 1

74
 3 - REMOVING THE ENGINE

Press out pins from piston ends in lifting hydraulic motors,

secure by fixture no. 2.

Install fixture no. 3, lower the hood, support

Remove hinges

75
3 - REMOVING THE ENGINE

Attach hooks of fixture no. 3.

Set hood aside using fixture no. 3.

76
 3 - REMOVING THE ENGINE

Loosen pouring throat, drain coolant.

Disconnect hoses 27, 28 and rubber elbow 35. Remove

hoses 83, 84 to the hydraulic oil radiator, plug up outlets.
27

35

83

84

77
3 - REMOVING THE ENGINE

Remove holders 8.

Loosen bolts 53.

53

Suspend radiator by hooks, set aside.

78
 3 - REMOVING THE ENGINE

Remove cover of hydraulic tank

Remove suction hose 51 from hydraulic tank to steering

pump.

51

79
3 - REMOVING THE ENGINE

Plug up outlet.

Disconnect hoses to steering pump, plug up.

Loosen bolt of clamp 23 on the turbo.

23 23

80
 3 - REMOVING THE ENGINE

Remove four bolts 28 on the air filter holder.

28

Disconnect wiring to filter sensor, set filter aside.

Loosen clamp on exhaust pipe 3.

81
3 - REMOVING THE ENGINE

Remove bolts of exhaust pipe holder 31.

31

Set muffler aside.

Plug up outlets

82
 3 - REMOVING THE ENGINE

Disconnect all wires – ground strip, starter wires, alternator

wires, water temperature and oil pressure sensor RPM meter,
and injection pump solenoid.

Disconnect cable to gas control

83
3 - REMOVING THE ENGINE

Disconnect intake and overflow of fuel.

Lift the cabin using hydraulic lift, then use crane to unload
the piston of the lifting hydraulic motor using fixture no.1.
1

Remove bolts 53.

Set rubber wall aside.

53

84
 3 - REMOVING THE ENGINE

Remove bolts 47 from flange 12.

47 12

Suspend pump on crane.

Slide out of the clutch 86, support.

86

85
3 - REMOVING THE ENGINE

Remove nuts of front engine silencing blocks 64.

64

Remove nuts of rear silencing blocks 64.

64

Suspend engine on crane by hooks

86
 3 - REMOVING THE ENGINE

Extract, set aside on support no. 4.

4 4

87
3 - REMOVING THE ENGINE

Failure Cause Remedy

Engine cannot Empty fuel tank. Replenish fuel and deareate the fuel system.
be started
and starter is
turning. Untightness of the fuel system. Inspect the connections, if tight; remove
untightness. Prime fuel with the hand priming pump.

Aerated fuel system. Deareate the fuel system.

Clogged pre-cleaner, fuel cleaners or distribution
system.
Clogged pre-cleaner, fuel cleaners or distribution
system by paraffin sediments during winter.
The starter turns slowly - poorly charged battery,
oxided terminals or loose clamps at the terminals.
Too dense oil used in winter.
The engine gets stopped after starting by the "engine
stop“ device, the indicator of hydraulic oil level is on.
The engine gets stopped after starting by the "engine
stop" device, the indicator of hydraulic oil level is off.
Faulty delivery valve at the injection pump.
Clean the distribution system and replace
the filter elements.
Clean the system, use the winter-grade fuel.
Inspect shape of the battery, replenish electrolyte.
Clean the contacts, grease and tighten the clamps.
Use oil suitable for the actual ambient temperature.
Replenish hydraulic oil up to the prescribed level.
Check the indicator of hydraulic oil level. Check
voltage at the engine STOP magnet Y5 (inspect the
fuse F3, cables, relay K3, connectors).
Let it to be inspected by the engine manufacturer’s
service.

Engine cannot The electrical system of the machine is Turn the battery disconnector to turn on the
be started and disconnected. electrical system.
starter is not
turning. Conditions of starting are not kept. The tilting arm with the travel control is lifted, or the
push button of the emergency brake is depressed.

The travel control is out of the neutral position and Put the travel control into the neutral position.
the indicator of neutral position is off.

Faulty battery of connections. Test the battery voltage, check the cables and
connections.
Starter. Inspect connection of the starter, check, if the pinion
shifts out.
Switch box. Check function and connection of the switch box
(cables, function of the relay K4, terminal switches
S13, S10, S11, terminals etc.).
Mechanical failure of the engine, the clutch or the Verify, if the engine can rotate, by turning the belt
hydrostatic system. pulley at the crankshaft.

88
 3 - REMOVING THE ENGINE

Failure Cause Remedy

The engine is Shortage of coolant. Quickly stop the engine, replenish coolant, find the
getting untightness and repair it.
overheated.
Clogged coolant radiator. Clean the radiator.
Failure of the belt tensioning, or broken belt. Repair the failure, replace the belt.

Improperly working thermostat. Verify function of the thermostat; replace if

necessary.
Considerable amount of dirt and sediments in the cooling Clean the cooling circuit.
circuit.
Faulty injection nozzles. Let expert to check them.
Improperly adjusted fuel volume supplied by Let to be adjusted in a specialized workshop.
the injection pump.
Ambient temperature too high. Work for a limited time and allow the engine to
cool down.
Improperly adjusted beginning of injection. Let expert to check it.
The engine is Engine oil level too low. Replenish oil.
not sufficiently
lubricated - Engine oil is leaking. Immediately stop the engine, inspect connections
the indicator of the lubrication system and repair the
of lubrication is untightness.
on. Used oil is of improper viscosity. Exchange oil for a recommended sort.
Overheated engine. Allow the engine to cool down. Seek for the
reason.
The engine runs Aerated fuel system. Deareate the fuel system, repair the untightness.
irregularly, with
low output.
Faulty injection nozzles. Let expert to check it.
Improper valve clearance. Let expert to check it.
Broken injection pipe. Let expert to check it.
Improperly adjusted injection pump. Let expert to check it.
The engine Increased underpressure in the inlet branch Check function of the underpressure switch.
excessively of the engine. Replace the filter elements if needed.
smokes.
Oil level too high. Lower oil level to the upper mark at the dipstick.

Poor compression due to burned or broken piston rings, Let the piston rings to be tested in a specia-lized
or due to wrong valve clearance. workshop; adjust the valve clearance.
Excessive oil Untight oil system. Repair the untightness.
consumption.
Untight piston rings, or generally worn engine. Let expert to check it.

The engine has Excessively clogged fuel cleaners. Replace the filter elements.
not sufficient
output. Wrong valve clearance. Adjust valve clearance.

Clogged holes of the injection nozzles; the injectors are Let expert to check it.
not adjusted to correct injection pressure.
Improperly adjusted injection pump. Improperly adjusted Let expert to check it.
advanced injection angle. The cylinders have not sufficient
compression pressure. Failure of the turbocharger.
Further possible failures are described in the instruction manual of the engine, which is supplied with the machine.

89
3 - REMOVING THE ENGINE

FIXTURES

no. 1 Installation – ND080080 (cab support)

no. 2 Installation – ND080220 (securing hydraulic cylin-

ders of hood lifting)

no. 3 Handling – ND101778 (hooks for installation of

hood)

no. 4 Installation ND080183 (engine support)

90
3 - REMOVING THE ENGINE

91
4 - DRUM REMOVAL

4 - DRUM REMOVAL

Attention! The mounting of the drum in the frame is different in roller ASC 200/250 compared to roller series ASC 70÷150. Please pay
attention to the text and illustrations pointing out these differences in order to prevent injuries and damage to replaced parts. Please
use recommended fixtures and special tools.

TECHNICAL DATA

DESCRIPTION

Vibrating drum together with the driving lugs is fixed to both sides of the front frame using rubberized metal pieces of the prescribed
stiffness. The vibration effect is generated by means of two eccentric pairs located on both sides of the drum. The eccentric pieces
are joined by a shaft, and actuated by a hydraulic motor that is located on the left side of the drum. The drum is driven by a hydraulic
motor located on the right side of the drum.

TECHNICAL DATA

Mo d e l AS C 7 0 D AS C 7 0 P D AS C 7 0 P D B

D rum di ameter mm [i n] 1300 [51.2] 1240 [48.8] 1240 [48.8]

D rum di ameter over the foot pads mm [i n] 1400 [55.1] 1400 [55.1]

D rum wi dth mm [i n] 1680 [65.7] 1680 [65.7] 1680 [65.7]

D rum thi ckness mm [i n] 25 [0.98] 15 [0.59] 15 [0.59]

Number of foot pads - - 104 104

Foot pad di mensi on mm [i n] - 80 [3.15] 80 [3.15]

Mo d e l AS C 9 0 D AS C 9 0 P D AS C 9 0 P D B

D rum di ameter mm [i n] 1300 [51.2] 1240 [48.8] 1240 [48.8]

D rum di ameter over the foot pads mm [i n] - 1400 [55.1] 1400 [55.1]

D rum wi dth mm [i n] 1680 [65.7] 1680 [65.7] 1680 [65.7]

D rum thi ckness mm [i n] 25 [0.98] 15 [0.59] 15 [0.59]

Number of foot pads - 104 104

Foot pad di mensi on mm [i n] - 80 [3.15] 80 [3.15]

92
 4 - DRUM REMOVAL

Mo d e l AS C 11 0 D AS C 11 0 P D AS C 11 0 P D B

D rum di ameter mm [i n] 1500 [59.0] 1440 [56.7] 1440 [56.7]

D rum di ameter over the foot pads mm [i n] 1640 [64.6] 1640 [64.6]

D rum wi dth mm [i n] 2200 [86.6] 2200 [86.6] 2200 [86.6]

D rum thi ckness mm [i n] 25 [0.98] 20 [0.79] 20 [0.79]

Number of foot pads 150 150

Foot pad di mensi on mm [i n] 100 [3.93] 100 [3.93]

Mo d e l AS C 1 5 0 D AS C 1 5 0 P D AS C 1 5 0 P D B

D rum di ameter mm [i n] 1500 [59.0] 1440 [56.7] 1440 [56.7]

D rum di ameter over the foot pads mm [i n] - 1640 [64.6] 1640 [64.6]

D rum wi dth mm [i n] 2200 [86,6] 2200 [86.6] 2200 [86.6]

D rum thi ckness mm [i n] 40 [1.57] 28 [1.1] 28 [1.1]

Number of foot pads - 140 140

Foot pad di mensi on mm [i n] - 100 [3.93] 100 [3.93]

Mo d e l AS C 2 0 0 D AS C 2 0 0 P D AS C 2 0 0 P D B

D rum di ameter mm [i n] 1700 [67.0] 1600 [63.0] 1600 [63.0]

D rum di ameter over the foot pads mm [i n] - 1840 [72.5] 1840 [72.5]

D rum wi dth mm [i n] 2240 [88.25] 2240 [88.25] 2240 [88.25]

D rum thi ckness mm [i n] 45 [1.77] 30 [1.18] 30 [1.18]

Number of foot pads - 150 150

Foot pad di mensi on mm [i n] - 120 [4.73] 120 [4.73]

Mo d e l AS C 2 5 0 D AS C 2 5 0 P D AS C 2 5 0 P D B

D rum di ameter mm [i n] 1700 [67.0] 1600 [63.0] 1600 [63.0]

D rum di ameter over the foot pads mm [i n] - 1908 [75.1] 1908 [75.1]

D rum wi dth mm [i n] 2240 [88.25] 2240 [88.25] 2240 [88.25]

D rum thi ckness mm [i n] 50 [1.97] 30 [1.18] 30 [1.18]

Number of foot pads - 150 150

Foot pad di mensi on mm [i n] - 154 [6.1] 154 [6.1]

93
4 - DRUM REMOVAL

F L U I D C O N T E N T S O F V I B R AT I N G R O L L E R S

Engine oil - API CE/SG, SAE 15W/40

Quantity l [gal US]

ASC 70/90 6,7 [1.77]

ASC 110/150 8 [2.1]

ASC 200/250 7,5 [1.98]

GREASE

BENZINA MOBIL ES SO SHELL CASTROL

PM-LA-2 Mobilgrease MP Multi-Purpose Retinax A Castrolease LM

Mobilgrease Special Grease H Alvania Spherol

M o b i l p l e x E P- 1 Grease No.3 Grease RBB2

94
 4 - DRUM REMOVAL

REMOVING THE DRUM FROM THE MACHINE

Lift the drum frame until the drum just touches the ground.
Support on both sides firmly with fixture no. 1.

Remove cover of vibration hydraulic motor.

Remove holders of vibration hydraulic motor hoses.

95
4 - DRUM REMOVAL

Remove four bolts on vibration hydraulic motor. Remove

lower bolts using fixture no. 2.

Slide out hydraulic motor and set aside on the side of the
frame.

96
 4 - DRUM REMOVAL

Remove holders of hoses on rear crossbeam of the frame.

Remove holders of hoses of the travel hydraulic motor.

Place a catch basin underneath the travel hydraulic motor.

97
4 - DRUM REMOVAL

Removal of travel hydraulic motor hoses.

Plug up outlets of hoses and the hydraulic motor.

Tie up hoses to the mirror on the cab.

98
 4 - DRUM REMOVAL

Disconnect wires from the travel hydraulic motor (sensor,

solenoid)

Unscrew plug in front cross beam 8, install hooks.

ASC 200/250 - For suspending the crossbeam of the machine

use 2 eyelets no. 7 (ND 090589), see fixtures Chapter 5
“Removing of the joint“.

99
4 - DRUM REMOVAL

Suspend crossbeam on the crane.

Remove bolts 17 and 16 on both sides, set crossbeam

aside.

17 16

Loosen connecting bolts 37 of the frame with the bracket on

the left side, and 9 on the right side.

37 9

100
 4 - DRUM REMOVAL

ASC 70÷150 - Slide off rubber mounting using fixture bolts no.
3

ASC 70÷150 - Tighten rubber mounting by 8–10 mm (0.3÷0.4

in).

8÷10
3

ASC 200/250 -Remove bolts and pads 29.

29

101
4 - DRUM REMOVAL

ASC 200/250 - Reinsert bolts and tighten to 30 mm (1.2 in).

30mm
(1.2 in)

ASC 70÷250 - After having removed bolts that connect the

frame of the drum, remove spacers.

ASC 200/250 - When reinstalling the spacers, insert front

spacers with hole down.

102
 4 - DRUM REMOVAL

ASC 200/250 - Rear spacers the other way around.

Roll the drum from the frame.

Install drain plug in the left lid in lower position.

103
4 - DRUM REMOVAL

Use chock no. 5 to prevent movement.

Unscrew drain plug 33 from the lid of the vibrator, drain oil to
catch basin.

33

Turn bracket 2 and remove bolts 39 one after the other. The
remaining two bolts in the horizontal axis to be removed first
39 after mounting to the fixture.

2 Note: applies to ASC 70÷150. In ASC 200/250 there is

another method used for mounting bracket 2, the remaining
two bolts to be removed in horizontal level.

104
 4 - DRUM REMOVAL

ASC 70÷150 - Place console 2 vertically and using fixture

no. 5 attach to the crane.

ASC 70÷150 - Remove last two bolts 39.

39

ASC 70÷150

39

39

105
4 - DRUM REMOVAL

ASC 70÷150 - Remove console together with the vibrator

plate from the drum – set aside. Remove fixture bolts no.3.
one after the other.

ASC 200/250 - Mount suspension eyelet no. 7 to bracket 2. Do

not insert a pad between bracket 2 and the eyelet, which is part
of fixture no. 7
Note: the pad is used for the removal of the other (right) side
of the drum.

ASC 200/250 - Suspend the bracket using fixtures no 6 and 7

positioned as illustrated, and remove remaining two bolts in
6 the horizontal axis

7
2

106
 4 - DRUM REMOVAL

Remove bolts 44, remove console 2 from rubberized metal

pieces.

Vibrator plate to be rotated and placed on the rubber

mounting.

Remove safety pad 31.

31

107
4 - DRUM REMOVAL

Place fixture no. 8 on nut 30.

Remove nut 30 and pad 31.

30 31

108
 4 - DRUM REMOVAL

Turn vibrator plate 5 with hub 9 upside down – support.

5

Remove bolts 42.

42 42

42

Insert bolts in the hole, fixture no. 9, by stepwise tightening

remove hub 9. If necessary use bolt fixture no. 9
Note: bolts (3 pieces) are part of fixture no. 9 as position 2
– see Fixtures.

109
4 - DRUM REMOVAL

Press out bearing 28 from the hub, seal ring 22, and collar /
23

23

22
28

VIBRATOR PLATE ASSEMBLY

FOLLOW REMOVAL PROCEDURE IN REVERSE ORDER DURING
ASSEMBLY

Press outer ring of bearing 28, turn and press outer ring of
28 the bearing, install seal ring 22 using fixture no. 10.
22

28

On the vibrator plate bearing install ”O” ring 26 and ring 13

preheated to 90 °C (when replacing). Insert inner part of the
bearing 28 - preheat to 90 ÷ 110 °C.

28

26
13

110
 4 - DRUM REMOVAL

Fill bearings with grease, insert hub 29.

29

Insert the inner part of bearing 28 - preheat to 90÷110 °C.

28

Insert pad 31, nut 30.

30 31

111
4 - DRUM REMOVAL

Tighten with fixture no. 8 (tap on the fixture while tighten-

ing).

Tighten the nut with torque using fixture no. 11

R o lle r T ig h t in g t o r q u e N m ( f t lb )
11
A S C 7 0 /9 0 7 0 ÷8 0 (5 2 ÷5 9 )

A S C 11 0 /1 5 0 7 5 ÷8 0 (5 6 ÷5 9 )

A S C 2 0 0 /2 5 0 8 0 ÷1 0 0 (5 9 ÷7 4 )

REMOVAL OF THE RIGHT SIDE OF THE DRUM

ASC 70÷150 - Turn the drum to position in Fig.

112
 4 - DRUM REMOVAL

ASC 70÷150 - Using fixture no. 5 suspend console 01 on

the crane.

01 5

ASC 70÷150 - Remove bolts 45.

45

ASC 70÷150 - Set the console with the driving lug aside.

03
1

113
4 - DRUM REMOVAL

ASC 200/250 - Revome holders 7.

ASC 200/250 - Turn the drum to position as in Fig., install

suspension eyelet no. 7 to bracket 1. Insert the pad of the fixture
7a between bracket 1 and eyelet no. 7.
Suspend bracket using fixtures no. 6 and 7 in position as in Fig.
7 7a

114
 4 - DRUM REMOVAL

Remove outer rubber mounting 35 and bracket 1.

35

REMOVAL AND INSTALLATION OF VIBRATORS -

THE RIGHT SIDE

ASC 70/ASC 90 - Attention! In roller ASC 70/90 the vibration

exciter in the twin version (left and right vibrator) of two
vibrators on the same shaft. For the reason of higher weight the
vibration exciter is remover (installed) in the vertical position
of the drum from the left side. When replacing the bearing of
the right lid, it is necessary to place the drum with its left side
down by means of two clamps no. 13 on suitable padding
(beams of hardwood).

After remove set lid 12.

12

115
4 - DRUM REMOVAL

ASC 110/150
ASC 200/250
Remove bolts 38 – suspend lid 8 on fixture no. 12, using three
bolts M16 in service holes „A“, press the lid from the front of the
drum.
A
A
12

38
8

Set lid aside.

12

Using same fixture remove vibrator.

ASC 70/ASC90 - Before removing the vibrator, position the
drum vertically with its right side down. Having removed the left
lid pull the vibrator out of the drum using fixture no. 14 (exten-
der for suspension eyelet)

12

116
 4 - DRUM REMOVAL

Remove bolts 40, lid 10, safety ring 18, press out outside
rings of bearings 19 from lids 8 and 10, remove connecting
shaft 5.
Not aplicable for ASC 70/ASC 90 40

10

19

Use same procedure for removing lids 7, 10 and vibrator on the

left side of the drum.

