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XG610H/XG612H/XG614H 全液压振动压路机

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Document No: CPSM 11 – 0003

XGMA (Sanming) Heavy Machinery Co., Ltd., China

Operation & Maintenance Instructions

of Hydraulic Vibratory Roller

Model XG610H/XG612H/XG614H

Compiled by

Translated by

Proofed by
We reserve the right for modifications without prior notice.

Address: Jinsha Industrial Park, Sanming, Fujian, China 365500

Phone No: 0086-598-5699176
Fax No: 0086-598-5699000
E-mail: sales@smzj.com
 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Contents

Contents
Contents........................................................................................................................................................... 1
Preface ............................................................................................................................................................. 5
Chapter 1 Safety Declaration ..................................................................................................................... 6
Chapter 2 Technical Performance and Parameters ..................................................................................... 7
2.1 Summary ...................................................................................................................................... 8
2.1.1 Machine signboard ................................................................................................................. 8
2.1.2 Application ............................................................................................................................. 8
2.1.3 The excellent features of this machine ................................................................................... 8
2.1.4 Requirements of working environment: ................................................................................. 9
2.1.5 Prohibited operation ............................................................................................................... 9
2. 2 Technical parameters ................................................................................................................. 10
Chapter 3 Operation, Application and Maintenance ................................................................................ 13
3.1 Familiarizing with instruments and switches on the machine .................................................... 13
3.1.1 Control mechanism and instruments .................................................................................... 14
3.1.2 Alteration of travel speed ..................................................................................................... 20
3.1.3 Operation of Emergency brake ............................................................................................. 21
3.1.4 Key-ignition switch .............................................................................................................. 22
3.1.5 Operator’s seat...................................................................................................................... 23
3.2 Running-in for new machine ...................................................................................................... 24
3.3 Operation and working ............................................................................................................... 26
3.3.1 Starting ................................................................................................................................. 26
3.3.2 Travelling ............................................................................................................................. 30
3.3.3 Parking ................................................................................................................................. 32
3.3.4 Working ................................................................................................................................ 34
3.3.5 Towing Roller ....................................................................................................................... 36
3.3.6 Maintenance of scrapers ....................................................................................................... 38
3.3.7 Application of Roller under special condition ...................................................................... 39
3.4 Application and maintenance of hydraulic system ..................................................................... 41
3.4.1 Hydraulic oil ......................................................................................................................... 41
3.4.2 Hydraulic pumps and motors................................................................................................ 42
3.4.3 Oil filter and air filter of the hydraulic tank ......................................................................... 43
3.5 Supply of oil, fuel, grease, water and other fluid ....................................................................... 44
3.5.1 Hydraulic Oil ........................................................................................................................ 45
3.5.2 Fuel/diesel ............................................................................................................................ 46
3.5.3 Gear oil for rear axle and wheel-side reducers ..................................................................... 46
3.5.4 Oil for diesel engine ............................................................................................................. 47
3.5.5 Coolant in engine radiator .................................................................................................... 48
3.5.6 Lubricating grease ................................................................................................................ 49
3.5.7 Lubricating oil in vibration exciter ....................................................................................... 50
3.5.8 Lubrication oil in the planetary reducer ............................................................................... 51
3.5.9 Table of fuel and lubricant .................................................................................................... 52
3.6 Inspection and maintenance ....................................................................................................... 53
3.6.1 Inspection at the parking site before operation..................................................................... 53

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

3.6.2 Inspection after one day’s operation ..................................................................................... 54

3.6.3 Periodic maintenance ........................................................................................................... 54
3.7 Lay-up of roller .......................................................................................................................... 59
3.7.1 Attention issues before lay-up .............................................................................................. 59
3.7.2 Tasks during lay-up .............................................................................................................. 60
3.7.3 Tasks before working after long-time lay-up........................................................................ 62
Chapter 4 Safety Issues ............................................................................................................................ 64
4.1 Safety rules ................................................................................................................................. 64
4.1.1 Signs of caution, warning and notice and their positions ..................................................... 64
4.1.2 Safety regulations ................................................................................................................. 66
4.1.3 Safety articles ....................................................................................................................... 66
4.1.4 Unauthorized modification ................................................................................................... 67
4. 2 Operation safety ........................................................................................................................ 67
4.2.1 Knowing the machine ........................................................................................................... 67
4.2.2 Getting on/off the machine ................................................................................................... 68
4.2.3 Driving on road .................................................................................................................... 69
4.2.4 Parking and leaving the machine .......................................................................................... 69
4.2.5 Fire prevention ..................................................................................................................... 69
4.2.6 First-aid preparation ............................................................................................................. 71
4.2.7 Preventing injuries of crushing or cut-off............................................................................. 72
4.2.8 Precautions on the accessories.............................................................................................. 73
4.3 Starting safety............................................................................................................................. 73
4.3.1 Overalls for Driver ............................................................................................................... 73
4.3.2 Surveying surrounding area before starting the machine ..................................................... 74
4.3.3 Inspection before starting the machine ................................................................................. 74
4.3.4 Starting the machine ............................................................................................................. 75
4.3.5 Inspection after starting the machine .................................................................................... 76
4.4 Travelling safety ......................................................................................................................... 77
4.4.1 The safety of driver and other people around machine ........................................................ 77
4.4.2 Keeping a good visibility ..................................................................................................... 77
4.4.3 Attention on the obstacles..................................................................................................... 78
4.4.4 Attention on traveling in bad environment ........................................................................... 78
4.4.5 Safe travel on the slope ........................................................................................................ 78
4.5 Working safety ........................................................................................................................... 79
4.5.1 Keeping a good operating practice ....................................................................................... 79
4.5.2 Ensuring ventilation when working in closed place ............................................................. 80
4.5.3 Keeping away from dangerous areas .................................................................................... 80
4.5.4 Keeping away from high-voltage cables .............................................................................. 80
4.6 Parking safety ............................................................................................................................. 80
4.6.1 General parking safety.......................................................................................................... 80
4.6.2 Parking at cold areas............................................................................................................. 81
4.7 Inspection and maintenance safety ............................................................................................. 81
4.7.1 General knowledge ............................................................................................................... 81
4.7.2 Maintenance in closed areas ................................................................................................. 84
4.7.3 Maintenance with frame jacked............................................................................................ 84

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Contents

4.7.4 Working under the machine .................................................................................................. 84

4.7.5 Working above the machine ................................................................................................. 84
4.7.6 Maintenance with the engine running .................................................................................. 85
4.7.7 Keeping out foreign objects.................................................................................................. 86
4.7.8 Cleaning machine ................................................................................................................. 86
4.7.9 Using heavy tools ................................................................................................................. 87
4.7.10 Maintenance by welding .................................................................................................... 87
4.7.11 Overhauling the cooling system ......................................................................................... 88
4.7.12 Overhauling the hydraulic system ...................................................................................... 90
4.7.13 Prevention of fire accident ................................................................................................. 91
4.7.14 Rules for filling fuel or lubricating oil................................................................................ 93
4.7.15 Maintenance of electric system .......................................................................................... 94
4.7.16 Maintenance of tyres .......................................................................................................... 97
4.7.17 Disposal of waste materials .............................................................................................. 100
4.8 Transportation safety ................................................................................................................ 100
4.8.1 Loading and unloading roller by self-running .................................................................... 100
4.8.2 Loading and unloading roller by lifting.............................................................................. 101
4.8.3 Transporting roller on road ................................................................................................. 103
Chapter 5 Troubleshooting ..................................................................................................................... 104
5.1 Failure of overall machine ........................................................................................................ 104
5.2 Failure in steering system ......................................................................................................... 105
5.3 Failure in electric system .......................................................................................................... 106
Appendixes Diagrams ............................................................................................................................ 109
Appendix 1 Schematic diagram of hydraulic system ..................................................................... 109
Appendix 2 Schematic diagram of electric system ........................................................................ 111

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Prefaces

Preface

This manual mainly provides you with some issues you may come across during the
process of normal operation and maintenance on this machine, along with the effective
suggestions on those issues, so as to help you use the machine safely and effectively. Please
read it carefully before your operation.
This manual contains: technical performance parameters, operating instruction,
maintenance, security, common failures and debugging. Because of the continual
improvement on the product design and the different configurations required by users, the
complete and latest data shall be obtained before working. Please contact the authorized
dealer of Sanming Heavy Machinery Co., Ltd. (SAHM Corporation) to update with the latest
information.
In the Chapter of ―Technical performance and parameters‖, the application, features,
overall configuration, general dimension and parameters of this machine are introduced.
In the Chapter of ―Operation and maintenance‖, the basic operating technology and the
directive contents of daily maintenance on the machine are introduced, guiding the operator to
be familiar with the correct inspection, starting, operation, shutdown procedure and the
maintenance period.
In the Chapter on ―Safety issues‖, the security issues on machine operation, daily
maintenance and minor repair are introduced. All shall be paid attention to.
In the Chapter of ―Troubleshooting‖, some common failures during operation of this
machine and their eliminating methods are introduced.
Information contained in this manual is based on the production when the manual is
published. SAHM Corporation reserves the right to modify any contents in this manual
without prior notice.

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

Chapter 1 Safety Declaration

Most accidents occur in the process of machine operation, maintenance and repair are
caused by not following the basic security rules and preventive measures. Generally speaking,
knowing the potential risk of danger in advance would avoid most of accidents.
Before the operation, maintenance and repair on the machine, do read and understand all
the security protection measures and warnings.
The basic security measures have been summarized in the ―Security Issues‖ Chapter in
this manual, as well as emphasized in the instruction of operation when there are risks of
danger. In addition, there are warning sign boards installed on the machine, for the operator to
recognize the particular danger. It will cause personal casualty if you do not pay enough
attention to all these issues. The warnings are marked out in graphical symbols both in this
manual and on the sign boards of machine.
Since we are unable to forecast all the potential dangers, the warnings referred in this
manual and on the machine will not cover all the dangers. If the procedures, tools, working
methods or operating technique are not particularly recommended by SAHM Corporation,
ensure that they are safe enough for you and other surrounding people. Meanwhile, be sure
that the operating methods or the maintenance procedures you select will not damage the
machine or cause any danger.

Warning

Improper operation, maintenance and repair are dangerous, and may

possibly cause personal casualty. Operation or maintenance and repair on this

machine are prohibited unless you have read and well-understood this

Operation & Maintenance Instructions.

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Parameters

Chapter 2 Technical Performance and Parameters

Drawing 1 Overall Dimension

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

2.1 Summary

2.1.1 Machine signboard

The product signboard is fixed in the middle-left side under the cab. There is one
inspection certificate and other enclosed documents delivered with each machine, for the
users’ identification and reference.

2.1.2 Application

As a vibratory roller with all-hydraulic dual drive and high grade fittings, the
/XG610H/XG612H/XG612H vibratory roller is mainly applicable to the basic compaction on
high-grade highway, mining road, railway, airport and water conservancy projects. Other
applications are not suggested.

2.1.3 The excellent features of this machine

● An engine with low fuel consumption and high quality, good dynamic performance
and large torque reserve.
● Dual drive on front and rear wheels, ensuring a good drive performance.
● Three sets of brake, making the machine safe and reliable.
● A spacious operation cab with sound insulation, thermal insulation and shock
absorption, along with the good visual field and the comfortable adjustable seat. The
machine is also equipped with an optional air conditioner and an optional
compactibility measuring instrument, according to users’ requirement.
● A vibratory eccentric block with large eccentric moment and large exciting force,
which improves the working efficiency effectively.
● A Cummins diesel engine with charge air cooler and electric-control system, the
exhaust of which meets with the European III standard.
● Different amplitudes available for the specific operation in accordance with the

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Parameters

working condition.
● The servo steering system with hydraulic assistance for flexible steering and stable
travel.
● Proper-matched power and excellent overall performance, making the outstanding
working efficiency available.

2.1.4 Requirements of working environment:

● Altitude: ≤3000m
● Environmental temperature: -10°~40°(the range can be adjusted if special measures
adopted)
● Since this roller is common construction machinery, do not apply it in those
environments with flammable and explosive articles, heavy dusts or poisonous gas.

2.1.5 Prohibited operation

● Start the engine by towing the machine.

● Operate a machine with loosen fuel cap or without fuel cap.
● Operated by a person without appropriate training.

Note!
● The vibratory drum on this machine is made of metal plate of Q420B, ensuring an
excellent structure strength. Operating machine on projects with debris and rubbles
will make some spots or crimping on the surface of drum, which is a normal
phenomenon and will not reduce its performance.
● Shifting the Vibration amplitude selection switch (11) is not allowed during the
vibration process; instead, if necessary, close vibration first and wait for several
seconds, select the desired amplitude and then restart the vibration.

