ASC 70
ASC 90
ASC 100
ASC 110
ASC 130
ASC 150
ASC 200
ASC 250
Workshop manual
Single drum roller
ASC 70, ASC 90, ASC 100, ASC 110,
ASC 130, ASC 150, ASC 200, ASC 250
Cummins Tier 1 - 3
08/2009
Workshop manual
Edition EN
Single drum roller
ASC 70, ASC 90, ASC 100, ASC 110,
ASC 130, ASC 150, ASC 200, ASC 250
Single drum roller
Cummins Tier 1 - 3
Workshop manual
Edition EN
05/2010
Preface
Information, specications, and recommended instructions for the assembly and disassembly of individual
components and parts of the machine contained in this publication are basic and nal information at the time
of the printing of this publication. Printer’s errors, technical modications, and modications of gures are
reserved. All dimensions and weights are approximate and, therefore, not binding.
Ammann Czech Republic a.s. reserves the right to perform modications without obligation to inform the
machine user. If you identify any dierences between the machine operated by you and the information contained in this publication, contact your local dealer.
Reproduction or copying of any kind is prohibited without the written permission of Ammann Czech Republic
a.s.
WORKSHOP MANUAL
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
%
1ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
2 ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
CONTENTS .......................................................................................................................................................3
1. INTRODUCTION ......................................................................................................................................5
2. SAFETY PRECAUTIONS .........................................................................................................................9
3. REPAIR SAFETY INSTRUCTIONS .........................................................................................................37
4. A SUMMARY OF APPLICATIONS .........................................................................................................43
5. DESCRIPTION OF THE MACHINE ........................................................................................................47
6. REMOVING THE ENGINE ......................................................................................................................61
7. DRUM REMOVAL ..................................................................................................................................81
8. ARTICULATED JOINT .........................................................................................................................115
9. REMOVAL OF PUMPS, CENTO CLUTCH ............................................................................................129
WORKSHOP MANUALContents
10. STEERING CYLINDERS .......................................................................................................................139
11. CONTROLS ..........................................................................................................................................143
12. THE DRIVER‘S STATION ASSEMBLY ..................................................................................................147
13. DISASSEMBLY OF HEATER ................................................................................................................153
14. ELECTRICAL INSTALLATION..............................................................................................................163
15. REMOVAL OF ROPS FRAME ...............................................................................................................183
16. ASSEMBLY OF SEGMENTS .................................................................................................................187
17. DISASSEMBLY OF WHEEL ..................................................................................................................199
18. REMOVAL OF HYDRAULIC MOTORS ................................................................................................203
19. REPLACING PRESSURE FILTER OF HYDRAULICS ............................................................................211
20. FILLING HYDRAULIC OIL ...................................................................................................................215
21. DISASSEMBLY OF LEVEL GAUGE ......................................................................................................219
22. DISASSEMBLY OF THE FLOATER .......................................................................................................223
23. ELECTRICAL SCHEMATA ....................................................................................................................227
24. HYDRAULIC .........................................................................................................................................299
25. DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS ..........................................................................339
26. CHECK THE TIGHTENING OF BOLTED CONNECTIONS....................................................................353
27. HAND SIGNALS...................................................................................................................................357
3ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
4 ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
5ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
WORKSHOP MANUAL
1. Introduction
6 ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
1. Introduction
This Service Manual splits into separate chapters, it includes technical data and assembly data, adjusting
guidelines, and instructions to use special tools, jigs and aids.
The major purpose of this Workshop Manual is to provide basic information on disassembly, assembly and
service repairs of the Machine’s main groups.
Machine group identication in this Manual corresponds to the Spare Parts Catalogue.
Before the assembly, itself, we recommend to always mark the parts disassembled, and this due their reas-
sembly, and to blind all the holes of individual parts of the hydraulic system so to prevent any contamination
of the hydraulic circuits.
When you install individual parts into the Machine, please tighten individual bolts or nuts as per the torque
tables (Annex) unless otherwise stated in the text.
ALWAYS observe safety instructions and precautions mentioned in Chapter 2.
Manufacturer improves continuously his products based on operation experience and latest knowledge.
Consequently, Manufacturer reserves the possibility of changes depending on development, and this against
the illustrations, descriptions, procedures or design patterns given in this Manual.
The roller should be used under conditions dened 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).
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.
Some expressions are used in the manual for better orientation, i. e. right, left, forward, backward – in the sense of the machine moving forward.
7ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
WORKSHOP MANUAL
282N100TA
REAR
LEFT RIGHT
FRONT
SYMBOLS OF THE SAFETY NOTICES IN THE MANUAL:
The notice warns of a serious risk of personal injury or other personal hazards.
The notice warns of possible damages to the machine or its parts.
The notice warns of the necessity of environmental protection.
! NOTICE !
As used in this operating manual, the terms „right“, „left“, „front“ and „rear“ indicate the sides of
the machine moving forward.
8 ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
9ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
WORKSHOP MANUAL
2. Safety precautions
10 ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
2. Safety precautions
Generalities
Read the Operation and Maintenance Instruction Manual 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 starting, 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
TION 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 considerably 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 certied safety clothes such as: hard hat, no-slip footwear, heavy
gloves, ear protection, safety glasses , reector 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 o 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, telephone lines,
sewers, overhead and underground electric lines and all other
possible obstacles.
Such paths should be opportunely dened 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. Dene the
rear upperstructure swing area and provide for opportune barriers to prevent access into it.
ATTEN-
Starting
Never start or operate a failed machine. Walk all around the
machine before mounting.
Before operating the machine, make sure that any possible dangerous condition has been properly removed. Before starting
machine, check that steering and attachment 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 ammable uids, never check fuel level, refuel,
charge the batteries or use the starting uid in the presence of
smoking materials, open ames 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 performance
or responds abnormally, have the machine checked 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, especially if not rmly 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 o the machine
while it is in motion.
Make sure that bystanders are clear of the machine operating
range before starting the engine and operating the attachment.
Sound the horn.
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 obstacles 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.
11ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
WORKSHOP MANUAL
Avoid kinking or twisting chains or cables.
Carefully inspect cables or chains for aws or problems before
proceeding.
Do not pull through a kinked chain or cable as the high anomalous stresses existing in this condition may induce 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 enough to withstand the
expected load.
Keep anyone clear of anchor points and cables or chains.
Do not pull or tow unless the operator’s compartments of
the machines involved are properly protected against possible backlash in case of cable or chain failure or detachment.
Be alert of soft ground conditions close to newly constructed
walls. The ll 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 action. 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 machine 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 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, res, ravines,
steep slopes, rough terrain, ditches, crowns, ridge trenches,
diggings in trac 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 reduce 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 experience 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. Remember 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 discontinue adherence or traction with the ground, especially near slopes or dropos.
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-os.
Never use the machine as a work platform or scaolding. 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 specied
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 working on
a slope.
Avoid travelling across slopes. Proceed from uphill downhill and
vice-versa.
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 machine stability.
Properly judge ground conditions with particular attention to
consistency of the area you are going to work on.
Keep the machine suciently 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.
- Dene 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 observing the machine,
any part of it and/or the load approaching the gas mains from
a standpoint more favourable than the Operator’s. This signal
12 ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
2. Safety precautions
man (agman) must be in direct communication with the Operator and the Operator must pay undivided attention to the
signals 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 international 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 regulations 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.
- Dene 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 (ag-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 suciently 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 required to prevent
possible cave-ins or landslides:
- near previous trenches lled with material, - in bad ground
conditions,
- when working trenches subject to vibration from railroads,
working machines or highway trac.
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 startup.
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 o the key-start
switch. Consult the Operation and Maintenance Instruction
Manual. ‚‘ Park the machine in a non-operating and no-trac
area. Park on rm 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 trac lanes cannot be avoided, provide appropriate ags, barriers, ares and other signals as required to adequately warn the oncoming drivers. Always switch o the keystart 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.
Securely block and lock the machine every time you leave it unattended. Return keys to the safe place previously agreed upon.
Perform all necessary operations for stopping as detailed in the
Operation and Maintenance Instruction Manual.
Drive the machine far from pits, trenches, rocky hanging walls,
areas with overhead electric lines, and slopes before stopping it
at the end of the working day. Move all controls to the position
specied for machine stopping. Refer the Operation and Maintenance Instruction Manual.
Never park on an incline without accurately blocking the machine to prevent unexpected movement.
Follow stopping instructions contained in the Operation and
Maintenance Instruction Manual.
13ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
WORKSHOP MANUAL
MAINTENANCE
Generalities
Carefully read the Operation and Maintenance Instruction 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, operating, 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 certied safety clothes such as: hard hat, no-slip footwear, heavy
gloves, ear protection, safety glasses, reector 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 o 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 operator 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, especially if
these are not secured.
Should it be necessary to move the attachment for maintenance
purposes, do not raise or lower the attachment 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 absolutely sure about your safety, do not stay or
walk under a raised attachment.
Do not place head, body, limbs, hands, feet or ngers near articulated cutting edges deprived of the necessary guards, unless
they are suitably and safely locked.
Never lubricate, repair or adjust the machine with the engine
running, except when this is specically required by the Operation and Maintenance Instruction Manual.
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 available, use machine grab rails and
steps. Always perform all service or maintenance work with the
greatest care and attention.
Shop and/or eld 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 requirements.
Do not check or ll fuel tanks or install batteries near burning
or smoking materials and open ames due to the presence of
ammable vapours.
The fuel ller pipe nozzle must be constantly kept in contact
with the ller neck and this even before fuel starts owing in.
Keep this contact from the beginning to the end of the fuelling
operation to avoid possible generation 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 machine on rm level ground providing safe support.
Use strong access ramps, with adequate height and angle. Keep
the trailer atbed free of mud, oil or slippery materials. Tie the
machine securely to the trailer.
Never align holes or slots using your ngers; always use appropriate aligning tools.
Remove all sharp edges and burrs from re-worked parts.
Use only approved and eectively grounded auxiliary power
sources for heaters, battery chargers, pumps and similar equipment to reduce electrical shock hazard.
Lift and handle heavy components using hoisting devices of appropriate capacity. Ensure the parts are supported 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 ammable uids to clean parts.
Use proprietary certied non-ammable, 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 regulations 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
ames or sparks nearby while refuelling the unit or handling
highly ammable materials.
Do not use open ames 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 mushroomed or damaged
heads. Always wear eye protections 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 qualied 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.
14 ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
2. Safety precautions
Stop the engine and move the safety lever to the lock position
before starting adjusting or repairing an assembly.
Do not carry out any work on the attachment without prior authorisation. Observe recommended maintenance and repair
procedures.
In case of eld service, move the machine to level ground and
block it. If work on an incline cannot be avoided, securely block
the machine and its attachments. 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 rmly 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 tted 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 re
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 ammable. Prepare parts in well
ventilated areas. Keep open ames away.
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 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 possible 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 produce steel splinters. Always wear certied
protection clothes such as safety gloves and glasses while handling them.
Handle all parts carefully. Keep hands and ngers away from
gaps, gears, and similar. Always use and wear certied 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 Instruction Manual for
correct maintenance procedure. Areas near articulated cutting
edges where mechanical parts are in motion are where personal
Do not smoke. Store
injuries are most likely to occur. Pay attention to prevent possible you are near a welding in progress.
ing 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 possible 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 produce steel splinters. Always wear certied
protection clothes such as safety gloves and glasses while handling them.
Handle all parts carefully. Keep hands and ngers away from
gaps, gears, and similar. Always use and wear certied 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 Instruction 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 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 reason.
Always install the safety stays for the hood and other hinged
covers before performing any maintenance or repair work in the
engine compartment.
Do not look the weld-
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 o.
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 ags.
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 avail-
15ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
WORKSHOP MANUAL
able, fabricate one using blocks. The ramp should be suciently
strong to support machine weight. Always load and unload on
level surface.
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 ngers 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
o or idling if hot. See the Operation and Maintenance Instruction Manual.
Keep the exhaust manifold and tube free from combustible
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 re 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.
Hydraulic system
Pressure uid escaping from a very small hole can be almost invisible and still have sucient force to penetrate the skin. Always
check any suspected pressure leaks using a piece of cardboard
or wood. Do not use hands. If injured by escaping uid, 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 Maintenance Instruction Manual.
Always use gauges of adequate capacity for pressure testing.
Refer to the Operation and Maintenance Instruction Manual or
Repair Manual.
Tools
Always keep head, body, limbs, feet, hands, and ngers 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 maintenance 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 nobody remain near the machine. Raise
the attachment slowly.
Do not use the machine to transport loose objects, unless proper securing devices are provided.
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 Operation
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 ammable. 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 ames 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
conned spaces. Ensure proper ventilation is provided to avoid
accidental explosions due to build-up of explosive gas released
during charging.
Disconnect batteries before working on the electrical system or
carrying out any other type of work.
Tyres and wheels
Make sure that the ination pressure of the tyres is according
to the specications issued by the Manufacturer 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 weldings,
heat-treatments or repairs not performed correctly can weaken
the wheel, thus causing subsequent damages or dangers.
Do not perform torch cutting or welding operations on rims
with tyres installed.
Spare tyres must be inated only as far it is necessary to keep the
rim components assembled; remember that when not installed
on the disc, a tyre inated 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 regulations.
Deate the tyres before removing them.
Before removing objects from the tyre tread, deate it.
Do not inate tyres with ammable gas: they may cause explosions and serious personal injuries.
After each shift check for loose screws and/or rim mounting
brackets. If necessary, tight them according to the instructions
herein contained.
16 ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
2. 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: indicates an imminent hazardous situation which, if
not avoided, will result in death or serious injury.
WARNING: indicated a potential hazardous situation which, if
not avoided, could result in death or serious injury.
CAUTION: indicates a potential hazardous situation which, if
not avoided, may result in minor or moderate injury.
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.
17ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
WORKSHOP MANUAL
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, qualied, authorized personnel to operate
the machine.
Keep your machine in proper working condition.
Unauthorized modications to the machine may impair the
function and/or safety and aect 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 rst consult your supervisor before operating and servicing the machine.
PREPARE FOR EMERGENCIES
Be prepared if a re starts or an accident occurs.
Keep the rst-aid kit and re extinguisher on hand. Thoroughly
read and understand the label attached to the re extinguisher
to use it properly. Establish emergency priority procedures to
cope with res and accidents.
Keep emergency numbers for doctors, ambulance service, hospitals and re department posted near the telephone.
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 tting 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
- Reective clothing
- Wet weather clothing
- Respirator or lter mask.
Do not take chances. Wear whatever is needed for the job at
hand.
18 ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
2. Safety precautions
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause impairment or loss
of hearing.
Wear a suitable hearing protective device such as earmus 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 signicant
accident, replace the seat belts even though they do not look
damaged.
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
VISUAL INSPECTION”.
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury. When you
get on and o 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 o the machine. Never mount or dismount a moving machine.
Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.
“MAINTENANCE”, paragraph “EXTERNAL
19ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
WORKSHOP MANUAL
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.
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 o.
Riders on machine are vulnerable to injury such as being struck
by foreign objects or being thrown o the machine.
Riders also obstruct the operator’s view, resulting in unsafe operation.
20 ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
2. 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 beforemoving 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 ags, signs, and markings used on the
job and conrm 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.
WORK WITH CAUTION
Accidental severing of underground cables or gas lines may
cause an explosion and/or re, 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 ber 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.
Conrm 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.
21ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
WORKSHOP MANUAL
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 congura-
tion.
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 trac.
INVESTIGATE JOB SITE BEFORE HAND
Clear all persons from area of operation and machine movement.
Make sure worksite footing has sucient strength to rmly support the machine.
When working close to an excavation, operate the machine with
che chassis frame positioned perpendicular to the cli face, so
that the machine can more easily evacuate if the cli face collapses.
Conrm 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 insufcient level lights up, ll 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.
22 ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
2. 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 at by grading.
-
Keep the blade low to the ground and close to the ma-
chine.
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 b e - come 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, conrm 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.
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.
23ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
WORKSHOP MANUAL
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 dierent 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-o lever to LOCK position.
Block both tyres if you must park on a slope.
Park a reasonable distance from other machine.
24 ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
2. 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-o 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.
25ASC 70 / 90 / 100 / 110 / 130 / 150 / 200 / 250
WORKSHOP MANUAL
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 rm 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 spe-
ed selector.
Avoid steering while driving up or down the ramp as it is
extremely dangerous.
If steering is unavoidable, rst move back to the ground or atbed, modify travelling direction, and begin to drive again.
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 atbed 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.
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