Sap'S: Guidelines ON Maintenance of Road Rollers 1984
Sap'S: Guidelines ON Maintenance of Road Rollers 1984
Sap'S: Guidelines ON Maintenance of Road Rollers 1984
S.
II
SAP’S
GUIDELINES
ON
MAINTENANCE OF ROAD ROLlERS
1984
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GUIDELINES
ON
MAI NTENANC[ OF ROAD ROLLERS
1984
<<
IRC Special Publication 25
Published by
The Indian Roads Congress
Copies can be had by V.P.P. from the
Secretary, Indian Roads Congress,
Jamnagar House, Shahjahan Road,
New Delhi-hO 011
Price Rs ~~OO
(Plus packing & postage)
NEW DELHI 1984
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Contents Page
1. What is a Road Roller ... 1
2. General 2
3. Do as You like—But Do This 3
4. Do as You like—But Don’t Do This .. 4
5. Action—Every Morning 5
6. Action—Every Evening .. 6
7. Preventive Maintenance just means
Periodic Effort ... 7
8 Hourly .. 8
60 Hourly ... 10
125 Hourly ... ii
250 Hourly ... 12
500 Hourly ... 13
1000 Hourly ... 14
1500 Hourly ... 16
2000 Hourly ... 17
8. Oils and Lubricants •.. 18
9. Safety ... 19
10. Trouble Shooting other than Engine ... 20
11. Trouble Shooting—Diesel Engine ... 22
12. Mobile Field Service Unit .. 26
13. Storage of Fuel ... 28
14. Guide to Good Rolling ... 29
15. Proforma of Log Sheet ... 33
16. Inspecting Officer’s Check Sheet for
Maintenance “. 34
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Members of the Highway Construction and Mechanization Committee
2. Lt. Ccl. C.T. Chari Superintending Engineer, E-in-C Branch, Army Headquarters
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Foreword
The art of compaction as the key to increased strength and improved perfor-
mance were know to man since early ages. This technique has since been refined
and perfected with the use of road rollers. Today in the field of road constructions
road rollers hold the key not only to quality construction but also improved mainte-
nance, helping in the creation of durable assets.
To meet the growing needs of traffic, there is a persistent demand to add
new lengths to our existing road network and strengthen or widen the important
arterial routes. The task is colossal and the funds inadequate calling for the high-
way engineers to utilise their ingenuity in meeting the demands. Road rollers play
a vital role in accomplishing this task and in order to get the maximum return from
the existing fleet of road rollers through systematic and timely maintenance under
well trained operators and mechanics is a must.
In keeping with this need, the Indian Roads Congress through its Highway Con-
struction and Mechanization Committee has prepared guidelines with essential
tips on operation, maintenance and repair of road rollers. These guidelines were
approved by the Executive Committee and the Council in their meetings held on the
7th December, 1983 and the 8th January, 1984 respectively.
It is hoped that this document would serve as an useful guide to the Highway
Engineers engaged in road construction.
K.K. SARIN
New Delhi Director General (Road Development) a
July, 1984 AddI. Secretary to the Govt. of India
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Guidelines on Maintenance of Road Rollers 1
control system
frame/chassis
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2 Guidelines on
General
Hullo!
Do as You like
But Do This
Do carry out the maintenance instructions.
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4 Guidelines on
Do as You like —
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Maintenance of Road Rollers 5
—;~\LI,~-
Action — Every Morning
You start work each morning and before the roller
goes for duty, it would be time well spent if you
ensure that these points are acted upon:
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6 Guidelines on
Preventive Maintenance
just means Periodic Effort
Thats no exaggeration. believe us. The emphasis is on
periodicity, which is every:
* 8 hours
* 80 hours
* 125 hours
* 250 hours
* 500 hours
* 1000 hours
* 2000 hours
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8 Guidelines on
8 Hourly
(i) General (a) Check oil, water or fuel
for leaks.
(b) Check for exhaust
smoke colour, noise, or
vibration,
(c) Check all bolts and nuts,
joints and connections,
if loose or deficient.