ASC 110/150
ASC 200/250 19
19
Warm up bearing rings 19 to 90–110 °C and slide off shafts.

117
4 - DRUM REMOVAL

ASC 70/90

Take out half-segments of rings 7 and the loose cam 2. The

rigid cam may be removed by milling the cam body 1 in its
3.4 weakest point, or use new shaft 3, 4 with cam 1.

If new parts are used in mounting the vibrator, warm up the

eccenter to 250÷350 °C, and place it on the fixture pad no.15,
and insert in it shafts 3, and 4 with key 11.
3,4
Attention: applicable to ASC 200/250. when handling eccen-
ter 1 use fixture no.16. When handling shafts 3 and 4 use fixture
no. 17.
11

15

118
 4 - DRUM REMOVAL

Press bushing 8 into cam 2 using fixture no. 18.

Calibrate bushing using fixture no. 18.

18

Further operations are identical for both sides od the drum

and follow the procedure in reverse. For installing outer 19
rings of bearings 19 to lids 7, 8, and 10, follow pairing with
internal bearing rings.
Attention: applicable to ASC 70/90. First install the right lid
with the bearing, position the drum vertically using clamps no.
13, and install the vibrator using fixture no. 14. When the
vibration exciter is in place, check axial free play of bearings
of the ecciter, see Fig. on next page - down there.

7,8

119
4 - DRUM REMOVAL

Install safety ring 17. For installation of connecting shaft 5,

one must observe the correct position of vibrators against
each other – this is done by groove „A“ on both ends of the
A shaft against pins 12 in cams 3 and 4.
The shaft (5) is not used for ASC 70/ASC 90.

5
17

Pins 12 to be pressed into both shafts 3 and 4, establish

position using fixture no.19.
Not applicable for ASC 70/ASC 90

12
3,4

After having installed lids 7 and 8, test using fixture no. 20.
Axial play of bearings of both vibratos to be 1,5–2,5 mm.

20

120
 4 - DRUM REMOVAL

For replacement of vibration hydraulic motors 35, hub 4 must

be heated up to 200 °C, and slid on the output shaft of the 35
hydraulic motor. The guide pin on the spline must move freely
to full stop and must not be forced.

Use Loctite-577 to glue bolts 14 of hydraulic motor 35.

14

DISMANTLING OF THE RUBBER MOUNTING ON ASC 200/250

THE LEFT SIDE

Ease the frame of the drum up to prevent the rubber mounting

from overstraining.

121
4 - DRUM REMOVAL

Remove holder 8.

8
8

Remove external rubber mounting 35.

35
35

122
 4 - DRUM REMOVAL

Loosen bolts of the rear rubber mounting.

Position spanner between the drum frame and the vibration

plate 5, unbrace.

123
4 - DRUM REMOVAL

Replace internal rubber mounting and tighten to torque – see

torque specification table.

Install external rubber mounting 35.

Mount holder, tighten bolts to torque – see torque specification

table.

Replace remaining rubber mounting one by one on the left side

of the drum using same procedure.

124
 4 - DRUM REMOVAL

THE RIGHT SIDE

Remove holder pos. 7.

Remove external rubber mounting 35.

35

125
4 - DRUM REMOVAL

Remove internal rubber mounting 35.

Position spanner between carrier 2 and the front face of the

2 drum, unbrace, replace rubber mounting, and tighten to torque,
see torque specification table.

Install external rubber mounting.

126
 4 - DRUM REMOVAL

Mount holder, tighten bolts of the holder and the rubber

mounting to torque – see table.

Replace remaining rubber mounting one by one on the right

side of the drum using same procedure.

127
4 - DRUM REMOVAL

FIXTURES

No.1 - ND 107453 - Handling (support under frame with drum)

ASC 70/90
No.1 - ND080088 - Handling (support under frame with drum)
ASC 110÷ASC 250

No.2 - ND090605 - Installation (for assembly of vibration hydromotor)

ASC 70÷ASC 250

No.3 - ND080073 - Installation - (bolts for clamping rubberi-

zed metal pieces)
Note: not used for ASC 200/250

No.4 - ND090535 - Handling (wedge for drums)

ASC 70÷ASC 250

No.5 - ND107327 - Handling (for consoles pos.2 and 30-1)

ASC 70/90
No.5 - ND080149 - Handling (for consoles pos.2 and 30-1)
ASC 110/150

No.6 - ND107322 - Handling (for consoles pos.2 and 30-1)

ASC 200/250

128
 4 - DRUM REMOVAL

No.7 - ND107323 - Handling (for consoles pos.2 and 30-1)

ASC 200/250

No.8 - ND080229 - Installation (for tightening nut KM26)

ASC 70÷ASC 150
No.8 - ND090613 - Installation (for tightening nut KM30)
ASC 200/250

No.9 - ND101781 - Installation (disassembly of hub 9,

vibration plate 3 and bearings 28)

Pos. 1 one version for ASC 70÷ASC 150

other version for ASC 200/250

Pos. 2 bolt M14 for rollers ASC 70÷ASC 150

bolt M16 for rollers ASC 200/250

No.10 - ND101776 - Installation (for pressing seal ring)

ASC 70÷ASC 150
No.10 - ND107119 - Installation (for pressing seal ring)
ASC 200/250

No.11 - ND101777 - Control (for checking prestress on

conical bearings in hub 9) - ASC 70÷ASC 150
No.11 - ND080219 - Control (for checking prestress on
conical bearings in hub) - ASC 200/250

No.12 - ND080148 - Installation (for lids 7, 8, 10 and vibrators)

ASC 110/150
No.12 - ND080203 - Installation (for lids 10, 11, 12 and vibra-
tors) - ASC 200/250

129
4 - DRUM REMOVAL

No.13 - ND090512 - Handling (clamp for installed of the

drum vertically) - ASC 70/90

No.14 - ND081983 - Handling (for shaft of vibrators)

ASC 70/90

No.15 - ND080297 - Installation (support for fixed excenter 1)

ASC 70/90
No 15 - ND080213 - Installation (support for fixed excenter 1)
ASC 110÷250

No.16 - ND081205 - Handling (for fixed eccenter 1)

ASC 200/250

No.17 - ND081213 - Handling (lifting for exciter shaft)

ASC 200/250

130
 4 - DRUM REMOVAL

No.18 - ND080145 - Installation (for pressing and calibration

of bushing 8) - ASC 70÷150
No.18 - ND080202 - Installation (for pressing and calibration
of bushing 8) - ASC 200/250

No.19 - ND080146 - Installation (for setting up position pin 12)

ASC 150÷250

No.20 - ND080147 - Control (axial play of bearings 14)

131
4 - DRUM REMOVAL

132
 5 – DISASSEMBLY OF ARTICULATED JOINT

5 - ARTICULATED JOINT

DESCRIPTION

ASC 70÷150 - The joint connecting the drum frame with the
rear frame is equipped with a large-size bearing 1 with cross 2
rollers allowing for the frame to swing in the vertical plane, and
two vertical pins 2 allowing for steering angle in the horizontal 1
plane.

ASC 200/250 - The joint connecting the drum frame with the
rear frame is equipped with a large-size bearing 1 with cross 1
rollers allowing for the frame to swing in the vertical plane, and
one vertical pin 2 allowing for steering angle in the horizontal
plane.

SPECIFICATIONS:

ASC 70/90 ASC 110/150 ASC 200/250

Frame swing in ver tical plane max. (±°) 12 10 10

Steering angle in horizontal plane max. (±°) 36 36 36

133
5 – DISASSEMBLY OF ARTICULATED JOINT

Place the machine on firm ground, support the frame in front

using fixture no. 1

Support frame in the rear using fixture no. 2

134
 5 – DISASSEMBLY OF ARTICULATED JOINT

Remove shims 11.

11

Using fixture no. 3 press out pins 10 out of the ends of pistons
of the linear hydraulic motor 1, rings 9, seal rings 21.

9 21
1

10

135
5 – DISASSEMBLY OF ARTICULATED JOINT

Remove hose clamps on the drum frame

Remove clamping of hoses on the hinge and the rear frame

136
 5 – DISASSEMBLY OF ARTICULATED JOINT

Remove cover of vibration hydraulic motor.

Remove vibration hydraulic motor, use fixture no. 4 for bottom

bolts

Slide hydraulic motor from the drum, set aside.

137
5 – DISASSEMBLY OF ARTICULATED JOINT

ASC 70÷150 - Suspend drum with the frame using fixture no.5.
For drum ASC 110/150 use two twin-hooks because of the
weight.

ASC 200/250 - For the manner of suspension see Fig.

138
 5 – DISASSEMBLY OF ARTICULATED JOINT

Remove bolts 40

40

18

Set aside the drum with front frame on the right side outside the
machine.

139
5 – DISASSEMBLY OF ARTICULATED JOINT

Place fixture no.8 underneath.

Place hoist under frame plate 2. Remove bolts 38.

38

140
 5 – DISASSEMBLY OF ARTICULATED JOINT

Plate 2 aside

141
5 – DISASSEMBLY OF ARTICULATED JOINT

Loosen bolts 37

37

Place fixture no.9 under the upper bolt, suspend on crane

using fixture no.10.
Set bearing aside,

10

142
 5 – DISASSEMBLY OF ARTICULATED JOINT

Loosen nut 25.

Remove nut 25 using wrench no. 11.

11

Remove clamps of the pin, press out the pins 12 using jack, see
Fig., or fixture no.12.

12

12

143
5 – DISASSEMBLY OF ARTICULATED JOINT

Using crane set hub assembly 3 aside.

Remove lids 10, 11, and spacing pads 13.

11

10

13

Press out bearings 24 using fixture no.13.

24

144
 5 – DISASSEMBLY OF ARTICULATED JOINT

FIXTURES

No.1 - ND084425 - Installation (front rack under the tractor

frame) - ASC 70÷250

No.2 - ND080211 - Installation (rear rack under the tractor

frame) - ASC 70+250
No.2 - ND080324 - Installation (rear rack under the tractor
frame) - ASC 110/150

No.3 - ND101782 - Installation (for pressing out pin 10 - hydr.

cylinder+joint) - ASC 70÷ASC 250

No 4 - ND090605 - Installation (wrench for assembly of vibra-

tion hydromotor) - ASC 70÷ASC 250

No.5 - ND090503 - Handling (chain double-hook 5.6t for the drum)

ASC 70/90
No.5 - ND090586 - Handling (chain double-hook 8t for the
drum) ASC 110/150

145
5 – DISASSEMBLY OF ARTICULATED JOINT

No.6 - ND090588 - Handling (chain four-hook for the drum)

ASC 200/250

No.7 - D090589 - Handling (lifting eye - screw M36)

ASC 200/250

No.8 - ND080088 - Installtion (support under frame with drum)

ASC 110÷250
No.8 - ND107453 -Installtion (support under frame with drum)
ASC 70/90

146
 5 – DISASSEMBLY OF ARTICULATED JOINT

No.9 - ND103875 - Handling (lifting eye for bearing 23)

ASC 70÷250

No.10 - ND080148 - Handling (together with ND 103875 sus-

pension eyelet) - ASC 70÷250

No.11 - ND090610 - Installation (wrench for nut KM 11)

ASC 70/90
No.11 - ND090610 - Installation (wrench for nut KM 14)
ASC 110/150
No.11 - ND107334 - Installation (wrench for nut KM 20)
ASC 200/250

No.12 - ND107333 - Installation (pressing for pin 12) A S C

70/90
No.12 - ND103877 - Installation (pressing for pin 12) A S C
110÷250

No.13 - ND090480 - Installation (for bearing pos.24∅99/ ∅81)

ASC 70/90
No.13 - ND090480 - Installation (for bearing pos.24∅129/ ∅105)
ASC 110/150
No.13 - ND090480 - Installation (for bearing pos.24∅198/ ∅180)
ASC 200/250

147
5 – DISASSEMBLY OF ARTICULATED JOINT

148
 6 - REMOVAL OF PUMPS, CLUTCH

6 - 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.

Remove bolts 53.

Set rubber wall aside.

53

Remove hose clamps.

149
6 - REMOVAL OF PUMPS, CLUTCH

Disconnect wires to hydraulic generators.

Remove hoses from hydraulic generators.

150
 6 - REMOVAL OF PUMPS, CLUTCH

Plug outlets of hydraulic generators and hose ends.

151
6 - REMOVAL OF PUMPS, CLUTCH

Suspend vibration hydraulic generator on the crane, re-

move bolts connecting both hydraulic generators.

Slide out and set aside.

152
 6 - REMOVAL OF PUMPS, CLUTCH

Suspend travel hydraulic generator on the crane.

Remove bolts 47, 56 off flange 12.

47 56 12

153
6 - REMOVAL OF PUMPS, CLUTCH

Slide out of clutch 86.

86

Set hydro generator with flange aside.

Remove bolts T1 of “A“ segment

T1

154
 6 - REMOVAL OF PUMPS, CLUTCH

Remove bolts T2, get the coupling segment 86 from the

hydraulic generator shaft, remove bolts T1 and segment „B“.

T1 B

T2

86

Remove bolts 55, and flange 12.

55
12

155
6 - REMOVAL OF PUMPS, CLUTCH

CLUTCH
ASSEMBLY CLUTCH
Install „A“ segments to the balance-wheel. Center the seg-
2 ments using fixture No. 2. Lubricate T 1 bolts under the head
with grease, tighten them by means of the torque as given in the
table. Check their position after tightening.

T1
A
A
A

Fix flange 12 on the flange of the travel hydraulic generator

and coupling 86 with „B“ segments. Tighten T 2 bolts of
coupling 86 by means of the torque as given in the table, see
next page.
12
T1

T2

86

When installing coupling 86, define axial clearance between

the balance-wheel face and the elastic element of clutch.
Measure the distance „a“ from the face of the balance-wheel
box.

156
 6 - REMOVAL OF PUMPS, CLUTCH

Measure distance „b“ from the elastic element face to the

seating area of flange 12

Difference in the distances a - b = 1 ÷ 3 mm

Colored (e. g. blue color) material is deposited on the thread The tandem of hydraulic generators including the connection
of the supplied countersunk hexagonal screws. Such material of hydraulic hoses and electrical wiring should be installed
includes a film of adhesive and prevents its releasing. The time using a crane in the opposite way.
of hardening of such adhesive material after screwing the bolts
is 4 ÷ 5 hours at the ambient temperature of 20 °C. The operation
of the machine should not start before this time period has
elapsed. Full hardening is finished after 24 hours. At higher Tightening torque
temperatures the hardening can be faster, e. g. 15 minutes at T 1 bolt 155 ÷ 165 Nm
70 °C (heating performed by a hot air fan). Temperature stability
T 2 bolt 120 Nm
of the bolts is between -80 ÷ +90 °C (-112÷ +194 °F) and they
can be used three times at maximum. The adhesive material
is sometimes wiped off and it is deposited between the head
of the bolt and the segment. This is not a defect, rather
advantage - both areas will adhere to each other better. If
original supplied bolts are not available, both the bored thread
and bolt must be carefully degreased and a layer of Loctite or
Omnifit should be applied to them.
Spring washers are not allowed!

157
6 - REMOVAL OF PUMPS, CLUTCH

FIXTURES
No.1 - ND080078 - Handling (cabin support)

No.2 - ND080155 - Assembly (for clutch)

158
 7 - STEERING CYLINDERS

7 - 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 dismounted hydraulic motor. Disconnect hoses and plug them up. Remove shims 11 and bolts 16, and press out pins 10
from the ends using fixture No.3. Push the piston rod in after the piston rod pin has been pressed out. Remove the linear hydraulic
motor from the machine using hoist, sliding it out through the rear frame opening towards the drum.

DISMANTLING THE LINEAR HYDRAULIC MOTOR -

REPLACING THE SEALS
Place a tray under the hydraulic motor and plug the holes. Drill
the safety pin out from the front cover face 10 (unlock the cover
safety 10) according to the type of the linear hydraulic motor.
Remove cover 10 using wrench No.1 (according to the type of
the linear hydraulic motor ) and slide piston rod 4 with piston
5 out, remove nut 8 and the piston. Remove cover 10. Replace
seals dip in oil before installation.

159
7 - STEERING CYLINDERS

Grease sliding faces, watch out for damage to sliding faces.

Install parts with new seals after straightening out the seals. At
least 15 minutes 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. Tighten threaded joints with
torque specified in the table.

ASEMBLY SEALING MATERIAL KITS

Item No. Description

1 Sealing

2 Collar

3 Scraping ring

4 Guiding band

5 Ring

6 Ring

Note:
The respective sealing material may be ordered as a kit from
the cylinder manufacturer specifying manufacturing number
of the equipment.

TIGHTENING TORQUE TABLE

ASC 70/90 - Hydraulic cylinder ∅80/∅

∅40-400

Connection of piston rod C o n n e c t i o n o f c y l i n d e r b o d y, c o v e r

Thread Ti g h t i n g t o r q u e N m [ f t l b ] Thread Ti g h t i n g t o r q u e N m [ f t l b ]

M 30x2 130 [96] M 85x1,5 180 [133]

ASC 110/150 - Hydraulic cylinder ∅90/∅

∅45-400

Connection of piston rod C o n n e c t i o n o f c y l i n d e r b o d y, c o v e r

Thread Ti g h t i n g t o r q u e N m [ f t l b ] Thread Ti g h t i n g t o r q u e N m [ f t l b ]

M 32x2 140 [103] M 95x1,5 200 [148]

ASC 200/250 - Hydraulic cylinder ∅110/∅

∅55-400

Connection of piston rod C o n n e c t i o n o f c y l i n d e r b o d y, c o v e r

Thread Ti g h t i n g t o r q u e N m [ f t l b ] Thread Ti g h t i n g t o r q u e N m [ f t l b ]

M 42x3 180 [133] M 115x2 220 [162]

160
 7 - STEERING CYLINDERS

FIXTURES
No.1 - ND101785 - Installation (wrench for removal of lid
of hydraulic cylinders ∅80/∅40) - ASC 70/90

No.1 - ND107337 - Installation (wrench for removal of lid

of hydraulic cylinders ∅90/∅45) - ASC 110/150
No.1 - ND101328 - Installation (wrench for removal of lid
of hydraulic cylinders ∅110/∅55) - ASC 200/250

No.2 - Assembly - ND101783 (for assembly of piston to hydr.

cylinder)

No.3 Assembly - ND101782 (for pressing pin 10)

161
7 - STEERING CYLINDERS

162
 8 - CONTROLS

8 - CONTROLS

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.

DISASSEMBLY AND ASSEMBLY OF STEERING

Remove steering wheel cup 6, remove nut 21, insert fixture

No.1 under the steering wheel, remove steering wheel using
steering wheel spanner, dismantle steering wheel bracket 1,
slide it with the steering rod 2 out from the steering column.
Dismantle securing rings 30, 31, press shaft 2 out together
with the bearing, remove bearing 9 from the shaft.

Press the bearing on the shaft (the bearing shall be degreased

and fresh grease shall be applied, see table in Section D),
secure with locking ring 31, press into bracket 1, secure with
locking ring 30, mount it to the steering column, check that no
clearance appears between bracket 1 and the steering co-
lumn after the shaft has been set in steering. Mount the
steering wheel.

163
8 - CONTROLS

ACCELERATOR CONTROL REMOVAL AND ASSEMBLY

Disconnect the accelerator cable.

