Common Trouble-Shooting Method of Road Roller

Common Trouble-shooting
Method of Road Roller
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Common Trouble-shooting Method of Road Roller
1. Road roller can’t travel, but vibration function is in

normal condition
Failure phenomenon:
Road roller can’t travel, vibration function is in normal
condition, engine revolution doesn’t drop, brake indicator
alarms.
Malfunction analysis:
(1) That vibration is normal, check oil filling pressure is normal
and oil filling valve failure has been eliminated.
(2) That brake indicator alarm and measured braking pressure
is too low, which means solenoid of pressure sensor is failed.
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check whether
(3) Check whether the emergency stop
button is reset
connection of operation device after faulty
operation
with main pump’s manual
servo valve is reliable; check
whether emergency stop
button is reset after faulty
operation (shown in Fig.1) Fig.1
(4) Measure travelling pressure, that if the pressure is low,

which means maybe controlling part of the oil pump or oil
pump and motor is failed; that if the pressure could be
over 40Mpa, which means travelling reducer is failed or
mechanical failure such as rear axle block, etc.
(5) As for problem in oil pump controlling, we should
mainly check emergency stop solenoid and manual servo
valve.

Trouble shooting method & process:

(1) Check whether emergency stop button and
travelling operation handle in the cab is in normal
condition. Check whether
emergency stop
button and travelling
(2) Check whether operation operation handle in
device and manual servo the cab is in normal
condition
valve is in proper
connection. (shown in Fig.2)
Fig.2
(3) That measured travelling pressure is very low, oil filling

pressure and case pressure is normal, which means oil pump
failure is impossible.

(4) Check emergency stop solenoid, that it is found that there is

no attraction when screw driver is closed to energized solenoid
and measured coil resistance is infinite, which means solenoid
is deenergized.
(5) If it still can’t travel after

replaced the solenoid, check emergency stop
solenoid is clamping
the port X1, X2. That it is stagnation
found there is no pressure oil,
which means emergency stop
solenoid is clamping
stagnation. The problem Measured resistance
could be solved after clean value of emergency
stop solenoid should
the valve core. (shown in be roughly 22 ohm
Fig.3)
Fig.3

2. High frequency vibration is normal and no low frequency

vibration
Failure phenomenon:
High frequency vibration is normal but there is no vibration when the equipment
turns to low frequency mode, and low frequency vibration pressure is nil, low
frequency indicator is light.
That high frequency vibration is normal, which eliminates the possibility of

vibration motor failure and mechanical failure. That low frequency indicator is light,
which means power supply for low frequency is normal. Thus problem maybe in
high and low frequency solenoid, it maybe results from the following reasons:
(1) Low frequency vibration solenoid is failed or deenergized.
(2) Valve core of three-position four-way changing valve is clamping stagnation or
failed.
(3) Safety valve controlling low frequency vibration is failed or clamping
stagnation.

(1) That voltage of low frequency solenoid measured by multi meter is 24V, which
means circuit of solenoid Y4 is normal, for further confirmation, exchange high and
low frequency solenoid. If the malfunction is still, that Y4 is failed could be
eliminated. (shown in fig.4)
(2) Exchange high and low frequency vibration relief valve, if the malfunction is still,
that high frequency relief valve is failed could be eliminated.
(3) Disassembly three-position four-way changing valve of vibration pump
controlling high and low frequency. If valve core is clamping stagnation, clean the
valve core and the machine will be in normal condition. (shown in Fig.5)
Exchange high Clean three-
frequency position
solenoid Y3, four-way
Y4 for trouble valve
shooting
Exchange
relief valve
for trouble
shooting
Fig.4 Fig. 5

3. Road roller can’t travel suddenly during operating

Failure phenomenon:
Road roller can’t travel suddenly, vibration function is in normal condition, no
any alarm, engine revolution doesn’t drop.
Because vibration and oil filling pressure is normal, check oil filling relief valve
failure could be eliminated. That there is no any alarm, which means pressure
relay is normal, so the following failure should be taken into consideration:
(1) Check whether emergency stop button is reset after faulty operation
(2) Check whether the connection of operation handle with main pump’s
manual servo valve is proper
(3) Measure travelling pressure, that if the pressure is low, which means maybe
controlling part of the oil pump or oil pump and motor is failed; that if the
pressure could be over 40Mpa, which means travelling reducer is failed or
mechanical failure such as rear axle block, etc.

