Operation & Maintenance Manual

Model CLG616/CLG614
Vibratory Roller

Jiangyin Liugong Road Machinery Co., Ltd

 Preface

Welcome to use roller series of the company, we prepare this operation &
maintenance manual for drivers, servicemen and technical managing personnel’ reference
in order to help users generally understand construction, performance, service and
maintenance of the rollers.
Before users operate this roller, please read this manual carefully. To take full
advantage of efficiency of the machine, prolong the service life of the machine and
reduce accidents, please seriously observe regulations of this manual.
When you use products of the company, please contact the company in time if you
find quality problems, we provide you with good quality service in time. We earnestly
expect a vast of users put forward valuable opinions for products of the company and tell
us by correspondence any time in order to improve quality of our products and better
service users.
To better meet requirements of users, the products of the company are improved
along with technical progress, there may be a little discrepancy between specific contents
of this manual and ex-factory products, please pay attention to that during operation. No
notice is given for any discrepancy.

Tables of Contents

1. Safety Information 3

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2. Outline 12
§2-1 Brief Introduction to Construction and Performance 12
§2-2 Main Technical Data 13
§2-3 Safety Operation Rules 15
§2-4 Schematic Diagram of Hydraulic System 16
§2-5 Schematic Diagram of Drive System 17
§2-6 Schematic Diagram of Electrical System 18
3. Operation and Applications 20
§3-1 Arrangement Diagram of Instrument Panel and Control Levers 20
§3-2 Preparation before Starting the Engine 21
§3-3 Starting the Engine 21
§3-4 Driving the Roller 22
§3-5 Vibratory Driving of the Roller 22
§3-6 Brake of the Roller 23
§3-7 Parking of the Roller 23
§3-8 Hoisting Instructions 23
§3-9 Transportation of the Roller 24
4. Instructions of Maintenance 26
§4-1 Lubrication and Oils 26
§4-2 Technical Maintenance 33
§4-3 General Troubles and Remedy 36

1. Safety Information

★ Warning Signs and Labels

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 There are several specific safety signs on your machine. Their exact location and
description of the hazard are descried in this section. Please take the time to familiarize
yourself with these safety signs.
Make sure that you can read all safety signs. Clean or replace these if you cannot
read the words or see the pictures. When cleaning the labels use a cloth, water and soap.
Do not use solvent, gasoline etc.
You must replace a label if it is damaged, missing or cannot be read. If a label is on a
part that is replaced. Make sure a new label is installed on the replaced part.

WARNING

● Don’t stand here while machine operating in case of serious accident, located on the
machine at the center pivot.

★ General Hazard Information

● Attach a “DO not Operate” or similar warning tag to start switch or controls before
serving or repairing the machine.
● Wear a hard hat, protective glasses and other protective equipment as required by
job conditions.
● Do not wear loose clothing or jewelry that can catch on controls or other parts of
the machine.
Make certain all protective guards and covers are secured in place on the machine.
● Keep the machine, especially the instrument panel, walkways and steps, free of
foreign material, such as debris, oil dirts, tools and put away other items which are not
part of the machine such as lunch-box and tools.
● Know the appropriate work-site hand signals and who gives them.
● Use all cleaning solutions with care.
● Report all needed repair.
● Do not allow unauthorized personnel on the machine.

★ Perform all maintenance unless otherwise specified as follows:

● Park the machine on the level ground.

● Shift the transmission control lever to the neutral position.
● Move all attachment controls to the holding position.
● Engage parking brake.
● Stop the engine.
● Turn off lock switch and remove the key.

★ Compressed Air

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● Compressed air can cause personal injury. When using compressed air for cleaning,
wear a protective face shield, protective clothing and protective shoes.
● The maximum air pressure must be below 0.3Mpa for cleaning purposes.

★Fluid Penetration
● Always use a board or cardboard when checking for a leak. Escaping fluid under
pressure, even a pin-hole size leak, can penetrate body tissue, causing serious injuries
and possible death. If fluid is injected onto your skin, it must be removed surgically by
a doctor familiar with this type of injury within a few hours.

★ Crushing or Cutting Prevention

● Support equipment and attachment properly when working beneath them. Do not
depend on hydraulic cylinders to hold it up.
● Never attempt adjustments while the machine is moving or the engine is running
unless otherwise specified.
● Stay clear of all rotating and moving parts.
● Make sure no foreign matters are in the fan blade. The fan blade can throw out or
cut dropping or entering foreign matters in the tools.
● Do not use a kinked or frayed wire rope cable. Wear gloves when handling the wire
rope cable.
● Chips or other debris can fly off objects when struck. Make sure no one can be
injured by flying debris before striking any object.

★ Burn Prevention

Coolant
● At operating temperature, the engine coolant is hot and under pressure. The radiator
and all lines to heaters or the engine contain hot water or steam. Any contact can cause
severe burns.
● Steam can cause personal injury.
● Check the coolant level only after the engine has been stopped and the filter cap is
cool enough to remove with your bare hand.
● Remove the cooling system filler cap slowly to relieve pressure.
● Cooling system conditioner contains alkali that can cause personal injury. Avoid
contact with the skin and eyes and do not drink. Allow cooling system components to
cool before draining.

Oils
● Hot oil and components can cause personal injury. Do not allow hot oil or
components to contact the skin.

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● At the operating temperature, the hydraulic tank is hot and can be under pressure.
● Remove the hydraulic tank filler cap only after the engine has been stopped and the
filler cap is cool enough to remove with your bare hand..
● Remove the hydraulic tank filler cap slowly to relieve pressure.
● Relieve all pressure in air, oil, fuel or cooling systems before any lines, fittings or
related items are disconnected or removed.

Batteries
● Batteries give off flammable fumes which can explode.
● Do not smoke when observing the battery electrolyte levels.
● Electrolyte is an acid and can cause personal injury if it contacts skin or eyes.

★ Fire or Explosion Prevention

● All fuels, most lubricants and some coolant mixtures are flammable.
● Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.
● Do not smoke while refueling or in a refueling area.
● Do not smoke in areas where batteries are charged, or flammable materials are
stored.
● Batteries in series may be located in separate compartments. When using jumper
cables always connect positive (+) cable to positive (-) terminal of battery connected to
starter solenoid and negative (-) cable from external source to starter negative (-)
terminal. If not equipped with starter negative terminal, connect to engine block.
● See the “Operation Section” of this manual for specific instructions.
● Clean and tighten all electrical connections. Check daily for loose or frayed
electrical wires. Have all loose or frayed electrical wires tightened, repaired or replaced
before operating the machine.
● Keep all fuels and lubricants stored in properly marked containers and away from
all unauthorized persons.
● Store all oily rags or other flammable materials in a protective container, in a safe
place.
● Do not weld or flame cut on pipes or tubes that contain flammable fluids. Clean
them thoroughly with nonflammable solvent before welding or flame cutting on them.
● Remove all flammable materials such as fuel, oil an d other debris before they
accumulate on the machine.
● Do not expose the machine to flames, burning brush etc., if at all possible.
● Shields, which protect hot exhaust components from oil or fuel spray in the event of
a line, tube or seal failure, must be installed correctly.
● Extinguishers should be prepared, you must know how to use it, check and repair
according to the information labels.

