DIRECTOR GENERAL
BORDER ROADS
GENERAL MAINTENANCE
INSTRUCTION NO: 236
ON
ESCORT HAMM VIBRATION TANDEM ROLLER
1. INTRODUCTION
1.1. Escort
HAMM model HD-85 having dual drum vibration Tandem Rollers. The machine is
intended exclusively for the customary use of compacting, load bearing, loose
ground, road foundations, road covering or similar surface. The eqpt is fitted with 04 cylinders
Kirloskar HA-494 diesel engine having 70 HP at 2500 rpm which provides 12 Volts,
155 AH battery for operating electrical system, hydrostatic power assisted
steering, hydrostatic transmission, infinitely variable with single lever
operation to drive both the drums, direct hydrostatic transmission, infinitely variable frequency adjustment for the
vibration of drums and also provide service brake and emergency stop brake by
means of hydrostatic transmission and spring-loaded disc brakes.
2. ACTION
2.1. USER
UNIT: - To carry out maintenance schedule and oil change etc as per periodicity
laid down by mobile maintenance team or as per team detailed by the Task Forces
and also follow safety precautions for optional utilization.
2.2. FIELD
WORKSHOP (GREF)
2.2.1. To
carry out and monitor maintenance schedule and oil changes etc as per
periodicity laid down by this instruction.
2.2.2. To
advise user units in respect of any lapses noticed.
3. DETAILS
3.1. The
details of maintenance, fuel, lubricants and safety precautions are as
under:-
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3.1.1.
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General maintenance and safety precaution.
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:
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Appx ‘A’
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3.1.2.
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Fuels oils and lubricants.
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:
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Appx ‘B’
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3.1.3.
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Periodical maintenance.
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:
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Appx ‘C’
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3.1.4.
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Technical details.
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:
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Appx ‘D’
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4.
Please acknowledge receipt.
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(Hari Prakash)
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SE (E&M) FS
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Dir (Tech)
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for Dir Gen Border Roads
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Appendix
‘A’ to GMI No 236.
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1.1.
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Careful maintenance of this machine ensures
maximum reliability and prolongs the service life of important
components. The work involved is small
compared to the problems which may occur, if these instructions are not
observed.
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1.2.
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Clean the machine and engine thoroughly
after completion of day work and before carry out any maintenance works.
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1.3.
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Make sure that the machine is on a level
ground and on a firm base, when the maintenance work is being carried out and
it should be done with engine shut down.
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1.4.
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De-pressurize hydraulic hoses before any
repair work is being done/ undertaken to avoid accidents.
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1.5.
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Disconnect battery and cover it with
insulating material or remove before performing work on electrical components
of the machine.
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1.6.
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The terms “R/L” are always referred to the
direction of travel.
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SAFETY PRECAUTION
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GENERAL
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1.1.
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Make sure that you are familiar with all
the accessories of your machine.
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1.2.
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Only operate the machine if you are
completely familiar with the operating and control elements as well as the
functioning of the machine.
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1.3.
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Wear protective clothing such as safety
helmets, safety shoes and gloves.
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1.4.
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Familiarise yourself with the area where
you will be working.
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1.5.
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The vibration must not be operated in the
directly vicinity of building. Prior
to switching on the vibration, ensure that no pipes in the ground can be
damaged or destroyed.
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1.6.
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In emergency situation and when the machine
is endangered, actuate the EMERGENCY STOP switch to bring the machine to an
immediate standstill.
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1.7.
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Note where the fire extinguishers and first
aid box are located and how they are used.
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1.8.
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Only use the roller for the purpose it is
intended.
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1.9.
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CAUTION:- Keep away from the machine’s
articulation area when the engine is running.
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PRIOR TO START
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2.1.
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Observe the operating instruction before
starting the engine.
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2.2.
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Check the machine for any obvious fault.
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2.3.
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Do not operate the machine with defective
instruments, warning lights or control elements.
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2.4.
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All safety devices must be in secure
position.
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2.5.