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

2. 2 Technical parameters

General dimension unit XG610H XG612H XG614H

Length mm 6194

Width mm 2250
Height (to the cab top) mm 3170
Wheelbase mm 3080
(Rear) wheels tread mm 1685
Minimum ground clearance mm 440

Performance parameters unit XG610H XG612H XG614H

Working mass kg 10600 12000 14000

Load on front wheel kg 6000 7200 8300
static load N/cm 276 331 382
Vibratory drum (diameter × φ1500mm×2130mm(without teeth)
mm
width) φ1686mm×2130mm(with teeth)
Travel speed Shift 1 0~7.1 km/h
km/h
Shift 2 0~8.5 km/h
Maximum Gradeability 50% 48% 40%
Vibratory frequency Hz 30 30 30
Vibratoryamplitude
mm 1.7/0.85 1.7/0.85 1.8/0.9
(max./min.)
Exciting force (max./min.) KN 225/112 247/127 260/135
Turning Radius (minimum) mm 6300 6300 6300

Engine
Model 6BT5.9-C150
Mode Turbocharing and water-cooled
Number of cylinder 6
Rated power 112kw
Rated rotating speed 2400R/min

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Parameters

Max. torque @ rotational speed 580N.M/1500R/min

Rated fuel consumption 235 g/KWh
Starting type Electric starting 24V. DC
Flameout type Electric control

Drive transmission system XG610H XG612H XG614H

Total transmission ratio of rear axle driving 67
Transmission ratio before driving axle 3
Fixing of rear axle Fixed on the traction frame
Tyre model 23.1—26—12PR
Inflation pressure for tyres 0.12~0.15MPa

Maximum output torque 50kNm

Brake torque 1000Nm

Hydraulic brake system

Engage pressure for brake on rear axle 10bar
Engage pressure for front wheel brake 18bar

Steering hydraulic system

Steering type Hydraulic-aided steering
Displacement/System pressure 20ml/rev /16MPa
Steering cylinder 2 - φ100×254mm(number-cylinder dia.× stroke)
Maximum steering angle 35°each of right & left
Maximum swinging angle 9°each of up & down

Driving hydraulic system

Model of driving pump T90R100
Displacement/System pressure 100ml/rev/38MPa
Oil charging pressure 2.4MPa
Control style of pump Manual-control, 24V.DC,
through two-position and two-way brake valve
Model of front driving motor MSE18
Model of rear driving motor T90M075

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

Control style of rear motors Electro-hydraulic two-point control,

24V.DC, low discharge when powered

Vibratory hydraulic system

Model of vibratory pump P7600
Displacement/System pressure 80ml/rev/18MPa

Model of vibratory motor M51

Operating way Electric control

Electric system
Voltage 24V. DC
Battery model N120 (2 batteries)
Rated voltage of lighting bulb 24V. DC

Rated voltage of engine starting motor 24V. DC

Air conditioner (optional)

Refrigeration capacity 5000W
Air blow capacity 480 m3/h
Rated system voltage 24V. DC
Type of refrigerant HFC134a (R12)

Capacity of tanks
Fuel tank 200L
Engine oil tank 15L
Hydraulic oil tank 130L
Lubricating oil tank of (rear) driving axle 23.4L
Lubricating oil tank of planetary reducer 3L

Refrigerant volume 950~1000g

Coolant volume on engine radiator 32kg
Lubricating oil tank of vibratory drum 40L

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

Chapter 3 Operation, Application and Maintenance

3.1 Familiarizing with instruments and switches on the machine

The cab of the hydraulic vibratory roller is elaborately designed for our user, providing a
pleasant and comfortable operating environment. Firstly, the operator should be familiar with
its controlling instrument and switches.
● Keys: Two sets of keys (two keys for each set) are equipped with the hydraulic
vibratory roller. They are:
a. Key to the cab door;
b. Key to engine ignition switch.
● Doors of cab: The opening handle on the doors are equipped with the door locks.
When closing the doors, plug in the key and rotate it to a certain position clockwise
to lock the doors completely.
● Control mechanism and instruments (referring to the following Drawing 2).
● Key-ignition switch (referring to the following Drawing 6).
● Operator’s seat (referring to the following Drawing 7).

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

3.1.1 Control mechanism and instruments

3.1.1.1 Allocation of instruments

Drawing 2 Control mechanism and instrument

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

Item Description Item Description

1 Electric fan 11 Vibration amplitude selection switch
2 Combined switch 12 Throttle lever
3 Electric fan 13 Forward/reverse travel lever
4 toplight 14 Shift switch
5 radio 15 Parking brake switch
6 Combined Meter 16 Ignition/vibration switch
7 Horn button 17 Cigar lighter interface
8 Steering signal switch 18 Air conditioning switch
9 Air conditioning wind speed switch 19 Steering wheel
10 Emergency brake button 20 --

3.1.1.2 Description of instrument functions

Combined switch (2): Controlling power-on/off of the headlights and taillights.
Horn button (7): Pressing this button for making a sound of horn.
Steering signal switch(8): Controlling the steering lamp, When it is swung forward, the
right-turn lamp and the right-turn indicator lamp will be on; while when it is
swung backward, the left-turn lamp and the left-turn indicator lamp will be on.
Emergency brake button (10): For sharp brake of machine in case of emergency. This button
should not be used for normal stop.

Note!
After returning to normal condition, the switch shall be turned along the direction
of arrow mark to bounce up; or the machine will stay in brake state and will not travel.

Vibration amplitude selection switch (11): Controlling 3 shift of vibration amplitude:

mid-position for no vibration; right for greater amplitude and lower frequency; left
for minor amplitude and higher frequency.
Throttle lever (12): Controlling the diesel engine’s throttle.
Forward/reverse travel lever (13): Used for controlling the stop, forward and backward travel
of machine. When the control lever is set in the mid-position, the roller will not
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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

move (machine brakes); when pushing the control lever forward, the roller will
travel forward; and vice versa. The operating speed is proportional to the swinging
angle of the control lever.

Note!
When starting the diesel engine, the Forward/reverse control lever shall be put in the
middle position.

Shift switch (14): Controlling 2 shift of travel speed range, the maximum of which are
different.
Parking brake switch (15): For brake of machine in parking
Ignition/vibration switch (16): It is an inter-lock switch. When it is on the vibrating position,
the engine can not be ignited, ensuring the machine will not vibrate right after the
engine starts. When it is turned to the vibrating position with engine running, the
machine begins to vibrate.

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

Drawing 3 Combined Meter

Item Description functions

1 Engine tachometer Displaying the rotating speed of diesel engine

2 Left-turn indicator lamp lights up when the left-turn light is turned on

3 Engine oil Displaying pressure of engine lubricating system: when the engine is
pressure running at its rated speed, the pressure falls in 207~414 kPa
gauge (or 2~4 kgf/cm2); when running at idle speed (i.e.
500~600rpm), the pressure should not be less than 69 kPa (or
0.7 kgf/cm2).
4 Left alarm light see next page

5 Voltage Displaying the voltage of electric power system, with normal scale between

meter 24~26 V. This voltage indicates whether the generator is charging the storage

batteries, indirectly.

6 Fuel level gauge Displaying the fuel level in the fuel tank

7 Right alarm light see next page

8 LCD screen see next page

9 Engine Displaying the water temperature of diesel engine, with normal scale
coolant between 85℃ and 93℃. Above 98℃, the engine should be
thermometer shut down immediately.

10 Right-turn indicator lamp lights up when the right-turn light is turned on

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

Drawing 4 Left alarm lamp on the Combined Meter

Item Description Functions

1 Engine alarm It lights up during the operation when certain
failure happens to the engine.
2 Engine oil pressure lamp when the pressure is normal, the lamp is off.
3 Air filter indicator lamp When the lamp lights up during the diesel engine’s

operation, which indicates that the air filter is clogged

4 Ready-for-start indicating The lamp being on is required when starting the N

lamp engine.
5 Preheating lamp N
6 Neutral shift It lights up when the Forward/reverse travel lever is

set in the mid-position,

7 -- N
8 Gearbox alarm N
9 Engine Temp alarm It lights up when the Engine Temp high than 102℃

10 --- N

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

Drawing 5 Right alarm light on the Combined Meter

Item Description Functions

1 Gearbox alarm N
2 charge indicator the lamp being on when the battery Charging
3 -- N
4 -- N
5 Preheating lamp N
6 Parking lamp It lights up when the machine parks by the Parking
brake switch and Emergency brake button
7 Engine stop alarm N
8 Gearbox alarm N
9 --- N
10 Fuel level alarm It lights up when Oil alarm

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

3.1.2 Alteration of travel speed

The travel speed can be altered by combined operation of the Shift switch (14) and the
Forward/reverse travel lever (13), as showing in the following diagram:

Travel lever at Travel lever at position Travel lever at position B2

position B0 B1
Shift switch at Neutral shift Stepless speed alteration Stepless speed alteration in
position I (no movement) in forward shift 1 (0~7.1 reverse shift 1 (0~7.1 km/h)
km/h)
Shift switch at Neutral shift Stepless speed alteration Stepless speed alteration in
position II (no movement) in forward shift 2 (0~8.5 reverse shift 2 (0~8.5 km/h)
km/h)

Drawing 6 Combined operation of travel speed control

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

3.1.3 Operation of Emergency brake

Drawing 7 Emergency brake

Brake：Press down to D2 for emergency brake of machine.
Release: Turn along the direction of arrow mark to bounce back to D1 for releasing brake.

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

3.1.4 Key-ignition switch

The Key-ignition switch (20) for engine also acts as electric lock for the power of entire
machine except ceiling light.

Drawing 8 Key-ignition switch

A0： Neutral position (no power) A1： Power-on A2： Ignition A3： flameout

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

3.1.5 Operator’s seat

Operator’s seat DS85H/90 is a shock-absorbing, adjustable seat which buffers shock for
comfortable operation.

A： Adjustable angle of seat back B：Forward and backward adjustable volume

C：Upward and downward adjustable volume

Drawing 9 Operator’s seat

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

3.2 Running-in for new machine

Though inspection and adjust has been carried out on this machine before leaving
factory, the service life would be greatly shortened if a new machine works in bad
environment for its beginning. Therefore, a run-in is required for a new machine in the
first 60 hours, and service and maintenance shall be carried out regularly.

Follow the next procedures during the running-in period:

● Run the engine at idle speed for 4-5 minutes after starting to warm up the engine.
● Suddenly accelerating the engine in the pre-heating stage is not allowed.
● Except for the emergency condition, sudden starting, acceleration, steering and brake
shall all be avoided.
● During the running-in period, the running-in for forward shift 1 and 2, backward
shift 1 and 2, greater amplitude vibration and minor amplitude vibration shall all be
arranged evenly.
● During the running-in period, the travel speed shall not exceed 70% of the rated
highest speed.
● Pay attention to the machine’s lubrication, replace or add the lubricant in accordance
with the specified time.
● The temperature of the pumps, motors, magnetic valves, planetary reducer, axles,
vibratory bearings and brake arrester shall be frequently paid attention to. If there
exists any over-heat phenomenon, cause shall be found out and debugging shall be
carried on.
● Check the fastening condition of bolts and nuts on every part.
● Replacing engine oil is also required after the expiration of running-in period.
The following work shall be carried out both after 10 hours’ running-in of a new roller
and the expiration of running-in period:

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

Notice
a. Overall inspection on the fastening condition of bolts and nuts on every part is
required, especially the bolts on cylinder cover of diesel engine, the fixing bolts for
engine, shock absorbers and rear axle, the nuts on wheel hub and the connecting bolts
on vibratory wheel. All of above-mentioned shall be checked at least for one time.
b. Clean both the rough and fine oil filter and the fuel filter.
c. Check the tightness of belts for cooling fan, generator and air conditioner
compressor.
d. Check the volume and charge capacity of electric fluid in storage batteries, and
tighten the connectors on batteries.
e. Check the oil level of the speed reducer.
f. Check the sealing performance of the hydraulic system and brake system.
g. Check the connection and fixing of the Forward/reverse travel lever (13).
h. Check the temperature and connection of each component in the electric appliance
system, along with the power supply state for engine, the working condition of
illumination and steering lamp.
i. Check if there exists any leakage in the hydraulic pipelines.

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

3.3 Operation and working

3.3.1 Starting

3.3.1.1 Overall inspection before starting

a. Release the steering locking mechanism and keep it in the unlocking position, so as to
make the roller available for steering.

b. Inspect the bottom and peripheral part of roller, check if there exists any loose bolts,
contaminant, oil leakage, coolant leakage or damage on the parts and components. The
other accessories and hydraulic parts shall also be checked.

c. The engine shall not be started until each component is confirmed to be normal.

Inspection before starting is shown as following:

Note!
All the above mentioned inspection shall be carried on with the machine stopped on
level ground first.

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

Notice

(i). Check the water level in the engine radiator;

(ii). Check the fuel level of the fuel tank;
(iii). Check the oil volume in oil basin of engine;
(iv). Check the sealing performance of each oil pipeline, water pipeline and other
components;
(v). Check the connection of batteries;
(vi). Check the oil volume in hydraulic oil tank;
(vii). Check the sealing performance of the hydraulic system pipelines and other
accessories;
(viii). Check the brakes of front and rear wheels;
(ix). Check if the emergency brake is reliable. The button shall be pulled up to
close the circuit;
(x). Check if the Forward/reverse travel lever (13) is flexible and is set in neutral
position; And the Ignition/vibration switch (16) shall be put in the ―ignition‖
position;
(xi). Check if the tyre pressure is normal;
(xii). Check the safety belt on operator’s seat and if other safety devices are
working normally;
(xiii). Check if the scraper is cleaned and its clearance with the wheel is proper;
(xiv). Check if the lock pin in the steering locking mechanism is pulled out;
(xv). Check if the lubricant in the planetary reducer, driving axle and vibratory
bearings of the vibratory drum has been filled up.

3.3.1.2 Starting engine

Electrical starting and electrical flameout are adopted for the engine of this machine. The
following shall be paid attention to during the operation.

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

Note

(i). Before starting, the Forward/reverse travel lever (13) of roller must be put in
neutral position; the Ignition/vibration switch (16) must be kept in ―Igintion‖
position, while the Emergency brake button (10) shall be pulled up to close the
circuit.
(ii). It is not allowed to open the throttle to its maximum during and right after
starting, so as not to damage the diesel engine’s components.
(iii). Follow the instructed procedures to start the engine.
(iv). Adjust the seat to make it comfortable for you to operate.
(v). Other operations on the diesel engine shall be carried on in accordance with the
application instruction of diesel engine, delivered with the machine.

The following are procedures of engine starting:

a. Put the Forward/reverse travel lever (13) on the right of operator’s seat in the neutral
position.

b. Put Vibration amplitude selection switch (11) in the middle position.

c. Switch on the Master electric brake

d. Plug the ignition key into the Key-ignition switch (electric lock) and turn it clockwise
to the ―power-on‖ position. The Fault indicating lamp, Parking lamp and
Ready-for-start indicating lamp will light up, and then will go out one by one after
several seconds.

e. Switch the throttle lever (12) to the position of 1/4 stroke.