★ Ether (if equipped with cold starter)

● Ether is poisonous and flammable.

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 ● Breathing ether vapors or repeated contact of ether with skin can cause personal
injury.
● Use ether only in well ventilated areas.
● Do not smoke while changing ether cylinders.
● Use ether with care to avoid fires.
● Do not store replacement ether cylinders in living areas or in the operator’s
compartment.
● Do not store ether cylinders in direct sunlight or at temperature above 39℃(120°F).
● Discard cylinders in a safe place. Do not puncture or burn cylinder.
● Keep ether cylinders out of the reach of unauthorized personnel.

★ Lines, Tubes and Hoses

● Do not bend or strike high pressure lines. Do not install bent or damaged lines,
tubes or hoses.
● Repair any loose damaged fuel and oil lines, tubes and hoses. Leaks can cause fires.
Contact Guangxi Liugong Machinery Co., Ltd for repair or replacement.
● Check lines, tubes and hoses carefully. Do not use your bare hand to check for
leaks. Always use a board or cardboard to check for leaks. Escaping fluid under
pressure, even a pin-hole size leak, can penetrate body tissue, causing serious injury,
and possible death. If fluid is injected into your skin, it must be removed surgically by
a doctor familiar with this type of injury within a few hours. See “Fluid Penetration” in
the “Safety Information” section for more details. Tighten all connections to the
recommended torque.
● 1,.End fittings damaged or leaking.
● 2. Outer covering chafed or cut and wire reinforcing exposed.
● 3. Outer covering ballooning locally.
● 4. Evidence of kinking or crushing of the flexible part of hose.
● 5. Armoring embedded in the outer cover.
● 6. End fittings displaced.
● Make sure that all clamps, guards and heat shields are properly installed to prevent
vibration, rubbing against other parts, and excessive heat during operation.

★ Tire

● Explosions of air-inflated tires with calcium chloride results from heat-induced gas
combustion inside the tires. The heat is generally produced by welding or heating rim
components, external flame, or excessive use of brakes.
● A tire explosion is much more violent than a blowout. The explosion can propel the
tire, rim and final drive components as far as 500m or more from the machine. Both
the force of the explosion and the flying debris can cause personnel injury or death,
and property damage.

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 ● Proper nitrogen inflation equipment and training in its use are necessary to avoid
over-inflation. A tire blowout or rim failure can result from improper or misused
equipment.
● Stand behind the tread and use a self-attaching chuck when inflating a tire.
● Servicing and changing tires and rims can be dangerous and should be done only by
trained personnel using proper tools and procedures. If correct procedures are not
followed while serving tires and rims, the assemblies could burst with explosive force
and cause serious personal injury or death. Follow carefully the specific information
provided by your tire or rim serving man or dealer.

★ Mounting and Dismounting

● Mounting and dismounting the machine only where steps and /or handholds are
provided.
● Use both hands and face the machine, when mounting and dismounting.
● Never get on or off a moving machine, never jump off the machine.
● Do not try to climb on or off the machine when carrying tools or supplies. Use a hand
line to pull equipment up onto the platform.

★ Before Starting the Engine

● Start only from the operator’s station. Never short across the starter terminals or across
batteries, as this could bypass the engine neutral-start system as well as damage the
electrical system.
● Check the condition of the seat belt and the fixed device of the seat belt are damaged.
Replace any damaged or worn parts. Replace the safety beat regardless of appearance
after three years’ use..
● Adjust the seat so that full pedal travel can be obtained with the operator’s back
against the seat back.
● Make sure the loader is equipped with a lighting system as required by conditions.
● Make sure all lights are working properly.
● Make sure no one is working on , underneath or close to loader before starting the
engine or beginning to move the loader. Make sure the area is free of personal.

★ Engine Starting
● Do not start the engine or move any of the controls if there is a “DO NOT OPERATE”
or similar warning tag attached to the start switch or controls.
● Move vibratory buttons to the HOLD position before starting the engine.
● Move the transmission control lever to the NEUTRAL.
● Engage the parking and secondary brake.
● Turn on negative switch.

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● Start and operate the engine in a well ventilated area only. In an enclosed area, vent
the exhaust to the outside.

★ Before Operating the Machine

● Clear all personal from the machine and the area.

● Clear all obstacles from the path of the machine. Beware of hazards such as wires,
ditches etc.
● Be sure all windows are clean. Secure the doors and windows in either the open or
shut position
● Make sure the machine horns are working properly.
● Fasten the seat belt securely (if equipped).
● Check for proper operation of all controls and protective devices whole moving
slowly in an open area.

★ Operation of the Machine

● Operate the machine only while seated.

● Operate the controls only with the engine running.
● The operator must be satisfied that no one will be endangered before moving the
machine.
● Before daily working, check for proper steering system and brake system are in good
condition, do not operate rollers if they are in bad condition. Please consult with the
Servicing Center of Liugong company for repair and replacement.
● Do not allow riders on the machine unless additional seat.
● Report any needed repairs noted during operation.
● Stay a safe distance from the edge of cliffs, overhangs and side areas.
● If the machine begins to sideslip on a slope, immediately stop operation and turn the
machine downhill.
● Keep the machine under control and do not work it over its capacity.
● Be sure the hitch points and the towing device are adequate.
● Connect trailing equipment to a drawbar.
● Never straddle a wire rope cable or similar device, nor allow others to do so.
● No personnel should be between the machine and trailing equipment. When
maneuvering to connect them. Block the tongue or hitch of trailing equipment to align it
with the drawbar or hitch.
● Know the maximum height and reach of your machine.
● Not to adjust the idle speed too slowly. In any case, when the oil pedal is free of
control, the engine does not stop. Recommended idle speed is suitable at 700～750rpm.

★ Machine Parking
● Park on a flat ground, Park the machine on the slopes if necessary, and place a wedge
under the drum to prevent the moving of the machine.

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● Apply the service brake to stop the machine.
● Move the transmission control lever to the NEUTRAL position.
● Engage the parking and secondary brake control.
● Stop the engine.
● Turn the start switch key to OFF and remove.
● Turn of the negative switch if the machine does not work for a long time.