Dismantle and lift the instrument panel, loosen nuts 22, remo-
ve accelerator 8, bracket 3 and lid 13. When the cable is to be
replaced, undo the clamp on the fuel injection pump lever.
Grease the new cable. Adjust clearance between lid 13 and the
switch, when reassembling the accelerator. Set the position of
lid 13 for the vibrator switch to engage at engine max. speeds.
1 mm Speed value (RPM)
22
ASC 70/ASC 90 2200+30
ASC 110/ASC 150 2250+30
ASC 200/ASC 250 2500+30

8 13
3

REMOVING AND REASSEMBLING TRAVEL CONTROL, BRAKE

ADJUSTMENT
Remove bolts 1, the instrument panel with the control, cabling.
Remove bolts 2 and the controller. Unscrew the controller
plastic cover, set the brake on the lever of the controller.

2
1

164
 8 - CONTROLS

FIXTURES
no.1 Assembly - ND080755 (washer for disassembly of ste-
ering wheel)

165
8 - CONTROLS

166
 9 - THE DRIVER‘S STATION ASSEMBLY

9 - THE DRIVER‘S STATION ASSEMBLY

DISMANTLING

Loosen nuts of the driver‘s station.

Fold the station using the lifting hydraulic motor

167
9 - THE DRIVER‘S STATION ASSEMBLY

Disconnect the cable on the injection pump 3, drain partially

the cooling fluid, disconnect heater hoses 1, 2, electrical
cables, remove power steering assembly underneath the
cabin, disconnect anchor chain, lower the cabin, hook up the
2 hoist by the eyelets on the cabin roof and lay it aside.
1
2 1

33

Assemble in reverse order, add cooling fluid.

CABIN
Disassembly of rear window wiper - remove cover 6 - , wiper,
nut on the shaft of wiper 1, bolts 9 see, clamps with the wiper
motor.

TIGHTENING TORQUE OF THE NUT ON THE WIPER ARM

Thre a d To rq ue [Nm]

6 M8 9 -1 0

M 10 25

9
9

168
 9 - THE DRIVER‘S STATION ASSEMBLY

Removing the front wiper - remove bolts 75 of the upper

cover 14

75
75
14

Disconnect cables, remove nut of drive 1 and the drive. Discon-

nect cables, remove clamp 6 with fan 14.

14
6 2 2
1

Remove nut of wiper 1, nut of drive shaft 2.

1
2

169
9 - THE DRIVER‘S STATION ASSEMBLY

DOOR LOCKS

Remove lower cover 10.

10

Remove nut 63, disconnect rods 64, 65, remove rod 64.

65

63

64

Remove flange 103, loosen bolts 75, remove handle with

push-button and washers.
75

103

64

75

170
 9 - THE DRIVER‘S STATION ASSEMBLY

Remove bolts 81, left and right lock 8, 9.

8
81

Assemble in reverse order. Set up the push-button and the lock

by adjusting nut 63.

SEAT

Fold control panel 1 on the right side of the seat, remove cover
2 below, disconnect cables, free and fold

The cover bellows, remove nuts, lift out the seat. Remove bolts
20, grid 8 on both sides.

20

171
9 - THE DRIVER‘S STATION ASSEMBLY

Remove cover 6, seat plate 1.

It does not make with the rollers from PIN:
ASC 70 0068
ASC 90 0039
1 ASC 110 0258
ASC 150 0237
ASC 200 0014
ASC 250 0008

Remove ball 13 from the seat plate, undo safety ring 26, pull
out pin 8, and spring 11. After checking of bullets 10 and rollers
9, grease.

172
 10 - DISASSEMBLY OF HEATER - AIR-CONDITIONING

1 0 - DISASSEMBLY OF HEATER 33

Loosen pouring plug 33

Loosen drain valve on the radiator.

Drain coolant into a ready container.

173
10 - DISASSEBMLY OF HEATER - AIR-CONDITIONING

Lift the cab.

Remove heater cover.

Disconnect air pipes, wiring, and remove heater cock from

the cabin frame.

174
 10 - DISASSEMBLY OF HEATER - AIR-CONDITIONING

Disconnect input and return heater hose.

Remove bolts that attach the return heater hose on the cover.

175
10 - DISASSEBMLY OF HEATER - AIR-CONDITIONING

Remove heating unit.

Remove heat exchanger.

Assembly reverse order. Fill up coolant level. Check water-

tight.

176
 10 - DISASSEMBLY OF HEATER - AIR-CONDITIONING

AIR-CONDITIONING

Heat is removed from evaporator 5 inside the cabin (low-

pressure loop) and delivered on the condenser 2, located in
front of the engine radiator (high-pressure loop). Compressor
1 sucks cooling vapors from the evaporator and presses them
to condenser 2. There the cooling vapors are condensed and
flow over dehydrating filter 3 to heat expanding valve 4. Valve
4 sprays liquid coolant to evaporator 5, where heat is absorbed
from the cabin, the liquid evaporates, and the vapors are
sucked in to the compressor.

Data:
Cooling power [kW] 3
Voltage [V] 24
Current [A] 6
Volume of air in evaporator [m 3/h] 400
Volume of air in condenser [m 3/h] 900
Coolant R 134a
Volume of coolant [kg] 0,95
High-pressure protection [MPa] 2,7
Low-pressure protection [MPa] 0,2

177
10 - DISASSEBMLY OF HEATER - AIR-CONDITIONING

DEFECTS IN AIR-CONDITIONING SYSTEM

Always call Service for repairs!

D e fe c t C auses

T he uni t c he c k c o m p r e s s o r b e l t
d o e s n' t
cool c h e c k e va p o r a t o r f a n - N G - c h e c k f u s e s
F 7 i n t h e f u s e b o x - s e e D r i ve r ' s M a n u a l

c h e c k c o o l a n t l e ve l i n i n s p e c t i o n h o l e o f
t h e d e h yd r a t o r f i l t e r - l e a k ( b u b b l e s ,
f o g g i ng up , e t c . )

c he c k e l e c t r o m a g ne t i c l a t c h, w i t h e ng i ne
r unni ng w i t h A / C o n - t he l a t c h d o e s n' t
r e a c t ( no c l i c k i n c o m p r e s s o r )
1 . f a ul t y f us e F 7 ,
2 . f a ul t y t he r m o s t a t ,
3 . f a ul t y p r e s s ur e f us e .

REPLACING (TIGHTENING) THE BELT

Loosen bolts 16, 17 and belt 13 (remove) by swinging com-

pressor 12 in (-) direction. Tighten using suitable lever by
swinging the compressor in (+) direction.

178
 10 - DISASSEMBLY OF HEATER - AIR-CONDITIONING

Electrical schematic of A/C

1 - Compressor
2 - Condenser fan
3 - A/C fan
4 - Fan control
5 - Accumulator
6 - Relays
7 - Switch
8 - Thermostat
9 - Pressure fuse
10 - Compressor fuse

179
10 - DISASSEBMLY OF HEATER - AIR-CONDITIONING

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
Should your skin come into contact with the coolant, wash the
affected spot with a large quantity of warm (not hot) water.
Protect the burn with sterile gauze and seek out medical help
immediately
Should anyone be overcome by vapors from the coolant, carry
such person on fresh air, and if necessary, perform artificial
respiration, and call for medical help.

180
 11 - ELECTRICAL INSTALLATION

11 - ELECTRICAL INSTALLATION

The electrical installations is valid for rollers with engine

B5.9 according to TIER I (It is also valid for the machine ASC
70/90 with engine Tier 2)

50 - Fuse box
Fuses in the upper row see:

Fuse (F1) -20 A (upper fuse) front and rear lights, front
silhouette lights and rear limit lights, au-
xiliary spotlights, instrument panel illumi-
nation, raising and lowering the hood and
driver’s station, license plate illuminati-
on.
Fuse (F2) -10 A service light plug, cab illumination, emer-
gency horn, directional lights, beacon.
Fuse (F3) -7,5 A brake, engine STOP, drive, vibration, bra-
ke lights, back-up horn, level of hydraulic
oil indicator, vibration on indicator, brake
indicator, neutral position of drive control
indicator.
Fuse (F4) - 7,5 A indicator of ASC differential lock
Fuse (F5) - 5 A coolant thermometer, hydraulic oil ther-
mometer, fuel gauge, speedometer, hour
counter, indicator of engine lubrication,
indicator of air filter clogging, indicator of
hydraulic filter clogging, indicator of char-
ging
Fuse (F6) - 15 A fan of ventilation, fan of heating, front &
rear windscreen wiper, windscreen wa-
sher
Fuse (F7) - 20 A reserve (air conditioning)
Fuse (F8) reserve
Fuse (F9) - 50 A this fuse protects the electrohydraulical
unit of hood & cabin lifting.

F9

Replace fuses with identically rated fuses only.

51 - Serial port ASC

181
11 - ELECTRICAL INSTALLATION

The electrical installations is valid for rollers with engine

QSB5.9 according to TIER II (Only for machine ASC 110 -
ASC 250)

42 - Fuse box
Fuses in the upper row see:

Fuse (F1) -20 A (upper fuse) front + rear lights, front par-
king + rear lights, auxiliary headlights,
dashboard illumination, lifting and lowe-
ring of bonnet and driver’s stand, license
plate illumination.
Fuse (F2) -10 A portable lamp connector, cabin illuminati-
on, horn, direction indicators, beacon.
Fuse (F3) -7.5 A brake, brake signal lamp, brake lights,
magnets - transporting speed of wheels,
travel servo valve, vibration magnets, vib-
ration-on signal lamp, back horn, hydraulic
oil level signal lamp, travel control neutral
position signal lamp
Fuse (F4) -10 A ASC (Anti Slip Control)
Fuse (F5) -15 A fuel gauge, revolution counter, hourmeter,
hydraulic oil thermometer, charging signal
lamp, air filter signal lamp, hydraulic oil
level signal lamp, water in fuel signal lamp,
maintenance signal lamp, stop engine sig-
nal lamp, engine warning signal lamp.
Fuse (F6) -15 A ventilation fan, heating fan, front and rear
washers, front and rear wipers.
Fuse (F7) -20 A reserve (air conditioning)
Fuse (F8) -20 A reserve
Fuse (F9) -50 A Secures protection of electric pump used
for lifting and lowering of bonnet and dri-
ver’s stand. Replace the fuse with a genui-
ne one of the same rate 50 A.

F9
Replace fuse with fuse of the same rate only!!!

41 - Serial port ASC

14 - The plug ECM (electronic control module) of engine

182
 11 - ELECTRICAL INSTALLATION

Engine fuses
Fuses F10 – F12 /7.5 A .... Power supply engine electronics
Fuse F13 – F14 /10 A ..... Power supply injection pump
Fuse F15 - reserve

F10 F11 F12 F13 F14

F15

183
11 - ELECTRICAL INSTALLATION

REPLACEMENT OF THE REVOLUTION COUNTER

for engine Tier 1

If you want to replace the revolution counter, you must set and
calibrate it depending on revolutions of the engine used – see
Table.
Switches 1, 2, 3 of the new revolution counter should be set
according to and installed into the instrument panel including
the wiring.

Start the engine and set maximum revolutions – check it using

a stroboscope or with a multimeter (1) connected to the supply
line to the revolution counter.

MACHINE ENGINE RPM 1

ASC 70 - ASC 90 B3.9-C99 2200 +30
ASC 110 B5.9-C148 2250 +50
ASC 150 B5.9-C148 2250 +30
ASC 200 - ASC 250 B5.9-C200 2500 +30

If the measured revolutions are different than those given in the

Table, set them to the value given in the Table using the stop
(1) on the adjusting screw of the fuel injection pump.

184
 11 - ELECTRICAL INSTALLATION

Set the revolution counter using potentiometer A depending

on engine max. revolutions.

Set idle 850 RPM of the engine – check it using a stroboscope

or multimeter.

Check idle RPM of the revolution counter. If the counter does

not show the measured value, the setting must be repeated.

REVOLUTION COUNTER REPLACEMENT

for the engine Tier 2 QSB5.9-C155 ASC 110-ASC 150
QSB 5.9-C205 ASC 200-ASC 250

Switches 1, 2, 3 of the new revolution counter should be set

according to and installed into the instrument panel including
the wiring.

Switch off IDLE switch (15). Set, e. g., 2300 RPM using the
revolution selector (8) and check whether the counter shows
the corresponding RPM.

185
11 - ELECTRICAL INSTALLATION

If it is necessary, set it using potentiometer A.

Switch on switch (15) – engine idling, and check if the revolu-

tion counter shows 850 RPM (the same for ASC 110 up to ASC
250). If the counter does not show the value measured, the
setting must be repeated.

NOTE:
The engine should be warmed to running temperature while
you are checking the revolution counter.

REPLACEMENT OF THE REVOLUTION COUNTER

for engine Tier 2 B4.5-C99 (ASC 70-90)

Switches 1, 2, 3 of the new revolution counter should be set

according to and installed into the instrument panel including
the wiring.

186
 11 - ELECTRICAL INSTALLATION

Start the engine and set maximum and idle revolutions – check
it using a stroboscope or with a multimeter connected to the
supply line to the revolution counter.
MACHINE ENGINE Max. RPM
ASC 70-ASC 90 B4.5-C99 2200 +30 1
Idle RPM
950 ±20

If the measured revolutions are different adjust max. speed

with the bolt (1) and adjust idle speed with bolt (2) of the fuel
injection pump.

1 2

Set the revolution counter using potentiometer A depending

on engine max. and idle revolutions.

187
11 - ELECTRICAL INSTALLATION

Battery connector is located on the left side under the cabin,

While working on electrical wiring, disconnect always the battery.

Electrical wiring – location of elements

188
11 - ELECTRICAL INSTALLATION

189
11 - ELECTRICAL INSTALLATION

BATTERIES INDICATION OF COMPLETED CHARGING

Two batteries 12 D HD 135 are connected in series and located Battery is considered fully charged when all cells bubble
to the rear of the frame. intensively and the electrolyte indicates density of 1.28 g/cu.cm.
The terminals read 15 to 16 V.
Full charge is checked after further two hours; values shouldn‘t
vary from initial readings. Battery is discharged when density
HANDLING drops to 1.12 g/cu.cm.
Instantaneous charge rate is indicated in the following table:
Fill cells with sulfuric acid of specific density 1.28 g/cu. cm, 5-
10 mm above the plates. Equalize the electrolyte and the battery
to 15 – 20 °C when filling. C h a r g e l e ve l i n % E l e c t r o l yt e d e n s i t y i n g / c u . c m
Let the electrolyte soak in the plates for 20 minutes, in batteries
older than 6 months for 3 hours. Top possible level drop to 5 100 1 ,2 8
– 10 mm above plates. Charge the battery according to table.
The highest charging temperature is 40 °C. If necessary, cool 70 1 ,2 3
by air flow or water bath, or lower charging current, or charge
intermittently. 50 1 ,2 0

Currents lower than those indicated in the table are beneficial, 20 1 ,1 5

however, charging will be prolonged. Leave input openings
uncovered. Check the level and density of the electrolyte when
finished charging. If necessary, top the level and adjust density
to 1.28 g/ cu.cm. Tighten the plugs after 2 hours of degassing,
flush the outside of the battery with water and clean dry. The values are correct for electrolyte temperature of 27 °C. At
temperature lowers by 15 °C the electrolyte density is higher
by 0.01 g/cu.cm. When topping up the electrolyte, density
CHARGING CURRENT TABLE - example readings are correct after 10 to 30 minutes of charging, depen-
ding on the current and the intensity of bubbling. The level may
be raised before charging up, to 5 to 10 mm above cell dividers.
Type Capac i t y Char gi ng

L100 100Ah 10A

190

MAINTENANCE DURING OPERATION
Correctly working charging circuit maintains the battery close
to full charge. The level of regulated voltage is between 27.6
and 28.4 V.
When the voltage level is adjusted to these values, the elect-
rolyte level is checked every 3 months. In summertime, check
once a week. Battery overcharging is indicated by the electro-
lyte volume decrease. Insufficient charge affects the density of
the electrolyte. Idle battery discharge is 1% of the capacity per
day.
Battery is charged by current 0,1 overall capacity until fully
charged.
The batteries must be kept clean, properly fastened, the holder
must not deform the battery block.
Vaporization of the electrolyte forms a layer of sulfites on the
surface of metal pieces, which must be cleaned. Cleaned
surfaces are to be protected by a light layer of Vaseline or oil.
Idle batteries must be charged up after two months.
SAFETY RULES
While handling full batteries one must be very careful. Use
gloves and goggles.
Stained skin must be washed and neutralized by soap and soda.
During charging the electrolyte develops oxygen and hydro-
gen, an explosive mixture. It is not allowed to handle open flame
near charging batteries. An explosion may occur if caused by
a spark resulting from disconnecting or loosening the clamp
while the charging current is present.
When removing the battery, disconnect minus cable first. It is
not allowed to disconnect the battery while the engine is
running.
11 - ELECTRICAL INSTALLATION
ALTERNATOR
The alternator is the source of electrical power.
A solid-state voltage regulator is part of the alternator, and
maintains the output voltage within specified limits indepen-
dently of revolutions, load, and ambient temperature.
Regulated voltage varies on clamp +B.
Independent fan cools the assembly, and turns in the marked
direction.
The alternator must always work with the battery connected,
plus side to clamp +B. It is not allowed to disconnect the battery
while operating the equipment.
Short circuits must be avoided. The alternator must be discon-
nected during repairs to electrical installation and welding.
During emergency starts, the auxiliary source may not be
disconnected before the battery has been connected. The
alternator must not run idle with the conductor off clamp “+B“
and clamp “+D“ on.
The burned out charge indicating bulb must be replaced
immediately. Without the bulb excitation of the alternator is not
present.
Note: During welding on the machine, the alternator – cables
off clamps “+B“ and “+D“ – as well as all devices containing
semi-conductors must be disconnected.
VISUAL INSPECTION OF MOUNTED ALTERNATOR
This inspection is for information only. A valid inspection must
be performed on a test bed under controlled load.
Correct operation depends on
- intact electrical installation
- good contacts on the clamps of the alternator, regulator,
and battery
- sufficient tension of the drive belt – force acting on the
shaft of the alternator may be only 800 N in the axis of the
belt drive.
A defect in the alternator or the regulator may cause the battery
to be either not fully charged or overcharged.
Normal inspection in the shop, when the assembly is not
suspect of being faulty, involves the check of the regulating
voltage and/or the response of the control bulb to increased
revolutions. With a meter on terminal “B+“ the regulated
voltage at average revolutions must be within 27-28,2 V.
191
11 - ELECTRICAL INSTALLATION

INSPECTING DEFECTS OF ALTERNATOR - REGULATOR VOLTAGE REGULATOR

Checking the alternator-regulator set – test conditions This is an integrated voltage regulator. The exciter circuit to the
- Remove regulator subassembly with the carbon brushes alternator is connected between terminals DF and D+ on the
holder from the alternator and replace with a reliably func- regulator. The regulator 2 itself is connected to the brush
tioning subassembly. holder and the entire subassembly is attached to the alternator
by two bolts. It is wired by three soldered circuits (B-, DF, D+)
Check regulated voltage on test bed. and a cable terminated in tube 6, 3, which slides on connector
“+D“ of the alternator. The regulator itself is not repairable.
Checking the alternator without the regulator – test condi-
tions.
• Remove regulator subassembly with the carbon brushes
holder and replace with modified brush holder, which has
one terminal grounded to chassis. The other lead has a tube
for the connector, which is to be attached to terminal D+,
and continues for about 20 cm to terminal B+ for short-term
excitation.
• Fasten the alternator to test bed with a voltmeter, an ampere-
meter, a load resistor, an RPM meter, and a battery, see Fig.
• Turn the alternator at about 1500 revolutions per minute.
• Excite the alternator with the end of the free lead from the
brushes and terminal D+ connected to terminal B+ for
about 2 to 3 seconds.
• Should the alternator fail to be excited, then it is defective.
Check the characteristic of the alternator.
If no defect can be found, check the regulator.
The cause may be found in a faulty connection between the
chassis of the alternator and the vehicle, eventually incorrect
ground connection of the battery.

