Workshop Manual
Pneu tyred roller
AP 240
AP 240
Pneu tyred roller
Cummins Tier 2
Workshop manual
01/2011
From Serial No.
ENEdition
3742050
Preface
Information, specication or recommended instructions to assemble or disassemble individual parts of sections of the Machine as included in this publication represent basic and nal information at the time this publication has been printed. Any printing errors, technical alterations or illustration changes are reserved. All the
dimensions and weights are approximate and therefore unbinding.
Ammann Czech Republic a.s. reserves the right to make changes any time with no obligation to inform Machine user. In the event any dierences are found between the Machine used by you and the data given in this
publication, please contact your dealer.
Any reprinting or dissemination of any type shall be preconditioned by a written consent from Ammann Czech
Republic a.s.
Ammann Czech Republic a.s. | Náchodská 145 | CZ–549 01 Nové Město nad Metují
+ 420 491 476 111 | Fax + 420 491 470 215 | info@ammann-group.com | www.ammann-group.com
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1AP 240
Contents
Preface ....................................................................................................................................................................................................................1
Contents ...........................................................................................................................................................2
1. Introduction ..............................................................................................................................................7
2. Safety precautions and instructions .....................................................................................................11
3. Review of applications ...........................................................................................................................19
4. Roller description ...................................................................................................................................21
5. Engine ......................................................................................................................................................25
5.1. Specications ......................................................................................................................................................................................26
5.1.1. Engine ..................................................................................................................................................................................... 26
5.1.2. Motor oils and grease used ............................................................................................................................................. 26
5.1.3. Coolant ...................................................................................................................................................................................27
5.2. Disassembly of the engine .............................................................................................................................................................28
5.3. Installation of the engine ................................................................................................................................................................ 33
5.4. Radiator disassembly and assembly ........................................................................................................................................... 34
5.5. Locating engine defects .................................................................................................................................................................. 35
5.6. Location of CLARK gearbox defects ............................................................................................................................................ 37
5.7. Fixtures ..................................................................................................................................................................................................38
6. Rear axle ..................................................................................................................................................39
6.1. Technical data - description ...........................................................................................................................................................40
6.1.1. Description ............................................................................................................................................................................ 40
6.1.2. Technical specications .................................................................................................................................................... 43
6.1.3. Torque ..................................................................................................................................................................................... 43
6.1.4. Lubricants and glues .........................................................................................................................................................44
6.2. Possible defects and remedies ......................................................................................................................................................44
6.3. Disassembly of axle ........................................................................................................................................................................... 45
6.3.1. Preparations ..........................................................................................................................................................................45
6.3.2. Axle disassembly from the machine ............................................................................................................................ 45
6.3.3. Disassembly of axle ............................................................................................................................................................ 47
6.3.4. Disassembly of drive housing ........................................................................................................................................48
6.3.5. Cleaning and inspecting parts ....................................................................................................................................... 51
6.4. Axle assembly ...................................................................................................................................................................................... 52
6.4.1. Drive housing assembly ...................................................................................................................................................52
6.4.2. Dierential assembly ......................................................................................................................................................... 58
6.4.3. Assembling axle to the machine ................................................................................................................................... 60
6.5. Fixtures ..................................................................................................................................................................................................61
2 AP 240
3AP 240
WORKSHOP MANUAL
7. Front axle ................................................................................................................................................63
7.1. Technical data...................................................................................................................................................................................... 64
7.1.1. Specications .......................................................................................................................................................................64
7.1.2. Lubricants and glues ..........................................................................................................................................................64
7.2.