1. Check whether emergency stop button and travelling operation handle in
the cab is in normal condition.
2. Check whether operation device and manual servo valve is in proper
connection.
3.That measured travelling pressure is very low, oil filling pressure and case
pressure is normal, which means oil pump failure is impossible.
4.Check emergency stop solenoid, that the measured coil resistance is
infinite, which means solenoid is deenergized, the road roller will travel in
normal condition after replace the solenoid.
Check emergency stop solenoid,
that the measured coil resistance is
infinite, which means solenoid is
deenergized, the road roller will
travel in normal condition after
replace the solenoid.

4. Engine revolution can’t be raised

Failure phenomenon:
Roller is flameout, restart engine, engine revolution can’t be raised and
manual and auto control of the operation system don’t work.
Engine failure
1. Operation button failure
2. Circuit failure
3. Stepping motor failure or driver failure
4. Program failure


(1) Start engine, that operate the manual throttle on the engine, and
revolution could be controlled, which means there is no problem in the
engine
Observe the
(2) Check connecting wire of indicator of
the PLC
the button on the panel, if it
is normal, then check the
resistor, if it is normal, which
will be showed through
indicator. (shown in Fig.6)
Fig.6
(3) Press the button, that indication of the indicator of the PLC is
normal, which means this branch of the circuit is normal, then
check whether the connecting wire between driver with stepping
motor is normal.

Stepping
(4) Press the button, stepping motor
motor will run with ‘ka ka’

noise, and throttle can be pulled,
then disassembly stepping
motor, check whether the inner
baffle ring is broken, if it is
normal, and inner circuit is
normal either, throttle pull-rod Fig.7
Ablation
will be available for operation point
(shown in Fig.7)
5.Check the output voltage of
driver, if it is wrong,
disassembly the driver, it will be
found that a integrated chip is
burned, and the engine
revolution control will be normal
after replace the driver. (shown
in Fig.8)
Fig.8

6. Oil leakage of road roller’s travelling reducer

Failure phenomenon:
There is oil leakage of a road roller’s travelling reducer, and it is from the
faying face between rotary part of the reducer and fixing part.
According to the phenomenon, floating seal ring of the middle part is
failed, in order to confirm the extent of the failure, also we should
disassembly the reducer and check it.
First teach the client how to remove the reducer and disassembly it
according to the process.

(1) Remove all the bolt of outer case, take apart rotary part with fixing part. Shown in
below figure.
dismantle
rotary part
of reducer
(2) Take away snap rings of 4 planet gear by snap ring plier. Shown in below figure.
dismantle fixing part of
reducer.
This snap ring should

be removed
There is small lock

nut in this gap.

(3) Take out the 2 lock nuts.

(4) Remove 4 planet gear, it maybe difficulty to do that, we can hit the
low end tightly by screwdriver or chisel, and we can take them out in
this way. Be careful not to damage the bearing of planet gear. Shown
in following figure
Remove this big lock nut.

(5) Remove the big lock nut below the planet gear, it maybe too tighten
to remove, that hit it for some times by hammer will loose the nut.
Shown in below figure.
(6) Take out the snap ring and brake block. Shown in below figure.
Remove brake block and

snap spring.

Removed part is shown in below figure.
(7) Finally, pry the edge by big screw driver, and we can take apart it
completely so that the inner float seal ring can be seen.

7. Air spring of left cab door is failed

Failure phenomenon:
After 597 hours operation, air spring of left cab door is failed.
(1) Piston rod of air spring is scratched or attached with sand or
concrete, which leads to the failure of air spring.
(2) Service life of air spring in ideal state is 20000 times, that cab
door is opened most frequently, which maybe shorten the service
life of air spring.


(1) Piston rod of air spring should be protected, can’t be scratched and
attached with foreign material.
(2) Replace new air spring.
Gas spring

8. Water temperature is too high and cooling water is boiling

Failure phenomenon:
Water temperature is too high and cooling water is boiling after road roller YZ20
worked for an hour.
First, check whether it is lack of cooling water, parking the vehicle on solidity and flat
road, and the warm machine should be cooled for 30 minutes, to avoid hurting
yourself by hot water. When checking, loose the nut of lower end of pipe, exhaust the
air, and fill in anti-freeze liquid from water filling port until it is full. Then, run the
vehicle for several minutes, and fill in anti-freeze liquid again. Only half liter of anti-
freeze could be filled in through checking.
(1) Anti-freeze liquid is metamorphose or there is no adequate liquid (anti-freeze liquid
can’t meet the requirements)
(2) Fan belt is loose or broken.
(3) Radiator is blocked up.
(4) Water pump is broken or thermostat is broken.
(5) Bearing of belt tensioning wheel axle is broken.