192
 11 - ELECTRICAL INSTALLATION

LIST OF POSSIBLE DEFECTS

SIGNS OF INSUFFICIENT BATTERY CHARGING

Indicator of charging is faulty regulator replace regulator

on during operation
faulty rotor - winding s/c to chassis replace rotor

faulty stator replace stator

faulty diode in the block replace diode

loose solder joints on diode terminals or the stator clean, resolder

Indicator not on after faulty indicator bulb replace bulb

ignition switched on
faulty connection on terminal +D, or on battery terminals clean contacts, tighten

faulty rotor - winding open replace rotor

carbon loose in the holder remove carbon, clean, or replace

fouled up collector rings clean

SIGNS OF OVERCHARGED BATTERY

faulty ground in charging circuit -clean ground lugs, tighten regulator-alternator, battery-chassis, chassis-engine

faulty regulator replace

faulty auxiliary diode replace

193
11 - ELECTRICAL INSTALLATION

STARTER TO FIND DEFECTS ON THE STARTER

OPERATION AND MAINTENANCE
• Good operation of the starter requires a proper and fully
charged battery.
• The starter has been designed for short-time operation.
Starting may not last longer than 5 seconds.
• When the engine starts, stop the starter. The pinion and the
starter bearing may be damaged.
• Input cables must have terminals fully tightened, insulation
must be perfect.
• The chassis of the starter is part of the electrical circuit.
Maintain seating surface clean and protect it against corro-
sion.
• If the starter doesn‘t operate, look for open leads between
the battery and the starter, between the engine chassis and
the starter, or between chassis and the battery.
• Check the crown-wheel teeth, the pinion, whether worn,
and grease.
• Every two years or while the engine is being repaired,
remove the starter, check the commutator, springs of the
brushes, and breaker contacts.
The brushes must touch the commutator by 3/4 of their surface
area, and must move freely. Contact faces of the breaker must
not be burned and must touch fully.
Before starting work, check that voltage is present on terminals
“30“ and “50“ (turn ignition key to “start“). An easy way to check
this is to turn the key and to observe, whether the intensity of
headlights decreases. This indicates the condition of battery-
starter state.
Preliminary inspection of the uninstalled starter
Connect terminal “30“ of the starter to a fully charged battery
and an ammeter with a large scale. By starting, current appears
on terminal “50“. The no-load current shouldn‘t exceed 120 A
(the momentary peak value should be disregarded). The starter
must run quietly. The pinion must slide out smoothly and return
to original position. When the pinion slides out, it shouldn‘t turn
over the face of the ring. After the current is turned off, the starter
may run for another eight seconds only. Check on the pressure
and shape of carbon brushes. The brushes must touch the
commutator by 2/3 of their area and must move freely in the
holders. The ratchet must have a noticeable axial clearance, up
to 1.3 mm, when the pinion is turned in the direction of the
starter, the free wheel must turn freely. With experience it is
sufficient for shop evaluation to test unloaded. It is, however,
recommended to use a test bed.

INSPECTION OF NO-LOAD RUN – ON THE EQUIPMENT

Test the starter in a position, when the pinion is not engaged

in the crown-wheel teeth. With the starter circuit on the pinion
must slide out and rotate. Unloaded starter may be left on for no
more than 10 seconds. Detailed procedure is described in the
Section “Informative Inspection of the starter“. Measured valu-
es must correspond to the table.

Us e d c u r r e n t Battery voltage RP M wh e n c o l d

ma x . 1 3 0 A 23 V Mi n . 4 0 0 0 r p m

The value of RPM in the table is for information only. It is

problematic to measure rpm by normally available shop tools
– it will not be measured.

194
 11 - ELECTRICAL INSTALLATION

STARTER DEFECTS AND REMEDIES

Defect Cause Remedy

Starter doesn't turn Open lead to terminal "30" Repair lead

Open lead to terminal "50" Repair lead

Defective ignition box Replace box

Carbonized contacts Replace contacts or the entire lid together with

bridge contacts

Open winding in the starter contactor Replace starter contactor

S/C in contactor (weak pull, heats up) Replace starter contactor

The contactor ratchet hangs up Loosen, clean, and lubricate

Starter runs freely Damaged sliding mechanism Replace, or repair

Pinion hangs up on the shaft Repair, sometimes it is necessary to

straighten the shaft

Starter doesn't switch off, remains on. Defective ignition box Replace ignition box
Disconnect battery immediately
(terminal grounded to chassis)! Carbonized contacts of starter contactor Replace contacts together with the bridge
contacts, or the entire contactor

Pinion seized on the shaft Replace pinion bearing. Remove sharp edges
on the shaft, clean (check shaft eccentricity)

Starter doesn't slide pinion to engage damaged fly wheel crown Repair crown or replace (find cause)

Pinion mills the fly wheel Broken spring Replace spring

Damaged pinion teeth Replace pinion (find cause)

Starter engages pinion (audibly), but Battery discharged Charge battery

engine doesn't turn
Damaged free wheel - slippage (broken Replace
bushing)

Burnt contacts of the starter contactor Replace

195
11 - ELECTRICAL INSTALLATION
De fe c t Ca us e
S t a r t e r u n r e l i a bl e . L o w Di s c h a r g e d b a t t e r y
out put
S o i l e d o r l o o s e c o n t a c t s i n c a bl e s
( t ransi ent r esi st ance)
Bat t er y defect i ve ( usual l y gradual
det er i orat i on i n st ar t i ng)
Da ma g e d c a r b o n b r u s h e s
S o i l e d a n d bu r n e d c o m mu t a t o r ( s o l d e r )
B r o ke n o r w e a k s p r i n g s o f b r u s h e s
S / C a r ma t u r e
Open exci t i ng coi l
St ar t er cont act or defect i ve ( t ransi ent
r esi st ance)
Open exci t i ng wi ndi ng of st at or on t he
t e r mi n a l o f s t a r t e r c o n t a c t o r
St ar t er noi sy St ar t er l oose i n f l ange
A r m a t u r e l o o s e ( s e i ze d b e a r i n g s )
M e c h a n i c a l d e fe c t - m i s c e l l a n e o u s
Br oken l i d ( ver y noi sy)
S t a r t e r g e t s ve r y h o t , S/ C i n t he exci t er ci r cui t
l ow p owe r
196
R e m e dy
Ch a r g e b a t t e r y
Cl e a n , t i g h t e n t h o r o u g h l y
R e p a i r d e fe c t s i n b a t t e r y
R e p l a c e b r u s h e s ( c o n c o m i t a n t r e p a i r o f c o m mu t a t o r )
C l e a n w i t h g a s o l i n e o r a l c o h o l . I f t h e c o m mu t a t o r i s
bu r n e d o r m i c a s h o w i n g b e t w e e n p l a t e s ( s t r o n g
s p a r k i n g ) , d i s a s s e m bl e s t a r t e r a n d m a c h i n e
commut at or. Mi l l out i nsul at i on, pol i sh commut at or. I f
necessar y, r esol der and/ or r epl ace rat chet .
Re p l a c e s p r i n g
Re p l a c e a r ma t u r e
Re p l a c e p a r t i c u l a r p a i r o f c o i l s
Repl ace i gni t i on box
Re s o l d e r t e r mi n a l
Ti ght en bol t s
Re p a i r
R e p a i r d e fe c t s
Repai r, r epl ace l i d
Re p a i r s h o r t o r r e p l a c e p a r t i c u l a r p a i r o f c o i l s
 12 - REMOVAL OF ROPS FRAME

12 - REMOVAL OF ROPS FRAME

Suspend ROPS on crane using hooks

Loosen bolts 6 (M24×80), set ROPS aside.

66

197
12 - REMOVAL OF ROPS FRAME

198
 13 - ASSEMBLY OF SEGMENTS

13 - ASSEMBLY OF SEGMENTS
Place the machine on a firm and flat ground

Suspend the front scraper with clamps for smooth drums on

the crane

Remove scarper bolts 9.

199
13 - ASSEMBLY OF SEGMENTS

Lower the scraper to ground and set aside.

200
 13 - ASSEMBLY OF SEGMENTS

Follow same procedure for removal of the rear scraper.

Remove plugs 5 in the drum frame

Clean thoroughly the surface of the drum

201
13 - ASSEMBLY OF SEGMENTS

Suspend the first segment behind the opening in the lug

Place it on the drum

202
 13 - ASSEMBLY OF SEGMENTS

Fasten with four clamps (two on each side). Before tighten-

ing even up segment edges with the edge of the drum.

Drive slowly forward for about 1.6 meters (5.25 ft), while
checking the clamps so that they wouldn’t interfere with the
drum frame.

203
13 - ASSEMBLY OF SEGMENTS

Situate the second segment to create a space of about 26 mm

(1,02 in) between the segments. Connect segments using
material 12, 16, and 21.

)
26 (1,02
V
V

Move forward again, set up the third segment and proceed as

before with the second segment.

Tighten bolts, move the machine so that the segments would

settle down on the drum, check bolts, tighten fully with torque
see chapter 24.

The second nut is a thread protection only. It must over-

hung the cud of the bolt. Distribute overhung evenly on all
bolts on the cizamference of the drum. /Overhung 6 mm
(0,24 in)/

204
 13 - ASSEMBLY OF SEGMENTS

Install segment scrapers supplied with the segments on the

front beam and the rear crossbeam of the drum frame. Adjust
gap between scraper and the drum to 30 mm. You may use for
installation also previously removed bolts and pads. Tighten
with torque - see chapter 24.

205
13 - ASSEMBLY OF SEGMENTS

206
 14 - DISASSEMBLY OF WHEEL

14 - DISASSEMBLY OF WHEEL
Hoist the rear frame of the machine, insert supports no. 1.

Remove bolts and washers pos. 12 and 15.

12
15

Remove tire with the disk, set aside, to use of fixture no. 2.

207
14 - DISASSEMBLY OF WHEEL

Install tire with the disk supplied in the set with the tamping
drum. Tighten with torque - see chapter 24.
2

FIXTURES

No.1 - ND080211 - Assembly (rear support for truck frame)

ASC 70/90, ASC 200/ 250
No.1 - ND0800324 - Assembly (rear support for truck frame)
ASC 110/150 2
No.2 - ND107325 - Handling (for removal of the wheel)
ASC 70/90
No.2 - ND080533 - Handling (for removal of the wheel)
ASC 110/150
No.2 - ND107324 - Handling (for removal of the wheel)
ASC 200/250

208
 15 - REMOVAL OF HYDRAULICS MOTORS

15 - REMOVAL OF HYDRAULIC MOTORS

REMOVAL OF HOOD HYDRAULIC MOTORS

Lift the hood, support by fixture no.1 in lifted position

Disconnect electrical wiring

1 1

209
15 - REMOVAL OF HYDRAULIC MOTORS

Press out pins 1, 4 from piston ends in lifting hydraulic motors,

secure by fixture no. 2.

1 4

Install fixture no. 3, lower the hood, support

3
3

Remove hinges

210
 15 - REMOVAL OF HYDRAULICS MOTORS

Attach hooks of fixture no. 3.

Set hood aside using fixture no. 3.

211
15 - REMOVAL OF HYDRAULIC MOTORS

Place a receptacle underneath the disassembled hydraulic

motor 11. Disconnect hoses, plug. Remove shims, press out
pins 4 from piston ends. Using lifting hydraulic motor remove
from equipment, remove hydraulic lock 17.

11 11

17

4
4 17

REMOVAL OF CABIN HYDRAULIC MOTOR FROM

EQUIPMENT

Lift cabin, support using fixture No. 4, place receptacle under

the hydraulic motor, press piston rod in the cylinder, remove
3
hydraulic motor with bracket 1 from the equipment, press out
4 pin 4, remove hydraulic lock 3.

REMOVAL OF LINEAR HYDRAULIC MOTOR –

REPLACEMENT OF SEALS

Place a receptacle under the hydraulic motor, plug openings.

Drill out safety pin from the face of the front lid 1 (bend lid 1
safety) depending on the type of the linear hydraulic motor.
Using fixture wrench No. 5, 6 (depending on the type of the
linear hydraulic motor) remove lid 1, slide piston rod 2 with
piston 3, remove nut 4 and the piston. Slide lid 1.

212
 15 - REMOVAL OF HYDRAULICS MOTORS

Replace seals after soaking seals in oil.

Item No. Description

1 Sealing

2 Collar

3 Scraping ring

4 Guiding band

5 Ring

6 Ring

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
straightened out. Wait at least 15 minutes before complete
assembly of the hydraulic motor after new seals have been
installed. For assembly of piston rod with the piston in the
cylinder use fixture No. 7. Threads to be tightened with torque
according in table

Tightening torque
linear hydraulic motor 40/22 linear hydraulic motor 25/18

Lid 10 connection to cylinder 1 Piston rod 4, nut 8 Lid 10 connection to cylinder 1 Piston rod 4, nut 8

Tightening Tightening
Thread Tightening torque Thread Thread Tightening torque Thread
torque torque

160 Nm 50 Nm 120 Nm 40 Nm
M45x1,5 M 16x1 M30x1,5 M 12x1,5
(118 ft-lb) (37 ft-lb) (89 ft-lb) (30 ft-lb)

NOTE: Proper seal sets for the linear hydraulic motor may
be ordered from the equipment manufacturer
indicating the S/N of the equipment.

213
15 - REMOVAL OF HYDRAULIC MOTORS

FIXTURES

No. 1 - ND080080 - Assembly (hood support) No. 5 Assembly - ND107335 (spanner for disassembly of
cover 1)

No. 6 Assembly - ND107337 (spanner for disassembly of

No. 2 - ND080220 - Assembly (securing the bonnet lifting cover 1)
cylinders)

No. 7 Assembly - ND101783 (for installation of piston to

hydraulic cylinder)

No. 3 - ND101778 - Handling (lifting eyes for assembly of

bonnet)

No. 4 - ND080078 - Handling (cabin support)

214
 16 - REPLACING PRESSURE FILTER OF HYDRAULICS

16 - REPLACING PRESSURE FILTER OF HYDRAULICS

Loosen filter body using wrench 27.

215
16 - REPLACING PRESSURE FILTER OF HYDRAULICS

Unscrew and remove the cover. Drain oil in a can.

216
 16 - REPLACING PRESSURE FILTER OF HYDRAULICS

Remove filter cartridge 17 see catalogue of spare parts –

replace. Check condition of sealing rings, smear rings with oil.
Tighten cover after filter replacement with torque 40 Nm.

17
17

217
17 - FILLING HYDRAULIC OIL

17 - FILLING HYDRAULIC OIL

Remove cover of the quick coupler on the filling throat.

Insert hose from the filling pump.

Submerge filling hose into the oilcan, and add oil to pre-
scribed level.

218
 18 - DISASSEMBLY OF LEVEL GAUGE

18 - DISASSEMBLY OF LEVEL GAUGE

Remove cover of hydraulic tank.

Remove cover of level gauge.

Loosen bolts attaching the level gauge.

219
18 - DISASSEMBLY OF LEVEL GAUGE

Disconnect and remove wiring.

220
 19 - DISASSEBMLY OF THE FLOATER

19 - DISASSEMBLY OF THE FLOATER

Loosen clamp on the cover of the floater, tilt cover.

Disconnect wiring.

Loosen connecting bolts.

221
19 - DISASSEMBLY OF THE FLOATER

Remove floater.

222
 20 - ELECTRICAL SCHEMATA

20 - ELECTRIC SCHEMATA

The electric installation consists of two accumulator batteries,

an alternator and other control and indicating devices. Opera-
tion 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 ma-
chine electric system.
In addition to the basic ”car-electricity” of the machine, there
are used electronic elements, some circuits are protected by
diodes, and some instruments include e.g. thyristors.
A hydraulic lock (ASC) is controlled by a control unit (SUSMIK)
located below the instrument panel. Therefore welding works
are prohibited on the machine, without disconnecting all
sensitive parts from the power supply and/or their dismantling,
if possible, in advance. For example, data inside the SUSMIK
equipment can be erased by welding close to it.

223
20 - ELECTRICAL SCHEMATA

WIRING SCHEME - FIAT (ASC 2-VALVE)

Legend: (the schematic reflects machine version that includes all controlling elements and accessories) - FIAT

A1 - Interrupter of direction lights (optional) S3 - Switch box

A2 - Brake timer S4 - Switch of front headlights
A3 - Travel control S5 - Switch of rear headlights
A4 - Controlling unit of differential lock (optional) S6 - Switch of warning lights (optional)
A5 - Sensor of longitudinal inclination (optional) S7 - Change-over switch of direction lights (optional)
B1 - Sensor of engine oil thermometer S8 - Switch of safety beacon (optional)
B2 - Sensor of hydraulic oil thermometer S9 - Push button of horn
B3 - Fuel level sensor S10 - Position switch of seat panel opening
E1 - Instruments illumination S11 - Push button of emergency brake
E2, 3 - Front outline lights (optional) S12 - Switch of back-up alarm (optional)
E4, 5 - Tail lights (optional) S13 - Switch of neutral (at the travel control)
E6, 7 - Front headlights S14 - Float of the hydraulic oil tank
E8, 9 - Rear headlights S15 - Pressure switch of steering
E10,11 - Left direction lights (optional) S16 - Switch - fast travel
E12,13 - Right direction lights (optional) S17 - Switch - speed preselector
E14 - Cabin illumination S18 - Change-over switch of vibration
E15 - Safety beacon (optional) S19 - Switch of vibration (at the travel control)
E16,17 - Brake lamps S20 - Terminal switch of the gas lever
E18 - Car make lighting S21 - Pressure switch of brake
E19,20 - Front auxiliary headlamp S22 - Switch of differential lock (optional)
F1-7 - Fuses S23 - Sensor of drum speed (optional)
G1,2 - Batteries S24 - Sensor of left wheel speed (optional)
G3 - Alternator S25 - Sensor of right wheel speed (optional)
H1 - Indicator of direction lights (optional) S26 - Pressure switch of engine lubrication
H2 - Horn S27 - Underpressure switch of air filter clogging
H3 - Back-up alarm (optional) S28 - Underpressure switch of hydraulic filter clogging
H4 - Indicator of hydraulic oil level S29 - Change-over of cabin ventilation
H5 - Indicator of neutral position of the travel control S30 - Switch of front windscreen wiper
H6 - Indicator of brake S31 - Switch of rear windscreen wiper
H7 - Indicator of vibration preselection S32 - Push button of windscreen washer
H9 - Indicator of engine lubrication S33 - Change-over switch of fan of heating
H10 - Indicator of charging S35 - Parking brake push button
H11 - Indicator of air filter clogging S36 - Limit switch of traction spin of the drum
H12 - Indicator of hydraulic filter clogging V1-5 - Blocking diode
K1 - Contactor X1 - Hand lamp socket
K2-8 - Auxiliary relay X2-24 - Connectors
M1 - Starter X25 - Diagnostic socket (optional)
M2 - Electric motor of hood & cabin lifting system X27 - Socket of safety beacon
M3 - Fan of cabin ventilation X28 - Connector
M4 - Front windscreen wiper Y1 - Electromagnetic valve cab lifting
M5 - Rear windscreen wiper Y2 - Electromagnetic valve cab lowering
M6 - Front windscreen washer Y3 - Electromagnetic valve hood lifting
M7 - Rear windscreen washer Y4 - Electromagnetic valve hood lowering
M8 - Fan of heating Y5 - Electromagnetic valve of engine STOP
P1 - Engine thermometer Y6 - Electromagnetic valve of brake
P2 - Hydraulic oil thermometer Y7 - Electromagnetic valve of fast travel speed (left wheel)
P3 - Fuel gauge Y8 - Electromagnetic valve of fast travel speed (drum)
P4 - Speedometer Y9 - Electromagnetic valve of vibration I.
P5 - Hour counter Y10 - Electromagnetic valve of vibration II.
Q1 - Battery disconnector Y11 - Electromagnetic valve of differential lock - LH wheel (opt.)
R1,2 - Resistors Y12 - Electromagnetic valve of differential lock - RH wheel (optional)
S1 - Push button of cabin lifting system Y13 - Servovalve of the pump of travel
S2 - Push button of hood lifting system Y14 - Electromagnetic valve of fast travel speed (right wheel)