(d) Read all guages and
meters.
(ii) Engine sump Check and top up oil.
(iii) Transmission Check oil level and top up.
(iv) Fuel tank Drain sediments and water
from sediment trap drain
plug.
r
(v) Fuel filter Drain sediments and water
from sediment drain plug.
(vi) Cooling system
(a) Top up coolant level.
(b) Chock fan belt. adjust
tension or replace.
(vii) Air filter Keep oil level up to groove
in level. Use new engine oil.
(viii) Final drive Check for oil leaks and
rectify,
(ix) Oil pressure Check oil pressure. Normal
working pressure is (40 to
60 psi) 2.8 to 4.2 kg/cm2
(x~ Dynamo charge Check dynamo charge rat-
ing.
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Maintenance of Road Rollers 9
60 Hourly
(i) General Carry out 8 hours task.
U (ii) Fuel pump chamber Drain the fuel pump
chamber (or when
the fuel spills from the
tell tale hole).
(iii) Battery Top up to ~“ (6 mm)
above plates with dis-
tilled water.
(iv) Sliding ballast weight Check rope for ten-
sions and rope grips
for tightness.
(v) Lubricating Points
(a) Starting handle shaft :Oil
(b) Starting spindle :Oil
(c) Clutch driver and Pour a little oil in one
casing of the four holes in
clutch casing also into
one of the two holes
in clutch drivers.
(d) Steering worm Grease
bearing
(e) Hydro steering ram :Oil
lever
Note: After attending to the maintenance enter the date of
maintenance in maintenance check sheet.
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Maintenance of Road Rollers 11
125 Hourly
(i) General Carry out 8 hours and
60 hours tasks.
250 Hourly
(i) General Carry out 8 hours, .60
hours and 125 hours
tasks
r
(iv) Prefilter Remove bowl and
clean.
500 Hourly
(i) General Carry out 8. 60. 125
and 250 hours tasks.
Drain, remove sump
(ii) Engine oil sump
and clean strainer.
Notes: (i) Change oil filter early hours under adverse working
condition.
(ii) No attempt should be made to adjust the injection
pressure without a proper testing equipment.
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14 Guidelines on
1000 Hourly
(i) General Carry out 8, 60, 125. 250 and
500 hours tasks.
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Maintenance of Road Rollers 15
Notes: (I) Inspect drained gear oil for metal particles. If any
found, suggest checking by mechanic. DO NOT RUN
THE MACHINE TILL RECTIFIED.
(ii) Do not attempt to adjust the FIP and governor in the
absence of proper testing equipment.
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16 Guidelines on
1500 Hourly
(i) General Carry out 8, 60, 125, 250 and
500 hours tasks.
2000 Hourly
(1) General Carry out 8, 60, 125. 250, 500
and 1000 hours tasks.
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18 Guidelines on
Transmission
Above 30°C SAE 140/HD 140
Below 30°C SAE 90/HD 90
Grease
Above 15°C Grease No. 2
15°Cto 10°C Grease No. I
Below 10°C Grease No. 0
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Maintenance of Road Rollers 19
Safety
Life and Property. Rules observed and enforced
contribute to safety. They are:
I. Read the manufacturer’s literature.
2. Only a qualified/licensed operator is allowed to
control the roller.
3. Unauthorised persons are not permitted on the
roller while in operation.
4. After starting the engine, before moving off,
look to both sides. rear and forward.
5. When working under the roller, engine must be
switched off and machine braked.
6. When travelling on gradients. gear changes shall
be done with roller stationary and braked.
7. When roller is parked, apply brakes. Choose
level ground for parking.
8. While turning the roller, it is preferable to engage
first gear.
9. Always keep close in to the near side of the road
when travelling up or down. It can help stop the
roller should something unforeseen happen.
10. When dismounting from the roller, the operator
should make it a habit to walk around it before
getting back on and starting it.
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20 Guidelines on
1. Slipping of clutch a) Worn clutch plate lining a) Adjust distance between the
clutch and pressure plate.
b) Oiled clutch plate lining b) Flush kerosene in the clutch
plate and allow it to dry.