Axle disassembly - valid up to the serial number 1189 ........................................................................................................ 65
7.2.1. Disassembly of axle from the equipment .................................................................................................................. 66
7.2.2. Disassembly of guiding pipe of the front axle .........................................................................................................67
7.2.3. Disassembly of fork ............................................................................................................................................................ 68
7.2.4. Cleaning and inspection of parts .................................................................................................................................. 70
7.3. Installation of front axle - valid up to the S/N 1189 ............................................................................................................... 71
7.3.1. Installation of guiding pipe and fork ........................................................................................................................... 71
7.3.2. Assembly of wheel hubs and shaft ............................................................................................................................... 73
7.3.3. Assembly of fork and shaft assembly with wheel hubs ........................................................................................ 75
7.4. Fixtures - valid up to the S/N 1189 ...............................................................................................................................................77
7.5. Assembly of axle to the machine ................................................................................................................................................. 81
7.6. Front Axle Disassembly - valid for rollers from serial number 1190 ................................................................................82
7.6.1. How to remove front axle from the Machine ............................................................................................................ 83
7.6.2. Dismantling wheel hubs, bearings, gufero rings ..................................................................................................... 86
7.6.3. Replace front axle’s sealants ............................................................................................................................................ 88
7.6.4. Assembling wheel hubs and bearings .....................................................................................................................100
7.7. Fixtures - valid for version from serial number 1190 ...........................................................................................................108
8. Flexible shaft .........................................................................................................................................113
8.1. Specications ....................................................................................................................................................................................115
8.1.1. Torque ...................................................................................................................................................................................115
8.1.2. Grease ...................................................................................................................................................................................115
8.2. Disassembly and re-assembly .....................................................................................................................................................115
8.2.1. Preparatory work ...............................................................................................................................................................115
9. Steering .................................................................................................................................................117
9.1. Specications - description ..........................................................................................................................................................119
9.1.1. Technical data ....................................................................................................................................................................119
9.1.2. Lubricants and glues ........................................................................................................................................................119
9.2. Possible defects and remedies ....................................................................................................................................................120
9.3. Disassembly and assembly of the steering assembly .........................................................................................................121
9.3.1. Preparatory work ...............................................................................................................................................................121
9.3.2. Disassembly of steering hydraulic generator U10 ...............................................................................................121
9.3.3. Disassembly of power steering ....................................................................................................................................122
9.3.3.1. Disassembly of steering column .................................................................................................................................122
9.3.4. Disassembly of linear hydraulic motor ......................................................................................................................123
9.3.5. Removal of power steering tank .................................................................................................................................128
9.3.6. Removal and installation of the lever assembly ...................................................................................................128
9.4. The front - axle alingment - valid up to the serial number 1189 ....................................................................................130
9.5. The front - axle alingment - valid for rollers from S/N 1190 ..............................................................................................131
9.5.1. Filling the hydraulic cylinders .......................................................................................................................................133
9.6. Fixtures ................................................................................................................................................................................................134
4 AP 240
Contents
10. Service brake.........................................................................................................................................135
10.1. Specications ....................................................................................................................................................................................136
10.1.1. Description ..........................................................................................................................................................................136
10.1.2. Specications .....................................................................................................................................................................137
10.1.3. Brake uid ............................................................................................................................................................................139
10.2. Defects .................................................................................................................................................................................................139
10.3. Disassembly and installation ......................................................................................................................................................141
10.3.1. Preparations ........................................................................................................................................................................141
10.3.2. Disassembly of pedal brake .........................................................................................................................................141
10.3.3. Disassembly of booster...................................................................................................................................................142
10.3.4. Disassembly of brake system ........................................................................................................................................143
10.4. Brake shoes adjustment ................................................................................................................................................................144
10.5. Service brake venting .....................................................................................................................................................................145
10.6. Machining brake drums .................................................................................................................................................................146
11. Parking brake ........................................................................................................................................147
11.1. Specications - description ..........................................................................................................................................................149
11.1.1. Description ..........................................................................................................................................................................149
11.1.2. Specications .....................................................................................................................................................................149
11.2. Maintenance ......................................................................................................................................................................................149
11.2.1. Disassembly and installation of the disk brake ......................................................................................................150