224
 20 - ELECTRICAL SCHEMATA

CAB LIFTING
CAB LOWERING

HOOD LIFTING
HOOD LOWERING

FRONT OUTLINE LIGHTS

TAIL LIGHTS

CAR MAKE LIGHTING

FRONT HEADLIGHTS

REAR HEADLIGHTS

FRONT AUXILIARY HEADLAMP

CABIN ILLUMINATION
LEFT FRONT DIRECTION LIGHT
LEFT REAR DIRECTION LIGHT
RIGHT REAR DIRECTION LIGHT
RIGHT FRONT DIRECTION LIGHT

SAFETY BEACON

HORN

BACK-UP ALARM

HYDRAULIC OIL LEVEL

ENGINE STOP

BRAKE LAMPS

BRAKE

PRESSURE SWITCH OF STEERING

FAST TRAVEL - LEFT WHEEL

FAST TRAVEL - RIGHT WHEEL

VIBRATION I

VIBRATION II

PRESSURE SWITCH OF BRAKE

225
20 - ELECTRICAL SCHEMATA

FAST TRAVEL (DRUM)

VALVE OF THE LEFT WHEEL

VALVE OF THE RIGHT WHEEL

SENSOR OF LONGITUDINAL INCLINATION

SENSOR OF DRUM SPEED

SENSOR OF LEFT WHEEL SPEED

SENSOR OF RIGHT WHEEL SPEED

SERVOVALVE

TEMPERATURE OF ENGINE

TEMPERATURE OF HYDRAULIC OIL

FUEL GAUGE / SPEEDOMETER

ENGINE LUBRICATION
AIR CLEANER/CHARGING/HOUR COUNTER
FILTER OF HYDRAULIC OIL

CABIN VENTILATION

FRONT WINDSCREEN WIPER

REAR WINDSCREEN WIPER

WINDSCREEN WASHER, FRONT

WINDSCREEN WASHER, REAR

FAN OF HEATING

226
20 - ELECTRICAL SCHEMATA

227
20 - ELECTRICAL SCHEMATA

WIRING SCHEME - CASE (ASC 2-VALVE)

Legend: (the schematic reflects machine version that includes all controlling elements and accessories) - CASE

A1 - Interrupter of direction lights (optional) S4 - Switch of front headlights

A2 - Brake timer S5 - Switch of rear headlights
A3 - Travel control S6 - Switch of warning lights (optional)
A4 - Controlling unit of differential lock (optional) S7 - Change-over switch of direction lights (optional)
A5 - Sensor of longitudinal inclination (optional) S8 - Switch of safety beacon (optional)
B1 - Sensor of engine oil thermometer S9 - Push button of horn
B2 - Sensor of hydraulic oil thermometer S10 - Position switch of seat panel opening
B3 - Fuel level sensor S11 - Push button of emergency brake
E1 - Instruments illumination S12 - Switch of back-up alarm (optional)
E2, 3 - Front outline lights (optional) S13 - Switch of neutral (at the travel control)
E4, 5 - Tail lights (optional) S14 - Float of the hydraulic oil tank
E6, 7 - Front headlights S15 - Pressure switch of steering
E8, 9 - Rear headlights S16 - Switch - fast travel
E10,11 - Left direction lights (optional) S17 - Switch - speed preselector
E12,13 - Right direction lights (optional) S18 - Change-over switch of vibration
E14 - Cabin illumination S19 - Switch of vibration (at the travel control)
E15 - Safety beacon (optional) S20 - Terminal switch of the gas lever
F1-7 - Fuses S21 - Pressure switch of brake
G1,2 - Batteries S22 - Switch of differential lock (optional)
G3 - Alternator S23 - Sensor of drum speed (optional)
H1 - Indicator of direction lights (optional) S24 - Sensor of left wheel speed (optional)
H2 - Horn S25 - Sensor of right wheel speed (optional)
H3 - Back-up alarm (optional) S26 - Pressure switch of engine lubrication
H4 - Indicator of hydraulic oil level S27 - Underpressure switch of air filter clogging
H5 - Indicator of neutral position of the travel control S28 - Underpressure switch of hydraulic filter clogging
H6 - Indicator of brake S29 - Change-over of cabin ventilation
H7 - Indicator of vibration preselection S30 - Switch of front windscreen wiper
H9 - Indicator of engine lubrication S31 - Switch of rear windscreen wiper
H10 - Indicator of charging S32 - Push button of windscreen washer
H11 - Indicator of air filter clogging S33 - Change-over switch of fan of heating
H12 - Indicator of hydraulic filter clogging S35 - Parking brake push button
K1 - Contactor S36 - Limit switch of traction spin of the drum
K2-8 - Auxiliary relay V1-5 - Blocking diode
M1 - Starter X1 - Hand lamp socket
M2 - Electric motor of hood & cabin lifting system X2-24 - Connectors
M3 - Fan of cabin ventilation X25 - Diagnostic socket (optional)
M4 - Front windscreen wiper X27 - Socket of safety beacon
M5 - Rear windscreen wiper Y1 - Electromagnetic valve cab lifting
M6 - Front windscreen washer Y2 - Electromagnetic valve cab lowering
M7 - Rear windscreen washer Y3 - Electromagnetic valve hood lifting
M8 - Fan of heating Y4 - Electromagnetic valve hood lowering
P1 - Engine thermometer Y5 - Electromagnetic valve of engine STOP
P2 - Hydraulic oil thermometer Y6 - Electromagnetic valve of brake
P3 - Fuel gauge Y7 - Electromagnetic valve of fast travel speed (left wheel)
P4 - Speedometer Y8 - Electromagnetic valve of fast travel speed (drum)
P5 - Hour counter Y9 - Electromagnetic valve of vibration I.
Q1 - Battery disconnector Y10 - Electromagnetic valve of vibration II.
R1,2 - Resistors Y11 - Electromagnetic valve of differential lock - LH wheel (optional)
S1 - Push button of cabin lifting system Y12 - Electromagnetic valve of differential lock - RH wheel (optional)
S2 - Push button of hood lifting system Y13 - Servovalve of the pump of travel
S3 - Switch box Y14 - Electromagnetic valve of fast travel speed (right wheel)

228
 20 - ELECTRICAL SCHEMATA

CAB LIFTING
CAB LOWERING

HOOD LIFTING
HOOD LOWERING

FRONT OUTLINE LIGHTS

TAIL LIGHTS

FRONT HEADLIGHTS

REAR HEADLIGHTS

CABIN ILLUMINATION
LEFT FRONT DIRECTION LIGHT
LEFT REAR DIRECTION LIGHT
RIGHT REAR DIRECTION LIGHT
RIGHT FRONT DIRECTION LIGHT

SAFETY BEACON
HORN

BACK-UP ALARM

HYDRAULIC OIL LEVEL

ENGINE STOP

BRAKE

PRESSURE SWITCH OF STEERING

FAST TRAVEL - LEFT WHEEL

FAST TRAVEL - RIGHT WHEEL

VIBRATION I
VIBRATION II

PRESSURE SWITCH OF BRAKE

229
20 - ELECTRICAL SCHEMATA

FAST TRAVEL (DRUM)

VALVE OF THE LEFT WHEEL

VALVE OF THE RIGHT WHEEL

SENSOR OF LONGITUDINAL INCLINATION

SENSOR OF DRUM SPEED

SENSOR OF LEFT WHEEL SPEED

SENSOR OF RIGHT WHEEL SPEED

SERVOVALVE

TEMPERATURE OF ENGINE

TEMPERATURE OF HYDRAULIC OIL

FUEL GAUGE / SPEEDOMETER

ENGINE LUBRICATION
AIR CLEANER/CHARGING/HOUR COUNTER
FILTER OF HYDRAULIC OIL

CABIN VENTILATION

FRONT WINDSCREEN WIPER

REAR WINDSCREEN WIPER

WINDSCREEN WASHER, FRONT

WINDSCREEN WASHER, REAR

FAN OF HEATING

230
20 - ELECTRICAL SCHEMATA

231
20 - ELECTRICAL SCHEMATA

WIRING SCHEME - FIAT - TIER I (ASC 4-VALVE) Also valid for ASC 70-90 with engine B4.5-99 TIER II
Legend: (the schematic reflects machine version that includes all controlling elements and accessories) - FIAT

A1 - Interrupter of direction lights (optional) S3 - Switch box

A2 - Brake timer S4 - Switch of front headlights
A3 - Travel control S5 - Switch of rear headlights
A4 - Controlling unit of differential lock (optional) S6 - Switch of warning lights (optional)
A5 - Sensor of longitudinal inclination (optional) S7 - Change-over switch of direction lights (optional)
B1 - Sensor of engine oil thermometer S8 - Switch of safety beacon (optional)
B2 - Sensor of hydraulic oil thermometer S9 - Push button of horn
B3 - Fuel level sensor S10 - Position switch of seat panel opening
E1 - Instruments illumination S11 - Push button of emergency brake
E2, 3 - Front outline lights (optional) S12 - Switch of back-up alarm (optional)
E4, 5 - Tail lights (optional) S13 - Switch of neutral (at the travel control)
E6, 7 - Front headlights S14 - Float of the hydraulic oil tank
E8, 9 - Rear headlights S15 - Pressure switch of steering
E10,11 - Left direction lights (optional) S16 - Switch - fast travel
E12,13 - Right direction lights (optional) S17 - Switch - speed preselector
E14 - Cabin illumination S18 - Change-over switch of vibration
E15 - Safety beacon (optional) S19 - Switch of vibration (at the travel control)
E16,17 - Brake lamps S20 - Terminal switch of the gas lever
E18 - Car make lighting S21 - Pressure switch of brake
E19,20 - Front auxiliary headlamp S23 - Sensor of drum speed (optional)
F1-9 - Fuses S24 - Sensor of left wheel speed (optional)
G1,2 - Batteries S25 - Sensor of right wheel speed (optional)
G3 - Alternator S26 - Pressure switch of engine lubrication
H1 - Indicator of direction lights (optional) S27 - Underpressure switch of air filter clogging
H2 - Horn S28 - Underpressure switch of hydraulic filter clogging
H3 - Back-up alarm (optional) S29 - Change-over of cabin ventilation
H4 - Indicator of hydraulic oil level S30 - Switch of front windscreen wiper
H5 - Indicator of neutral position of the travel control S31 - Switch of rear windscreen wiper
H6 - Indicator of brake S32 - Push button of windscreen washer
H7 - Indicator of vibration preselection S33 - Change-over switch of fan of heating
H9 - Indicator of engine lubrication S35 - Parking brake push button
H10 - Indicator of charging S36 - Limit switch of traction spin of the drum
H11 - Indicator of air filter clogging V1,2,4,5- Blocking diode
H12 - Indicator of hydraulic filter clogging V3 - Blocking diode (only machine with signalling of sound lift cabin)
H13 - Indicator of differential lock (ASC) X1 - Hand lamp socket
K1 - Contactor X2-24 - Connectors
K2-8 - Auxiliary relay X25 - Diagnostic socket (optional)
M1 - Starter X27 - Socket of safety beacon
M2 - Electric motor of hood & cabin lifting system Y1 - Electromagnetic valve cab lifting
M3 - Fan of cabin ventilation Y2 - Electromagnetic valve cab lowering
M4 - Front windscreen wiper Y3 - Electromagnetic valve hood lifting
M5 - Rear windscreen wiper Y4 - Electromagnetic valve hood lowering
M6 - Front windscreen washer Y5 - Electromagnetic valve of engine STOP
M7 - Rear windscreen washer Y6 - Electromagnetic valve of brake
M8 - Fan of heating Y7 - Electromagnetic valve of fast travel speed (left wheel)
P1 - Engine thermometer Y8 - Electromagnetic valve of fast travel speed (drum)
P2 - Hydraulic oil thermometer Y9 - Electromagnetic valve of vibration I.
P3 - Fuel gauge Y10 - Electromagnetic valve of vibration II.
P4 - Speedometer Y11 - Electromagnetic valve of differential lock - LH wheel backward(opt.)
P5 - Hour counter Y12 - Electromagnetic valve of differential lock - LH wheel forward (opt.)
Q1 - Battery disconnector Y13 - Servovalve of the pump of travel
R1,2 - Resistors Y14 - Electromagnetic valve of fast travel speed (right wheel)
S1 - Push button of cabin lifting system Y15 - Electromagnetic valve of differential lock - RH wheel forward (opt.)
S2 - Push button of hood lifting system Y16 - Electromagnetic valve of differential lock - RH wheel backward (opt.)

232
 20 - ELECTRICAL SCHEMATA

CAB LIFTING
CAB LOWERING

HOOD LIFTING
HOOD LOWERING

FRONT OUTLINE LIGHTS

TAIL LIGHTS

CAR MAKE LIGHTING

FRONT HEADLIGHTS

REAR HEADLIGHTS

FRONT AUXILIARY HEADLAMP

CABIN ILLUMINATION
LEFT FRONT DIRECTION LIGHT
LEFT REAR DIRECTION LIGHT
RIGHT REAR DIRECTION LIGHT
RIGHT FRONT DIRECTION LIGHT

SAFETY BEACON

HORN

BACK-UP ALARM

HYDRAULIC OIL LEVEL

ENGINE STOP

BRAKE LAMPS

BRAKE

PRESSURE SWITCH OF STEERING

FAST TRAVEL - LEFT WHEEL

FAST TRAVEL - RIGHT WHEEL

VIBRATION I
VIBRATION II

PRESSURE SWITCH OF BRAKE

233
20 - ELECTRICAL SCHEMATA

FAST TRAVEL (DRUM)

VALVE OF THE LEFT WHEEL BACKWARD

VALVE OF THE LEFT WHEEL FORWARD

VALVE OF THE RIGHT WHEEL FORWARD

VALVE OF THE RIGHT WHEEL BACKWARD

SENSOR OF LONGITUDINAL INCLINATION

SENSOR OF DRUM SPEED

SENSOR OF LEFT WHEEL SPEED

SENSOR OF RIGHT WHEEL SPEED

SERVOVALVE

TEMPERATURE OF ENGINE

TEMPERATURE OF HYDRAULIC OIL

FUEL GAUGE / SPEEDOMETER

ENGINE LUBRICATION
AIR CLEANER/CHARGING/HOUR COUNTER
FILTER OF HYDRAULIC OIL

CABIN VENTILATION

FRONT WINDSCREEN WIPER

REAR WINDSCREEN WIPER

WINDSCREEN WASHER, FRONT

WINDSCREEN WASHER, REAR

FAN OF HEATING
RESERVE (AIR–CONDITIONING SYSTEM)

RESERVE

234
20 - ELECTRICAL SCHEMATA

235
20 - ELECTRICAL SCHEMATA

WIRING SCHEME - CASE - TIER I (ASC 4-VALVE) Also valid for ASC 70-90 with engine B4.5-99 TIER II
Legend: (the schematic reflects machine version that includes all controlling elements and accessories) - CASE

A1 - Interrupter of direction lights (optional) S5 - Switch of rear headlights

A2 - Brake timer S6 - Switch of warning lights (optional)
A3 - Travel control S7 - Change-over switch of direction lights (optional)
A4 - Controlling unit of differential lock (optional) S8 - Switch of safety beacon (optional)
A5 - Sensor of longitudinal inclination (optional) S9 - Push button of horn
B1 - Sensor of engine oil thermometer S10 - Position switch of seat panel opening
B2 - Sensor of hydraulic oil thermometer S11 - Push button of emergency brake
B3 - Fuel level sensor S12 - Switch of back-up alarm (optional)
E1 - Instruments illumination S13 - Switch of neutral (at the travel control)
E2, 3 - Front outline lights (optional) S14 - Float of the hydraulic oil tank
E4, 5 - Tail lights (optional) S15 - Pressure switch of steering
E6, 7 - Front headlights S16 - Switch - fast travel
E8, 9 - Rear headlights S17 - Switch - speed preselector
E10,11 - Left direction lights (optional) S18 - Change-over switch of vibration
E12,13 - Right direction lights (optional) S19 - Switch of vibration (at the travel control)
E14 - Cabin illumination S20 - Terminal switch of the gas lever
E15 - Safety beacon (optional) S21 - Pressure switch of brake
F1-9 - Fuses S23 - Sensor of drum speed (optional)
G1,2 - Batteries S24 - Sensor of left wheel speed (optional)
G3 - Alternator S25 - Sensor of right wheel speed (optional)
H1 - Indicator of direction lights (optional) S26 - Pressure switch of engine lubrication
H2 - Horn S27 - Underpressure switch of air filter clogging
H3 - Back-up alarm (optional) S28 - Underpressure switch of hydraulic filter clogging
H4 - Indicator of hydraulic oil level S29 - Change-over of cabin ventilation
H5 - Indicator of neutral position of the travel control S30 - Switch of front windscreen wiper
H6 - Indicator of brake S31 - Switch of rear windscreen wiper
H7 - Indicator of vibration preselection S32 - Push button of windscreen washer
H9 - Indicator of engine lubrication S33 - Change-over switch of fan of heating
H10 - Indicator of charging S35 - Parking brake push button
H11 - Indicator of air filter clogging S36 - Limit switch of traction spin of the drum
H12 - Indicator of hydraulic filter clogging V1,2,4,5- Blocking diode
H13 - Indicator of differential lock (ASC) V3 - Blocking diode (only machine with signalling of sound lift cabin)
K1 - Contactor X1 - Hand lamp socket
K2-8 - Auxiliary relay X2-24 - Connectors
M1 - Starter X25 - Diagnostic socket (optional)
M2 - Electric motor of hood & cabin lifting system X27 - Socket of safety beacon
M3 - Fan of cabin ventilation Y1 - Electromagnetic valve cab lifting
M4 - Front windscreen wiper Y2 - Electromagnetic valve cab lowering
M5 - Rear windscreen wiper Y3 - Electromagnetic valve hood lifting
M6 - Front windscreen washer Y4 - Electromagnetic valve hood lowering
M7 - Rear windscreen washer Y5 - Electromagnetic valve of engine STOP
M8 - Fan of heating Y6 - Electromagnetic valve of brake
P1 - Engine thermometer Y7 - Electromagnetic valve of fast travel speed (left wheel)
P2 - Hydraulic oil thermometer Y8 - Electromagnetic valve of fast travel speed (drum)
P3 - Fuel gauge Y9 - Electromagnetic valve of vibration I.
P4 - Speedometer Y10 - Electromagnetic valve of vibration II.
P5 - Hour counter Y11 - Electromagnetic valve of differential lock - LH wheel backward(opt.)
Q1 - Battery disconnector Y12 - Electromagnetic valve of differential lock - LH wheel forward (opt.)
R1,2 - Resistors Y13 - Servovalve of the pump of travel
S1 - Push button of cabin lifting system Y14 - Electromagnetic valve of fast travel speed (right wheel)
S2 - Push button of hood lifting system Y15 - Electromagnetic valve of differential lock - RH wheel forward (opt.)
S3 - Switch box Y16 - Electromagnetic valve of differential lock - RH wheel backward (opt.)
S4 - Switch of front headlights

236
20 - ELECTRICAL SCHEMATA

237
20 - ELECTRICAL SCHEMATA

FAST TRAVEL (DRUM)