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

f. Sound the horn for alarming, which is always suggested before starting.

g. After that, the engine can be started by turning the key clockwise further to ―ignition‖
position.

Note!
One ignition shall NOT exceed 5~10 seconds, or the key should be released to
bounce back to power-on position. The continual working time of starting motor shall
NOT exceed 15 seconds. If re-starting is required, the interval shall be longer than 1
minute.
If starting fails for three times in series, then the cause shall be located and
eliminated before re-starting the engine another time.

h. After starting, run the engine at idle speed for 5-10 minutes, with the rotating speed
between 600 and 750rpm. Pay attention to all the instruments. If they are in normal
condition, the machine is ready for further operation of traveling and working.

Starting at low temperature

If the ambient temperature is very low, and after the three lamps are off, turn the key
clockwise further to ―ignition‖ position, the Ready-for-start indicating lamp (17) (blue) will
be on again and the engine is carrying on pre-heating. Wait until the Ready-for-start
indicating lamp (17) is off again and then ignite the engine.

3.3.1.3 Operation after starting

a. Run the engine at a low speed and check the pressure indication of engine oil. If it
fails to fall into the normal range within 10 seconds, check out the cause and restart
the engine after the cause is eliminated. Otherwise, it may lead to a major engine
fault.

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

Warning!
Running the engine at a high speed with the pressure of engine oil not reaching the
specified value will damage the turbo-charger.

b. After starting, run the engine at idle speed for 5-10 minutes, and the temperature of
water (engine coolant) will be over 55℃.

Notice!
It is not allowed to run the engine for over 20 minutes, with the Forward/reverse
travel lever (13) at its neutral position, no matter at high or low speed.

c. Except the above-mentioned, other inspections on the roller before travelling or

working shall include the following:

Note

(i). Check if every switch, lamp, horn, window screen wiper and control handle are
in normal condition.
(ii). Check if there exists any leakage in every system.
(iii). Check if there exists any abnormal noise in the engine and transmission system.
(iv). Check if the brake is normal.

3.3.2 Travelling

3.3.2.1. Moving
In order to avoid accidents, ensure there is no person staying on or around the machine
and always sound the horn to alert before moving. Ensure the machine is always under
control.
a. Adjust the throttle lever (12) to the position where engine is running at 2300 rpm,
shown on the Engine tachometer

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

b. Release the Emergency brake button (10) and Parking brake switch

c. Push the Forward/reverse travel lever (13) to a desirable option to move the machine
forward or backward.

d. It is prohibited to run the machine at a high speed on slope or ground with bad
surface condition.

e. Change to a proper shift before running down a slope. DO NOT shift during running
down.

f. DO NOT run in over speed downhill. Deceleration can be control by the

Forward/reverse travel lever (13).

3.3.2.2 Shift of speed and direction

a. In order to improve the operating comfort and extend the service life of transmission
components as more as possible, always stop the roller before shifting the travel direction
(either from forward to backward or from backward to forward).

b. The travel speed of machine is controlled by the Forward/reverse travel lever (13). The
speed is proportional to the swinging angle of the control lever.

c. The engine throttle should be set at its maximum during working to ensure the best
working efficiency and compaction effect. Operating the machine with vibration at a
lower throttle may reduce the compaction effect, attenuate its function and damage the
hydraulic components.

3.3.2.3 Steering
a. Turn the steering wheel (19) to a desirable direction for steering during the machine

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

is traveling.

b. Articulating pin is applied as the steering center of this machine, with the front and
rear frames swinging around it.

c. Steering at a high travel speed is very dangerous, and is prohibited by all means.

d. Steering on a slope can easily lead the machine to roll over and is also prohibited by
all means.

3.3.2.4 Emergency brake

In case of emergency, just press the Emergency brake button (10) down (D2), and it
will cut off the hydraulic return circuit automatically. In this case, the machine will stop
sharply, the engine will flame out automatically and the Emergency brake lamp will be on.
After that, stop the machine following the normal stop procedure.
To restart the machine, turn the Emergency brake button (10) along the arrow mark to
release the brake first.

Note!
The emergency brake is of certain damage to the machine; therefore, it shall not be
used for the normal parking.

3.3.3 Parking

3.3.3.1 Procedures of stopping machine

a. Put the Forward/reverse travel lever (13) in the neutral position.

b. Turn the throttle level (12) to the low throttle, and turn the Key-ignition switch
(electric lock) to the flameout position.

Note!
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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

Park the machine on a level floor free of risk of falling-off rock, landslide and
flood.

Notice!
It is prohibited to stop the machine on a slope. If stopping on a slope is
inevitable, then the wheels must be blocked by an obstacle, so as to prevent the
machine sliding.

3.3.3.2 Procedures of engine flameout

a. Run the engine at idle speed for about 5 minutes to cool down each part.

b. DO NOT turn the Key-ignition switch (electric lock) clockwise to the ignition
position (A2) before engine flameout.

c. Pull out the key and keep it well.

d. Switch down Master electric brake (1).

3.3.3.3 Leaving the machine

a. When getting off the roller, please use the ladder and handrail mounted on it, and face
to the roller. Jumping from the roller is prohibited.
b. Check if there exist any crumby materials accumulating on the components of engine.
Clean them off so as to prevent a fire accident.

c. Clear all the flammable materials around the roller, so as to prevent a fire accident.

d. Close the window and lock the cab doors, as well as other maintenance gates.
Remember to take away the keys.

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

3.3.3.4 The following work should be done after everyday’s operation

Note

(i). Check the fuel.

(ii). Check the oil level and cleaning condition in the engine bottom. If the oil level is too
high and the oil become thinner, found out the cause and get rid of it.
(iii). Check if there exists any leakage in each oil pipeline, water pipe, air pipe and other
components.
(iv). Check the fixing and/or sealing condition of vibratory drum, hydraulic motor,
hydraulic pump, steering unit, rear axle etc., as well as any overheating phenomenon on
them.
(v). Check tightness of bolts on the wheel hubs and transmission shaft, and of other pins
as well.
(vi). The cooling water without antifreeze shall be discharged in the cold weather (below
0℃ ).
(vii). Check if the working condition of vibratory drum is normal.
(viii). Check if the appearance and pressure of tyres are normal.
(ix). Grease each lubricating point as specified.
(x). Clean the dust and dirt on machine, especially on the vibratory drum.

3.3.4 Working

3.3.4.1 Preparation for working

Clean the working site, level up the dented surface and eradicate the obstacles that
would damage the tyre and disturb working.

3.3.4.2 Procedures of working (compaction)

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Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

a. Confirm that the engine is running at the rated 2300rpm.

b. Release the Emergency brake button (10).

c. Switch the Ignition/vibration switch (16) to the desired position (―ignition‖ for either
starting engine or travel; ―vibration‖ for vibration and travel).

d. Ensure no obstacles along where the roller travels.

e. According to the construction process requirement, put the Vibration amplitude

selection switch (11) in the desired position.

f. According to the construction process requirement, pull the Forward/reverse travel

lever (13) to gain a proper travel speed.

g. Roll over the working surface to and fro for compaction, in accordance with the
working speed, vibratory parameters and compacting time numbers specified in the
construction process.

Note!
(i). During the process of vibratory compaction, the vibration shall be closed
first before changing the roller’s travel direction, and start vibration again after driving
the roller to the reverse direction. Shifting the Vibration amplitude selection switch (11)
is not allowed during the vibration process; instead, if necessary, close vibration first
and wait for several seconds, select the desired amplitude and then restart the vibration.
(ii). The driver shall keep close attention to its travel direction, and adjust it with
the steering wheel at any moment, during the process of operation and working,.
(iii). Always keep an eye on the readings of each instrument and alarm device,
which shall all be within the normal range and without any abnormal action.
(iv). Do stop the machine and service immediately if any failure happens to the
roller.
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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

3.3.5 Towing Roller

The roller can be towed over a short distance at low speed, if necessary. Follow the next
steps for towing:
a. There, on the driving motor, is a multi-function valve, on which the left and right
bypass valves (item 1 and 2 in the following Drawing 7) are mounted. Turn the left and
right bypass valves anticlockwise for 3 turns respectively. More specifically, two
wrenches are to be used. As shown in the Drawing 7, use a wrench of 1-1/16 inch to
loosen outer nuts on the bypass valves while the inner nuts are locked by a wrench of
1-1/4 inch. Turn the outer nuts anticlockwise for 3 turns ONLY for opening the bypass
valves, BUT NOT the inner ones, which are used to fix the whole multi-function valve
after adjustment of pressure. In reverse, screw the nuts clockwise to close the bypass
valves after towing.
1

Drawing 10 Left and right bypass valves on the driving pump

Note!
(i). DO NOT turn the nuts anticlockwise for more than 3 and a half turns; otherwise
the multi-function valve may leak.
(ii). This bypass valves are used to release system pressure for temporary towing the
roller at a low speed and over a short distance under emergency condition when the
system is blocked. Long distance or high-speed towing is not allowed. The travel speed
of towing shall not be over 1km/h, and the time shall not be over 5 minutes; otherwise,
the pump and the motor may be damaged.

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Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

b. release brake of the normally-engaged arrester an axle.

c. Carry on the towing operation.

d. After towing, please don’t forget to tighten up the left and right bypass valves, and
the cut-off valve on manual pump as well.

Note!
Generally speaking, the traction distance shall not be over 300 meters. Tow
the roller uphill when the roller is blocked during running down a slope to avoid
sliding.

Drawing 11 Towing the roller uphill on a slope

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

3.3.6 Maintenance of scrapers

Two scrapers (item b in the following Drawing 12) are installed at front and rear of the
drum, preventing the dirt and clay from sticking or gathering around the drum surface. Since
these scrapers may become loosened after a period’s operation, regular adjustment is
required.
For adjustment of the scrapers (b), loosen up the bolts (a) in both sides of the steel wheel,
and adjust the scrapers to a proper position, then tighten the bolts. Check if there is any
deflection between the scrapers and the steel drum. If there are, re-adjust them. The clearance
between the scraper and the drum is preferably about 16mm.

Note!
A severe over-deflection of the scrapers to the drum will result in sooner wear of
the scrapers.

Drawing 12 Scrapers before and behind the drum

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

3.3.7 Application of Roller under special condition

3.3.7.1 Application in the cold season and low-temperature region

If the ambient temperature is too low, there would be difficulty for starting engine, and
the engine coolant in radiator would freeze. So, take the following measures:

a. The fuel, hydraulic oil and lubricant with low viscosity shall be adopted, and the
antifreeze shall be added to the engine coolant. For the detailed requirement of above
fluid, please refer to the Table of fuel and lubricant.

b. The following are precautions on application of antifreeze fluid:

Notice

Keep the antifreeze fluid a certain distance from open fire, and no smoking during
the filling.
(i). Do use any antifreeze fluid that contains methanol, ethanol or propanol.
(ii).Any anti-leakage agent is prohibited, no matter it is used alone or mixed with
antifreeze fluid.
(iii). Don’t mix up different antifreezes for application on this machine.

c. Precaution measures after everyday’s operation in cold weather

Carry out the following works to prevent the sludge, water or snow that is sticking
to the machine from freezing and affecting the next day’s operation:

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

Note

(i). Clean the sludge, water and snow on the machine, so as to prevent them from
coming into the sealing places and freezing there, which would damage the sealing
elements.
(ii). Park the roller on a dry and hard floor. If it is impossible, then park it on a wood
board, so as to prevent the roller being frozen on the ground and free of trouble for
the next day’s operation.
(iii). If no antifreeze is used, drain off the water in the water tank, engine and
hydraulic radiators, evaporator of air conditioner and the relevant pipelines after
everyday’s operation, so as to prevent freezing.
(iv). Since the batteries capacity will decrease greatly under low temperature, they
shall be covered or moved to a warmer place, and installed the next day before
working.

d. Works after the cold season

The following works shall be carried on when the weather is getting warmer:
Replace with new fuel, hydraulic oil and lubricating oil (grease); if no permanent
antifreeze is used, drain off all the coolant in the cooling systems, clean the systems and
fill up with new coolant.
3.3.7.2 Application in high-temperature region
Since working under extremely high temperature will make the engine overheat and its
efficiency decrease, the efficiency of hydraulic transmission decrease and the friction pairs
wear sooner, the following measures shall be taken:

a. Carry on the maintenance of cooling system more frequently. The transmission

V-belts of fan shall be inspected and tightened more frequently, and the dust
accumulating on the air radiator, engine radiator, oil radiator shall be cleaned in time.
b. Replace with comparatively-thick lubricant, gear oil, hydraulic oil, and lubricating
grease with higher dropping point.

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

3.4 Application and maintenance of hydraulic system

3.4.1 Hydraulic oil

a. Low-freezing point, anti-wear hydraulic oil N68 is used for this roller.

b. When filling new hydraulic oil, fill it into the hydraulic tank after passing a filter
device (10μm) first. When replacing the oil, clean the hydraulic oil tank first before
filling.

c. Please check whether the hydraulic oil level in the tank is slightly above the middle
calibration of the hydraulic gauge every day before starting the machine. If the oil level
can’t be seen, fill up with oil of the same brand and grade.

d. If replacing of hydraulic oil with different brand and grade is necessary, please drain
off the former oil in the system, and clean the system with new oil to be used and drain
it off again before filling the tank up with new oil.

e. After a long-time lay-up, drain out the deposited water by unscrewing down the drain
plug at the bottom.

f. The container and filling devices should be cleaned before using and storage, so as to
prevent the oil being polluted.

g. Please keep the hydraulic system clean. Clean out the oil sludge and metal filings in
the oil tank in time.

h. In normal condition, the hydraulic oil should be replaced at least every year (every
2000 hours). But if any deterioration or impurities are discovered in the oil during the
inspection, clean the tank and replace with fresh oil as specified.

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

Note
(i). Please be careful when checking the oil level. For example, the machine must be stopped
on a level ground and the engine shall be in flameout.
(ii). Mix up of two or more types of oil for use is prohibited.
(iii). The container and filling devices should be cleaned before using and storage, so as to
prevent the oil being polluted.
(iv). DO check if there exists any leakage after oil filling or replacing.