★ Others

● The various kinds of fuel, lubricant and grease must keep clean, without impurity.
● Often clean strainer of diesel fuel pump (manual pump).
● When filling with hydraulic oil, you should use oils with the same brand and
specifications as the oil tank according to the manual, fill the machine with 10μm filter,
please contact Liugong company if it’s difficult to do so.
●Replace the filter Strictly following the change intervals of the manual, no repeat use
after cleaning.
● To facilitate operation, preferably fix the mark post and post flag in the spare parts
during operation, the fixing position of the mark post is located at two corners behind the
machine.
● Replace new filter elements after all hydraulic oil filters are used for 500 hours, no
repeat use after cleaning.

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 2. Outline

§2-1 Brief Introduction to Construction and Performance

CLG616 & CLG614 rollers are heavy type vibratory rollers with great centrifugal
force and high static linear pressure, they are suitable for compaction of non-viscous
materials such as sand soil, gravel, detritus and mixed stones materials and rock fill
section and quasi-viscous clay. They are mainly used for compaction of large-sized base
course projects such as high-class roads, mines, dams, airports, ports, railways and
industrial sites, they are an indispensable compaction machinery for modern roads and
other engineering base construction.
Construction of CLG616 & CLG614 vibratory roller: they have a smooth drum at
the front and a wide base engineering machinery tires at the rear. The front drum is
vibrated and rear drum is driven, front and rear frame are articulated. They have
hydraulic steering, hydraulic vibration and synchronous shift gear control. Therefore,
they have reliable performance and optimal functions/price ratio. They have the
following features:
1. CLG616 & CLG614 are fitted with world advanced Shanghai D4114ZLG1B diesel
engine, they have strong power, reliable performance, extra low oil consumption,
cleanness and friendly environment.
2. Delay changeover function of the vibratory system enables stable changeover of high
and low amplitude to avoid impact on the hydraulic system by malfunction, and prolong
service life of the hydraulic components.
3. The rollers have special transmissions with synchronizer, providing convenient and
comfortable shift gear.
4. The rear axle is fixed with differential mechanism and caliper disc brake, mechanical
driven, it has strong tractive force and good passing performance.
5. The rollers have articulated frame, fully hydraulic steering, small turning radius,
convenient and flexible operation, compact structure and convenient repair.
6. The rollers have wide base engineering machinery tires with strong prick proof and
cutting resistance, they can be driven and operated under very bad ground condition.
7. Brake system: service brake system-air ejection oil caliper disc type; park brake
system-internal expanding drum type. They provide convenient operation, strong brake
force, compact structure, convenient removal, safety and reliability.
8. The diesel engine is inverted type, stream overall turnover engine hood is made of
glass fiber reinforced plastics, convenient in repair and maintenance.
9. The wide and bright cab provides wide and open vision.
10. The rollers have superior quality rubber components with three-level vibration
absorption.

§2-2 Main Technical Data and Overall Dimensions of CLG616 & CLG614 (See
Fig.2-1)

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 Model
Items
CLG616 CLG614

Operating weight Kg 16000 14000

Weight of Front Drum Kg 8150 7150
Weight of Rear Drum Kg 7850 6850
Vibratory Frequency Hz 30 30
Centrifugal Force KN 300/160 270/135
Amplitude mm 1.9/1.0 1.75/0.85
Static Linear Pressure N/cm 380 328
Operating Speed Ⅰ Km/h 2.6 2.6
Ⅱ Km/h 5.2 5.2
Ⅲ Km/h 11 11
Gradeability % 30 30

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Turning Radius Internal side mm ≤4000 ≤4000
External side mm ≤6500 ≤6500
Minimum Ground Clearance mm 440 440
Overall Dimensions(L×W×H) mm 6145×2300×3040 6145×2300×3040
Roller Drum Data (Diameter×Width) mm ф1535×2130 ф1535×2130
Drum Rim Thickness mm 30 30
Drive Type Mechanical single drive
Operating Pressure of Vibratory System MPa 18
Hydraulic System Steering System MPa 16
Rated Voltage of Electrical System V 24
Lubrication of Diesel Engine 14
Fuel Tank 285
Oiling Hydraulic Oil Tank 120
Amount of Vibratory Chamber 2×2.3
Each Oil L
Primary Transmissions 9
Tank Secondary Transmissions 5.5
Final Drive 13
Rear axle
Wheel Reductor 3.5×2
Electrical Rated Voltage V 24
System Model of Battery Delphi BA31750B
Model of Diesel Engine D4114ZLG1B
Rating Speed 2100r/min
Rating Power 105kw
Tyre Size 20.5-25-16PR

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 Fig.2-1 Overall Dimensions of CLG616 & CLG614

§2-3 Safety Operation Rules

1. No informal driver of the vibratory roller drives the vibratory roller, a formal driver
should be on the machine to guide the learning driver.
2. Before the driver operates the vibratory roller, first understand main performance,
construction features, main points of operation and maintenance method of this
machine as well as road traffic rules.
3. Before starting the machine, check the machine as required and make various
preparation, remedy in time if you find any problems, or you can’t start the machine.
4. Before starting the machine, observe pedestrians and obstacles are around the machine,
sound the horn while starting the machine.
5. Never check, repair and maintain the vibratory roller while the engine runs, place a
wooden cushion under the drums or eject rear drum with jack if it’s necessary to do so ,
and the machine should be driven by skilled driver.
6. Never allow personnel to get on or off the machine during operation, only one person
is seated at the cab, no person seat at any place except the cab.
7. Avoid improper high speed and never take a sudden turn while driving the machine.
8. While driving on down slope, never release shift gear to coast down hills, and avoid
stopping the engine, the engine speed should be kept at above minimum operating
speed. Particularly on sudden turning slope mountain areas, select low speed gear, also
the engine speed is kept at about 1000 r/min.
9. Pay attention to carrying capacity sign of bridges while passing bridges and see if the
machine is allowed to pass.
10. When you change forward & reverse direction and change speed, first turn the control
lever to the NATURAL position, turn to the required gear to run after parking the
machine.
11. When the air pressure indicated in the air pressure gauge is below 0.45Mpa, never
drive and operate the machine.

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12. During operation of the vibratory roller, stop the machine for 15 minutes with an
interval of about one hour, then carry out the vibratory operation, its purpose is to
prevent excessive oil temperature to reduce frequency, even damage parts to affect
operation.
13. When you check and repair engine or the electrical system, always turn off master
power switch, and turn off power.
14. After operating the machine and before leaving the cab, stop the engine and turn off
power, turn other control levers to the neutral position, and engage the manual brake.
15. When you open the hot water tank of the engine and hydraulic oil tank cap, wear
gloves, slowly release to prevent hot water and oil inside the tank ejecting to burn
people.
16. Be care to prevent fire, no smoke while filling oil and maintaining.
17. Always use clean oils with specified brand and quality standard.
18. Always remove the cooling water in the diesel engine during cold weather to avoid
frost cracking of the engine, if the cooling water has been mixed antifreeze, follow the
temperature resistant scope to determine if it’s necessary to remove antifreeze.

§2-4 Schematic Diagram of Hydraulic System

Change Valve, Vibratory Motor, Filter, Oil Tank, Steering Cylinder, Steering Gear, Vibratory Pump, Steering Pump,
Radiator

Fig.2-2 Schematic Diagram of Hydraulic System of CLG616 & CLG614

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 §2-5 Schematic Diagram of Drive System

1- Secondary Transmissions 2-Priamry Transmissions 3- Clutch 4-Diesel Engine 5-Vibratory Pump 6-Radiator 7-Steering Pump 8-Steering Gear 9-Steering Cylinder 10-Vibratory Drum
11-Vibration Exciter 12-Vibratory Motor 13- Rear Axle 14-Tire 15-Hydraulic Oil Tank 16- Drive Shaft 17- Brake

Fig. 2-3 Schematic Diagram of Drive System of Vibratory Roller

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 § 2-6 Schematic Diagram of Electrical System

Rear Light, Front Light, Left Steering Light, Right Steering Light, Room Light, Electric Fan, Alarm Light（Optional）, Alarm Light Switch（Optional）, Water Pump, Horn, Brake Air Pressure Alarm Switch, Power Control, Start, Stop, Steering Light, Combination Switch, Air Conditioner,
Power Equipment, Power Relay, Starting Relay, Stop Relay,︱Front︱Light Relay,︱Rear︱Light Relay, Blink Relay, Time Relay, Spare, Tachometer, Fuel Gauge, Water Temperature Gauge, Engine Oil Pressure, Voltage Gauge, Hour Meter, Oil Temperature Gauge, Ignition Light Switch, OFF,
Run, Start, Solenoid Valve, Solenoid Valve, Solenoid Valve︱Minor Vibration︱Solenoid Valve︱Major Vibration︱,Front Windshield Wiper, Oil Pressure Alarm Switch, Oil Pressure Sensor, Water Temperature Sensor, Oil Temperature Sensor, Fuel Level Sensor, Speed Sensor, Cut-off Valve,
Battery, Switch, Start End, Control End, Alternator, Start Motor, Air Conditioner︱Optional︱, Compressor Clutch, Cooling Fan, Pressure Switch, Evaporator Assembly, Front Light Switch, Rear Light Switch, Windshield Wiper Switch, Horn Switch, Minor Vibration︱Background Light︱
Switch, Steering Light Switch, Major Vibration︱Water Pump︱Switch,
Technical requirements: Parts with dotted line are optional or remaining parts in harness to improve universalization.

Fig. 2-4 Schematic Diagram of Electrical System of CLG616 & CLG614 Vibratory Roller

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 3. Operation Manual

§3-1 Instrument Panel and Controls Diagram

1-Tachometer 2-Fuel Meter 3- Left Steering Indication Light 4-Voltage Gauge 5-Charge Indication Light 6-
Air Pressure (Low) Alarm Indication Light 7-Oil Temperature Gauge 8-Right Steering Indication Light 9-Oil
Pressure Guage10- Hour Meter 11-Water Temperature Gauge 12-Ignition Switch 13-Major Vibration Switch 14-
Steering Light Switch 15-Minor Vibration Switch 16- Horn Switch 17-Windshield Wiper Switch 18-Rear Light
Switch 19-Front Light Switch 20- Clutch Pedal 21-Hand Brake 22-Manual Accelerator 23-Inverse &
Forward and Shift Gear Handle 24-Brake Pedal 25-Foot Accelerator Pedal

Fig.3-1 Schematic Diagram of Instrument Panel and Controls

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 §3-2 Preparation before Starting the Engine

Read this manual and the manual of the diesel engine before operation and perform
the following inspection according to the requirement.
1.Check engine oil level that should be kept within the dipstick scale.
2.Check coolant level of the radiator, replenish if insufficient.
3.Check oil amount of the fuel tank, and fill oil with the filter.
4.Check hydraulic tank oil level that should be kept within the dipstick scale.
5.Check vibratory control switch is at the HOLD position.
6.Check the shift gear lever is at the NATURAL position.
7.Check joints of each part for looseness.
8.Check air pressure of tire is normal.
9. Engage the manual brake handle to actuate the brake handle so as to prevent the
unexpected slippage.

§3-3 Starting the Engine

1.Turn the negative switch to “ON”.

2.Insert the start key into the start switch and turn the switch to ON.
3.Check electrical equipment such as fuel gauge, ammeter, steering indication light, brake
light and horn are in good condition.
4.Turn the manual accelerator lever to 1/4 position, press down the start button to start the
engine. When the engine is started, release the start button at once to avoid damaging
the gear and burning the starter. Each starting time can’t exceed 15 seconds at most, if
the engine fails to start at that time, start again after an interval of one minute, if the
engine can’t be started for three or four trials, find out the cause and remedy the
trouble, then try again.
5. Increase the accelerator gradually after starting the engage, warm up the engine at the
speed of 1000r/min for three or five minutes, also check the air pressure gauge is normal,
and check each oil pipe and water pipe for leakage.

§3-4 Driving the Roller

1. After racing and warming up the engine, the engine oil temperature reaches above 45℃,
air pressure to 0.6Mpa, when other instruments indicate normally, then drive the roller.
2. To ensure the normal steering condition, turn the steering wheel left and right, observe
the steering condition.
3. When starting the roller, do not allow any person to stand in front of and behind the
machine, remove obstacles on the road surface if any.
4. Release the manual accelerator lever, depress down the clutch pedal, engage the shift
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 gear to the required position (refer to the speed shift gear label), engage the change
lever to the required driving direction, slowly release the clutch pedal, then drive the
roller.
Ⅰ Operating position or driving position 2.5~2.6Km/h
Ⅱ Operating position or driving position 5.0~5.1Km/h
Ⅲ Driving position 10.7~11Km/h
5. Turning the accelerator lever adjusts speed. Increasing the engine speed increases the
roller speed, reducing the engine speed reduces the roller speed.

§3-5 Vibratory Driving of the Roller

Note: When the roller stays still, you can’t directly start vibration, or damaging the
roller.
1. Before start the vibratory operation of the roller, start the roller for about five minutes.
2. During operation, first turn the engine accelerator to middle speed, engage the shift gear
and start the roller, turn on the vibratory switch, then turn the manual accelerator lever
of the engine to ON. When you want to change the driving direction of the roller, first
stop vibration, then repeat the second step.
3. During operation, changing turning direction of the vibratory switch can adjust
amplitude, frequency and centrifugal force to obtain optimal compacting effects.
4. Before stopping vibration, the accelerator of the diesel engine should be at the high
speed, avoid stop vibration at low speed.