VALVE OF THE LEFT WHEEL BACKWARD

VALVE OF THE LEFT WHEEL FORWARD

VALVE OF THE RIGHT WHEEL FORWARD

VALVE OF THE RIGHT WHEEL BACKWARD

SENSOR OF LONGITUDINAL INCLINATION

SENSOR OF DRUM SPEED

SENSOR OF LEFT WHEEL SPEED

SENSOR OF RIGHT WHEEL SPEED

SERVOVALVE

TEMPERATURE OF ENGINE

TEMPERATURE OF HYDRAULIC OIL

FUEL GAUGE / SPEEDOMETER

ENGINE LUBRICATION
AIR CLEANER/CHARGING/HOUR COUNTER
FILTER OF HYDRAULIC OIL

CABIN VENTILATION

FRONT WINDSCREEN WIPER

REAR WINDSCREEN WIPER

WINDSCREEN WASHER, FRONT

WINDSCREEN WASHER, REAR

FAN OF HEATING
RESERVE (AIR–CONDITIONING SYSTEM)

RESERVE

238
20 - ELECTRICAL SCHEMATA

239
20 - ELECTRICAL SCHEMATA

WIRING SCHEME - AMMANN-TIER I (ASC 4-VALVE) Also valid for ASC70-90 with engine B4.5-99TIER II
Legend: (the schematic reflects machine version that includes all controlling elements and accessories)
A1 - Interrupter of direction lights (optional) S7 - Change-over switch of direction lights (optional)
A2 - Brake timer S8 - Switch of safety beacon (optional)
A3 - Travel control S9 - Push button of horn
A4 - Controlling unit of differential lock (optional) S10 - Position switch of seat panel opening
A5 - Sensor of longitudinal inclination (optional) S11 - Push button of emergency brake
B1 - Sensor of engine oil thermometer S12 - Switch of back-up alarm (optional)
B2 - Sensor of hydraulic oil thermometer S13 - Switch of neutral (at the travel control)
B3 - Fuel level sensor S14 - Float of the hydraulic oil tank
E1 - Instruments illumination S15 - Pressure switch of steering
E2, 3 - Front outline lights (optional) S16 - Switch - fast travel
E4, 5 - Tail lights (optional) S17 - Switch - speed preselector
E6, 7 - Front headlights S18 - Change-over switch of vibration
E8, 9 - Rear headlights S19 - Switch of vibration (at the travel control)
E10,11 - Left direction lights (optional) S20 - Terminal switch of the gas lever
E12,13 - Right direction lights (optional) S21 - Pressure switch of brake
E14 - Cabin illumination S23 - Sensor of drum speed (optional)
E15 - Safety beacon (optional) S24 - Sensor of left wheel speed (optional)
F1-9 - Fuses S25 - Sensor of right wheel speed (optional)
G1,2 - Batteries S26 - Pressure switch of engine lubrication
G3 - Alternator S27 - Underpressure switch of air filter clogging
H1 - Indicator of direction lights (optional) S28 - Underpressure switch of hydraulic filter clogging
H2 - Horn S29 - Change-over of cabin ventilation
H3 - Back-up alarm (optional) S30 - Switch of front windscreen wiper
H4 - Indicator of hydraulic oil level S31 - Switch of rear windscreen wiper
H5 - Indicator of neutral position of the travel control S32 - Push button of windscreen washer
H6 - Indicator of brake S33 - Change-over switch of fan of heating
H7 - Indicator of vibration preselection S35 - Parking brake push button
H9 - Indicator of engine lubrication S36 - Limit switch of traction spin of the drum
H10 - Indicator of charging V1,2,4,5- Blocking diode
H11 - Indicator of air filter clogging V3 - Blocking diode (only machine with signalling of sound lift
H12 - Indicator of hydraulic filter clogging cabin)
H13 - Indicator of differential lock (ASC) X1 - Hand lamp socket
K1 - Contactor X2-24 - Connectors
K2-8 - Auxiliary relay X25 - Diagnostic socket (optional)
M1 - Starter X27 - Socket of safety beacon
M2 - Electric motor of hood & cabin lifting system Y1 - Electromagnetic valve cab lifting
M3 - Fan of cabin ventilation Y2 - Electromagnetic valve cab lowering
M4 - Front windscreen wiper Y3 - Electromagnetic valve hood lifting
M5 - Rear windscreen wiper Y4 - Electromagnetic valve hood lowering
M6 - Front windscreen washer Y5 - Electromagnetic valve of engine STOP
M7 - Rear windscreen washer Y6 - Electromagnetic valve of brake
M8 - Fan of heating Y7 - Electromagnetic valve of fast travel speed (left wheel)
P1 - Engine thermometer Y8 - Electromagnetic valve of fast travel speed (drum)
P2 - Hydraulic oil thermometer Y9 - Electromagnetic valve of vibration I.
P3 - Fuel gauge Y10 - Electromagnetic valve of vibration II.
P4 - Speedometer Y11 - Electromagnetic valve of differential lock - LH wheel bac-
P5 - Hour counter kward(opt.)
Q1 - Battery disconnector Y12 - Electromagnetic valve of differential lock - LH wheel forward
R1,2 - Resistors (opt.)
S1 - Push button of cabin lifting system Y13 - Servovalve of the pump of travel
S2 - Push button of hood lifting system Y14 - Electromagnetic valve of fast travel speed (right wheel)
S3 - Switch box Y15 - Electromagnetic valve of differential lock - RH wheel forward
(opt.)
S4 - Switch of front headlights
Y16 - Electromagnetic valve of differential lock - RH wheel
S5 - Switch of rear headlights
backward (opt.)
S6 - Switch of warning lights (optional)

240
20 - ELECTRICAL SCHEMATA

241
20 - ELECTRICAL SCHEMATA

FAST TRAVEL (DRUM)

VALVE OF THE LEFT WHEEL BACKWARD

VALVE OF THE LEFT WHEEL FORWARD

VALVE OF THE RIGHT WHEEL FORWARD

VALVE OF THE RIGHT WHEEL BACKWARD

SENSOR OF LONGITUDINAL INCLINATION

SENSOR OF DRUM SPEED

SENSOR OF LEFT WHEEL SPEED

SENSOR OF RIGHT WHEEL SPEED

SERVOVALVE

TEMPERATURE OF ENGINE

TEMPERATURE OF HYDRAULIC OIL

FUEL GAUGE / SPEEDOMETER

ENGINE LUBRICATION
AIR CLEANER/CHARGING/HOUR COUNTER
FILTER OF HYDRAULIC OIL

CABIN VENTILATION

FRONT WINDSCREEN WIPER

REAR WINDSCREEN WIPER

WINDSCREEN WASHER, FRONT

WINDSCREEN WASHER, REAR

FAN OF HEATING
RESERVE (AIR–CONDITIONING SYSTEM)

RESERVE

242
20 - ELECTRICAL SCHEMATA

243
20 - ELECTRICAL SCHEMATA

Wiring scheme - according to TIER II, ASC 4 - valves, Ammann, with engine QSB for ASC 110-250
Legend: (the schematic reflects machine version that includes all controlling elements and accessories)
A1 - Interrupter of direction lights (optional) S5 - Switch of rear headlights
A2 - Brake timer S6 - Switch of warning lights (optional)
A3 - Travel control S7 - Change-over switch of direction lights (optional)
A4 - Controlling unit of differential lock (optional) S8 - Switch of safety beacon (optional)
A5 - Sensor of longitudinal inclination (optional) S9 - Push button of horn
B1 - Sensor of cooling liquid level S10 - Position switch of seat panel opening
B2 - Sensor of hydraulic oil thermometer S11 - Push button of emergency brake
B3 - Fuel level sensor S12 - Switch of back-up alarm (optional)
E1 - Instruments illumination S13 - Switch of neutral (at the travel control)
E2, 3 - Front outline lights (optional) S14 - Float of the hydraulic oil tank
E4, 5 - Tail lights (optional) S15 - Pressure switch of steering
E6, 7 - Front headlights S16 - Switch - fast travel
E8, 9 - Rear headlights S17 - Switch - speed preselector
E10,11 - Left direction lights (optional) S18 - Change-over switch of vibration
E12,13 - Right direction lights (optional) S19 - Switch of vibration (at the travel control)
E14 - Cabin illumination S20 - Terminal switch of the gas lever
E15 - Safety beacon (optional) S21 - Pressure switch of brake
F1-9 - Fuses S23 - Sensor of drum speed (optional)
F11-16 - Fuses of engine S24 - Sensor of left wheel speed (optional)
G1,2 - Batteries S25 - Sensor of right wheel speed (optional)
G3 - Alternator S26 - Pressure switch of engine lubrication
H1 - Indicator of direction lights (optional) S27 - Underpressure switch of air filter clogging
H2 - Horn S28 - Underpressure switch of hydraulic filter clogging
H3 - Back-up alarm (optional) S29 - Change-over of cabin ventilation
H4 - Indicator of hydraulic oil level S30 - Switch of front windscreen wiper
H5 - Indicator of neutral position of the travel control S31 - Switch of rear windscreen wiper
H6 - Indicator of brake S32 - Push button of windscreen washer
H7 - Indicator of vibration preselection S33 - Change-over switch of fan of heating
H9 - Indicator of engine lubrication S35 - Parking brake push button
H10 - Indicator of charging S36 - Limit switch of traction spin of the drum
H11 - Indicator of air filter clogging S37 - Engine idle speed switch
H12 - Indicator of hydraulic filter clogging S38 - Engine diagnostic switch
H13 - Indicator of differential lock (ASC) S39 - Trouble shooting switch
H14 - Stop engine warning lamp - red S40 - Water in fuel sensor
H15 - Water in fuel warning lamp V1,2,4,5 - Blocking diode
H16 - Engine defect warning lamp - yellow V3 - Blocking diode (only machine with signalling of sound lift cabin)
H17 - Maintenance indicator lamp - it is not conected X1 - Hand lamp socket
K1 - Start relay X2-24 - Connectors
K2-9 - Auxiliary relay X25 - Diagnostic socket (optional)
K10 - Preheating relay X27 - Socket of safety beacon
M1 - Starter X28-33 - Connectors
M2 - Electric motor of hood & cabin lifting system X34 - Engine diagnostic (electronic control module)
M3 - Fan of cabin ventilation X35-40 - Connectors J1939
M4 - Front windscreen wiper X41-42 - Connectors
M5 - Rear windscreen wiper Y1 - Electromagnetic valve cab lifting
M6 - Front windscreen washer Y2 - Electromagnetic valve cab lowering
M7 - Rear windscreen washer Y3 - Electromagnetic valve hood lifting
M8 - Fan of heating Y4 - Electromagnetic valve hood lowering
P1 - Engine thermometer Y5 - Electromagnetic valve of engine STOP
P2 - Hydraulic oil thermometer Y6 - Electromagnetic valve of brake
P3 - Fuel gauge Y7 - Electromagnetic valve of fast travel speed (left wheel)
P4 - Speedometer Y8 - Electromagnetic valve of fast travel speed (drum)
P5 - Hour counter Y9 - Electromagnetic valve of vibration I.
Q1 - Battery disconnector Y10 - Electromagnetic valve of vibration II.
R1,2 - Resistors Y11 - Electromagnetic valve of differential lock - LH wheel backward(opt.)
R3 - Engine preheating Y12 - Electromagnetic valve of differential lock - LH wheel forward (opt.)
R4 - Engine speed control Y13 - Servovalve of the pump of travel
S1 - Push button of cabin lifting system Y14 - Electromagnetic valve of fast travel speed (right wheel)
S2 - Push button of hood lifting system Y15 - Electromagnetic valve of differential lock - RH wheel forward (opt.)
S3 - Switch box Y16 - Electromagnetic valve of differential lock - RH wheel backward (opt.)
S4 - Switch of front headlights

244
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245
20 - ELECTRICAL SCHEMATA

246
20 - ELECTRICAL SCHEMATA

247
20 - ELECTRICAL SCHEMATA

Wiring scheme - according to TIER II, ASC 4 - valves, CASE, with engine QSB for ASC 110-250
Legend: (the schematic reflects machine version that includes all controlling elements and accessories
A1 - Interrupter of direction lights (optional) S5 - Switch of rear headlights
A2 - Brake timer S6 - Switch of warning lights (optional)
A3 - Travel control S7 - Change-over switch of direction lights (optional)
A4 - Controlling unit of differential lock (optional) S8 - Switch of safety beacon (optional)
A5 - Sensor of longitudinal inclination (optional) S9 - Push button of horn
B1 - Sensor of cooling liquid level S10 - Position switch of seat panel opening
B2 - Sensor of hydraulic oil thermometer S11 - Push button of emergency brake
B3 - Fuel level sensor S12 - Switch of back-up alarm (optional)
E1 - Instruments illumination S13 - Switch of neutral (at the travel control)
E2, 3 - Front outline lights (optional) S14 - Float of the hydraulic oil tank
E4, 5 - Tail lights (optional) S15 - Pressure switch of steering
E6, 7 - Front headlights S16 - Switch - fast travel
E8, 9 - Rear headlights S17 - Switch - speed preselector
E10,11 - Left direction lights (optional) S18 - Change-over switch of vibration
E12,13 - Right direction lights (optional) S19 - Switch of vibration (at the travel control)
E14 - Cabin illumination S20 - Terminal switch of the gas lever
E15 - Safety beacon (optional) S21 - Pressure switch of brake
F1-9 - Fuses S23 - Sensor of drum speed (optional)
F11-16 - Fuses of engine S24 - Sensor of left wheel speed (optional)
G1,2 - Batteries S25 - Sensor of right wheel speed (optional)
G3 - Alternator S26 - Pressure switch of engine lubrication
H1 - Indicator of direction lights (optional) S27 - Underpressure switch of air filter clogging
H2 - Horn S28 - Underpressure switch of hydraulic filter clogging
H3 - Back-up alarm (optional) S29 - Change-over of cabin ventilation
H4 - Indicator of hydraulic oil level S30 - Switch of front windscreen wiper
H5 - Indicator of neutral position of the travel control S31 - Switch of rear windscreen wiper
H6 - Indicator of brake S32 - Push button of windscreen washer
H7 - Indicator of vibration preselection S33 - Change-over switch of fan of heating
H9 - Indicator of engine lubrication S35 - Parking brake push button
H10 - Indicator of charging S36 - Limit switch of traction spin of the drum
H11 - Indicator of air filter clogging S37 - Engine idle speed switch
H12 - Indicator of hydraulic filter clogging S38 - Engine diagnostic switch
H13 - Indicator of differential lock (ASC) S39 - Trouble shooting switch
H14 - Stop engine warning lamp - red S40 - Water in fuel sensor
H15 - Water in fuel warning lamp V1,2,4,5 - Blocking diode
H16 - Engine defect warning lamp - yellow V3 - Blocking diode (only machine with signalling of sound lift cabin)
H17 - Maintenance indicator lamp - it is not conected X1 - Hand lamp socket
K1 - Start relay X2-24 - Connectors
K2-9 - Auxiliary relay X25 - Diagnostic socket (optional)
K10 - Preheating relay X27 - Socket of safety beacon
M1 - Starter X28-33 - Connectors
M2 - Electric motor of hood & cabin lifting system X34 - Engine diagnostic (electronic control module)
M3 - Fan of cabin ventilation X35-40 - Connectors J1939
M4 - Front windscreen wiper X41-42 - Connectors
M5 - Rear windscreen wiper Y1 - Electromagnetic valve cab lifting
M6 - Front windscreen washer Y2 - Electromagnetic valve cab lowering
M7 - Rear windscreen washer Y3 - Electromagnetic valve hood lifting
M8 - Fan of heating Y4 - Electromagnetic valve hood lowering
P1 - Engine thermometer Y5 - Electromagnetic valve of engine STOP
P2 - Hydraulic oil thermometer Y6 - Electromagnetic valve of brake
P3 - Fuel gauge Y7 - Electromagnetic valve of fast travel speed (left wheel)
P4 - Speedometer Y8 - Electromagnetic valve of fast travel speed (drum)
P5 - Hour counter Y9 - Electromagnetic valve of vibration I.
Q1 - Battery disconnector Y10 - Electromagnetic valve of vibration II.
R1,2 - Resistors Y11 - Electromagnetic valve of differential lock - LH wheel backward(opt.)
R3 - Engine preheating Y12 - Electromagnetic valve of differential lock - LH wheel forward (opt.)
R4 - Engine speed control Y13 - Servovalve of the pump of travel
S1 - Push button of cabin lifting system Y14 - Electromagnetic valve of fast travel speed (right wheel)
S2 - Push button of hood lifting system Y15 - Electromagnetic valve of differential lock - RH wheel forward (opt.)
S3 - Switch box Y16 - Electromagnetic valve of differential lock - RH wheel backward (opt.)
S4 - Switch of front headlights

248
20 - ELECTRICAL SCHEMATA

249
20 - ELECTRICAL SCHEMATA

250
20 - ELECTRICAL SCHEMATA

251
20 - ELECTRICAL SCHEMATA

WIRING SCHEME - ACCORDING TO TIER 2, ASC 4 - VALVES, FIAT, WITH ENGINE QSB FOR ASC 110-250
Legend: (the schematic reflects machine version that includes all controlling elements and accessories
A1 - Interrupter of direction lights (optional) S4 - Switch of front headlights
A2 - Brake timer S5 - Switch of rear headlights
A3 - Travel control S6 - Switch of warning lights (optional)
A4 - Controlling unit of differential lock (optional) S7 - Change-over switch of direction lights (optional)
A5 - Sensor of longitudinal inclination (optional) S8 - Switch of safety beacon (optional)
B1 - Sensor of cooling liquid level S9 - Push button of horn
B2 - Sensor of hydraulic oil thermometer S10 - Position switch of seat panel opening
B3 - Fuel level sensor S11 - Push button of emergency brake
E1 - Instruments illumination S12 - Switch of back-up alarm (optional)
E2, 3 - Front outline lights (optional) S13 - Switch of neutral (at the travel control)
E4, 5 - Tail lights (optional) S14 - Float of the hydraulic oil tank
E6, 7 - Front headlights S15 - Pressure switch of steering
E8, 9 - Rear headlights S16 - Switch - fast travel
E10,11 - Left direction lights (optional) S17 - Switch - speed preselector
E12,13 - Right direction lights (optional) S18 - Change-over switch of vibration
E14 - Cabin illumination S19 - Switch of vibration (at the travel control)
E15 - Safety beacon (optional) S20 - Terminal switch of the gas lever
E16,17 - Brake lights (optional) S21 - Pressure switch of brake
E18 - Car make lighting (optional) S23 - Sensor of drum speed (optional)
F1-9 - Fuses S24 - Sensor of left wheel speed (optional)
F11-16 - Fuses of engine S25 - Sensor of right wheel speed (optional)
G1,2 - Batteries S26 - Pressure switch of engine lubrication
G3 - Alternator S27 - Underpressure switch of air filter clogging
H1 - Indicator of direction lights (optional) S28 - Underpressure switch of hydraulic filter clogging
H2 - Horn S29 - Change-over of cabin ventilation
H3 - Back-up alarm (optional) S30 - Switch of front windscreen wiper
H4 - Indicator of hydraulic oil level S31 - Switch of rear windscreen wiper
H5 - Indicator of neutral position of the travel control S32 - Push button of windscreen washer
H6 - Indicator of brake S33 - Change-over switch of fan of heating
H7 - Indicator of vibration preselection S35 - Parking brake push button
H9 - Indicator of engine lubrication S36 - Limit switch of traction spin of the drum
H10 - Indicator of charging S37 - Engine idle speed switch
H11 - Indicator of air filter clogging S38 - Engine diagnostic switch
H12 - Indicator of hydraulic filter clogging S39 - Trouble shooting switch
H13 - Indicator of differential lock (ASC) S40 - Water in fuel sensor
H14 - Stop engine warning lamp - red V1,2,4,5 - Blocking diode
H15 - Water in fuel warning lamp V3 - Blocking diode (only machine with signalling of sound lift cabin)
H16 - Engine defect warning lamp - yellow X1 - Hand lamp socket
H17 - Maintenance indicator lamp - it is not conected X2-24 - Connectors
K1 - Start relay X25 - Diagnostic socket (optional)
K2-9 - Auxiliary relay X27 - Socket of safety beacon
K10 - Preheating relay X28-33 - Connectors
M1 - Starter X34 - Engine diagnostic (electronic control module)
M2 - Electric motor of hood & cabin lifting system X35-40 - Connectors J1939
M3 - Fan of cabin ventilation X41-42 - Connectors
M4 - Front windscreen wiper Y1 - Electromagnetic valve cab lifting
M5 - Rear windscreen wiper Y2 - Electromagnetic valve cab lowering
M6 - Front windscreen washer Y3 - Electromagnetic valve hood lifting
M7 - Rear windscreen washer Y4 - Electromagnetic valve hood lowering
M8 - Fan of heating Y5 - Electromagnetic valve of engine STOP
P1 - Engine thermometer Y6 - Electromagnetic valve of brake
P2 - Hydraulic oil thermometer Y7 - Electromagnetic valve of fast travel speed (left wheel)
P3 - Fuel gauge Y8 - Electromagnetic valve of fast travel speed (drum)
P4 - Speedometer Y9 - Electromagnetic valve of vibration I.
P5 - Hour counter Y10 - Electromagnetic valve of vibration II.
Q1 - Battery disconnector Y11 - Electromagnetic valve of differential lock - LH wheel backward(opt.)
R1,2 - Resistors Y12 - Electromagnetic valve of differential lock - LH wheel forward (opt.)
R3 - Engine preheating Y13 - Servovalve of the pump of travel
R4 - Engine speed control Y14 - Electromagnetic valve of fast travel speed (right wheel)
S1 - Push button of cabin lifting system Y15 - Electromagnetic valve of differential lock - RH wheel forward (opt.)
S2 - Push button of hood lifting system Y16 - Electromagnetic valve of differential lock - RH wheel backward (opt.)
S3 - Switch box