2. Frequent and sharp Broken gear teeth Disassemble gear box and
knocks in power replace broken gears by new
transmission ones. Remove broken teeth
from casing if any.
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22 Guidelines on
Engine turns over No fuel is injected into the Check for air leaks. flow obstruc-
freely but does not fire cylinder tions, faulty fuel pump or faulty
installations. Check for water
in fuel; if found. drain the
system till alt water is
eliminated,
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Maintenance of Road Rollers 23
3. Engine speed is a) Water in fuel pipes a) Drain system until all water
irregular and dirt is removed.
b) Air in fuel system b) Bleed the fuel system free
of air.
NOTE: The relation between the colour of the smoke and the conditions responsible for
the same are:
White smoke a) Low combustion temperature which occurs with a low
compression pressure.
b) White smoke due to steam may be caused by water leak-
ing into system.
Grey smoke (light Result of poor combustion due to causes mentioned above.
grey to black)
Bluish smoke Indicates burning or lubricating oil, or due to fuel oil impinging
on the walls of combustion chamber due to plugged up fuel
nozzle holes.
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26 Guidelines on
Air compressor to supply high and tow pressure air for tyre inflation and other
purposes.
High pressure air operated grease dispenser pumps for pressure greasing. (Three
hand grease guns for each group of 10 machines could also be kept as stand-by).
Three low pressure air operated oil dispenser pumps for light-medium oils. These
pumps are mounted on drum sleeves suitable for accommodating standard 45
gallon capacity drums.
Hose reels. Six reels are mounted at the rear of the unit to accommodate hoses
for various services. These reels are provided with brake device to prevent uncoil-
ing during transit.
Hoses. These are reinforced, oil and grease resisting rubber hoses.
Sheet iron trays, say about 60 cm square and 10 cm deep for use when draining
the oil sump. washing filter elements. etc.
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Maintenance of Road Rollers 27
10 litres, 5 litres and 1 litre. ~ litre measures with pour spouts for filling fuel and oil.
Oil cans.
STAFF
A team of five persons, including a senior person, namely, Chargeman or Foreman,
is normally recommended. This will include a driver and a two or more lube men,
It may take 10 to 15 minutes only for the maintenance work to be done on one
machine with a mobile service unit, if this work is properly organised.
FUNCTIONS
It is suggested that:
The Unit move as per a planned programme.
The Unit carry fast moving spares like fan belts, clamps. hoses. fitters of various
types. etc. so that those can be replaced on-site.
The Unit carry out periodical adjustments/checks like fan belt, brake and clutch
free play. tappet clearance, efficiency of injector, etc. and record the same in the log
book of the roller.
The Unit carry out preventive repairs in addition to checking maintenance.
The Unit act as a watch dog on maintenance and serviceability of rollers in the
sector of responsibility.
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28 Guidelines on
Storage of Fuel
It is necessary that diesel oil is stored in a storage tank and all the sediments are
allowed to settle for 24 hours before it is pumped out into the fue Itank of the
machine. In case of rollers, the storage tank may be 45 gallons barrels and the
pumping done with the help of semi-rotary hand pump with filter fitted near the
outlet. In no case the buckets and funnels should be used for refuelling in the field.
Two suggested methods for mounting the drums properly are given below:
1~ 2
S.dim~nf
(r~ai~jieis
tNcaygeParacl)
11
MOUNTED ON A FRAME USING A SE.MI- ROTAR~( PUMP
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Maintenance of Road Rollers 29
Roads must be smooth. safe for traffic, durable, economical and provide a comfor-
table ride. Materials and mixes alone do not guarantee quality and precision. What
is the use of good stone, of the best asphalt, of the most accurate laboratory
technique, of the most advanced mixing equipment if at the end, incorrect rolling
is applied and compaction is poor. Therefore, compact correctly with suitable
rollers and apply proper rolling procedures. This will guarantee level and durable
surfaces. Remember, everything depends on your skill and care when putting your
machine to work.
Number of passes?
Rolling speed
Rolling pattern ?
The number of passes will obviously depend upon the material to be compacted.
Sand and gravel in base and sub-bases will require four to six passes. For bitu-
minous work. this will depend upon the layer thickness.
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30 Guidelines on
The speed of rolling affects the degree of compaction. For a particular level of
compaction, the higher the speed, the more the number of passes required. So
remember, the rolling speed will depend upon type of mix, thickness of layer, den-
sity requirement. surface finish and number of passes. Normally rolling speed
would be 5 to 7 km per hr. On a thin hot layer you may run faster—sometimes
upto 10 km per hr. Tender mixes, on the contrary, may require very low rolling
speeds. On thick layers on harsh mixes a speed of 3 to 5 km per hr is recom-
mended.
Now let’s come to the rolling pattern. You must decide on this aspect carefully so
that uniform compaction is obtained over the entire width.
If you are rolling gravel, start from the edges and proceed towards the centre. with
an overlap of atleast half the width of roller in the longitudinal direction.
If you are roIling macadam. roll from edges with roller runnig forward and backward,
until the edges are firmly compacted. The roller is then moved gradually from edge
to the centre, parallel to the centre line. The overlapping is done uniformly with
rear wheel track by half width and this is continued until the entire area is rolled.
There should be no creeping of aggregates visible on rolling.
Start by compacting the joints, first transverse, then longitudinal. Start by rolling
the lowest edge, which generally would also be the outside edge, and roll rest of
the pavement running forward and backward in parallel paths with 10 cm to 20 cm
overlap.
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Maintenance on Road Rollers 31
Follow -the paver as closely as possible, keep running forward and backward in
same rolling lane. Change to another roIling lane only on an already compacted
area. Turning movements on a hot mix will leave impressions and even lead to
cracks. If you have to change speed. do so smoothly. And should you need a
break. never park the roller on hot mix—now that’s obvious, don’t you think?
Well, rolling of joints requires special care and some expertise. Remember, rolling
is always done in the direction of joints.
The joint could be compacted with the roller working on the cold lane and with a
10 cm to 20 cm overlap on the hot lane, or
The joint could be compacted with the roller working on the hot lane with a 10 cm
to 20 cm overlap on the cold lane, This is specially suitable when traffic is heavy
and space is restricted.
For finish rolling, run one or two passes on the surface after the asphalt mix is
cooled somewhat. Finish rolling is performed only to smooth out the last rolling
marks.
And now for some general tips. Should you be on a slope, keep front roll ahead.
You must see that during rolling, no interruption occurs due to any reason. When
you change direction, let the roller glide to a final stop and then start smoothly into
the other direction without toss of time.
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32 Guidelines on
Let~snow sum up alt that has been said, with ten basic rules:
1. Follow the paver as closely as possible.
2. The joints should be compacted first.
3. Start compaction of the lane at the lowest edge.
4. White rolling on steep slopes, keep front roll ahead.
5. Change the rolling speed smoothly.
6. Run forwards and backwards in the same rolling lane.
7. Change rolling lanes on the cold side, avoid lane changes
where the mix is hot. ~
8. Run in parallel rolling lanes. Reverse at another section
than in adjacent rolling lanes.
9. Keep the drums sufficiently wet to avoid pick-up,
but not more than necessary.
10. Do not let the roller stand stilt on hot mixes.
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Maintenance of Road Rollers 33
1. 2. 3. 4. 5. 6, 7. 8. 9. 10. 11.
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34 Guidelines on Maintenance of Road Rollers
1. 60 Hrs.
Maintenance
2. 125 Hrs.
Maintenance
3. 250 Hrs.
Maintenance
4. 500 Hrs.
Maintenance
5. 1000 Hrs.
Maintenance 4
Records of
6. Engine Oil
Change
Note.~ This sheet must be kept with each road roller operator and produced on demand.
This sheet provides maintenance check for 1000 Hrs and should be changed as and
when complete.
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