Check the fan belt and its tension level, if it is normal, inquire client’s operator,
whether he has filled in different type of anti-freeze liquid, if they say what they fill
in is 45# anti-freeze liquid, eliminate metamorphose of anti-freeze liquid, and run
the vehicle, listen whether there is abnormal noise from belt tension wheel, if it is,
disassembly the belt tension wheel, it will be found that inner bearing is failed, and
the problem could be solved after replace the failed bearing.
Anti-freeze
liquid
check thermostat and
observation
the tension of belt.
windows

9. Engine revolution drops when climbing or vibration

Failure phenomenon:
After 20 mins working, engine revolution happens to drop when climbing or
vibration, the revolution decreases from 2400rpm to 1300rpm
(1) Fuel filter and air filter is too dirty.
The failed
(2) There is gas leakage from oil pipeline. fuel injector
(3) Fuel supply pump rack is clamping

stagnation and transmission pump is wear.
(4) The fuel injector is wear.
(5) High pressure fuel pump is wear.

(1) Replace fuel filter core and clean air filter core—effect is not obvious.
(2) Put fuel sucking pipe of transmission pump into fuel tank directly bypass the filter—
the phenomenon is still.
(3) It is considered transmission pump has been wear, because fuel viscosity is high
when cold, and it could meet pressure requirements, after temperature is raised, fuel
viscosity becomes low, so it couldn’t meet pressure requirements and the revolution will
drop with heavy loads. But the fact is not –the phenomenon is still after replace the
transmission fuel pump.
(4) Check injection nozzle, it is found that 2 fuel injector is failed, therefore, replace the
2 fuel injector, but the problem is not solved yet.
(5) After the mentioned process, the problem must be in monoblock pump, after
replace the 6 monoblock pump it will works in normal condition.
Monoblock pump

10. Flameout can’t be achieved by key switch

Failure phenomenon:
Flameout can’t be achieved by key switch for road roller YZ18, and it is
required flameout in manual mode after each operation. Hour meter starts
to work the moment switch is engaged, and charging indicator is not light.
That engine can’t flameout is usually caused by improper assembly of
flameout solenoid and the failure of solenoid, or solenoid is clamping
stagnation in throttle-open position, and it maybe caused by that flameout
solenoid is continuously energized which is in constant open position. Check
the working condition of flameout to estimate whether solenoid is good or
not and the energization condition.

First turn key switch to on position, and listen whether there is ‘tick tack’
when solenoid is engaged, or take out the solenoid, and check whether shift
fork of solenoid works in normal condition when energized. Check battery
observing spot, if it is black, requires charging, which means battery is
normal, after that, it shows the flameout solenoid is in good condition.
(1) Check energization condition of flameout solenoid, and it is found that
flameout solenoid is still energized and in throttle-open position after turn off
the power supply by key switch. And it is found the power is from generator
after checking.
There is clamping
stagnation between
flameout solenoid
and rack.

(2) After analysis, there is shortcut in a certain position of terminal D+

and B+ s’ circuit.
(3) Check the circuit step by step, till figure out the shortcut spot and re-
cabling, the problem will be solved.
There is 24V current

of D+ circuit, and it
turns into low level
after engine startup.

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Common Trouble-Shooting Method of Road Roller

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Common Trouble-shooting

Method of Road Roller

SANY Heavy Industry Co.,Ltd. Quality Changes the World

1. Road roller can’t travel, but vibration function is in

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(4) Measure travelling pressure, that if the pressure is low,

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Trouble shooting method & process:

(3) That measured travelling pressure is very low, oil filling

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(4) Check emergency stop solenoid, that it is found that there is

(5) If it still can’t travel after

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2. High frequency vibration is normal and no low frequency

That high frequency vibration is normal, which eliminates the possibility of

Trouble shooting method & process:

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3. Road roller can’t travel suddenly during operating

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4. Engine revolution can’t be raised

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Trouble shooting method & process:

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motor will run with ‘ka ka’

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6. Oil leakage of road roller’s travelling reducer

Trouble shooting method & process:

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This snap ring should

There is small lock

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(3) Take out the 2 lock nuts.

Remove this big lock nut.

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Remove brake block and

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Removed part is shown in below figure.

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7. Air spring of left cab door is failed

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Trouble shooting method & process:

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8. Water temperature is too high and cooling water is boiling

Trouble shooting method & process:

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9. Engine revolution drops when climbing or vibration

(3) Fuel supply pump rack is clamping

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10. Flameout can’t be achieved by key switch

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(2) After analysis, there is shortcut in a certain position of terminal D+

There is 24V current

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