252
20 - ELECTRICAL SCHEMATA

253
20 - ELECTRICAL SCHEMATA

254
20 - ELECTRICAL SCHEMATA

255
21 - HYDRAULIC

21 - HYDRAULIC

HYDRAULIC CIRCUIT CONNECTIONS - TWO VALVES ASC

ASC 70/90

Legend:
1 - Pump of travel
2 - Pump of vibration
3 - Hydromotor of the drum drive
4 - Hydromotor of vibration
5 - Hydromotor of the wheels drive
8 - Pump of steering
9 - Power steering unit
10 - Valve ASC
11 - Hydraulic cylinders of steering
12 - Block of divider
13 - Pressure switch
14 - Suction basket
15 - Block of filtration
16 - Filling socket
17 - Oil level gauge
18 - Cooler combined
19 - Non-return valve
20 - Thermoregulator
21 - Measuring quickcoupler
22 - Filling quickcoupler
23 - Quickcoupler
24 - Quickcoupler
25 - Thermometer sensor
26 - Aggregate
27 - Manual pump
28 - Lifting block
29 - Hydraulic lock
30 - Hydraulic motor for lifting the cabin
31 - Hydraulic motor for lifting the hood

256
 21 - HYDRAULIC

ASC 70/90

257
21 - HYDRAULIC

HYDRAULIC CIRCUIT CONNECTIONS - 4 VALVES ASC

ASC 70/90

Legend:
1 - Pump of travel
2 - Pump of vibration
3 - Hydromotor of the drum drive
4 - Hydromotor of vibration
5 - Hydromotor of the wheels drive
8 - Pump of steering
9 - Power steering unit
10 - Valve ASC
11 - Hydraulic cylinders of steering
13 - Pressure switch
14 - Suction basket
15 - Block of filtration
16 - Filling socket
17 - Oil level gauge
18 - Cooler combined
19 - Non-return valve
20 - Thermoregulator
21 - Measuring quickcoupler
22 - Filling quickcoupler
23 - Quickcoupler
24 - Quickcoupler
25 - Thermometer sensor
26 - Aggregate
27 - Manual pump
28 - Lifting block
29 - Hydraulic lock
30 - Hydraulic motor for lifting the cabin
31 - Hydraulic motor for lifting the hood

258
 21 - HYDRAULIC

ASC 70/90

259
21 - HYDRAULIC

HYDRAULIC CIRCUIT CONNECTIONS IN ASC 110 Legend:

AND ASC 150 - TWO VALVES ASC 1 - Pump of travel
*2 - Pump of vibration
**2 - Pump of vibration
The connections of hydraulic circuit are identical in both *3 - Hydromotor of the drum drive
machine types. The only difference is in the type of pumps and
**3 - Hydromotor of the drum drive
hydraulic motors.
*4 - Hydromotor of vibration
Machine ASC 110 uses vibration pump 90R042 and vibration
hydraulic motor 90M042 **4 - Hydromotor of vibration
5 - Hydromotor of the wheels drive
Machine ASC 150 uses vibration pump 90R055 and vibration
hydraulic motor 90M055 8 - Pump of steering
Moreover, it differs in the set-up of the over-flow valve that 9 - Power steering unit
controls pressure in the body of the vibration pump, where in 10 - Valve ASC
ASC 110 pressure has been set to 42 bar, and in ASC 150 to 11 - Hydraulic cylinders of steering
28 bar. The control pressure in the bodies of travel pumps has
12 - Block of divider
been set in both cases to 22 bars.
13 - Pressure switch
14 - Suction basket
15 - Block of filtration
16 - Filling socket
17 - Oil level gauge
18 - Cooler combined
19 - Non-return valve
20 - Thermoregulator
21 - Measuring quickcoupler
22 - Filling quickcoupler
23 - Quickcoupler
24 - Quickcoupler
25 - Thermometer sensor
26 - Aggregate
27 - Manual pump
28 - Lifting block
29 - Hydraulic lock
30 - Hydraulic motor for lifting the cabin
31 - Hydraulic motor for lifting the hood

* - ASC 110
** - ASC 150

260
 21 - HYDRAULIC

ASC 110/150

261
21 - HYDRAULIC

HYDRAULIC CIRCUIT CONNECTIONS IN ASC 110 Legend:

AND ASC 150 - 4 VALVES ASC 1 - Pump of travel
*2 - Pump of vibration
**2 - Pump of vibration
The connections of hydraulic circuit are identical in both *3 - Hydromotor of the drum drive
machine types. The only difference is in the type of pumps and
**3 - Hydromotor of the drum drive
hydraulic motors.
*4 - Hydromotor of vibration
Machine ASC 110 uses vibration pump 90R042 and vibration
hydraulic motor 90M042 **4 - Hydromotor of vibration
5 - Hydromotor of the wheels drive
Machine ASC 150 uses vibration pump 90R055 and vibration
hydraulic motor 90M055 8 - Pump of steering
Moreover, it differs in the set-up of the over-flow valve that 9 - Power steering unit
controls pressure in the body of the vibration pump, where in 10 - Valve ASC
ASC 110 pressure has been set to 42 bar, and in ASC 150 to 11 - Hydraulic cylinders of steering
28 bar. The control pressure in the bodies of travel pumps has
13 - Pressure switch
been set in both cases to 22 bars.
14 - Suction basket
15 - Block of filtration
16 - Filling socket
17 - Oil level gauge
18 - Cooler combined
19 - Non-return valve
20 - Thermoregulator
21 - Measuring quickcoupler
22 - Filling quickcoupler
23 - Quickcoupler
24 - Quickcoupler
25 - Thermometer sensor
26 - Aggregate
27 - Manual pump
28 - Lifting block
29 - Hydraulic lock
30 - Hydraulic motor for lifting the cabin
31 - Hydraulic motor for lifting the hood

* - ASC 110
** - ASC 150

262
 21 - HYDRAULIC

ASC 110/150

263
21 - HYDRAULIC

ASC 200/250 - two valves ASC

Legend:
1 - Pump of travel
2 - Pump of vibration
3 - Hydromotor of the drum drive
4 - Hydromotor of vibration
5 - Hydromotor of the wheels drive
8 - Pump of steering
9 - Power steering unit
10 - Valve ASC
11 - Hydraulic cylinders of steering
12 - Block of divider
13 - Pressure switch
14 - Suction basket
15 - Block of filtration
16 - Filling socket
17 - Oil level gauge
18 - Cooler combined
19 - Non-return valve
20 - Thermoregulator
21 - Measuring quickcoupler
22 - Filling quickcoupler
23 - Quickcoupler
24 - Quickcoupler
25 - Thermometer sensor
26 - Aggregate
27 - Manual pump
28 - Lifting block
29 - Hydraulic lock
30 - Hydraulic motor for lifting the cabin
31 - Hydraulic motor for lifting the hood

264
 21 - HYDRAULIC

ASC 200/250

265
21 - HYDRAULIC

ASC 200/250 - 4 valves ASC

Legend:
1 - Pump of travel
2 - Pump of vibration
3 - Hydromotor of the drum drive
4 - Hydromotor of vibration
5 - Hydromotor of the wheels drive
8 - Pump of steering
9 - Power steering unit
10 - Valve ASC
11 - Hydraulic cylinders of steering
13 - Switch
14 - Suction basket
15 - Block of filtration
16 - Filling socket
17 - Oil level gauge
18 - Cooler combined
19 - Non-return valve
20 - Thermoregulator
21 - Measuring quickcoupler
22 - Filling quickcoupler
23 - Quickcoupler
24 - Quickcoupler
25 - Thermometer sensor
27 - Valve plate
28 - Aggregate
29 - Manual pump
30 - Lifting block
31 - Hydraulic lock
32 - Hydraulic motor for lifting the cabin
33 - Hydraulic motor for lifting the hood

266
 21 - HYDRAULIC

ASC 200/250

267
22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS

22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS

RECOMMENDED TOOLS FOR SERVICING SAUER 90 R HYDRAULIC GENERATORS AND MOTORS

Torque wrench: 5,5 - 300 Nm

Set of open-end wrenches 1 1/16”, 3/8 - 5/16”, 7 mm, 10 - 11 mm
Ring wrench (open-ended) 24 - 27 mm
Wrench hexagonal (imbus) 5 mm
Set of imbus wrenches (internal hex) 2.5, 3, 4, 5, 6, 8, 10, 12, 14, 17 mm (metric thread)

METERING DEVICES

Pressure gauge to 6 MPa (60 bar) - 2 pieces (filling pressure)

Pressure gauge to 60 MPa (600 bar) 2 pieces (high pressure loop)

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 22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS

TEST SPOTS ASC 70/90, ASC 200/250

For easy diagnostics of hydraulic loops, the measuring

pins are terminated in the panel and equipped with quick-
couplers for easy and drip-proof connection of measuring ASC 70/90
devices (thread M 16x2).
Maximal pressure

MPa [PSI]

Pressure in the circuit

1 1 35* [5075]
of backward travel

2 Pressure in the circuit

2 35* [5075]
of forward travel

3 Pressure in the circuit

3 35 [5075]
of vibration I
4
Pressure in the circuit
4 35 [5075]
of vibration II
5
Pressure in the circuit
5 18** [2610]
of steering

6 Feeding pressure 2,4*** [348]

ASC 200/250

Maximal pressure

6 MPa [PSI]

Pressure in the circuit

1 42* [6090]
of backward travel

Pressure in the circuit

2 42* [6090]
of forward travel

Pressure in the circuit

3 35 [5075]
of vibration I

Pressure in the circuit

4 35 [5075]
of vibration II

Pressure in the circuit

5 20** [2900]
of steering

6 Feeding pressure 2,2*** [319]

* The value will increase by supplementary pressure, i.e.,

by up to 3 MPa (435 PSI)
** Total pressure in the return line of steering (supplemen-
tary pressure + flow losses)
*** The value at idle speed [it is higher at maximum speeds;
max. 3.0 MPa (435 PSI).

269
22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS

TEST SPOTS ASC 110/150

For effective tests of hydraulic loops the test spots are acces- 1
sible from the dashboard, where quick-couplers have been
installed for easy and drop-free connection of metering devi- 2
ces through threaded holes M 12x1,5. 3
4
Max. pressure
5
MPa [PSI]
6
Pressure in the circuit
1 42 * [6090]
of backward travel

Pressure in the circuit

2 42 * [6090]
of forward travel

Pressure in the circuit

3 40 [5800]
of vibration I

Pressure in the circuit

4 40 [5800]
of vibration II
* The value will increase by supplementary pressure, i.e.,
Pressure in the pump by up to 3 MPa (435 PSI)
5 19** [2755]
of steering
** Total pressure in the return line of steering (supplemen-
6 Feeding pressure 2,2*** [319] tary pressure + flow losses)
*** The value at idle speed [it is higher at maximum speeds;
max. 3.0 MPa (435 PSI).

INSPECTION AND ADJUSTMENTS

INSPECTION OF SAFETY VALVE FOR FILLING PRESSURE

Mark the position of the valve in relation to the cylinder body.
Loosen the counter-nut 1-1/16“, remove safety valve. Check
valve cone and seat. In re-assembly observe the correct
position of the valve to the mark. Tighten the counter-nut with
torque 46-55 Nm (34-41 ft lbs).

ADJUSTMENT OF SAFETY VALVE FOR FILLING PRESSURE

Loosen counter-nut 1-1/16“ and turn set-up plug. By turning c/

w the pressure increases, cc/w decreases. Thereafter tighten
counter-nut with torque 46-55 Nm (34-41 ft lbs).

270
 22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS

PLUGGING OUTLETS A AND B OF THE HYDRAULIC

GENERATORS

Remove high pressure hoses and plug openings A and B with

suitable balls.

B
B
A

SAFETY HIGH PRESSURE VALVE

The safety high pressure valve is part of the multi-functional

valve, which contains also the by-pass valve.

271
22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS

Dividending of the multi-functional valve into.

Assembly of the multi-functional valve.

272
 22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS

ADJUSTMENT OF SAFETY PRESSURE

Turn the screw by the internal hexagonal socket while holding

the middle hexagonal head. Turning c/w the pressure increa-
ses, cc/w decreases. One turn changes pressure by 9,3 MPa
(1349 PSI). In the set position hold the set-up screw using key
and tighten counter-nut with torque 16 Nm (12 ft lbs). Use same
procedure for the second multi-functional valve.

ADJUSTMENT OF BYPASS VALVES, SEE FIG.

By-pass valve is part of the multi-functional valve. Opening

and closing of valves is done with the motors shut down. For
the middle screw of the multi-functional valve use key 1-1/16“,
and for the large screw us key 1-14“. Turn the middle screw 3
turns cc/w – by-pass valve is open. Do not turn by more than
3.5 turns - a considerable amount of oil would leak out.

273
22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS

INSPECTION AND ADJUSTMENT OF VIBRATION FREQUENCY

Frequency measurement should be performed while the

machine is running at maximum RPM with the engine
warmed up to the running temperature and with hydrau-
lic oil minimum temperature of 50 °C (122 °F).
1
Before setting frequency, check and set engine RPM
according to the Table and then set the revolution
counter.
The engine should be warmed to running temperature
while you are setting the engine.

Adjust max. speed of the engine / for engine TIER I

Measure max. speed of engine by means of the stroboscope
or multimeter (1). The machine without load.

NOTE: Electric wiring for the revolution counter is always led

and ended under the instrument panel and it can be used for
connecting the multimeter for check-up of engine revolutions
instead of the stroboscope.

Adjust with regulating bolt 1 of injections pump.

Machine RPM Engine

ASC 70 - ASC 90 2200+30 B3.9-C99 1
ASC 110 2300+50 B5.9-C148
ASC 150 2250+30 B5.9-C148
ASC 200 - ASC 250 2500+30 B5.9-C200

Check measured RPM to the revolution counter. If necessary,

set the counter after lifting off the instrument panel from the A
bottom using adjusting screw A.

274
 22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS

ADJUSTING MAX. REVOLUTION

of engine Tier 2 B4.5-C99 (ASC 70-90)

Start the engine and set maximum 2200+30 revolutions – check

it using a stroboscope or with a multimeter connected to the 1
supply line to the revolution counter

NOTE:
Electric wiring for the revolution counter is always led and
ended under the instrument panel and it can be used for
connecting the multimeter for check-up of engine revolutions
instead of the stroboscope.

If the measured revolutions are different adjust max. speed

with the bolt (1).

Check measured RPM of engine with the revolution counter.

If necessary, set the counter after lifting off the instrument panel A
from the bottom using adjusting screw A.

NOTE:
RPM of engines:
QSB5.9-C155 TIER II for rollers ASC 110-ASC 150
QSB 5.9-C205 TIER II for rollers ASC 200-ASC 250
are controlled by ECM (electronic control module) of the
engine. They are set by the manufacturer and it is nor neces-
sary to set them again.

275
22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS

Adjust frequency vibration

1
Place sensor 2 of the instrument 1 to the damping plate of the
drum and measure the frequency. 2

If the frequency differs from that specified in this manual, adjust it by means of the adjusting screws
on the pump of vibration.

Adjust with the engine off!!!

Machine ASC 70 ASC 90 ASC 110 ASC 150 ASC 200 ASC 250

High amplitude Hz [VPM] 30 [1800] 30 [1800] 32 [1920] 29 [1740] 28 [1680] 28 [1680]

Low amplitude Hz [VPM] 40 [2400] 40 [2400] 35 [2100] 35 [2100] 34 [2040] 34 [2040]

276
 22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS

ASC 110/150
A
ASC 200/250
Loose the lock nut (2) and using the screwdriver turn the
adjusting screws (1) (unscrewing means higher frequency
and opposite).
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 manu-
facturer. Do not switch the frequencies - the lower frequency
must comply with the higher amplitude and opposite. Manu-
facturer adjusts the lower frequency and the higher amplitude
2
at the same direction as if the roller travels forward.
B
1

ASC 70/90
The frequency of high amplitude vibration is adjusted by the
lower screw (2) only. Loosen safety screw (3) and using
wrench turn the set-up screw (2), adjust to required value, and
tighten safety screw. Frequency increases with the screw
being turned ccw, and vice versa.

Adjust with the engine off!!!

! NOTE !
The zero position of the hydraulic generator power
cylinder has been adjusted by the manufacturer on the
upper screw (1). Any handling of this screw is not
permitted.
The frequency meter may be ordered from the anufactu-
rer or your dealer.

277
22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS

RELEASING TRANSMISSION AND WHEEL HYD-

RAULIC MOTOR BRAKES

ASC 110/150 - Release hose 4 and quick-coupling 3 in clamp 5.

5
4 3

ASC 110/150 - Disconnect quick-coupling 2 of hose 1 from

pressure filter to hydraulic tank.

ASC 110/150 - Quick-couple hose 4 to the manual hydraulic

generator with quick-coupling 2 on hose 1.

2
3

278
 22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS

ASC 70/90
ASC 200/250
1
Release hose 4 by quick coupler 3 in clamp 5.
Disconnect hose 1 from pressure filter to hydraulic tank in quick
coupler 2.
2

5 3 4

ASC 70/90
ASC 200/250
Connect quick coupler 3 on hose 4 to manual hydraulic 4
generator with quick coupler 2 in hose 1.
2
3

ASC 70/90
ASC 200/250
Then short-circuit hydraulic travel loop. Two multi-purpose


safety valves are located on the hydraulic travel generator.

Unscrew middle section (1) from the valves [hexagonal 27 mm
(11/16")] by three turns cc/w.

1
1

279
22 - DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS

Turn key in switch box to position I.

Insert lever in the manual hydraulic generator and start pum-

ping, until brake indicator goes off.

( 1
Brakes of the machine have been released for towing.