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Do not carry with you any movable objects
or secure them to the machine.
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2.6.
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Keep oily and inflammable material away
from the machine.
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2.7.
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Before entering the operator’s cabin, check
if persons or obstacles are beside or beneath the machine.
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2.8.
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Be careful when entering the operator’s
cabin, use stairs and handles.
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2.9.
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Adjust your seat before starting the
engine.
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STARTING
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3.1.
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When starting, all operating levers must be
in “neutral position”.
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3.2.
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Only start the engine from the operator’s
seat.
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3.3.
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Check the indicating instruments after
start to assure that all functions are in order.
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3.4.
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Do not leave the machine unobserved when
the engine is in running condition.
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3.5.
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When starting with the help of another
battery, connect positive point to positive and negative point to
negative. Always connect the earth
wire (negative) last and disconnect it first.
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3.6.
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CAUTION:- Exhaust gases are toxic; always ensure
an adequate supply of fresh air when starting the engine in indoors.
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OPERATION
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4.1.
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Before starting the machine for work, check
all controls, lighting and horn for proper working.
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4.2.
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Match the speed of the engine to the
operating conditions.
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4.3.
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Keep away from edges and slopes.
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4.4.
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Always switch on the lights when visibility
is poor and in the dark.
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4.5.
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Always maintain an adequate distance to
building pit edges and embankments.
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4.6.
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The vibration must not be operated in the
directly vicinity of buildings (danger of collapse). Prior to switching on the vibration, ensure
that no pipes in the ground (gas, water, sewage, electricity) can be damaged
or destroyed.
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4.7.
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The machine must be inspected for
externally visible damage and defects at least once per shift.
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4.8.
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During use, watch control and display
devices on the instrument panel at regular intervals.
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4.9.
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In the event of functional disturbances,
the machine must be immediately shut down and secured, rectify faults without
delay.
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4.10.
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Always drive with due care on slopes and
always directly up or down slope (never at an angle). Always shift to the
lower travel speed range when approaching the slope.
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4.11.
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Change the direction of travel by bringing
the machine to rest.
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4.12.
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When driving the machine in reverse
direction, check there is no person or obstacle in the way.
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4.13.
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Do not try to climb into the machine when
it is moving.
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4.14.
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Do not use then machine to transport
persons.
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4.15.
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Watch out for unusual noises or smoke when
operating the machine.
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4.16.
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Do not switch on the vibration, when the
machine is on highly compacted material such as asphalt or concrete.
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PARTING
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5.1
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Before leaving the machine, shift the
control lever to “Neutral” apply the parking brake and switch off the engine,
using the main battery switch.
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5.2.
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If possible park the machine on a level and
firm ground.
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5.3.
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If you have to park the machine on a
gradient, position your machine at a right angle to the slope and put wedges
under the drums or wheels.
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5.4.
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Never jump from the machine (danger of
injury), use the steps and handles.
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MAINTENANCE
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6.1.
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Make sure that the machine is on flat,
load-bearing surface when carrying out repair and maintenance work.
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6.2.
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When working on the machine secure the
articulated joint with the brace.
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6.3.
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Make sure that maintenance work may only be
carried out by skilled personnel.
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6.4.
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Attach a warning sign to the steering wheel
if the machine is defective.
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6.5.
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Before starting work, check that all drums
or wheels are locked in position and that the battery is disconnected.
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6.6.
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During maintenance work, always firmly
tighten loosened screw connection.
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6.7.
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Check connections and fittings for leaks
once all works have been completed.
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6.8.
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Wipe away any fuel or oil which has been
spilled on the machine.
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6.9.
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Do not smoke when filling the tanks or
checking the level of acid in the battery.
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6.10.
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Never check the level of acid of the
battery, or the fuel with a naked flame.
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6.11.
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Be careful with cleaning agents, gasoline
or other easily inflammable substances must never be used for cleaning
purpose.
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6.12.
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There is a danger of scalding if the engine
oil or hydraulic oil is drained at operating temperature.
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Appx ‘B’ to GMI No.
236
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Fuels
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7.1.
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Only use commercially available brand
diesel fuel with sulphur content less than 0.5 %. With higher sulphur
content, the engine oil must be changed more frequently. At low temperatures,
only ever use winter grade diesel fuel.
The machine should never be allowed to run out of fuel, otherwise the
filter and injection lines will have to be bled.
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7.2.
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The following fuel specifications are
permitted: -
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7.2.1.
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a)
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Din 51601.
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b)
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BS 2869: A1 and A2 (With A2, note the
sulphur content)
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c)
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d)
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W-F 800 C: DF-A, DF-1 and 2.
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7.3.
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At low temperatures, the flow and
filtration capacity of the diesel fuel is inadequate (crystallized
paraffin). For this reason, during the
winter months, diesel fuels are available with improved low temperature characteristics. At the onset of winter, ensure that refill
with winter diesel fuel.
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Engine oil: Use only winter-grade engine
oil at low temperatures.
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Hydraulic Oil
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8.1.
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Only use ELFONA-68 (make IOC) or Shell
Tellus-68 (make Shell) hydraulic oils of specification DIN-515224/2 for the
hydraulic system.
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Gear/Vibrator Oil
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9.1.
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Only use multi-purpose gear/vibrator oils
of class API, GL-5 MIL for the vibrators, drum and differential drives, ie.
Servo gear super 85W-90.
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9.2.
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This is top performance class hypoid oil
for vibrator, drum and differential drives subject to heavy loads.
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9.3.
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The additives in this oil ensure
wear-resistant lubrication under all application conditions.
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Lubricating grease
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10.1.
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Use of EP high pressure grease, lithium
soaped (penetration 2) for lubrication purposes ie. Servo grease MP.
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Notes on the Fuel/Hydraulic system
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11.1.
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The service life of the diesel engine and
the hydraulic system/pump/units are governed primarily by the cleanliness of
the fuel/hydraulic oil.
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11.2.
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Keep the fuel/hydraulic oil free of
contamination and water, otherwise the engine’s injection elements/hydraulic
pump, valves will be damaged.
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PERIODICITY OF OIL/FILTER CHANGES
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S/No
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Description
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50 Hrs
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250 Hrs
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500 Hrs
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1000 Hrs
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2000 Hrs
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1st Change
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1.1.
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Engine oil and filter.
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*
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1.2.
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Gear oil change. (Torque Hub)
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*
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1.3.
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Hydraulic filter.
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*
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1.4.
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Gear Oil. (Drum & Differential)
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*
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1.5.
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Hydraulic oil.
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*
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Regular change intervals
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1.1.
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Fuel filter.
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*
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1.2.
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Engine oil and filter.
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*
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1.3.
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Hydraulic filter.
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*
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1.4.
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Gear oil.
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*
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1.5.
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Hydraulic oil.
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*
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1.6.
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Air filter inner.
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*
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*
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1.7.
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Air filter outer.
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Clean
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*
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*
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1.8.
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Air Breather.
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*
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1.9.
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Drum Breather.
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Clean
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*
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*
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1.10.
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Hydraulic strainer.
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*
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Appx ‘C’ to GMI No. 236
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PERIODICAL MAINTENANCE
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MAINTENANCE TASK (EVERY 08-10
OPERATING HOURS/DAILY)
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1.1.
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Check engine oil level and top up if
required.
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1.2.
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The service life of the filter cartridge in
the air filter depends on correct removal of dust by discharge valve. If discharge valve is jammed or clogged,
the cartridge gets clogged quickly due to excessive dust, squeeze the dust
discharge valve, clean discharge slots.
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1.3.
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Removed filter bowl with strainer and
clean.
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1.4.
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Check hydraulic oil level.
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1.5.
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Fill diesel tank after day’s work to avoid
condensation of water.
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1.6.
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Dirt tends to accumulate on the engine
cooling fins, where surface gets contaminated with oil or fuel. If
contamination is oily, spray the engine with diesel oil or cold cleaning
agent and clean it, with a water jet after allowing an adequate soaking time.
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1.7.
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Check air intake system for leakage.
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1.8.
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Check visual inspection for damage.
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1.9.
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Check hydraulic flexible hoses regularly
and replace them in case of damage.
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1.10.
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Check lighting system.
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1.11.
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Check electrically operated, monitoring
equipment/gauge/warning lamp for correct functioning, which are fitted on the
panel. Example: engine temperature, water temperature, hydraulic oil
temperature gauges and other warning lamps.
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MAINTENANCE TASK (EVERY 50
HOURS/WEEKLY)
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2.1.
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Carry out 10 operating hour’s maintenance
tasks.
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2.2.
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Air filer outer and Drum breather to be
cleaned and fitted.
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2.3.
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All grease nipples to be cleaned and
lubricate with grease.
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2.4.
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Clean out side of battery and check acid
level, if required top up with distilled water only.
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2.5.
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Apply mineral jelly to the cable terminal
to prevent corrosion. Do not apply
grease. Clean vent holes of the vent
plugs of battery for free ventilation.
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2.6.
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Battery mounting to be checked for
rigidity.
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2.7.
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Check oil level in transfer case.
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MAINTENANCE TASK (EVERY 100 OPERATING
HOURS)
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3.1.
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Carry out 10 and 50 operating hour’s
maintenance tasks.
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3.2.
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Clean cooling system.
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3.3.
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In case of ‘Air Lock’ bleed the fuel system
to remove air.
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3.4.
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Clean the water sprinkler pump filters both
front, rear and refits it.
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MAINTENANCE TASK (EVERY 250 OPERATING
HOURS)
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4.1.
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Carry out 10, 50 and 100 operating hours
maintenance task.
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4.2.
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V-Belt tension to be maintained between 10
mm to 15 mm.
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4.3.
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Change engine oil and replace oil filter
element.
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4.4.
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Replace fuel filter element.
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4.5.
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Change gear oil in respect of Torque Hub.
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4.6.
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Replace Hydraulic oil filter element.
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4.7.
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Clean cooling fins of the engine and
hydraulic oil coolers.
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4.8.
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Blow cooling air ducts with compressed air.
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4.9.
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If contamination is oily, spray the engine
with diesel oil or cold cleaning agent and clean with a water jet after an
adequate soaking time.
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4.10.
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Check oil level of vibration bearing shaft (Front) and the exciter shaft
(Rear) of drums and in case oil to be drained, oil drain plug to be kept at
the lowest point, while draining
and to keep it at the highest point while filling the chamber.
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4.11.
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Clean drum breather hole in the cover under
the vibration motor.
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MAINTENANCE TASK (EVERY 500 OPERATING
HOURS)
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5.1.
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Carry out 10, 50, 100 and 250 operating
hours’ maintenance tasks.
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5.2.
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Clean fuel tank.
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5.3.
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Check screw connections of air intake pipe,
exhaust pipe, oil pan, engine mounting, air cleaner and elastic suspensions.
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5.4.
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Check electric exciter circuit.
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5.5.
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Check water sprinkling is done, by
operating switch in the instrument panel.
Water pump of water sprinkler is operated by solenoid valve operated
electrically.
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5.6.
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Change gear oil in respect of drum and
differential.
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5.7.
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Replace Air filer elements inner and outer.
|
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5.8.
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Replace Air breather and drum breather.
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MAINTENANCE TASK (EVERY 1000
OPERATING HOURS)
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6.1.
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Carry out 10, 50, 100, 250 and 500
operating hour’s maintenance tasks.
|
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6.2.
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Clean fuel pump strainer.
|
||||||
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6.3.
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Change hydraulic oil.
|
||||||
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6.4.
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Change oil in transfer case.
|
||||||
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6.5.
|
Check valve clearance: The clearance should be as under :-
|
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Exhaust (Cold)
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:
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0.15 mm.
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Intake (Cold)
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:
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0.15 mm.
|
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Appx ‘D’ to GMI No. 236
|
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TECHNICAL DETAILS
|
|||||||
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1.1.
|
Technical data
|
||||||
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(a)
Weights:-
|
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Operating weight Total
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:
|
9300 Kgs.
|
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Axle load front
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:
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4650 Kgs.
|
||||
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Axle load rear
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:
|
4650 Kgs.
|
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Static linear load, Front
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:
|
27.6 Kg/Cm.
|
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Static linear load, Rear
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:
|
27.6 Kg/Cm.
|
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Vibration: Direct hydrostatic -
Vibrator drive to both drum.
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:
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Front/Rear.
|
||||
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Frequency
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:
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0-30/42 Hz.
|
||||
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Nominal amplitude
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:
|
1.27/0.75 mm.
|
||||
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Total compaction force
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:
|
225/245 kN.
|
||||
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Working width
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:
|
1,680 mm.
|
||||
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Turning circle radius
(external/ internal)
|
:
|
6,200/4,550 mm.
|
||||
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Drum diameter
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:
|
1,200 mm.
|
||||
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(b) Capacities:
-
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|
|||||
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Fuel tank
|
:
|
155 Ltrs.
|
||||
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Engine (for oil Change)
|
:
|
10
Ltrs.
|
||||
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Oil tank hydraulic system
|
:
|
70
Ltrs.
|
||||
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Drum (each)
|
:
|
10
Ltrs.
|
||||
|
|
Water tank sprinkling for front and rear
drum
|
:
|
700 Ltrs.
|
||||
|
(c) Engine:-
|
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|
|||||
|
|
KOEL Diesel engine, (04 stroke, 04 cylinder, air cooled)
|
:
|
Type HA 494.
|
||||
|
|
Rating according to ISO 9249 at 2,500 rpm.
|
:
|
51 KW/70 HP.
|
||||
|
|
Rating according to SAE J1349 at 2,800 rpm.
|
:
|
62 KW/84 HP.
|
||||
|
(d) Electrical
stem: -
|
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|
|||||
|
|
Operating voltage
|
:
|
12 Volts.
|
||||
|
|
Battery
|
:
|
01 No. 12 V, 155 Ah.
|
||||
|
(e) Transmission:
-
|
|
|
|||||
|
|
Hydrostatic transmission, Infinitely
variable, single
lever operation
|
:
|
All wheel drive to both drum.
|
||||
|
|
Speed
|
:
|
0-9.5 Km/Hr.
|
||||
|
|
Climbing ability with Vibration up to.
|
:
|
30 %
|
||||
|
|
Climbing ability without
Vibration up to
|
:
|
45 %
|
||||
|
(f) Vibration:
-
|
|
|
|||||
|
|
Direct hydrostatic transmission, infinitely
variable frequency adjustment.
|
||||||
|
|
Stage 1: Frequency/Amplitude
|
:
|
Max. 30 Hz/1.27 mm.
|
||||
|
|
Stage 2: Frequency/Amplitude
|
:
|
Max. 42 Hz/0.75 mm.
|
||||
|
(g) Steering:
-
|
|
|
|||||
|
|
Hydrostatic power-assisted steering using
an articulated reciprocating compensation 10o upwards and downwards.
|
||||||
|
(h) Service
brake:-
|
|
|
|||||
|
|
During use, the machine is braked by the
hydrostatic transmission. Wear free braking.
|
||||||
|
(j) Emergency
stop brake: -
|
|
|
|||||
|
|
By mean of hydrostatic transmission and
spring-loaded disc brakes.
|
||||||
|
(k)
Water sprinkling:-
|
|
|
|||||
|
|
Pressure sprinkling foot actuation and
automatic pause.
|
||||||
|
(l) Special
equipment: -
|
|||||||
|
|
On request, the machine can be equipped
with extensive special accessories.
Subject to design, weight and dimensional modifications.
|
||||||
|
1.2.
|
Dimension sheet not attached.
|
||||||
|
|
|
||||||
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