§3-6 Brake of the Roller

This vibratory roller has two brake types. Their operation and application are as
follows:
1. Foot brake
Foot brake of the roller is air ejection oil caliper disc brake, when depressing down
the brake pedal, compressed air enters the air booster pump through the brake valve, so that
the booster pump produces high pressure oil, and enters caliper disc brake to actuate brake.
Because this brake type is air boost, therefore, ensure compressed air in the reservoir is
kept at 0.6-0.85Mpa. The foot brake is used for service brake.

2. Hand brake
Manual brake is drum brake, this brake is fixed at the output shaft of the transmissions.
When the manual brake lever is engaged, internal expanding drum brake produces brake.
Manual brake is mainly used for parking brake.

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 Note: At emergency case, besides you depress down the foot brake, you should use
manual brake to guarantee service safety.

§3-7 Parking of the Roller

1. Never leave the roller while the engine is running.

2. Park the roller at the roadside, engage manual brake while parking the machine.
3. If parking the roller at the slope, block the roller drum with a wedge.
4. Pleas turn off the negative switch if the machine is not used for a long time.

§3-8 Hoisting Instructions

1.Before hoisting the roller, remove the fixed arm at the rear frame, and fix the roller pin
with pins to avoid turning of the roller while hoisting (see Fig.3-2).
2. During hoisting, place the steel ropes or iron chains through the hoisting eye in front of
and behind the roller, pay attention to the gravity center of the whole machine to avoid
damaging the steel ropes or scraping the parts of the roller (see Fig.3-2).
3. Under hoisting load, do not allow any person to walk under the hoisting articles.
4. After the roller is hoisted, return the fixed arm to the original position.

14T & 16T weight each

This position is locked with the fixed rod.

Fig. 3-2 Schematic Diagram of Hoisting the Roller

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 §3-9 Transportation of Roller

1. Railway train, large-sized platform carrying truck or ships may be used for long distance
transportation. You should carry out the following work besides you observe the
regulations of the railway department:
(1) Tire and vibratory drum are placed with triangle wooden cushion, fix the machine body
with ropes or thick steel wires to avoid turnover.
(2) Turn off the power switch, every lever is the middle position, engage the manual
brake.
(3) During transportation in winter or severe cold areas, empty water of the cooling
system of the engine.
2. During middle distance transportation (30 kilometers), driving vibratory rollers mode
may be used, the driving speed is selected according to the road course and road
surface, note that oil temperature and water temperature of reduction gear and
transmissions are not allowed to exceed 95℃, stop and check the machine at once if
temperature is too high, then start the machine after temperature is cooled down.
3.Towing
Never tow the roller, pay attention to the following unless emergency accident
occurs:
(1) If the engine is used, always keep the engine in a running state to guarantee steering and
brake.
(2) When the engine is not used, because the steering device does not work, remove four
pieces of oil pipes connected to the cylinder.
(3) Never tow the roller for a long distance, the towing speed must be kept within
2~3Km/h.
(4) Strictly follow the road traffic rules.

24
 4. Instructions of Maintenance

To guarantee normal work of the roller for a long time, you should carry out
maintenance for the roller. Carry out maintenance for the engine according to the manual of
the engine along with the machine, other maintenance should be performed according to
the following items.

§4-1 Lubrication and Oils

1. Oils of the roller

(1) Strictly follow the specified oil brand (See Table 1).
(2) When filling the machine with fuel oil, operating oil of the hydraulic system, lubricant
and grease, clean the oil lubricators, and clean oiling parts to avoid water, mud and
foreign matters entered into oil.
(3) Always fill various oils with filters in addition to grease.
(4) When filling grease, fill the oiling parts till grease is overflowed, wipe out the
overflowed grease.
(5) When replacing new oil, remove dirty oil while it is hot after stopping the machine, fill
clean oil and let the engine run at idle for several minutes, after the engine is stopped,
remove cleaning oil of each part, fill new clean oil, let the engine runs at low speed,
then fill clean oil till required oil level is obtained. Periodically clean the fuel oil tank.
(6) During different seasons, replace operating oil and lubrication oil types according to
actual conditions and application requirement.
(7) When filling various oils or checking oil amount, keep the roller at the level position.
Besides you use dipstick or oil level meter, fill the rear axle with oil till the oil plug is
overflowed oil, oil amount of the vibratory drum is 2.3L, primary transmissions 7.5L
and secondary transmissions 4.5L.
25
(8) Notices of oil filling
A. Replenish oil in the diesel oil tank in time to avoid drainage out. Check diesel oil tank
once a month for pollution and deposited matters, and clean oil filters.
Replace the diesel engine oil regularly, because mechanical foreign matters in oil
increases as time goes by, more foreign matters results from resultants produced in
oxidized and worn parts, burnt residues in the cylinder and dropping dust from outside.
When these foreign matters reaches 0.4~0.5%, oil becomes blackened, physico-chemical
index becomes worse. Oil should be changed under its hot state.
B. Periodically check cleanness of hydraulic oil. Method: take out oil drop from the oil tank
and drip on the No. 240 Mu filter paper, appearance of a light yellow ring indicates oil
can be kept used ； Obvious yellow ring on the paper and being blackened in the
center indicates oil is polluted, always replace new oil with a 10μm filter, never fill oil
tank directly, never use mixture of several hydraulic oils.
C. Always use JG3 grade brake fluid stipulated in GB10830-1998 or Mobil DOT3 brake
fluid.
D. Antifreeze of the engine is selected according to different areas and the manual of the
engine, antifreeze has been filled at ex-factory, the operating temperature does not
exceed -35℃.
2. Lubrication of the vibratory roller
Proper lubrication can greatly reduce wear of each part of the machine to ensure
good service performance of the machine and prolong the service life of the machine. The
operating oil is used for either lubrication or cooling in the hydraulic system and vibratory
drum of the roller. Therefore, periodical oiling has important significance on the normal
application of the roller.
For lubrication position and lubrication intervals table, see Table 2 and Fig.4-1.
Notes:
1. Besides you carry out routine inspection and oiling of the machine when you operate the
machine, periodically change and replace oil. Lubrication intervals are divided into
five kinds, weekly (or every 50 hours), monthly (or every 200 hours), quarterly (or
every 500 hours), every half a year (or 1000 hours) and every year (or 2000 hours).
2. If oil is checked deteriorated, replace oil at once. Oil is deteriorated in a short time after
oil is replaced, look for the cause and remedy the trouble in time. For detailed
lubrication method of the engine, please refer to the manual of the engine.