11.2.2. Removal and installation of the spring-loaded cylinder ....................................................................................151
12. Inating the tires ..................................................................................................................................153
12.1. Specications ....................................................................................................................................................................................155
12.1.1. Description ..........................................................................................................................................................................155
12.1.2. Specications .....................................................................................................................................................................155
12.2. Removal and installation ...............................................................................................................................................................156
12.2.1. Control valve .......................................................................................................................................................................156
12.2.2. Rotor .....................................................................................................................................................................................156
13. Wheels ...................................................................................................................................................157
13.1. Specications ....................................................................................................................................................................................159
13.1.1. Description ..........................................................................................................................................................................159
13.1.2. Specications .....................................................................................................................................................................159
13.2. Removal of wheels ...........................................................................................................................................................................160
13.2.1. Preparation for work ........................................................................................................................................................160
13.2.2. Front axle wheels ..............................................................................................................................................................160
13.2.3. Rear axle wheels ................................................................................................................................................................161
13.3. Removal and installation of tires ................................................................................................................................................161
13.4. Installation of wheel to the machine ........................................................................................................................................161
5AP 240
WORKSHOP MANUAL
14. Electrical wiring ....................................................................................................................................163
14.1. Description .........................................................................................................................................................................................165
14.1.1. Battery breaker ..................................................................................................................................................................165
14.2. Battery ..................................................................................................................................................................................................166
14.2.1. Specications .....................................................................................................................................................................166
14.2.2. Operation .............................................................................................................................................................................166
14.2.3. Indications of full charge ................................................................................................................................................166
14.2.4. Service during operations .............................................................................................................................................167
14.2.5. Safety regulations .............................................................................................................................................................167
14.3. Alternator ............................................................................................................................................................................................168
14.3.1. Checking the alternator on the roller ........................................................................................................................168
14.3.2. Determining defects of alternator-regulator ..........................................................................................................169
14.3.3. Voltage regulator ..............................................................................................................................................................169
14.4. Starter ...................................................................................................................................................................................................170
14.4.1. Operation and maintenance .........................................................................................................................................170
14.4.2. Check of idling – on the machine ...............................................................................................................................170
14.4.3. Starter defects ....................................................................................................................................................................171
15. Annexes .................................................................................................................................................173
Bolted connection checking, tightening ..............................................................................................................................................174
Wiring Diagram (to S/N 1908)
Wiring Diagram (for S/N 1909÷1970)
Wiring Diagram (for S/N 1971÷3742036)
Electric installation scheme (from S/N 3742037)
Layout of wiring elements in the Machine
Hydraulics Diagram
Air Distribution System
Hand Signals
.......................................................................................................................................................................................195
....................................................................................................................................................................................................198
...................................................................................................................................................................176
.....................................................................................................................................................180
..............................................................................................................................................184
...............................................................................................................................188
...........................................................................................................................................192
................................................................................................................................................................................196
6 AP 240
1. Introduction
WORKSHOP MANUAL
7AP 240
8 AP 240
1. Introduction
The roller, series AP 240, is designed for compacting operations of medium to large magnitudes in the construction of highways, railroads, airports, dams, industrial tracts, harbors, etc. Specications of the machine,
weight, tire sizes, turning radius, leveling of front wheels, and the rst-rate engine, provide for an ecient
roller with very good output, high reliability, and safety in operations. The fact that the ination of tires can be
adjusted continuously allows for compacting of all kinds of materials in a wide range of consistency, and for
the optimal adaptation of the roller.
The roller is well suited for compacting asphalt mixtures, hydraulically compacted mixtures, clay soils, and soil
mixtures of sand and gravel. However, it is nor suited for rocklls.
The roller operates under conditions specied in standards ČSN IEC 721-2-1 (038900): WT, WDr, MWDr - that is
mild, warm and dry, hot and dry environment at temperatures of –15 °C (5 °F) to 45 °C (113 °F).
The roller is manufactured to most modern rules and standards of work safety.
There exists danger of damage or injury, should the roller be applied incorrectly, by untrained personnel, or
for other than specied purposes.
The main purpose of this manual is to provide basic information for the disassembly, assembly, and service
of the main construction elements of the roller. The manual consists of separate chapters in reference to the
catalogue of spare parts, and contains data on assembly, adjustment, and instructions for the application of
special tools and xtures.
The manufacturer improves the product continually under application of the most recently gained experience
and know-how, and for that reason, reserves the right to install modications that have not been included in
the pictures, descriptions, and/or construction details of this manual.
This Manual is copyrighted and it is not permitted to copy and distribute it or its parts.
The text in this Manual refers to right, left, forward, or backward from the direction of forward travel.
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