3.4.2 Hydraulic pumps and motors

a. Unauthorized adjustment of the pressure and flow of pumps is prohibited. The user
should take the responsibility of faults and loss result from unauthorized adjustment. If
the adjustment is really necessary, please contact the service department of SAHM
Corporation.

b. Every day before starting, please check the connection tightness of pumps; check out
any loosening phenomena on nuts used to fix the flexible shaft to the pump and on the
coil of electromagnetic valve.

c. When the hydraulic pump and motor are necessary to be dismantled for repair
because of faults, please contact the service department of SAHM Corporation, or it
should be carried out by professionals.

d. Under low-temperature environment, run the engine at idle speed for 10~15 minutes

after starting to warm up first; otherwise, the pump and motor may wear sooner, and

their service spans may reduce.

e. If shifting between high vibration amplitude and low vibration amplitude is necessary,
close vibration first and wait for 10 seconds and then carry out this task, otherwise the

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

hydraulic elements would be damaged by its impaction.

f. The hydraulic oil to be filled into the system should be the one with its purity meet
the standard of 18/15(GB/T14039-93) or NAS Grade 10 (American standard), or the
hydraulic elements would wear excessively.

3.4.3 Oil filter and air filter of the hydraulic tank

a. The first replacement of the oil filter element and the air filter cartridge should be
carried out after 500 hours’ operation with a new machine. Thereafter, the replacement
should be carried out every 1500 hours’ operation, if not disturbed by abnormal
occasion.

Note!
Hydraulic oil shall be filled into the housing of filter element first before replacing
the hydraulic oil filter.
The filter element is a screw-on type, which should NOT be installed too tightly, so
as to prevent the damage of sealing element.

b. Make sure the new–replaced, new-brand oil filter’s performance and parameter
equals to that of original ones; or the filtering precision of the system would be reduced.

c. When the machine is working under extreme environment with thick dust or
excessive moisture, the service interval of air filter, which is installed in the filling port
of hydraulic tank, should be shortened.

d. There is a vacuum meter installed on the filter in suction port of driving pump. The
readings on the vacuum meter shall be checked after having started the machine every
day. Filter element shall be replaced if the pointer is in the yellow zone, i.e. the reading
of the vacuum meter is 9~11inHg.

Note!
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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

Pointing to the red zone (about 20inHg) indicates that the filter element is
seriously jammed and should be replaced immediately. However, when starting the
engine at low temperature, the reading of a normal meter may also fall into the red
zone, but it will return to the green zone (about 6inHg) after 10-15minutes when
the engine warms up.

3.5 Supply of oil, fuel, grease, water and other fluid

Dangerous

危险
When checking or replacing the oil and coolant, please be careful and don’t get scalded.

Note

a. The oil and fuel must be clean. The diesel must be deposited for 72 hours; the
hydraulic oil to be filled into the system should be the one with its purity meet the
standard of 18/15(GB/T14039-93) or NAS Grade 10 (American standard), or the
hydraulic elements would wear excessively.
b. The oil filler and the filling ports must be cleaned, so as to prevent the water and
contaminants coming into the fluid.
c. When inspecting the oil level, the machine shall be kept in the level condition.
d. Different fluid with various corresponding viscosity and grade should be used
under different ambient temperature, strictly referring to the Table of fuel, oil and
lubricant.
e. Mix up of two or more types of oil or fuel for use is prohibited, or it would lead
to aging failure of rubber and sooner wearing of the parts.
f. Do check out any leakage after filling or replacing oil every time.

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

3.5.1 Hydraulic Oil

3.5.1.1 Checking oil level

Check the oil level on the gauge of hydraulic oil tank. The oil level shall be slightly
above the middle calibration on the gauge; if not, fill it up.

Note!
Stop the engine when checking the oil level.

3.5.1.2 Replacing hydraulic oil

a. Stop the machine in a place convenient to drain off the oil, and then open the engine
hood.
b. Turn off the air filter cover while the oil is still warm, and screw down the drain plug
under the hydraulic tank to drain the oil.

c. Clean the inside of the tank, as well as the filling port and the filters in oil suction and
return ports. Replace the damaged filters.

Drawing 13 Hydraulic tank and its filling port

d. Screw on the drain plug again and the filter.

e. Fill in fresh oil through the filling port until it reaches the middle calibration on the
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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

gauge. Direct filling oil into the tank without through the filter is not allowed. Close the
filter cover.

f. After filling, run the engine at a low speed (idle speed) for several minutes and the oil
level will drop a little. Refill any oil if the oil level does not reach slightly above the
middle calibration on the gauge.

g. Close the engine hood.

3.5.1.3 Discharging sundries

The water and sundry substances accumulated in the tank can be discharged out from the
drain plug.

3.5.2 Fuel/diesel

3.5.2.1 Checking fuel level

Check the fuel level on the Fuel level gauge (13) (and hour meter) on the instrument
panel in the cab.

3.5.2.2 Cleaning the fuel tank

The water and sundry substances accumulated in the tank can be discharged out from the
drain flange when removed. Clean the filling port and fuel suction filter as well. Replace the
damaged filter elements.

3.5.3 Gear oil for rear axle and wheel-side reducers

3.5.3.1 Checking oil level

Screw off the plug on the filling (inspection) port of master transmission of the rear axle
to check the oil level. It is appropriate if it reaches the port; if not, fill it up.

3.5.3.2 Replacing gear oil

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

a. Screw off the drain plugs of master transmission and wheel-side reducers respectively
to drain off the used gear oil while the oil is still warm right after stopping engine. And
then screw on these plugs.

b. Screw off the plugs on both of left and right wheel-side filling (inspection) ports and
on master transmission filling (inspection) port. Fill in fresh oil respectively from the
three ports until the oil flow out of the respective filling (inspection) ports. When filling
oil into wheel-side reducers, the arrow mark should be made to point downward and the
inspection ports at the end of arrow mark. Screw up the plugs after filling.

3.5.4 Oil for diesel engine

3.5.4.1 Checking engine oil level

a. Pull out the oil dipstick, dry up its front part with a lint-free cloth and insert into the
port again. Then the engine oil level can be checked when it is pulled out again.

b. The oil volume is appropriate if the oil level is between the upper and lower marks on
oil dipstick. If it is lower than the lower mark, then filling up to the upper mark is
necessary.

c. Oil volume inspection shall be carried on before operation of machine or 15 minutes

later after engine stops.

d. The engine oil should be checked at certain interval to see if there is any polluting or
mixing of sundry substances. Replacing with fresh oil is required if there exists severe
pollution.

3.5.4.2 Replacing engine oil

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

a. First, drain off the used engine oil from the drain port after screwing down the plug (a)
under engine oil basin, and then fill in fresh oil through filling port until it reaches the
upper mark on the oil dipstick.

b. Run the engine at low speed (idle speed) for a while and then stop the engine to
check the oil level. Add more oil if the oil is insufficient.

c. DO NOT fill too much oil to over the upper mark.

d. The replacement of the engine oil must be carried on under the heat-engine condition.

3.5.5 Coolant in engine radiator

3.5.5.1 Filling coolant

a. If the temperature of engine water (coolant) is too high, check the water volume in
radiator first before filling-up. Besides checking water volume, it is also required to
check whether the holes of radiator core is jammed, and whether there is any damage on
the hoses. Ensure that the cap is fixed on the radiator, or the water may have evaporated
from the port, leading to the over-heat.

b. The cooling water shall be replaced only when the radiator is cooled down. Before
replacing, open the radiator cap first, and then screw off the drain valve at the bottom to
drain out the cooling water completely.

c. After replacement, run the engine for a while and the fluid level will drop a little. And
then stop the engine to add more coolant.

d. For cleaning the interior of radiator, please fill the radiator with coolant and run the
engine at a high speed, to make the coolant circulate. Then drain the water out from the
drain valve again. After that, run the engine at low speed, while filling the coolant once
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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

more with not closing the radiator cap and the drain valve, until the clean coolant flows
out of the drain valve.

Cautious

It is absolutely prohibited opening a screw-on radiator cap right after the engine
shuts down or with the engine running. It is very dangerous since the
high-temperature coolant will spray out.

Note!
If it is really necessary to open a screw-on radiator cap right after the engine shuts down
or with the engine running, cover a cloth over the cap first, and then screw it down slowly
and carefully.

3.5.5.2 Precaution issues

a. DO NOT take the coolant into your mouth and eyes.

b. Keep the child away from the coolant.
c. Replace the coolant once a year.

3.5.6 Lubricating grease

There is 1 lubricating grease cup (a) for the drum, locating in the connection between the
drum bracket and the driving motor. The lithium-base grease of ZL-2 or grease equal to that
is used here.
There are 4 lubricating grease cups (b) on the articulating joint of front and rear frame.
The lithium-base grease of ZL-2 or grease equal to that is used here.
For the specific lubricating positions, you may also refer to lubrication indicating board
(lubricating diagram) on the left side under the cab.

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

Drawing 13 Greasing points on the roller

3.5.7 Lubricating oil in vibration exciter

The vibratory bearing on the eccentric shaft of vibratory drum is lubricated by the
engine oil SAE15W-40.
There are a drain plug (a) and an oil indicator plug (b) on the vibratory rolling steel
drum.
When oil draining is required, screw off the drain plug (a) and oil indicator plug (b), and
run the drum to make the port for drain plug (a) at its lowest position, then the oil will be
drained off.
Before filling oil, run the drum to make the port for drain plug (a) at its highest position.
The port for oil indicator plug (b) will be at 26°below the horizontal line of drum axis. Fill
up the drum with specified engine oil from the port for drain plug (a) until the oil flow out of
the port for oil indicator plug (b). And then screw up the two plugs.

Warning

No spark, flame, or burning objects around the machine during oil filling or draining.

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

Drawing 14 Oil ports on vibration exciter

3.5.8 Lubrication oil in the planetary reducer

Installed on the left side of vibratory drum, the planetary reducer shall be lubricated by
vehicle gear oil of SAE 85 W90（API GL5-MIL2105-B）. Before filling, clean out the
contaminants and grease around the filling port first, and then screw down the plug on the oil
indicating port (b), which should be set on the horizontal line beforehand. If no oil flows out
of the port, fill in oil from the filling port (a) after its plug being screw down. The plug (c) is
used for draining the gear oil.

Drawing 15 Oil ports on planetary reducer

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3.5.9 Table of fuel and lubricant

Fluid type Specification Applying assembly Volume

Fuel In summer In winter Fuel tank 200L

Light diesel 0# Light diesel -20#

or -35#

Engine oil SAE 15 W-40CD or CF-4 15W40 Diesel engine

Pin shafts for working device ，

Lithium-base grease of ZL-2 (2#) and oil cylinder, frame pin, 4kg
Lubricating
or ZL-3 (3#) swinging pin of front frame,
grease
splines of transmission shaft,
etc.

Hydraulic oil Low-freezing point, anti-wear Hydraulic system 130L

hydraulic oil N68 (Q/SH303
495-2007)

Gear oil Vehicle gear oil SAE 85 W90 Rear axle for master 18×2L
transmission and wheel-side
reducer

Cooling Mixture of Mixture of water Engine radiator water tank 32kg

water water & -35℃ & -45 ℃
antifreeze antifreeze

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

3.6 Inspection and maintenance

The high performance of roller results from frequent inspection and maintenance. It is
absolutely wrong to think that inspection and maintenance are not necessary while the
machine is working normally.
Proper and regular inspection and maintenance can not only lead to extension of
machine’s service life, but also to discovering faults earlier, which would save time for repair
and cost of maintenance.

3.6.1 Inspection at the parking site before operation

Note

a. Water level in the engine radiator;

b. Oil volume in the engine oil basin;
c. Fluid volume in the fuel tank, hydraulic tank;
d. Sealing performance of various oil pipelines, water pipelines, air pipeline and
their accessories;
e. Connection of batteries;
f. Whether the Forward/reverse travel lever (13) can be moved smoothly and is set
in its neutral position;
g. Whether the pressure of tyres is normal;
h. Whether there is any loosening phenomenon with the bolts on wheel hubs, fixing
bolts on rear axle, connecting bolts of vibratory drum and other bolts.

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3.6.2 Inspection after one day’s operation

Note

a. Check the fuel reserve.

b. Check the oil level in engine oil basin and its cleanness. If the level becomes
higher and the oil becomes thinner, find out the reason and eliminate the causes.
c. Check out any leakage in the oil pipelines, water pipelines and their accessories.
d. Check the fixing and sealing conditions of hydraulic pump and rear axle; and if
there is overheating as well.
e. Check if there is any loosening phenomenon with the bolts on wheel hubs,
connecting bolts of vibratory drum and other pins.
f. Grease every lubricating point as specified in the schedule.

Notice!
The inspection and maintenance of roller shall be carried on properly and take care to
avoid any accidents or injuries. No fire and smoking during inspection and maintenance.
Meanwhile, fire extinguisher shall get ready for emergency.

Note!
If there are any flaws being checked out, mark the positions and fix them after the entire
inspection.

3.6.3 Periodic maintenance

The proper lubrication and maintenance of roller will ensure failure-free operation and
longer service life. Since it makes the working time of roller extended and the operating cost
reduced, the required time and expenses for scheduled periodic maintenance get redeemed.
Periodic maintenance can be classified into 7 interval groups, after 10, 50, 100, 200, 500,
1000 and 2000 hours respectively.

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

Note

a. According to various working environment of machine, e.g. high temperature, high

humidity, low temperature, dusty place, high-altitude area, etc., alteration of the
interval and contents of periodic inspection and maintenance is necessary. You may
consult to the authorized dealer of SAHM Corporation.
b. When replacing the engine oil, gear oil or hydraulic oil, drain off the used fluid
completely and clean up the corresponding systems first, before filling.

Each longer-interval maintenance task should include all maintenance items of

shorter-interval.

3.6.3.1 After every 10 hours’ (or one day) operation

a. Check the abnormal conditions, e.g. oil leakage and water leakage, by eyes around
the machine.

b. Check the engine oil level.

c. Check the fuel level and the oil level in hydraulic tank.

d. Check the lighting and the instruments.

e. Check the pressure and wearing of tyres. Pressure range: 0.11~0.15Mpa.

f. Check the clearance between the front and rear scrapers and the vibration drum.

g. Check the Air filter indicator lamp for the engine.

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3.6.3.2 After every 50 hours’ (or one week) operation

a. Tighten the connecting bolts on vibratory drum and rear axle.

b. Check the forward/reverse shift control system.

c. Grease to the lubricating points of bearings on fan shaft, on articulated points of front
and rear frames, on transmission shaft, front frame and other parts.

d. Screw down the drain plug at the bottom of fuel tank, to discharge the deposit and
mixture of water.

e. Check out any leakage in the hoses and their connections.

3.6.3.3 After every 100 hours’ (or half a month) operation

a. Check the tightness of fixing bolts on the wheel hub.

b. Check the oil level in rear axle.

c. Clean the air filter for engine.

d. Check the engine oil volume; if necessary, fill up from the filling port.

3.6.3.4 After every 200 hours’ (or one month) operation

a. Check the tightness of V-belts on the engine fan and generator, and the compressor of
air conditioner.

b. Check the load-bearing welding lines and fixing bolts on vibration drum and front

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and rear frames. Check to see if there are any cracks and loosening on them.

c. Clean the engine oil filter and the diesel filter.

d. Replace the engine oil, in accordance with the oil quality and using condition of
engine.

e. Adjust the tightness of V-belt on engine fan

Press the middle point of V-belt between the pulleys of generator and engine fan,
by one finger with 6 kg of force. The normal flexure is about 10mm. The bolts and nuts
shall be firmly screwed and locked after adjustment.

f. Check the oil level in planetary reducer.

g. Check the batteries.

3.6.3.5 After every 500 hours’ (or a quarter) operation

a. Tighten the connecting bolts between rear axle and rear frames.

b. Replace the engine oil.

c. Replace the oil filter and air filter of hydraulic system.

d. Check the shock absorber on vibration drum and their connection bolts.

e. Check and lubricate the steering unit, steering articulation and steering cylinders.

3.6.3.6 After every 1000 hours’ (or half a year) operation

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a. Replace the gear oil in rear axle.

b. Replace the hydraulic oil filter.

c. Check the brake performance.

d. Clean up the fuel tank and replace the diesel filter.

e. Check the pressure of various systems comprehensively and adjust them if necessary.

f. Check the performance of various instruments and switches.

g. Carry on the maintenance for diesel engine in accordance with the application
instruction of diesel engine.

3.6.3.7 After every 2000 hours’ (or one year) operation

a. Carry on the service for the engine in accordance with the application instruction of
diesel engine.

b. Disassemble the steering unit and steering valve for examination, and adjust its
steering angle if necessary.

c. Figure out the volume of wearing and leakage of hydraulic pump by observing
without-control declining of vibratory frequency, checking the electro-hydraulic
directional valve and measuring the working pressure of hydraulic system.

d. Check out any cracks of all the welding lines of vibration drum and frames, as well
as the fastening conditions of their bolts and nuts.

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Operation, Application & Maintenance

e. Check the welding lines of wheel hubs and other load-bearing positions; rectify their
deformation.

f. Check the performance of steering system.

g. Replace the hydraulic oil in system, together with its fine filter.

3.7 Lay-up of roller

3.7.1 Attention issues before lay-up

If the long-time lay-up is going to be carried on, carry out the following work first:

a. Clean up each part of the roller, air-dry them and lay up the roller in a dry storehouse.
If it has to be laid up in the open air, pack it on a concrete ground with good drainage,
and cover it with canvas.

b. Fill up the fuel tank and grease all the lubricating points before lay-up.

c. Coat a layer of thin grease on the exposed parts of the rod of cylinder.

d. Take down the negative electrode of the storage batteries and close the cover of
battery case, or dismantle the batteries from machine and store them separately.

e. If the temperature falls below 0℃, the cooling water in the engine radiator shall be
discharged, unless it is mixed with antifreeze.

f. Set the Forward/reverse travel lever (13) in its neutral position.

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3.7.2 Tasks during lay-up

3.7.2.1 During day-to-day lay-up

a. Turn the Key-ignition switch (electric lock) (20) to its Neutral position (A0) before
pulling out the key. Keep well the key.

b. Lock up all the parts that are equipped with locks, and then pull out the keys and
keep them well.

c. In winter or the cold weather of below 0℃, add antifreeze to the cooling water; or the
cooling water shall be completely discharged, so as to prevent freezing of water and
fracture in engine.

3.7.2.2 During long-term lay-up

The lay-up of roller can be classified into short-term one, which is not longer than 2
months, and long-term one. The parking site shall be with cover, ventilation and dry condition,
away from any corrosive and harmful substances and gas. Before lay-up, the exposed,
easy-to-rust parts, e.g. cylinder rods, shafts etc., shall be coated with anti-rust grease. The
surface of machine shall be coated with a layer of wax before long-term storage.

a. During short-term (or less than 2 months) unused period:

Besides the tasks during day-to-day lay-up, the machine shall be run for traveling
once a week.

b. During long-term (or more than 2 months) unused period:

Besides the tasks during day-to-day lay-up, the following items shall also be
carried on:

(i). Check whether the oil and fluid reach their specified level respectively.

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(ii). Lay the roller on solid, hard ground on a higher place, taking into account of the
rainfall in rainy season.

(iii). Dismantle the storage batteries from machine.

If the machine will be idled for a long time, it is recommended to take down
their connectors to reduce self-discharging. If the machine is to be stopped in a hot
or humid area for a long time, the batteries shall be dismantled from machine and
stored in a dry place. In that case, inspection shall be carried on once for each six
months, so as to judge whether supplementary charging is required. Judge if
charging is necessary according to the colors displaying in the observing hole on the
batteries: green means that the batteries can work normally; black, charging is
necessary; white, replacing batteries is required.

(iv). Cover those parts that would be damaged by moisture entering, such as
ventilating devices, air filters and so on.

(v). Make the tyres at their rated standard pressure, and check out the wearing and
damage.
In order to unload the weight on the tyres, it is the best way to support the
machine on its frames and make its tyres loaded no weight. However, if it is
impossible to support on frames, then checking the pressure at least once every 2
weeks, to make sure there is proper pressure in the tyres.

(vi). Carry out an inspection once a week, to ensure the roller will resume to work
whenever necessary: start the engine and make the roller travel for certain distance
forward and backward after the engine warms up; coat the exposed parts with a
layer of grease after operation.

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Warning

When using the anti-rust agent indoors, open the doors and windows to keep ventilated,
so as to vent the poisonous gas.

3.7.3 Tasks before working after long-time lay-up

a. Remove the damp-proof slipcover.

b. Clean off the anti-rust grease coated on the exposed parts.

c. Discharge the oil in the engine oil basin, planetary reducer and driving axle, then
clean the tanks and fill with fresh oil.

d. Discharge the sundries and water in the hydraulic oil tank and fuel tank.

e. Take off the cylinder cover of engine, oil the valves and rocker shaft, and check the
performance of each valve.

f. Fill the coolant in accordance with the specifications.

g. Install the dismantled storage batteries after charging, and connect it to the cables.

h. Charge the tyres in accordance with the specified pressure.

i. Carry on the inspection before operation (items of section 3.6.1).

j. Carry out a warm-up running for the engine.

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k. Grease the lubricating points on each articulated position.

Note

If monthly maintenance on the roller hasn’t been carried during its lay-up,
please consult with SAHM Corporation or its authorized distributor.

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Chapter 4 Safety Issues

4.1 Safety rules

4.1.1 Signs of caution, warning and notice and their positions

There are signs of caution, warning and notice labeled on certain positions of this
machine as shown on the following Drawing 16. Please read their instructions carefully and
follow these signs and instructions when operating roller.
The signs and their allocation are introduced in this section.
These signs of caution, warning and notice should be kept appropriately; if they are lost,
damaged or the letters and figures on them become indistinct, please fix them up or replace
with new ones. When replacing the parts with these signs of caution, warning and notice, the
signs should be replaced as well.
When cleaning these signs, use cloth and soapsuds, instead of detergent, gasoline or
things like that.

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Drawing 16 Sign & labels on the roller

Item No. Specification Item No. Specification

1 Lifting marks 7 Hydraulic tank sign
2 Handrail signs 8 Forward/reverse operation mark
3 Scalding warning label 9 Squeezing warning labels

4 Electric lock sign 10 Stair signs

5 Notice label 11 Lubricating diagram
6 Hydraulic draining mark 12 Fuel tank sign

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4.1.2 Safety regulations

a. Keep yourself in a fit state during operating roller. DO NOT drive the machine when
you don’t feel good, for example, when you are not healthy; when you have just had
medicine and are sleepy; after you drink. Driving roller in those cases will lead to
mistake of operation, which will hurt yourself and others people.

b. Thoroughly understand all the safety rules and regulations for the operation. Know
well of all the signals during work, and recognize the meanings of various flag signals,
signs and other signals.

c. Ensure that all members understand the sign language used when there are operators
and commanders working together.

4.1.3 Safety articles

a. Personal protective appliances are required during operation and maintenance,

according to specific working conditions, such as wearing hard-material safety hamlet,
safety goggles, safety boots, vest with reflecting sign, face guard, earplugs and gloves
etc.

Drawing 17 Safety articles for operator

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b. When scattering metal chips and minor sundries, especially when using a hammer to
nail up a pin, or using compressed air to clear off the impurities in an air filter, DO wear
safety goggles, hard-material safety hamlet, and thick gloves.

c. Please DO NOT wear slack clothes during operation; or you may be entangled into
some control systems or the moving components, causing serious injury or casualty.

d. DO NOT wear any clothes with too much oil, to prevent catching fire.

e. Since the compressed air may cause the personal casualty, DO wear face guard,
protective overalls and safety boots. The pressure of compressed air used for cleaning
shall be lower than 0.3MPa.

f. Check the performance of all safety articles before using.

4.1.4 Unauthorized modification

Any modification of machine that is not approved by SAHM Corporation may result in
dangerous accidents.
All modification can be carried on ONLY after consulting with and being approved by
SAHM Corporation or its authorized distributors.
SAHM Corporation will NOT take the responsibilities of any injuries and damages
resulting from unauthorized modification of roller.

4. 2 Operation safety

4.2.1 Knowing the machine

a. Only the trained and authorized professionals are allowed to carry on the operation
and maintenance on this machine.

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b. Know well of and follow strictly all the safety regulations, precaution issues and
directors for operation and maintenance of machine.

c. Study and understand the enclosed documents on machine, as well as the structure,
operation and maintenance instruction, the function and allocation of every buttons,
switches, handles, instruments and alarming device on the machine.

d. Thoroughly understand all the rules and regulations for operation, along with all the
signals during working.

e. Clear off any oil and grease attaching to the operating devices and surrounding areas
right after, to avoid sliding risk.

f. Carry on various inspections before and after operation respectively, such as,
checking if all the safety devices are working normally; checking if there exists any
wearing on the tyres and if the tyre pressures are normal, and so on. Neglecting the oil
leakage, water leakage, gas leakage, deformation, loosening phenomenon and abnormal
noise are hidden risks of faults and serious accident. Therefore, periodic inspection shall
be carried on as specified.

4.2.2 Getting on/off the machine

a. Before getting on/off the machine, the handrails and stairs shall be checked first. Any
oil, grease or even mud on them shall be cleaned off immediately, so as to prevent
sliding.

b. Jumping on/off the machine is absolutely prohibited. No getting on/off the machine
when it is moving, either.

c. When getting on/off the machine, do please face to it and use the ladder and handrail,
keeping three parts of your body secured at any time (i.e. two feet and one hand, or two
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hands and one foot), so as to keep your balance.

d. Holding any control levers is absolutely not allowed when getting on/off the
machine.

e. DO NOT climb on/down the machine with tools or other instruments on you, but,
instead, lift them with rope after getting on/off the machine.

4.2.3 Driving on road

a. Survey the road to see if there is dense fog, smog or sandstorm that makes a bad
weather and impedes operator’s vision.

b. Examine the conditions of road and working site in advance, to see if there exist any
dents, obstructions, sludge, and ice and snow, etc.

4.2.4 Parking and leaving the machine

a. DO lock the doors when leaving the machine.

b. When leaving the driver’s seat, DO set Forward/reverse travel lever (13) in its
neutral position first and set the machine in brake state, so as to prevent accidents of
sliding and moving.

c. Before leaving the machine, DO set Forward/reverse travel lever (13) in its neutral
position, flame out the engine, and lock all locks. Take away the keys and keep it with
you.

4.2.5 Fire prevention

Since the fuel, lubricant and cooling mixture used on the roller engine are the flammable
substances, it is very dangerous with fire near the machine. Therefore, the following shall be
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paid attention to:

a. Keep flame away from the above-mentioned flammable fluid.

b. Flame out the engine for fueling up; No smoking and keep away from open fire
during fueling.

c. The tank caps of above-mentioned flammable fluid should be screwed on tightly.

d. Store the above-mentioned flammable fluid in containers with corresponding marks,

and place the containers in safe areas according to classification, and keep them away
from non-staff-members.

e. Clear off the flammable materials accumulated on the machine, such as fuel,
lubricating oil or other rag chippings, and ensure no oilcloth or other flammable goods
around.

f. Electric welding or flame cutting on pipelines with flammable fluid within is not
allowed. Instead, they can be carried out after cleaning these pipelines with
incombustible liquid.

g. Since flammable substances, such as wilted grass and waste paper, near the exhaust
pipe will lead to fire accident easily for a working the machine, close attention shall be
paid to when working in areas with such kind of substances.

h. Even when parking a machine, close attention shall be paid to those areas with
flammable substances, such as wilted grass and waste paper, since there are still many
parts in their high temperature, especially the exhaust pipe.

i. Check if there is any leakage of fuel, engine oil and hydraulic oil; if there is,

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maintenance or replacement with the damaged elements shall be immediately carried on.
Operation of machine can be carried out ONLY after these parts are cleaned up.

j. Since there may be explosive gas produced near the storage batteries, DO NOT make
fireworks close to them. Maintain, service and use the batteries strictly in accordance
with the provided instruction;

Drawing 18 No fire around the storage batteries

k. Open fire (e.g. match, lighter, etc.) is not allowed to be used for checking the dark
place.

i. Fire extinguisher and the knowledge of its usage shall be gotten ready for operation of
machine and their maintenance shall be carried on in accordance with the instruction on
plate.

4.2.6 First-aid preparation

The following precaution issues should be prepared in advance for in-case emergency of
injury or fire:

a. Fire extinguisher shall be gotten ready and the knowledge of its usage shall be known
by carefully reading of its instruction.
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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

b. A first-aid kit must be equipped with in the working site. Periodic inspection is
required, and drugs shall be supplemented if necessary.

Drawing 19 Fire extinguisher & first-aid kit for emergency

c. The operator should know well of how to deal with any accident of fire or injury.

d. Figure out the telephone number (e.g. of doctor’s, emergency center, fire station, etc.)
for contact under the emergency situation. Please label these telephone numbers in
advance on specified places and ensure that all staff know the numbers and how to
contact.

4.2.7 Preventing injuries of crushing or cut-off

a. DO NOT enter, or put hands, arms or any parts of body among the movable
components, e.g. place around the articulated joint of front and rear frames. The running
machine may result in serious accident or casualty when approaching these parts. If
approaching these parts is necessary, DO stop the engine first.

b. When working under the machine, the equipments or accessories shall be properly
supported, instead of depending only on the hydraulic cylinder for support. Any
movement of the control mechanism or leakage of the hydraulic pipeline would make
certain accessories fall down.

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c. Any adjustment is not allowed to be carried on during the machine is running or the
engine is working unless specified in instruction,

d. Keep away from any rotating or moving part.

e. Ensure that no sundries among the fan vanes, which will shoot out or cut off the
dropping-in or pushed-in tools and sundries.

f. An inspection or service with the engine running is very dangerous and should be
avoided in principle.

4.2.8 Precautions on the accessories

a. When installing and using the back-up accessories, please read the instruction on the
relevant accessories and the information concerning the accessories in the manual.

b. Do not use accessories unapproved by SAHM Corporation or its authorized dealer;

or it may result to safety troubles, affection to normal operation, shortening of service
life for the machine.

c. SAHM Corporation may not take any responsibilities of injuries, accidents and
damages resulting from unauthorized using accessories.

4.3 Starting safety

4.3.1 Overalls for Driver

The driver shall wear personal protective items in accordance with the working
conditions. For example, safety hamlet, overalls with tight cuffs on sleeves and trousers，
safety boots, safety goggles, gloves and gauze mask.

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4.3.2 Surveying surrounding area before starting the machine

a. Before starting operation, survey surrounding areas carefully to check out any latent
risky abnormity.

b. Check the ground condition, and figure out an optimum and safest working measure.

c. If working on a street, there should be specific traffic director(s); or fences around the
working site and signs of ―Keep Out‖ should be set up, so as to protect the passers-by
and the passing vehicles.

d. Effective ventilation shall be ensured when working indoors or in closed areas, so as

to prevent toxication from waste gas.

4.3.3 Inspection before starting the machine

A careful inspection shall be carried out on the machine every day before starting, and
the daily maintenance shall be carried on regularly. Any abnormal conditions discovered shall
be immediately reported to the administrator and get repaired before operation.

a. Check out any faults of oil leakage, water leakage, gas leakage, bolt loosening,
abnormal noise, damage or lost of the parts, etc.

b. Check if the coolant level, fuel level and oil level in the engine oil basin are normal;
if the air filters are choked.

c. Check if all the lightings and the signal lamps are normal; if not, repair is necessary.

d. Check if all the instruments are working normally, as well as if the control levers are
set in right positions.

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e. Clean out all the dirt on the window glasses of cab and all the lamps, so as to
guarantee a good visibility.

f. Any parts and tools shall not be left around the driver’s seat. Vibration might be
generated during travel and working and these objects may fall off or damage the
control levers and instruments; or even may move any control lever and start a working
device, causing accidents.

g. Adjust the driver’s seat to a position convenient for operation, and check if there is
any damage on the safety belt and its fixing device. The safety belt shall be replaced
after every three years.

h. Clear off the grease on the handrails and stairs, along with the sludge on the boots, so
as to prevent sliding when getting on/off machine and affecting operation.

4.3.4 Starting the machine

a. Before getting on the machine, please check if there is anybody nearby or

above/under the machine, who shall be asked to leave, and then starting the machine is
allowed.

b. Starting the engine is prohibited if an alarm sign of ―No operation‖ is labeled on the
control lever.

c. Sit on the seat first and adjust it to make you comfortable to operate; then fasten your
safety belt.

d. Be familiar with the alarm devices, instruments and manipulating mechanism on the
instrument panel.

e. Confirm whether the parking (normal) brake is arresting, and whether all the
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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

manipulating mechanism are set in their neutral positions.

f. Sound the horn to make people around to leave.

g. Start the engine, following the instruction.

h. Only start the engine in the cab. Do not start the engine by short-cutting the circuit of
starting motor, i.e. starting the system through bypass, which would damage the electric
system of machine, and therefore, is very dangerous.

4.3.5 Inspection after starting the machine

After starting the machine and before the operation, the following inspection shall be
carried on, so as to ensure there is no hidden safety trouble.

a. Check if there is any abnormal noise or vibration when the engine is running; if there
is, which indicates that there is fault on the machine, report to the administrator and
repair it before operation.

b. Check the controlling of engine rotational speed by turning the throttle level (12)
with the Forward/reverse travel lever (13) at its neutral position.

c. Observe the instrument, apparatus and alarming lamp and ensure that they are
working within the specified scales.

d. Operate all the control levers to ensure they work smoothly.

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4.4 Travelling safety

4.4.1 The safety of driver and other people around machine

a. Please keep a good operating habit for personal safety of you and people around.

b. Before starting the roller, sound the horn to alert first. Starting is allowed after safety
has been confirmed.

c. It should be especially ensured that no people or obstacles are either before or behind
or left of or right of the roller.

d. Stretching either your hands or legs out of the cab would cause injury easily, which is
totally prohibited. And do not put either your hands or legs on any the working devices.

e. Please keep concentrated during operation, for carelessness would lead to a

catastrophe. Pay close attention to the condition and people around along the travelling
direction, and sound the horn to alert when risk is discovered.

f. Travelling with the cab door opening is not allowed.

4.4.2 Keeping a good visibility

a. Slowdown or cease traveling when reaching an area with bad visibility, or crossroad.

b. The visibility is low in a weather of sand-dust, thick fog or rainstorm, and pay special
attention under those weather.

c. Travel at a speed that is applicable to the illumination during the night working and
headlight and alarming lamp on the cab top shall be turned on during the operation.

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4.4.3 Attention on the obstacles

When traveling or steering in a narrow area, please pay attention to the security around;
reduce the speed, confirming whether there are any obstacles around.

4.4.4 Attention on traveling in bad environment

a. Pay closer attention when working and traveling under bad environment.

b. Keep the roller away from cliff or deep gully; or collapse may happen because of the
weight or vibration of machine, leading to roll-over of machine and personal casualty.

c. If working in an area with risk of falling-off rock or roll-over is necessary, work with
a machine equipped with FOPS (falling-objects-protective-structure).

4.4.5 Safe travel on the slope

a. Running traversing a slope or shifting forward/reverse direction on a slope may lead

to a roll-over of roller and therefore is very dangerous and prohibited.

b. Steering on a slope shall also be avoided; instead, steer only when the roller has
reached a flat ground.

c. Alter to a proper travel speed shift before running downhill. Shift during running
downhill is prohibited.

d. Please carefully operate when traveling on a slope, for the roller’s gravity center has
moved to either the front drum or the rear wheels.

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4.5 Working safety

4.5.1 Keeping a good operating practice

a. Always sit on the driver’s seat all the time during operation, and buckle up the safety
belt and be protected by other safety protective devices. The roller shall be always kept
under control.

b. Observe and notice any faults carefully, which should be reported and repaired
immediately. However, repairing a working part is not allowed, so the machine should
be stopped for repair of any parts.

c. Working shall not be carried on until the conditions around have been confirmed to
be suitable.

d. Observe the backside of roller carefully before reverse.

e. Stop working when the visibility is low because of smoke, fog or dust. Illumination
equipment is required if the light in the working site is insufficient.

f. Please keep the following essentials in mind during the night working:

Note

(i). Ensure there are lighting equipments installed for sufficient light;
(ii). Ensure the normal condition of the working lamp on the roller;
(iii). Illusion on the height and distance of other objects will easily occur during the
night working.
(iv). Keep cautious during the night working and stop the machine more frequently to
survey the surrounding environment and to examine the machine.

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4.5.2 Ensuring ventilation when working in closed place

a. If it is required to operate the machine or deal with the fuel in a closed place or a site
with poor ventilation, doors and windows shall be opened to guarantee sufficient
ventilation, so as to prevent gas poisoning. Ventilation equipment such as fans shall be
installed if sufficient ventilation can’t be ensured after opening the doors and windows.

b. When working in a closed place, fire extinguisher should be got ready first, and
know well of its location and usage.

4.5.3 Keeping away from dangerous areas

Ejecting the engine exhaust to, or even making the exhaust pipe close to, flammable
substances will easily caused fire accident. Therefore, pay more special attention when
working in areas with flammable substances such as oil and grease, cotton, paper, wilted
grass and chemicals etc.

4.5.4 Keeping away from high-voltage cables

Please don’t make the machine touch the overhead electric cables, or even close to
high-voltage cables, so as to prevent electric shock.

4.6 Parking safety

4.6.1 General parking safety

a. Stop the machine on ground as flat as possible.

b. Parking on a slope should be avoided if possible. If the machine has to be stopped on

a slope, then stop on a slope with gradient not more than 10%, and block its wheels with
wedge blocks, so as to prevent the machine moving.

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c. When parking the machine, shut down the engine and put the Forward/reverse travel
lever (13) in its neutral position. Lock all the locks on machine and take the keys away.
When getting off the machine, climb down slowly, facing to the roller. Jumping down is
prohibited. Ensure three parts of your limbs secured on the handrail and the ladder when
climbing down.

Warning

Either getting on or off a travelling roller is absolutely prohibited.

4.6.2 Parking at cold areas

a. After having completed the work, please clear off the water, snow or sludge sticking
to the electric wires, electric connection plugs, switches or sensors, along with the
covering parts of these components. If not, the water among them would freeze, which
may lead to unpredictable failures on the machine when operating the next time.

b. Preheating shall be carried on thoroughly, or the machine without thorough

preheating will reflect slowly to the controlling of control lever and unpredictable
accidents may be resulted in.

4.7 Inspection and maintenance safety

4.7.1 General knowledge

a. Staff for operating and maintaining this machine should be professionals with
training and qualification. No people unrelated to the on-process operation or
maintenance is allowed to enter the working area. If necessary, a watchdog should be
appointed to take guard responsibility.

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b. The maintenance of machine shall be carried on in accordance with the specified

procedures. If you are uncertain of the procedures, please contact SAHM Corporation.

c. When carrying on maintenance on machine, assembling or dismantling any parts, a

working commander shall be nominated beforehand, to work out a schedule and
procedure.

d. Please wear working overalls with tight cuffs of sleeves and trousers, as well as a
safety hamlet and goggles.

Drawing 20 Overalls for working

e. Please use the proper maintenance tools instead of the damaged and low-quality ones.

f. In order to prevent personal injury, shut down the engine, set the brake well and block
the machine with wedges during maintenance.

g. Strictly follow the notes on the labels. The most important precautions are written on
the labels attached on the machine; if they are lost or stained, stick new ones or clean
them up.

h. Before carrying on the maintenance, a label of ―No operation‖ or other similar

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warning labels shall be labeled on the starting switch and instrument panel, so as to
prevent other people’s starting the engine or operating the control lever, which may
cause injuries or casualties.

Drawing 22 ―No Operation‖ warning sign for maintenance

i. The working commander nominated beforehand is also asked to be in charge of the

work of assembling or dismantling any parts.

j. Since the fuel and engine oil belong to the dangerous goods, do not close any open
fire and flame to those goods, as well as lubricating grease and oilcloth.

k. No smoking when fueling up or checking the power supply.

l. The parts and components dismantled from machine shall be put in a safe place, and
ensured no falling off. A sign of ―Keep Out‖ shall be hanged on the rail around, so as to
prevent the irrelative people getting close to.

m. Keep non-staff away from the machine and its parts.

n. Keep clean and tidy around the maintenance working site, with no shattered oilcloth
and lubricating oil (grease), so as to prevent fire accident or tumbling of people.

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4.7.2 Maintenance in closed areas

Since the engine exhaust may cause decease or even casualty, vitalization devices are
required if it is necessary to start the engine in closed area. Or at least open the door and
window for ventilation.

4.7.3 Maintenance with frame jacked

a. When jacking either the front or rear frame of roller, nobody is allowed to enter from
the other end.

b. Before jacking a frame, wedge the wheel from the other end; when having jacked the
frame, put pad blocks under the machine for additional support.

4.7.4 Working under the machine

a. The machine shall be stopped on a solid flat ground.

b. The tyres and the steel drum shall be fixed with wedge blocks.

c. Working under unstably-supported machine is prohibited.

4.7.5 Working above the machine

a. Cleanness and obstacle-free shall be ensured when carrying on the maintenance

above the machine, and the following precautions shall be paid attention to so as to
prevent falling off.
Note

(i). Ensure there is no scattered lubricating oil or grease around;

(ii). Do not scatter tools around and disorderly.
(iii). Pay attention to your every walking step, so as to prevent falling-off.

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b. Jumping off the machine is prohibited by all means. When getting on/off the machine,
do please face to it and use the ladder and handrail, ensure three parts of your limbs
secured on the handrail and the ladder.

c. Adopt other protective measures if necessary.

d. Since the top of engine hood is smooth, it is dangerous to stand there, and thus is
prohibited.

e. Since the tyre is slippery, it is dangerous to stand above it, and therefore don’t do that.

4.7.6 Maintenance with the engine running

In order to prevent the injury, maintenance with the engine running should be avoided. If
it has to be carried out, pay close attention to the following precautions:

a. Specify a driver sitting on the driver’s seat, who is ready to shut down the engine at
any time. All other workers must keep all-time contact with that driver.

b. DO NOT touch the high-temperature parts such as the exhaust pipe and silencer, so
as to prevent scalding.

c. Pay close attention when operating close to rotating parts, which may entangle your
limbs and parts of your body.

d. Please don’t touch any control lever. If it has to be carried out, alert other workers
first, ensuring they are at the safe place.

e. Any tools or any parts of body should not approach the fan leaves or V-belts；Or it
may cause serious injury.

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f. DO NOT blindly adjust the parts that you don’t quite understand.

4.7.7 Keeping out foreign objects

a. When carrying on overhauling by opening the manholes or near the filling ports of
tanks, be careful not to leave any foreign objects such as nuts, bolts, cotton and cloth, or
tools etc. in the machine. Or it may lead to damage on the machine, misoperation or
other failures. Any foreign objects dropped into the machine should be taken out as
soon as possible.

b. When carrying on the maintenance, don’t bring any unnecessary tools and parts with
you or in your pockets.

4.7.8 Cleaning machine

a. Clean the machine in time, so as to prevent the contaminants or sludge on the

machine splashing into the eyes, or sliding and falling-down accidents caused by oil and
grease.

b. Use incombustible detergent when cleaning the machine.

c. When cleaning the inside parts of machine, stop the engine, put the Forward/reverse
travel lever (13) in its neutral position, and ensure the parking brake of machine.

d. When cleaning the machine, wear slip-proof shoes for walking on the wet surface;
when cleaning the machine with high-pressure water, wear protective overalls.

e. DO NOT sprinkle water directly on the electric elements such as sensors and electric
connection plugs etc., or it may lead to operation failures of these elements.

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Note

When cleaning the filter elements with compressed air, DO wear protective
overalls and goggles.

4.7.9 Using heavy tools

a. When using the hammer, wearing protective goggles, safety helmet and other
protective overalls is required; pad with a copper bar between the hammer and the
blown parts.

b. Hammering a hard part such as pins or bearings, may cause injury by debris flying
into eyes, and thus should be prohibited.

c. Please be careful when using heavy tools and objects, avoiding falling off.

4.7.10 Maintenance by welding

The electric welding shall be carried on by the qualified welder and equipped with the
appropriate equipment. Since the electric welding may generate poisonous gas, cause fire
accident and result in electric shock, unqualified welder is not allowed to carry on this
operation. The following precaution issues shall be followed during the welding:

a. Cut off the connection of terminals of storage batteries, so as to prevent the

explosion.

b. Clear off the paint on places need welding, so as to reduce harmful gas.

c. Avoid carrying out electric welding on hydraulic equipment or pipelines, or places

near them, since it may generate flammable steam or sparks and lead to fire accident or
explosion.

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d. Cover with fireproof plates on places of rubber hoses, electric cables or pressured
pipelines, since any spark sprinkled on these parts may lead to a sudden fracture of pipe
or damage on the insulating cover of electric cables.

e. Pay close attention when carrying on welding near the tyres since they may explode.

f. Always wear protective overalls when carrying on the electric welding.

g. Keep good ventilation for the working site of electric welding.

h. Clear up all the flammable materials, and equip the working site with fire
extinguisher.

i. Any reconstructions that would affect the vehicle’s performance, safety and strength
shall not be carried on at working site.

4.7.11 Overhauling the cooling system

a. The temperature of hydraulic oil, oil and water in engine and radiator are still very
high right after working, and there are pressures within the containers of those fluids.
Therefore, any attempt to open the caps of those fluid tanks, or to deal with oil and
water, or to replace the filters may lead to serious scalding. All the above-mentioned
attempts should be carried on after the temperature is lowered and following the next
instructions:

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Drawing 23 High-temperature fluid right after working

b. When checking the cooling water, shut down the engine to cool down water, so as to
prevent it gushing out of tank. Screw down the cap slowly to release pressure within the
tank. You may put your hand close to the tank of radiator to feel the temperature of air
there, so as to judge the temperature of cooling water, BUT NOT touch the radiator.

c. When checking the hydraulic oil, shut down the engine to cool down oil, so as to
prevent it gushing out of tank. Screw down the cap slowly to release pressure within the
tank. You may put your hand close to the hydraulic tank, hydraulic radiator or the
hydraulic oil itself, to feel the temperature of air there, so as to judge the temperature of
oil, BUT NOT touch the radiator, tank or hydraulic oil.

d. When the engine is still hot right after shut-down, please DON’T touch the engine
surface, the exhaust pipe, the silencer and the electric relays, so as to prevent being
burnt.

e. When the engine is still hot right after shut-down, please DON’T dismantle the
engine oil thermo-sensor, water thermo-sensor and hoses of air conditioner, so as to
prevent scalding.

f. DON’T get the eyes or skin in touch with substances from the cooling system since
they consists of alkaline matters.

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g. Use appropriate containers to contain the fluid when replacing the coolant, engine oil,
filters or other parts and components, and dispose of it properly in accordance with
local environmental protection regulations.

h. DON’T get open fire close to the connecting pipelines when dismantling the air
conditioner compressor; otherwise, poisonous gas may be produced.

4.7.12 Overhauling the hydraulic system

a. Get the hydraulic cylinders and other hydraulic devices secured, cool down the
hydraulic oil and release all the pressure within the system before overhauling the
hydraulic system.

b. DON’T bend or hammer-blow the high-pressure pipelines; DO NOT install

abnormally-bended or damaged hard pipes or hoses on the machine.

c. Any loosening or damage on pipelines of the fuel and lubricating system, or on pipes
and hoses of the hydraulic system should be fixed or replaced in time, since the leakage
may cause fire accident.

d. Please check the pipelines, hard tubes and hoses carefully, and tighten all the joints in
accordance with the specified torque.

e. DO NOT check the leakage with your bare hand, instead, by using a plate or
paperboard. Even the leakage of pressured-fluid as tiny as a pinhole may also penetrate
the muscle, causing casualties. If you are splashed with this fluid on the skin, treat this
trauma by experienced surgeon as soon as possible.

f. If the following problems are discovered on hydraulic hoses, replacement is required.

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Note

(i). Damage or leakage on the joint.

(ii). Wearing or dissevering on the outer layer of hoses, along with exposure of steel
wire on the reinforced layer of hoses.
(iii). Swelling on parts of hoses.
(iv). Obvious torsion or flattening on hoses.
(v). The steel wire on reinforced layer of hoses penetrate into its outer layer.
(vi). Disturbing connection of joints.

g. Ensure the proper installations of all pipe clips, protective plates and heat-proof
covers, so as to prevent wearing from overheat or friction with other parts.

h. Use appropriate containers to contain the hydraulic oil when replacing the oil, filters
or other parts and components, and dispose of it properly in accordance with local
environmental protection regulations.

4.7.13 Prevention of fire accident

a. When filling fuel, the engine shall be closed. No smoke and open fire around during
fueling.

b. Keep away from open fire for storage of fuel, lubricating oil or other flammable
substances.

Drawing 24 No open fire when fueling

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c. Clear off the flammable materials accumulated on the machine, such as fuel,
lubricating oil or other rag chippings, and ensure no oilcloth or other flammable goods
around.

d. Since explosive gas may be produced near the batteries, DON’T get it close to the
fireworks. The instructions should be followed strictly for the maintenance, service and
usage of storage batteries.

e. When parking machine, pay attention to the parking site, ensuring there are no
flammable substances around the exhaust pipe and other high-temperature parts, such as
wilted grass, paper and so on.

f. Check out any leakage of fuel, engine oil and hydraulic oil. If there is any leakage,
replace the damaged hoses and clear them up before other operation.

g. Check out any damage and electricity leakage on the electric cables, and replace the
damaged ones.

h. When cleaning the parts and components, use incombustible solution instead of
gasoline or other flammable fluid.

i. Electric welding or flame cutting on the pipes or cases containing flammable liquid is
not allowed; instead, clean them up with the incombustible fluid before welding or
cutting.

j. Use aether strictly in accordance with its instruction since it is flammable and shall be
kept away from fireworks.

k. Before service, check whether the fire-extinguishing system is perfect first, and know
well of the location and usage of fire extinguisher and first-aid kit.

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l. DO NOT use open fire (e.g. match and lighter) to check dark places.

Drawing 25 No open fire for checking dark places

4.7.14 Rules for filling fuel or lubricating oil

Since the fuel, lubricating oil, hydraulic oil and anti-freezing fluid can all be kindled by
the open fire, the following rules shall be followed strictly:

Note

(i). When filling up the fuel or lubricating oil, the engine shall be stopped first.
(ii). No smoking.
(iii). The overflowing fuel, lubricating oil, hydraulic oil, anti-freezing fluid shall be
cleaned off immediately.
(iv). All caps of the tanks for fuel, lubricating oil, hydraulic oil and anti-freezing fluid
shall be screwed on firmly.
(v). Keep a good ventilation for places of filling or storing fuel, lubricating oil, hydraulic
oil and anti-freezing fluid.

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4.7.15 Maintenance of electric system

4.7.15.1 General issues on electric system maintenance

a. The maintenance of electric system shall be carried on by electrician with

qualification.

b. When charging the storage batteries with outer power supply, the ground cable shall
be connected last before charging, so as to prevent generating sparks around the battery,
which would lead to explosion.

c. Take off the key from the Key-ignition switch (electric lock) (20) before servicing the
electric system.

4.7.15.2 Maintenance of storage batteries

The batteries used on this machine are maintenance-free ones, which requires for no
maintenance during the normal application.
If the machine will be idled for a long time, it is recommended to take off their
connectors to reduce self-discharging. If the machine is to be parked in a hot or humid area
for a long time, the batteries shall be dismantled from machine and stored in a dry place. In
that case, inspection shall be carried on once for each six months, so as to judge whether
supplementary charging is required. Judge if charging is necessary according to the colors
displaying in the observing hole on the batteries: green means that the batteries can work
normally; black, charging is necessary; white, replacing batteries is required.
Since the electrolyte in the batteries consists of sulfuric acid, and hydrogen may be
produced from the batteries, improper dealing with the batteries may lead to serious injury or
fire accident. Therefore, the following precautions shall be followed strictly:

a. Keep the lighted cigarette or open fire away from the batteries.

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b. Wear safety goggles and rubber gloves when you have to touch the batteries during
work.

Drawing 26 No bare hand when serving the batteries

c. Wash the clothes that are splashed with electrolyte from the batteries immediately
with a large amount of water.

d. It will cause you blind if the electrolyte from batteries splashes into your eyes, which
should be washed with a large amount of water immediately, and go to see a doctor
right after.

e. In case you drink some electrolyte by neglect, drink water, milk, raw egg or edible oil
as much as possible, and immediately call for help from the doctor or the emergency
center.

f. The engine shall be shut down before carrying on the work relating to the batteries.

g. Avoid connecting metal objects such as tools to the batteries by neglect, since the
metal objects will short-cut circuit between the positive (+) and negative (-) terminals of
batteries.

h. When installing or dismantling the batteries, checking out which one is the positive

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(+) or negative (-) terminals respectively should be carried out first. When installing the
batteries, the positive (+) terminal shall be connected first; when dismantling the
batteries, the negative (-) terminal (the grounding one) shall be disconnected first.

i. When cleaning the top surface of batteries, wipe it with cloth. DO NOT use any
gasoline, solution, organic solution or mixture of detergent.

j. Always keep the bolts on clamp plates of batteries tightened firmly.

k. To charge the batteries with an outer power supply, take the batteries off from the
machine.

l. When fixing the electric system or carrying out electric welding on the machine, take
off the negative (-) electrode first to cut down the circuit of electric current.

4.7.15.3 Charging for the batteries

When charging the batteries with an outer power supply, mis-operation may lead to
explosion. Therefore, the operation should be carried on in accordance with the application
regulations of batteries, the relevant charging regulations in this instruction, and the following
precautions as well.

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Note

a. Charging shall be carried on in place with good ventilation, while the cover of
batteries shall be taken off, so as to diffuse the hydrogen and prevent explosion.

b. Set the voltage of charger in consistent with that of the batteries. Wrong setting
voltage may lead to overheating and catching fire of charger, and even explosion.

c. Connect the positive (+) charging clincher of charger with the positive terminal (+)
of batteries, and then connect the negative (-) charging clincher with the negative (-)
terminal of batteries. The connection of two terminals must be firmly screwed.

d. If the charging rate of batteries is lower than 1/10, then high-speed charging shall
be carried on, with the value set below the rated capacity of batteries. However,
extraordinarily heavy charging current may lead to leakage or evaporation of
electrolyte, which may lead to catching fire or cause explosion.

4.7.16 Maintenance of tyres

4.7.16.1 Service of tyres

a. The explosion of tyre may blow its parts and components such as tyre, wheel hub and
driving axle away to as far as 500 meters or even farther. The explosion and its
splashing fragment may lead to accident of serious injury and casualty. Therefore, a
normal pressure of tyre must be ensured. DO NOT inflate the tyres above the rated
pressure.

b. The pressure of tyres may increase a little with the heat generated from running. It is
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a normal phenomenon and shall not be deflated intentionally. Instead, decelerate or stop
the machine to cool down the tyres. However, the overheated tyre may lead to explosion,
which shall be paid attention to.

c. When deflating the tyre to adjust the pressure, keep away from the tyre as far as
possible or stand behind it.

d. Inflating the flammable gas into the tyre is prohibited. Dry nitrogen is recommended.
If the air has been inflated into the tyre, nitrogen can also be inflated into it for adjusting
the pressure, since nitrogen will mix up well with the air. Inflating nitrogen into tyre
will reduce the risk of tyre explosion, since it is not combustion-supporting and it will
help to prevent the tyres rubber from oxidation and embrittlement, as well as the wheel
hub from corrosion.

e. Proper nitrogen inflating tools and training on using these tools are required, in order
to avoid excessive inflation.

f. Check the tyres and wheel hubs every day and see if there is any damage on the tyres,
such as cracks and protrusion. Operation with low-pressure tyres is also prohibited.

g. Check if the connecting bolts and nuts of wheel hub are lost, as well as whether the
tightening torque on the connecting nuts of wheel hub meets the value suggested by the
manufacturer.

h. When inspecting the tyres, DO NOT enter into areas in front of or behind the
direction of tyre rotating. Instead, enter from its flanks. When dismantling one tyre, the
other tyres shall be fixed with wedges.

i. When carrying on welding near the tyre, be more careful since it may lead to
explosion of the tyre.

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j. Since it is a dangerous task to repair the tyre and wheel hub, only professionals with
training are allowed to carry on this task, with special tools and following proper
procedures.

k. Replace the tyres with specified ones and ensure the specification and patterns are the
same.

4.7.16.2 Storage of tyres

Drawing 27 Storage of tyre

a. As a basic principle, the tyres shall be stored in the warehouse, where unauthorized entry is
forbidden. If the tyres have to stored outdoors, fences shall be set up around and a sign of
―Keep Out‖ be hung up.

b. The tyre shall be stored in dry and clean place, since the hydrosphere may quicken the
oxidation of rubber, and the contaminants or oils may erode tyres. The storage site should be
heat-insulated, shadowy without much sunshine and frequent air blowing. The tyres in
storage shall be covered with canvas, plastic cloth or other dustsheet. Improper storage will
reduce the quality and service life of tyre greatly.

c. Stand the tyre on level ground and firmly block it with wedge block, so as to prevent
falling-off even when it is touched by unauthorized persons. If the tyre is laid on its side, it

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will become flattened and its quality would be reduced. The tyre in storage shall be rotated
for one time each month at least, to an angle of 90°.

d. If the tyre is falling down, run away as soon as possible. Any attempt to support
falling-down tyres will lead to serious injury since all the tyres used on construction
machinery are very heavy.

4.7.17 Disposal of waste materials

When disposing waste materials, pay attention to prevent pollution, especially where
human and animals live:
a. It is forbidden to pour the waste oil into the sewer system and river.

b. The oil drained from machine shall be contained in containers instead of direct
discharging onto the ground.

c. Follow the relevant laws and regulations when dealing with the harmful substances or
parts with harmful substances, such as lubricating oil, lubricating grease, fuel, coolant,
solvent, filter and storage batteries, and so on.

4.8 Transportation safety

4.8.1 Loading and unloading roller by self-running

a. Take special care when loading and unloading roller since it is a task with potential
danger. When driving a roller onboard a truck or ship, run the engine at low speed and move
slowly.

b. The loading and unloading of roller shall be carried out on solid and flat ground. Keep
a safe distance from the verge of road.

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c. During loading and unloading of roller, the wheels of transportation vehicle shall be
fixed, so as to prevent vehicle moving. Put pad blocks under the springboard for driving-on.

d. When driving roller aboard or off-board, use skew plates with enough strength,
adequate width and length to make a slope for safe loading and unloading. The angle of slope
shall not exceed 15°, while the distance between the skew plates shall be in accordance with
the (rear) wheels tread of roller.

e. Ensure firm fix of the skew plates and the two plates on each side are of the same
slope and height.

f. Ensure a clean surface of the skew plate, free of lubricant, oil spots, ice and loosening
materials. The dirt on the roller tyres shall be cleared off.

g. Steering on the skew plate is prohibited. If necessary, drive the roller off the skew
plates and steer on a flat found before running aboard again.

h. After loading, please wedge the roller tyres, and then use a rope with enough strength
to fasten and fix the roller, so as to prevent it moving during transportation.

4.8.2 Loading and unloading roller by lifting

When moving the roller onto a ship, a train or a truck, you may lift it from the lifting
eyes on the front and rear frames.
The roller weighs about 12.3 tons. Pay attention to the load limitation of lifting devices
since it is extremely dangerous to lift above the limitation.
Before lifting, lock the front and rear frames of machine with locking pin (b) in the
articulated joint, and put 4 slings or lifting chains through each of the 4 lifting eyes on frames
respectively, or put 2 slings or lifting chains respectively through each of the 2 front lifting
eyes and 2 rear lifting eyes, then bring them together to a crane hook. Ensure that all lifting
devices have sufficient weight-bearing capacity.
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Note

● Before lifting, set the roller suitable for transportation: align the front and rear
frames on the same axis, and lock the front and rear frames with lock pin, and make
the steering cylinders full with hydraulic oil, so as to prevent the mutual swinging of
front and rear frames during lifting.
● The Forward/reverse travel lever (13) shall be set in the neutral position.
● Shut down the engine and lock all gates and doors with key and then take off all
the keys.
● Ensure nobody in the cab during lifting.
● Putting 1 sling through the 2 lifting eyes on both front and rear frames for lifting is
prohibited.
● Ensure the roller can be keep in level condition during lifting.
● Pay attention to avoiding the damages of the hood, cab and hydraulic pipelines.
● Ensure no passer-by and vehicle entering area under the lifted roller.

Drawing 27 Lifting of roller

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Safety Issues

After loading, please wedge the roller tyres, and then use a rope with enough strength to
fasten and fix the roller, so as to prevent it moving during transportation.

4.8.3 Transporting roller on road

a. When delivering the roller on a truck, follow the transportation regulations, especially
on loading capacity, height, width and length, and traffic rules in the national and local laws.

b. When confirming the transportation route, the weight, height, width and length of
roller shall be taken into consideration.

c. When passing through a bridge or private area, ensure no exceeding the load
limitation of these buildings. When traveling on public road, follow the relevant
specifications.

d. When making option among various transport plans, you may need to consider
dismantling the machine. In that case, please contact SAHM Corporation or its authorized
dealer.

The precaution measures for operation, maintenance and service in this manual are
applied to the specified machine. SAHM Corporation may NOT take the responsibilities
resulting from operation, maintenance and service not mentioned in this manual. Instead, the
user should take the responsibilities. Therefore, it is highly suggested NOT to carry on any
operation prohibited in this manual in any occasion.

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Chapter 5 Troubleshooting

5.1 Failure of overall machine

Failures Cause of failures Eliminating methods

a. Insufficient hydraulic oil. a. Check the oil level and fill the
Excessively
tank
high
b. Accumulating dirt on surface of radiator. b. Clean off the dirt.
hydraulic
oil
c. Excessive inner leakage in the pumps, c. Get it repaired or replaced.
temperature
motors or cylinders.
a. Insufficient hydraulic oil. a. Check the oil level and fill the
Excessively
tank up.
low
b. Blocked fine filter on vibratory pump. b. Replace the filter element.
vibratory
c. Excessive inner leakage in the pump or c. Get it repaired or replaced.
frequency
motor.
a. Failure on the brake valve or broken a. Get it repaired or replaced.
electric circuit.
No b. Failure on the travel plunger pump or b. Get it repaired or replaced.
travelling of the motor.
machine c. Extremely low system pressure resulting c. Get it repaired or replaced.
from failure on the high-pressure
overflow valve.
a. Insufficient cooling water. a. Check the water level and fill the
Excessively tank up.
high water b. Accumulating dirt on surface of radiator. b. Clean off the dirt.
temperature c. Extreme loosening of fan belt on c. Get it adjusted or replaced.
in cooling
system d. Failure on water pump or thermostat of d. Get it repaired or replaced.
engine.

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Troubleshooting

5.2 Failure in steering system

Failures Cause of failures Eliminating methods

a. Extremely low temperature or high a. Wait until warm-up.

viscosity of hydraulic oil.
b. Wearing and inadequate flow in b. Check or replace the steering
Arduous steering
the steering pump. pump.
and deficient
c. Extremely low pressure in the c. Adjust the pressure to the specified
steering torque.
safety valve. value.
d. Severe inner leakage in the d. Get it repaired or replaced.
steering valve.

a. Deficient flow in the steering a. Get it repaired or replaced.

Slow turning both to pump.
the left and right. b. Severe inner leakage in the b. Get the cylinder repaired or the
steering cylinders. sealing element replaced.

Normal when Add more oil in time.

Air taken into the system, resulting
steering slowly, but And turn the steering wheel further
from extremely low level of
arduous when after the steering cylinders have been
hydraulic oil.
steering fast. at its max limitation, to vent air in he
overflow valve.

a. Low pressure in the steering a. Adjust the system pressure.

Normal steering system.
when under small b. Wearing and inadequate flow in b. Check or replace the pump.
resistance, but slow the steering pump.
steering under large c. Severe inner leakage in the c. Repair the cylinders and replace
resistance (either to steering cylinders. the sealing elements.
the left or right). d. Severe inner leakage of the d. Get it repaired or replaced.
steering valve.

Completely-broken steering pump or

Steering failure. Get it replaced.
safety valve, or fractured rectangular
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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

key.

a. Air existing in the steering a. Inspect and repair the sealing of

hydraulic circuit. suction joint of steering pump.
b. Wearing and deficient flow in the b. Inspect or replace the steering
Large noise from steering pump. pump.
the steering pump. c. Inadequate oil viscosity. c. Replace the oil with specified one.

d. Insufficient hydraulic oil. d. Fill the tank up.

5.3 Failure in electric system

Failures Cause of failures Eliminating methods

a. Damaged batteries or insufficient a. Charging with outer power supply
electric quantity. or replace the batteries.
b. Damaged Key-ignition switch b. Replace the switch or relay.
or starting relay.
The diesel c. Excessively thick engine oil. c. Replace the engine oil.
engine is d. Poor contact or short-cut in d. Checking and repairing.
difficult to electric circuit.
start or can not e. Excessive wearing or poor e. Checking and replacing.
be started at contact of the carbon brush。
all. f. Damaged electromagnetic switch f. Check if the coil is in good
or connecting fork on the starting condition, the contactor neat, the
motor. connecting fork working well, the
spring not broken, the teeth not
fractured; repair it if not.
g. Burn-out rotor on the starting g. Replace with a new starting motor.
motor

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Troubleshooting

h. Fusing fuse h. Replace the fuse.

Abnormal a. Loosening or falling-off of its a. Tighten the connections.
indication of connecting wire.
the b. Damaged sensors. b. Replace the sensors.
instruments. c. Damaged instruments. c. Replace the instruments.
The alarming The wire of buzzer is connecting to Wrap up the wire to make it insulated.
devices do not other metal.
cease buzzing.
No power a. Loosening connecting wire. a. Tighten the connection.
from engine b. Loosening V-belt. b. Adjust the tightness of V-belt.
generator or c. Damaged electric current
low adjuster or generator. c. Replace the generator.
power/large
power current.

No lighting on a. Fusing fuses. a. Replace the fuse.

lamps. b. Broken filaments. b. Replace the bulb.
c. Falling-off of connecting wire. c. Tighten the connection.
No charging or a. Loosening connection from the a. Turn the Key-ignition switch
low charging positive pole (+) of generator. (electric lock) (20) to ―power-on‖ but
current for the not to ―ignition‖, and the voltage from
batteries. the positive pole (+) of generator shall
b. Loosening connection or open be 24V.
circuit for the batteries. b. Check visually and tighten it.
c. Loosening V-belt. c. Check visually and tighten it.
d. Damaged electric current d. Turn the Key-ignition switch
adjuster on generator. (electric lock) to ―power-on‖ but not
to ―ignition‖. For a separately-excited
generator, the voltage on the D+ end
shall be 24V, and the charging
indicator lamp is on. If not, inspection
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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

on the charging exciting circuit shall

be carried on. For a self-excited
generator, the voltage on the B+ end
should be 24V. If not, check out any
loosening on the wire connecting the
B+ end of generator and the batteries,
and then tighten it. Otherwise, replace
the electric current adjuster on
generator.
Excessively a. Serious electricity deficiency on a. For a self-excited generator, check
large charging the batteries. the B+ end of the generator with a
current for the voltmeter after having started the
batteries for diesel engine. If the current is over
long time. large but the voltage is below 25V,
then there must be something wrong
with the batteries.
b. Short-circuit damage on one or b. Repair or replace the batteries.
two lattices of the batteries.
c. Short-circuit or damage on the
electric current adjuster. c. Replace the adjuster.

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Appendixes

Appendixes Diagrams

Appendix 1 Schematic diagram of hydraulic system

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 XGMA (Sanming) Heavy Machinery Co., Ltd., Fujian, China

No. Specification No. Specification

1 Vibratory pump 13 Front driving motor
2 Vibratory overflow valve 14 Flushing valve
3 Vibratory electromagnetic valve 15 Rear driving motor

4 Hydraulic reversing valve 16 Flushing valve

5 Vibratory motor 17 Steering pump
6 Steering cylinders 18 High-pressure overflow valve
7 Brake electromagnetic valve 19 Charge overflow valve
8 Manual servo valve 20 Charge pump
9 Buffering valve 21 Suction pump

10 Steering unit 22 Driving pump

11 Steering overflow valve 23 Radiator
12 NOT in this Roller

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 Operation & Maintenance Instructions of Hydraulic Vibratory Roller Appendixes

Appendix 2 Schematic diagram of electric system

R1
指示灯
（绿）
R0
R2

M2 M3 M1

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