Table 1 Oils of the Vibratory Roller

26
Type Climate Standard code Oil brand Position Remarks

Cold
Fuel of GB252-87 -35 -50
weather
diesel Light diesel Fuel oil tank
Winter -20 *-10
engine oil
Summer *0 10
Cold
GB11122-97 5W/30
Engine weather Oil sump of diesel
CF
oil of Winter *15W/40 engine
Diesel engine
the
Summer oil 15W/40
engine
Vibratory chamber of
Gear Heavy load Mobilube
Year vibratory drum
oil gear oil GL-5 HD 80-90

Hydra Cold Anti-rub Home Used for gear

Hydraulic oil tank
ulic oil weather hydraulic oil made 46# pump

Final drive and wheel

Winter 75W reductor of axles,
GB13895-92
primary
Gear Summer Heavy load *85W/90 transmissions,
oil gear oil
secondary
GL-5
Year *85W/90 transmissions and
gearbox
Brake Cold Mobil brake Air boost pump
DOT3
fluid weather fluid clutch cylinder
GB5671-85
Universal Roller bearing
Grease Year
vehicle And each pin & shaft
lithium grease
Winter Users should
Glycol use it
Mobil
Antifre type- Water tank according to
Year antifreeze
eze 37℃ the local
climate
Note: The items marked with * are common brand.

27
 Table 2 Lubrication Intervals Table
Lubrication intervals
Lubricatio Lubrication Every half a Every year Lubrication
Lubrication parts Weekly or Monthly or Quarterly or Remarks
n points type year or 1000 or 2000 diagram No.
50 hours 250 hours 500 hours
hours hours
Diesel For detailed change intervals, refer
Oil sump of diesel engine oil △ to the manual of the diesel engine
Engine 1 ● ◎ 5
Engine ○
oil
Transmiss Primary transmissions 1 ○ △ ● 3 For oiling method, see Fig. 4-2
Gear oil
ions body Secondary transmissions 1 ○ △ ● 2 For oiling method, see Fig. 4-2
For oiling method, see Fig. 4-3
Final drive 1 ○ △ ● 7
Rear axle
Wheel reductor 1 ○ ● 8
Brake
Air boost pump of brake system 1 ○ ● 9
fluid
Hydraulic For oiling method, see Fig. 4-5
Hydraulic oil tank 1 ○ ◎ ● 1
oil
Hydraulic Vibratory drum For oiling method, see Fig. 4-4
2 Gear oil △ ○ ● 13
system vibratory bearing
Steering cylinder
4 Grease ▲ 10
support bearing
Clutch Oil cup of master cylinder of Brake
1 ○ ● 12
clutch fluid
Release bearing of Clutch 1 Grease ▲ 4
Fork shaft of clutch release 2 ▲ 4

29
Drive
Drive shaft 2 ▲ 6
shaft
Steering articulated bearing 4 ▲ 11
Articulated points of each controls Some Grease ▲ Not given
Symbols: ΔFirst change after running-in of new machine. ○ Check oil level and replenish oil.
▲ Replenish grease. ● Replace new oil.
◎ Quarterly change oil.

30
1-Hydraulic Oil Tank 2-Secondary Transmissions 3-Primary Transmissions 4-Release Bearing 5-Oil Sump of Diesel Engine 6-Drive Shaft 7-Final Drive of Rear Axle 8-Wheel Reductor of
Rear Axle 9-Air Boost Pump 10-Steering Cylinder Bearing 11-Steering Articulated Bearing 12-Oil Cup of Master Cylinder of Clutch 13-Exciting Chamber of Vibratory Drum

4-1 Schematic Diagram of Lubrication and Oiling Position

31
Oiling Inlet of Primary Transmissions, Oiling Inlet of Secondary Transmissions, Oil Inlet of Secondary Transmissions, Oil
Release Outlet of Primary Transmissions, Oil Release Outlet of Secondary Transmissions

Fig. 4-2 Schematic Diagram of Refilling or Renewing of Primary and Secondary

Transmissions

Remove End Cover at the Oiling Position, Oil Level Surface, Oil Release Plug, Oil Filling Orifice Plug(Oil Level Plug),
Final Drive, End Cover, Oil Release Plug, Wheel Reductor

Fig. 4-3 Schematic Diagram of Refilling or Renewing oil of Rear Axle

31
Inspection Eye, Oil filling orifice plug is at top position., Oil Level Orifice Plug Position

Fig. 4-4 Schematic Diagram of Refilling or Renewing of Vibratory Drum

Oil Filling Orifice, Oil Level (Oil Temperature) Gauge, Oil Release Orifice

Fig. 4-5 Schematic Diagram of Refilling or Renewing of Hydraulic Oil Tank

§4-2 Periodical Technical Maintenance

Under general operation condition, periodical technical maintenance besides daily

(including inspection) is divided into five levels of maintenance, weekly (about 50 hours),
monthly (about 250 hours), quarterly (about 500 hours), every half a year (about1000 hours)
and every year (about 2000 hours). Maintenance intervals should be determined in according
to operation level, specific conditions and actual technical condition of the machine, for
operating unit, refer to this maintenance items.
● Daily technical maintenance (8~10 hours)
(1) Check engine oil level in the engine crankcase.
(2) Check for oil level of fuel tank and water tank level and replenish as sufficient as
possible.
(3) Check oil, water and air for leakage.
(4) Check engine, oil pump, hydraulic motor, hydraulic steering gear and transmissions for
tightness, sealing and abnormal phenomenon.
(5) Check connecting bolts of drive shaft, pin & shaft for looseness or missing.
(6) Cary out necessary cleaning, and remove oil dir, mud and foreign matters of the machine.
(7) Check abnormal sound or improper phenomenon of each moving part.
(8) Check each instrument inside the cab is in a good condition, and check clutch pedal, and
check service brake pedal for free travel.
32
(9) Check brake and steering system and related parts of service safety are in a good
condition.
● Weekly technical maintenance (50 hours)
Besides daily technical maintenance items, additional items are needed:
(1) Replenish oil and change oil according to the lubrication table.
(2) Check vibratory chamber for leakage through steel drum plate observing hole.
(3) Check the fan and the engine belt for tightness.
(4) Check battery electrolyte.
(5) Check the brake-shoe of the disc brake for wear and determine if the master pump of the
operating system, master pump of the brake and master pump of the clutch are necessary
to exhaust air according to the conditions.
(6) Check for direction and shift lever, check each control pedal works normally and flexible
and park brake for reliability.
(7) Clear away dusts on the radiator (often do this particularly under the very dirty operating
environment).
● Monthly technical maintenance (250 hours)
Besides daily and weekly technical maintenance items, additional items are needed:
(1) Replace engine oil filter, coolant filter and air filter.
(2) Replace diesel engine oil.
(3) Check tire for air pressure and wear.
(4) Check or replace hydraulic oil filter of hydraulic system.
(5) Replenish drive shaft with grease according to the lubrication table.
(6) Check oil level of axels and each gearbox according to the lubrication table.
(7) Check lubrication oil level of the vibratory drum.
(8) Check and tighten bolts of the rear axle housing and brake.
(9) Check important structural parts such as front and rear frame, vibratory drum and bearing
block etc. for damage.
(10) Check and tighten connected bolts of bearing block, absorber and side plate of the
vibratory drum.
●Quarterly technical maintenance (500 hours)
Besides daily, weekly and monthly technical maintenance items, additional items are
needed:
(1) Check the electrical equipment, wires and terminals.
(2) Check engine valve clearance for the first time within 20 hours after running-in of the
machine.
(3) Replace diesel oil filter.
(4) Check oil injection quality and pressure of oil injection pump.
(5) Check operating condition of oil injection pump, adjust again if necessary.
(6) Check distribution timing and advance angel for oil supply, adjust and correct if
necessary.
(7) Clean fuel tank and oil pipes.
(8) Check and clean & unclog vent plug and hole of each part.
(11) Check each part of the service brake system, clutch operation system, adjust and repair
if necessary.
(12) Check working condition of the steering cylinder, check and repair if necessary.
33
 (13) Replace inner gear oil of the vibratory drum.
(14) Check each absorber for damage.
(15) Replace all filter elements of the hydraulic system.

● Every half a year technical maintenance (1000 hours)

Besides daily, weekly, monthly and quarterly technical maintenance items, additional
items are needed:
(1) Clean oil sump of the engine, fuel tank and pipes.
(2) Carry out overall lubrication cleaning and oil change according to the lubrication table.
(3) Check the park brake for wear, and replace or repair.
(4) Check each meter and light.
(5) Check the starting motor, charge alternator, lubrication bearing, and make necessary
adjustment or replace.
(6) Check each part of the engine and make necessary adjustment or replace.

● Every year technical maintenance (2000 hours)

Besides the above technical maintenance items, additional items are needed:
(1) Carry out overall inspection and measurement for the engine, and determine necessary
repair scope according to results.
(2) Check, measure and repair transmissions, clutch, axles and vibratory drum or replace
damaged parts according to the actual conditions.
(3) Carry out overall inspection and measurement for park brake system, service brake
system and clutch system, repair or replace damaged parts.
(4) Check the vibratory drum and frame for deformation, crack or damage, repair promptly if
any.
(5) Check the steering gear, repair or replace damaged parts.
(6) Check performance of the whole machine, look for troubles and remedy the troubles in
time.

§4-3 General Troubles and Remedy

Position Troubles Possible Cause Remedy

34
(1) 1. Charge.
Engine 2. Check wiring for correct
1.Inadequate power of battery
series tightness, clean dusts and oil
2. Falling of terminals or poor
dirts on the contact surface.
contact of starting circuit.
3. Correct and replace carbon
3. Poor contact between carbon
Hard start of brush, clear away rectifier
brush and rectifier of starting
the diesel surface with a sand paper and
circuit.
engine or it fail blow clean dust.
4. Little diesel oil in oil tank or
to start 4. Refill new oil ad required.
poor quality.
5. Clean inlet pipeline and filter.
5. Clogged fuel pipeline or filter.
6.Check leaked parts and take
6. Air entered in the fuel system.
measure for air exhaust.
7. Other diesel engine troubles.
7. Refer to the manual for the
diesel engine.
1. Low air temperature or poor
1. Select qualified diesel oil by
fuel oil quality.
quarter.
Great smoke is 2.Overload of the engine.
2. Remove overload.
produced 3. Clogged air filter, not smooth
3. Clean air filter.
during air inlet.
4. Adjust advance angel of oil
working of the 4. Too late oil injection.
injection.
diesel engine 5. Other causes, such as wear of
5. Check and adjust according to
oil pump, oil nipple, valve and
the manual of the diesel engine.
piston ring.
Inadequate 1. Blocked oil or air. 1.Check and clean.
force of diesel 2. The accelerator is not depressed 2.Check accelerator lever system
engine, fails to fully. and adjust.
rated speed 3. Trouble of the diesel engine. 3. Check and repair.
1. Too low oil level of crankcase
or wrong oil brand. 1. Use sufficient qualified engine
Too high water
2. Failure of thermostat. oil.
temperature
3. Insufficient cooling water or 2. Replace thermostat.
and oil
poor circulation. 3. Add water and check pipeline.
temperature of
4. Loose fan belt, low speed 4. Adjust tensile force of belt or
the diesel
reduced, wind amount reduced. replace the belt.
engine
5.Possible failure of temperature 5. Replace.
gauge or temperature sensor.
Incomplete 1. Big clearance of release 1. Adjust clearance
release or bearing and release lever. 2.Replace new parts.
combining 2. Excessive wear of friction lining. 3. Remove oil dirts on the
force of the 3. Oil dirts of the friction lining surface.
clutch surface. 4.Replace new parts.
4. Burnt release bearing.

35
 1. Dropped spring of release 1. Fix again or replace with new
Clutch does bearing. parts.
not work 2. Burnt release bearing. 2.Replace with new parts.
3. Broken friction lining. 3.Replacewith new parts.

Position Troubles Possible Cause Remedy

1. Adjust clearance.
Deviated 1. Large clearance of bearing or gear.
(2) Rear axel 2. Properly fix again.
running 2. Poor fixing of tire.
and drive shaft 3. Tighten bolts of drum
drum 3. Loose tightening bolt of drum housing.
housing.
1. Little fixing clearance of bearing or gear. 1. Adjust again.
2. Excessive or less of lubrication oil. 2. Remove oil or replenish oil.
Heated
3. Clogged vent hole. 3. Clean vent hole.
4. Damaged seals, leaked oil. 4. Change seal, add oil.
1. Loose connecting bolt and tightening
1. Tighten or replace.
nuts of axles, even dropping.
2. Refill grease to the drive
Abnormal 2. Insufficient lubrication oil to produce
shaft.
sound friction.
3. Refill sufficient qualified
3. Wrong lubrication oil specification or
lubrication oil.
insufficient lubrication oil.
1. Damaged oil seal, aging and deteriorated. 1.Replace oil seal.
Oil leakage
2. Loose bolts. 2.Righten.
1. Improper adjustment and incomplete
The roller
release of the clutch. 1. Adjust.
fails to run
(3)Transmissions 2. Improper adjustment of controls; 2. Check and adjust.
or difficult
3. Dropping of synchronizer insert； 3. Repair.
gear
4. Serious wear of synchronizer ring and 4. Replace synchronizer ring.
engagement
near failure.
1. Refill sufficient qualified
1. Insufficient or excessive lubrication oil.
lubrication oil.
Heated 2. Damaged seals, oil leaked.
2. Change seal and add oil.
3. Clogged vent hole.
3. Clean vent hole.
Loud noise 1. Excessive wear of gear. 1. Replace new parts.
1. Broken connecting bolts of steering gear. 1.Replace.
(4)Steering Failure of
2. Broken spring of steering gear 2.Replace.
system steering
3. Broken oil steering pump. 3.Replace.
1. Oil leakage of pipeline, broken seal. 1.Replace seal and tighten
More steering
2.Leaked cylinder. joints.
rounds,
3. Reduced displacement of steering gear 2.Replace seal.
insufficient
rotor. 3.Replace.
steering force.
4.Too low pressure of steering valve. 4. Adjust pressure to12Mpa

36
 1. Too low speed of the diesel engine.
Slow and 1. Increase speed.
2.Leaked oil steering pump.
hard 2. Check and repair.
3. Poor lubrication of bearing parts of
steering 3. Refill grease.
steering shaft.
1. Too low oil level in oil tank, air sucked
1. Renew oil.
in the oil pump.
2. Repair and replace damaged
2. Flaw at the pipeline or damaged seal,
Unstable pipes and seal.
air entered.
steering, 3. Carry out steering operation
3. Air released in oil after long time
chattering for several times from left to right
parking, stored on the upper parts of the
or from right to left at the
steering cylinder.
original place to empty air.

Position Troubles Possible Cause Remedy

(5)Brake 1. Air leaked in pipeline or
system continuous service of brake to
cause too low air pressure. 1.Check air leakage and
2. Worn and leaked booster cup. troubleshooting.
3. Air leakage in pedal valve. 2. Replace.
4. Clogged oil inlet of master 3. Check and repair.
Inadequate brake pump. 4. Clean and unclog.
brake force 5. Too little brake fluid of master 5. Refill brake fluid.
brake pump. 6. Check and repair.
6. Oil leaked in brake pipeline or 7. Remove air.
caliper disc brake. 8. Replace new pad.
7. Air in brake pipeline.
8. Worn brake pad or oil
immersed.
1. Clogged exhaust of pedal. 1.Check and repair.
Abnormal 2. Poor booster action. 2.Check booster.
release of 3. Air in oil brake system. 3.Remove air.
brake 4. Broken brake cup, piston 4.Check, clean and replace
seized up. oil seal.
Slowly air 1. Worn parts such as air 1.Check and repair or
pressure compressor piston and cylinder, replace.
increase of the improper work. 2.Tightenand replace seal.
engine, quick 2. Loose and air leaked pipeline 3.Check and repair.
reduction of joints. 4.Check and repair or
air pressure 3. Air leaked in pedal valve. replace.
after parking 4. Unsealed air reservoir; valve,
safety valve.

37
 1.one side failure or poor effect
1. Check and repair.
of left and right drum brakes.
Not centering 2. Check and repair.
2. Failure of brake booster.
of brake 3.Have the same air pressure
3. Different air pressure of left
of left and right tires.
and right tires.

Position Troubles Possible Cause Remedy

1. Check and repair
1. Failure of electric wiring.
Vibratory wiring.
2. Worn oil pump and oil motor,
drum fails 2. Replace vibratory
seriously leaked.
to vibrate or pump & motor.
3. Clogged filter of hydraulic system.
inefficient 3. Replace filter element.
4. Low level, wrong oil brand.
vibratory 4. Refill qualified oil to
5. Aging and hardened rubber absorber
frequency the specified level.
(6)Vibratory of steel drum, reduced elasticity.
5. Replace absorber.
drum
1. Broken rubber absorber. 1. Replace rubber
2. Loose or broken connecting bolts of absorber.
Poor rubber absorber, vibratory motor and 2. Tighten bolts and
vibratory other parts. replace bolt as required.
effects 3. Broken bearing of vibratory drum. 3. Replace bearing.
4. More bubbles in operating oil. 4. Refill oil or change
oil.
Soon 1. The key is not at ON after running 1. Turn to ON position.
exhausted the machine for a long time, no 2. Do additional
battery charge. operation and charge
2. Too short circulating time of the battery.
roller, insufficient battery charge. 3. Find out and repair.
3. Short-circuited in the electrical 4. Adjust electrolyte
(7)Electrica system. gravity, charge again.
l system 4. Battery terminal is sulphided, thus
failing to charge.

Fluctuating
1. Loose terminal from battery to 1. Find loose terminal
ammeter
ammeter. and tighten.
pointer

38
 Insufficient
1. Charge or replace
force of 1. Insufficient battery power.
battery.
starting 2. Loose terminal.
2. Tighten.
motor
Electrical
1. Broken instrument or sensor. 1. Replace.
instrument
2. Loose terminals. 2. Tighten.
fails to
3. Broken wires and electricity leakage. 3. Repair or replace.
work

Position Troubles Possible Cause Remedy

(7) 1. Adjust tightness of belt.
Electrical 2. (1) Check the alternator generates
system electricity with AC voltage gauge.
Connect voltage gauge (+) to “B+”
terminal of alternator, voltage gauge (-) to
housing of alternator, while the engine is
running, voltage gauge indicating battery
voltage to about 28 volts indicates
Alternator does
alternator properly work, if readings of the
not generate
voltage gauge is not changed, it indicates
electricity or 1. Too loose drive belt
alternator does not generates electricity.
charge voltage and slipped.
(2) Check the alternator generates
is low 2. Failure of alternator.
electricity with a bulb. First remove “B+”
(insufficient
terminal cables of alternator, then connect
battery charge).
live wire of the bulb (such as lights on the
panel) to “B+” terminal, it’s not necessary
to connect other terminal (ground), while
the engine runs at low speed, the bulb
lights, it indicates alternator generates
electricity, if it fails to light, alternator
does not generate electricity, alternator
fails to work, remove troubles and repair.
Excessive 1. Poor contact of carbon 1. Remove and repair.
swinging of brush of alternator. 2. Remove and repair.
ammeter pointer 2. Burnt and poor contact
of adjuster.

39
 1. Too high voltage of
adjuster.
1. Adjust again to the specified scope.
2. Burnt contact of
Excessive 2. Remove and check, and repair or
adjuster.
charge power replace new one.
3. Dropping coils of
3. Remove the adjuster and weld again.
adjuster to lose
adjustment.
1. Burnt contact of horn 1. Replace with new one.
Horn fails to relay. 2. Check and repair or replace with new
sound 2. Burnt horn coils. one.
3. Trouble on the circuit 3. Check and repair.
Steering light 1. Broken fuse. 1. Replace corresponding fuse.
fails to light 2. Trouble on the circuit 2.Check blinking relay and bulb.
Other illumination
1. Broken fuse. 1.Check fuse.
lights and
2. Trouble on the circuit 2. Check wiring and repair.
indication lights
3. Trouble of bulb. 3. Check bulb.
fail to light

40