Before you release the brakes, wedge the
both drums against any spontaneous
movement of the machine thereafter.
When towing the roller, check, if the
brakes do not get warm because of insufficient relea-
sing. When the brakes of gears, hydromotors are
released and the hydraulic circuit short-circuited, no
braking system is available! All the service, emergency
and parking brakes are out of operation!
Do not start the engine during towing.
For towing use undamaged ropes or tow bars of suffici-
ent capacity 1.5 x higher than the weight of the towed
vehicle. Do not use a chain for towing!
Nobody may be on the vehicle that is being towed with
non-functioning motor.
It is necessary to maintain the minimal deviation from
the direct towing angle. Maximum deviation is possible
within 30°.
Smooth and constant movement must be maintained in
towing. Do not exceed towing speed by more than 2 km/
hour (1.2 mph) and do not tow for more than 300 m
(0.19 miles)
The towing machine should correspond by its size to the
damaged machine. It must have sufficient towing power,
weight and braking effect.
When towing down hill an additional machine must be
attached to the rear end of the machine. This way it is
possible to prevent an inadvertent movement of the
damaged machine.
These are general requirements for a safe towing of the
machine under normal conditions. Any possibly different
situation that could occur during towing must be consul-
ted with the dealer
When towing is completed, return the machine into its
original shape.
When finished with towing, wedge both drums and
wheels and prevent spontaneous movement.

280
 23 - TROUBLE SHOOTING

23 - TROUBLESHOOTING

1. Oil leaking under the vibration lid

2. Oil leaking betwen the vibrating plate and the hub or from the deaeration plug
3. Vibration not on – hydraulic system OK
4. Oil leaking from joints of high-pressure hoses (travel or vibration hydraulic motor, hydraulic
generators)
5a,b. The machine stops spontaneously and the engine dies
6a,b. Vibration off
7. Only one amplitude available
8. The brakes are off, yet the machine doesn’t travel (electrical)
9. The machine vibrates also with low revolutions of the engine
10. The machine does not reach specified frequency
11. The machine has low pull
12. The machine’s brakes are permanently on (electrical)
13. The machine is not running at travel speed (electrical)
14. The machine is not running (brake off) – hydraulic
15. The machine is not moving forward or back, or has lower pull in one direction
16a,b.ASC is not working (electrical) - 2 valves, 4 valves
17. Steering is not functioning, the wheel jams
18. Steering is not working in a difficult terrain
19. Steering works to one side only
20. Steering wheel does not release brake
21. During start the machine brakes are permanently off (electrical)
22. Oil leaks out of hydraulic tank
23. Hydraulic oil foams up
24. Hydraulic oil is hot
25. The machine cannot be started

281
282
1 Oil runs under vibration lid

Check breather whether free

23 - TROUBLESHOOTING

YES NO

check tightness of loosen or replace breather

screws of the lid

add oil to vibrator

screws loose screws tight test the machine

tighten screws empty oil from vibrator oil leaking?

test the machine remove lid
replace “O”-ring
fill oil in vibrator
test the machine
oil leaking? YES NO

OK
continue operation
NO YES
 2 Oil leaking betwen the vibrating plate and
the hub or from the deaeration plug

check oil level

in vibrator

level high level normal

release oil from vibrator according to the service manual

disassembly the vibration plate with
the hub and replace the
sealing ring
remove vibration hydraulic motor
check seal on shaft
add oil and test the machine

seal defective
OK
continue operation
replace seal or hydraulic motor

283
23 - TROUBLE SHOOTING
284
3 Vibration not working – hydraulics OK

check oil for metal cuttings

following the manual
23 - TROUBLESHOOTING

YES NO

instructions remove vibrator lids from check clutch spline

drums between hydraulic motor and vibrator

check bearings
defective splines
replace nut and clutch

defective bearings

test vibration
replace bearings
check freedom of vibrators
machine vibrates

assemble drum
fill oil in vibrators OK
test vibration continue operation
 4 Oil leaking from connectors of high-pressure hoses
(travel and vibration hydraulic motor, hydraulic generators)

check tightness of screws

on mounting segments

screws loose screws are tight

tighten screws evenly loosen both segments

on both segments replace ”O”-ring on high-pressure
hose, clean seating surface
reinstall

defect corrected?
OK
continue work

YES NO

285
23 - TROUBLE SHOOTING
286
5a During work (travel) the machine stops
spontaneously and the engine dies

out of fuel?

NO
23 - TROUBLESHOOTING

YES

fuel gauge is on zero? low oil in hydraulic tank?

NO YES NO YES

replace defective fuel gauge defective electrical wiring inspect machine and find the location of
continue 5.b visible oil leak from the circuit or the
hydraulic unit
fill fuel, try starting engine
(If the fuel suction circuit is filled with excessive air, starting
will not be easy. Fuel must be pumped in manually using
pump behind the right wheel on the side of engine; oil leak found?

Engine starts? correct defect YES NO

YES NO fill up hydraulic tank with specified fluid

through a pressure filter unit behind the
right door under the cabin

OK
continue work
 continuation of 5a
5b
all functions for starting the machine
OK?

YES NO

1.) free emergency brake

starter turning?
2.) fold control panel
3.) place control lever to position 0

NO YES
check magnet
check voltage on breaker, check breaker Y5 for turning off the engine
K1, if defective, replace defect corrected?
defect corrected?

YES NO
YES NO
check control leads of magnet
from K3 to Y5 and from M1 to Y5 and
replace starter function of S14 - defect corrected?

YES NO

OK
continue work replace magnet Y5

287
23 - TROUBLE SHOOTING
288
6a Vibration off

NO travel control in null position? YES

specified engine rpm adjusted? set controls outside null position steering working?
23 - TROUBLESHOOTING

NO YES machine is vibrating? NO YES

set rpm to more than 2000 check vibration switch S18, NO YES replacing steering hydraulic generator
magnets Y9 and Y10, relays K5 and K7,
switch S19, gas switch of the engine
S20, wiring and connectors
machine is vibrating?
check safety valve of travel hydraulic
generator, Page 266
machine is vibrating?
YES NO
machine vibrates?
OK
NO YES continue work
YES NO
check supplementing pressure in
hydraulic generator - min. 22/24 bar.,
Page 266 - see the table

supplementing pressure OK?

NO YES continue in Table no. 6b

 6b Vibration off

continue in Table 6a

check safety pressures of vibration check waste flow through vibration

hydraulic pump see tab. page 265 with hydraulic motor with vibration on (max.
sealed outlets “A” and “B” 15 l/min.)
page 267 - vibration on max. 5 s at
maximum revolutions

is it more than specified?

safety maximum safety pressures
reached?

NO YES

YES NO
check high-pressure safety replace hydraulic motor
valves of vibration hydraulic generator
page 267 - clean
replace hydraulic generator

machine vibrating?
machine vibrating?

NO YES
NO YES

OK
continue in Table no. 3 continue work

289
23 - TROUBLE SHOOTING
290
7 Only one amplitude on

check switch S18

and magnets Y9, Y10
23 - TROUBLESHOOTING

magnets cores activate vibration?

YES NO

check safety pressures of vibration replace distributor with magnets

hydraulic generator see p. 265 with
sealed outlets “A” and “B” see page 267

vibration OK?
Safety pressure reached?
check flushing valve of vibration
hydraulic motor NO YES
NO YES

valve stuck in extreme position

clean safety valve see page 267 - unstuck

vibration OK? vibration OK?

OK
YES NO YES continue work
 8 Brakes are off, yet the machine does not move

check safety switch S21 - must be

disconnected for the machine to move

OK?

NO YES

replace switch check leads from F3, K6, S16, S17,

and A3 to Y13

defect corrected?
wiring OK

YES NO
defect corrected?

OK
YES NO
continue work

check individual elements K6, S16,

defect corrected?
S17, A3, Y13, faulty replace

check gear-box Trasmital,

YES defect corrected? NO YES
faulty replace

291
23 - TROUBLE SHOOTING
292
9 The machine vibrates even at low engine
revolutions - valid for engine B5.9. TIER I

check position of plate 13 see

page 163
23 - TROUBLESHOOTING

position is incorrect adjustment correct

adjust clearance of plate to overlap sensor B replace switch see page 163
at 2000 rpm of engine check free play plate
to sensor to be 1 mm see page 163

defect corrected?
defect corrected?

OK
continue work
 10 The machine does not reach required frequency

using vibration meter see page 270

adjust frequency by set-screws on vibra-
tion hydraulic generator page 270

check safety pressures of vibration hy-

adjust required frequency can frequency be adjusted? draulic generator with sealed outlets “A”
to page 270 of Shop Manual
YES NO and “B” page 265-266 switched on for
less than 5 s at maximum revolutions

replace vibration hydraulic motor YES Maximum pressures reached?

NO

check safety valves

and clean page 267

OK maximum pressures reached?

YES does it have required frequency? YES
continue work

NO NO

replace vibration hydraulic motor replace hydraulic generator

293
23 - TROUBLE SHOOTING
294
11 The machine has low pull

measure maximum safety pressures.

check operation electro magnet of 2nd Is it up to max. pressure ? See table check and clean
speed of wheels and drum YES pages 265 NO safety valves page 267
23 - TROUBLESHOOTING

check maximum safety pressure

OK does it reach max. pressure?

safety pressure reached ? YES YES
continue work

NO
NO
YES
check safety pressures of travel
hydraulic generator to page 266 with
sealed outlets “A” and “B” to page 267
safety pressure reached? deflect travel lever for up to 5 sec. at
maximum revolutions.

in succesive steps blind hydromotors

YES safety pressure reached?
find out faulty one and replace it

NO NO

OK replace pump
YES safety pressure reached?
continue work
 12 Brakes are permanently on

check fuse F3
replace faulty fuse

have conditions for releasing brakes

on the machine complied with?
YES defect corrected? NO 1) emergency brake off
2) control lever out of neutral

adjust to correct position NO YES

defect corrected? check voltage on A2 INP

OK voltage present
YES voltage is not present
continue work

check wires from F3, K5, and V1 replace timer

to A2 INP, V2 and S15

defect corrected?

check wires from A2 to Y6

or function of Y6
NO YES

295
23 - TROUBLE SHOOTING
296
13 The machine does not move at transport speed

check switch S16

NO OK? YES check relay K6, el. magnet Y7, Y14

23 - TROUBLESHOOTING

replace switch YES defect corrected?

transport speed OK? NO NO

YES check drum travel hydraulic motor

solenoid Y8

OK
YES OK?
continue work

NO

replace hydromotor or ask Sauer for

repair

YES defect corrected?

 14 The machine does not move (brakes off) = hydraulics

check safety pressures of travel hydraulic

check maximum safety pressures tab. generator page 265 with sealed outlets
page 265. Max pressure is OK? NO “A” and “B” to page 267 deflect travel lever
for up to 5 sec. at maximum revolutions.

replace clutch CENTA NO engine drive correct? NO safety pressure reached?

defect corrected?

YES YES

YES
replace pump in succesive steps blind hydromotors,
fin out faulty one and replace it

safety pressure reached? NO

safety pressure reached?

YES

YES
OK
continue work

297
23 - TROUBLE SHOOTING
298
15 The machine does not move neither forward nor
back, or has noticeable low pull in one direction

seal outlets “A”, “B” of pumps, page 267

move travel lever momentarily forward

23 - TROUBLESHOOTING

or back and measure that safety

pressure (see tab. on page 265) has
been reached

YES NO

the defect is caused by stuck valve in remove applicable safety valve

roller travel hydraulic motor clean or replace

open up and clean NO pump reached safety pressure?

Does the machine work properly? YES

YES NO the machine works properly?

OK YES
continue work
 16a ASC does not work - 2 valves

NO indicator of switch ASC is on? YES

check wiring from F4, S22 to A4 attach the Notebook, set up the basic
table over ”0”,
check for error message

wiring open wiring OK NO errors?

correct and test the machine Program ASC is defective mechanical seizing of control valves YES
Sauer

defect corrected? attach the Notebook and repair using “E” set up table of errors,
which evaluates
check valve control ASC the type of defect

NO YES defect corrected?

defect corrected? correct

YES
YES defect corrected?

OK
YES
continue work

299
23 - TROUBLE SHOOTING
300
16b ASC does not work - 4 valves

NO is red diode of Susmic blinking ? YES

check wiring from F4, to A4 attach the Notebook, set up the basic
table over ”0”,
23 - TROUBLESHOOTING

check for error message

wiring open wiring OK NO errors?

correct and test the machine Program ASC is defective mechanical seizing of some control YES
valve Sauer

defect corrected? attach the Notebook and repair using “E” set up table of errors,
which evaluates
check valve control ASC the type of defect

NO YES defect corrected?

defect corrected? correct

YES
YES defect corrected?

OK
YES
continue work
 17 Steering is defective, the wheel gets stuck

check servo

defective servo

replace

defect corrected?

YES

OK
continue work

301
23 - TROUBLE SHOOTING
302
18 Steering does not work in difficult terrain

attach manometer page 265 check

steering pressure
in an extreme position of the wheel

low pressure
23 - TROUBLESHOOTING

check seals of steering cylinders

defect corrected?

NO

replace servo

YES defect corrected?

OK
continue work NO

YES replace steering hydraulic generator

 19 Steering goes to one side

defective servo reverse valve

replace servo

check seals of steering cylinders

OK
continue work

303
23 - TROUBLE SHOOTING
304
20 The machine’s brakes stay on when the steering wheel is turned

defective pressure steering switch S15

replace switch S15

23 - TROUBLESHOOTING

defect corrected? YES

NO

check voltage lead to A2 contact INP

voltage present
(with pressure in steering)
OK
continue work
replace breake timer A2
voltage not present

check wires from F3 to S15

and from S15 to A2/INP

defect corrected YES

 21 After starting, the machine’s brakes remain on

check pressure switch

of steering S15 - it switches et first after
pressure reaches steering circuit

NO is voltage on permanently? YES

check timer switch A2 replace S15

OK? defect corrected?

NO YES NO

replace A2 check magnet Y6

whether on seizing

OK
continue work YES

replace Y6

YES defect corrected?

305
23 - TROUBLE SHOOTING
306
22 Oil leak from hydraulic system

check the tightness of hydraulic

system circuit,
and gear-boxes Trasmital

defect corrected?
23 - TROUBLESHOOTING

YES NO

add oil to tank using pressure filler check level

of oil in vibrator

OK
continue work level is high

replace shaft seal

vibration hydraulic motor

YES defect corrected?

NO

steering pump putting oil into

corrected ?
engine
 23 Hydraulic oil foams up

check tightness of suction

from tank to steering hydraulic
generator repair

YES defect corrected? NO

check hydraulic oil quality

oil is OK

replace steering hydraulic generator

OK
YES defect corrected?
continue work

307
23 - TROUBLE SHOOTING
308
24 Hydraulic oil is too hot

clean hydraulic oil cooler

YES defect corrected? NO

23 - TROUBLESHOOTING

check travel pressure pages 265, if

pressures are still high, correct
machine load – for compacting
use only low (1st) gear

YES defect corrected? NO

defect corrected? check function of thermostat

check vibration pressure -if values

remain high, the bearing of vibrators
NO may be seizing up – check and/or
replace bearings

OK
YES defect corrected? NO
continue work

defective steering joint (seizing up), or

steering hydraulic cylinders
check - repair

YES defect corrected?

 25 The machine cannot be started

Is the starter turning?

fuel in tank? YES NO is the battery disconnect on?

YES NO NO YES

Is the hydraulic oil level indicator on? add fuel switch battery contact on have all conditions for machine travel
been complied with? (travel controller
in null position, lifting arm in working
position, emergency brake off)
YES NO defect corrected?

set to correct position NO YES

add hydraulic oil to specified level NO YES

defect corrected? NO
check voltage on engine magnet
STOP Y5, check fuse F3, relay K3, check fuel loop, for air in the system,
wiring, connections fuel filters, pressure valve in fuel pump
check batteries, contacts, starter leads,
YES function and wiring of switch box,
relays K4, switches S13, S10, S11,
defect corrected? defect corrected? check the engine by pulling
on the drive belt
OK
continue work
NO YES NO YES

YES defect corrected?

replace floater in hydraulic tank

309
23 - TROUBLE SHOOTING
24 - TIGHTENING TORQUES

INSPECTION, RE-TIGHTENING OF BOLTED CONNECTIONS

• Regularly check, whether the bolted connection are not loose.

• Use torque limiting wrenches to tighten the bolts and nuts.

Table of Tightening Torques For Bolts With Metric Threads

Torque

Fo r b o l t s Fo r b o l t s For bol ts
Bol t 5. 8 ( 5 S) 8 . 8 ( 8 G) 10. 9 ( 10 K)
si ze
Nm l b- f t Nm l b- f t Nm l b- f t

M4 2 1 3 2 4 3

M5 4 3 6 4 8 6

M6 7 5 10 7 14 10

M8 16 12 22, 5 17 32, 5 24

M1 0 31, 5 23 44 32 62 46

M1 2 53 39 75 55 105 77

M1 4 79 58 118 87 165 122

M1 6 113 83 165 122 226 167

M1 8 172 127 245 181 343 253

M2 0 226 167 314 232 441 325

M2 2 284 209 392 289 559 412

M2 4 392 289 549 405 755 557

Data shown in the table are torques at dry thread (of friction
coefficient = 0,14). The data are not valid for lubricated thread.

The self-safety nuts can be used

maximally 3 times when approved.

310
 24 - TIGHTENING TORQUES

Tightening moments for the sliding nuts with the tightening

circle “O” – hoses

Nm lb-ft

Size spanner Worm Hose Nominal Min Max Nominal Min Max

14 M12x1.5 6 20 15 25 15 11 18

17 M14x1.5 8 38 30 45 28 22 33

19 M16x1.5 8 45 38 52 33 28 38

10

22 M18x1.5 10 51 43 58 38 32 43

12

24 M20x1.5 12 58 50 65 43 37 48

27 M22x1.5 14 74 60 88 55 44 65

15

30 M24x1.5 16 74 60 88 55 44 65

32 M26x1.5 18 105 85 125 77 63 92

36 M30x2 20 135 115 155 100 85 114

22

41 M36x2 25 166 140 192 122 103 142

46 28

50 M42x2 30 240 210 270 177 155 199

50 M45x2 35 290 255 325 214 188 240

M52x2 38 330 280 380 243 207 280

42

311
24 - TIGHTENING TORQUES
Table of tightening moments for necks with tightening Table of tightening moments for plugs with flat packing
edge, or with flat packing

Tightening moments for the necks Tightening moments for the plugs

G-M Nm lb -ft G-M Nm lb -ft

G 1/8" 25 18 G 1/8" 15 11

G 1/4" 40 30 G 1/4" 33 24

G 3/8" 95 70 G 3/8" 70 52

G 1/2" 130 96 G 1/2" 90 66

G 3/4" 250 184 G 3/4" 150 111

G 1" 400 295 G 1" 220 162

G 11/4" 600 443 G 11/4" 600 443

G 11/2" 800 590 G 11/2" 800 590

M 10 x 1 25 18 M 10 x 1 13 10

M 12 x 1,5 30 22 M 12 x 1,5 30 22

M 14 x 1,5 50 37 M 14 x 1,5 40 30

M 16 x 1,5 60 44 M 16 x 1,5 60 44

M 18 x 1,5 60 44 M 18 x 1,5 70 52

M 20 x 1,5 140 103 M 20 x 1,5 90 66

M 22 x 1,5 140 103 M 22 x 1,5 100 74

M 26 x 1,5 220 162 M 26 x 1,5 120 89

M 27 x 1,5 250 184 M 27 x 1,5 150 111

M 33 x 1,5 400 295 M 33 x 1,5 250 184

M 42 x 1,5 600 443 M 42 x 1,5 400 295

M 48 x 1,5 800 590 M 48 x 1,5 500 369

312
 24 - TIGHTENING TORQUES

Notes:

313
Notes: