R-SERIES WALK-BEHIND ROLLERSstampede.africa/wp-content/uploads/2018/04/Oper... · 3. Tips for...

Copyright © STAMPEDE - 2017

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R-SERIES

WALK-BEHIND ROLLERS

PR 39

PR 60

PR 62

PR 75

PR 90

Version: 2.0

(with Single-Shaft Vibrator system)

Released: July 2017


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2

INDEX to pages

SECTION 1 – OPERATING INSTRUCTIONS

1. Safety

1. Foreword and Basic overview of the machine Page 3

2. Basic description and intended use of the machine Page 4

3. Intended use of the machine and Limitations Page 4

4. Basic requirements for machine operator Page 4

2. Operation of the machine

1. Starting and stopping of the engine – HATZ versions Page 5, 6

2. Starting and stopping of the engine - KOHLER version Page 7

3. Starting and stopping of the engine - HONDA Petrol version Page 8

4. Moving machine forward / backwards Page 9

5. Switching the vibration ON and OFF Page 9

3. Tips for getting best compaction results

1. General Hints and Tips for the operator Page 10

2. Layer thickness / number of passes guide Page 11

3. Working on slopes and near embankments that can collapse Page 11

4. Daily Maintenance checks / actions Page 12

SECTION 2 – SERVICING INSTRUCTIONS / SCHEDULES

1. Servicing – The Roller Page 13 – 17

General

Servicing Schedule Specifics/details to Service items

2. Servicing – HATZ engine Page 18, 19

3. Servicing – KOHLER engine 0

4. Servicing – HONDA Petrol engine Page 21, 22

SECTION 3 – ANNEXES

Hydraulic Diagram Page 23

Technical Data Page 24 - 26

Other Annexes Page 27


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Foreword

This Manual is intended to familiarize the users of STAMPEDE Walk-behind Rollers with

the machine, its proper and safe operation, daily maintenance and will guide the

customer’s servicing staff through regular Servicing as required for this machine.

The information contained in this Manual is specific to current production machines at

time of publication of this Manual and may be different from previous or future versions

of the equipment. STAMPEDE reserves the right to make technical changes to their

equipment without notice.

Further details may be obtained at any time from STAMPEDE’s Service Centre.

Overview of the machine

4 Lifting Eyes

Always use adequately rated Lifting Straps

when lifting the machine!

Never stand below / near suspended loads!


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4

1. Safety

1.1. Basic description of the machine

The machine is a double-drum Walk-behind (Pedestrian) Vibrating Roller, powered by

either a HATZ, YANMAR or KOHLER air cooled Diesel engine or a Honda air cooled

Petrol engine and can be operated either with or without the vibration system switched

on. The machine’s drive systems for both the propulsion of the machine as well as its

vibration system is hydro-static, driven by an engine-mounted double pump. Both drums

are permanently driven from a central hydraulic motor through a gear drive.

The machine’s vibrating system is of the ‘single-shaft’ design which makes the bottom

half of the machine (below the Rubber Buffers) vibrate and transfers resultant ‘impact

forces’ to both drums, vastly assisting the machine’s compaction ability due to

utilisation of dynamic forces . The Vibrator Shaft is located in the vibrator housing and

driven by a single hydraulic motor which is directly flanged to the vibrator shaft.

The machine’s upper frame is isolated from the vibrating forces acting on its lower

frame by Rubber Buffers.

1.2 Intended use of the machine

The machine is intended to be used for compaction of all commonly used materials in

construction of roads, parking lots, walkways, trenches, bridge and backfilling works.

Such materials include in-situ soils, sand, gravel, sand/gravel mixtures and asphalt.

1.3 Limitations of intended use of the machine

The machine may not be used on hard surfaces such as existing asphalt, concrete, etc.

and may also not be used for compaction of Rock Fills with stone particles exceeding

reasonable dimensions for the size of machine, but limited in any event to <75mm in

diameter.

The machine is not suitable for effective compaction of highly cohesive materials such

as clay, silt and materials of an organic nature.

1.4 Basic requirements for the machine operator

The machine must be started and operated only by suitably qualified and physically able

adults who have acquainted themselves with and do understand this Manual or have

been properly trained and instructed on the safe and correct operation of the machine,

in line with this Manual.

Operation of the machine by under aged youngsters or persons under the influence of

drugs/alcohol is specifically prohibited.


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2. Operation of the machine

2.1.1 Starting and stopping of the engine – HATZ 1D42/50 / 1D81

1. Visual checks

Check engine oil level

(if necessary top up with SAE 15W40)

Check hydraulic oil level

Check fuel level in tank

2. Make sure Vibration is OFF

3. Pull Decompression lever UP – all the way

4. Insert Crank Handle – observe correct position for

you to stand in, see graphic on RH side

5. Turn Crank Handle in COUNTERCLOCKWISE direction 5 x whilst increasing speed

6. When engine has started, remove crank handle and replace in its storing position

The engine will accelerate to full throttle speed automatically

2.1.1.1 Stopping the engine – HATZ

Pull the RED Stop Lever (1) at R/H side of engine

as shown in graphic here

STARTING

PROCEDURE

2 3

4 5 6

1


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2.1.2 Starting and stopping of the engine – HATZ 1B40 (on model PR39)

2.1.2.1 Stopping the engine

Push Accelerator Lever IN,

see graphic (1) on RH side

IMP

OR

TAN

T

1


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2.2 Starting and stopping of the engine – KOHLER 15KD440 / 15KD350

The engine will start easily if you follow the Procedure of steps 1 – 2 – 3 as described

below

Step 1: Pull the Starter Rope OUT slowly, all the way to the end; do this 2 – 3 times, in

particular when the engine is cold

Step 2: Let the Starter Rope IN all the way down, then bring it slowly OUT a bit to the point

where you feel resistance for the first time

Step 3: Now grab the Starter Rope Handle firmly with BOTH hands, support your foot

against the machine for extra stability and give it ONE HARD, LONG PULL –

all the way out, and without slowing down

An inadequate pull (step 3) may result in the engine firing ‘backwards’ in which case

smoke will be ejected from the Airfilter.

Should this occur STOP the engine immediately and repeat above starting procedure

doing it properly.

2.2.1 Stopping the engine

Pull the RED Stop Lever (1) at R/H side of engine


1 2 3

1


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2.3 Starting and stopping of the engine – HONDA

1. Visual checks

Check engine oil level (if necessary top up with SAE 15W40)

Check hydraulic oil level

Check fuel level in tank

2. Make sure Vibration is OFF

3. Open Fuel Valve lever – all the way

4. Set the Choke Lever to CLOSED (not required when engine is warm already)

5. Turn red Starting Switch into ON position

6. Pull Starter Rope

When the engine has started, slowly open up the Choke Lever into its OPEN position.

The engine will now accelerate to full speed automatically

When the engine is cold it is good practice to let the engine run for 2 – 3 minutes before

engaging any load – this will give the engine and the hydraulic oil a chance to warm up to

reasonable operating temperature.

2.3.1 Stopping the engine – HONDA

Turn the RED Starting Switch (5) into its OFF position


STARTING

PROCEDURE

3 4 5 6

OFF

6

0


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2.4 Moving the machine forward and backwards

The forward / reverse movement of the

machine is controlled with the hand control

lever at the end of the Steering Handle (1)

Pushing the lever UP will make the machine

move FORWARD, pushing it DOWN will make

the machine move BACKWARDS – the further

the lever is pushed, the faster the machine will

move in the desired direction

When changing direction, do this in a SLOW

movement of the lever to allow the machine to

change direction SMOOTHLY – never go from

fully forward into fully reverse!

The Control Lever is designed as a ‘Dead Man’s Handle’ –

it will automatically return into its NEUTRAL position as soon

as the operator lets go of the Lever, and the machine will automatically

come to an immediate stop.

2.5 Switching the vibration ON and OFF

The vibration is switched ON and OFF with the vibration control lever (2) above

(which is part of a hydraulic valve)

Pushing the lever FORWARD will switch the vibration ON, moving it BACKWARDS

will switch the vibration OFF – do not attempt to operate the machine with the lever

positioned in an in-between position

When the machine is cold in the morning, it is good practice to ‘feed in’ the Vibration

slowly a couple of times, by moving the vibration control lever gradually into the ON

position – this will ease the load on the engine

1

2


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3. Tips for getting best compaction results

3.1 General Hints and Tips for the operator

To get good compaction results, you always need to run the machine SLOWLY – Halving the speed of the machine will give you more than double the Compaction Performance!

o When operating with Vibration ‘ON’, always drive machine SLOWLY – this means less than half of normal walking speed

o Reduction of the speed of the machine is particularly important when thick

layers or difficult materials are compacted

o You may increase the speed of the machine slightly for the last 1 or 2

passes

o On certain materials (eg. sands) it is good practice to do the last 1 – 2

passes with the vibration switched OFF

Always do compaction work, following a method - in terms of rolling speed and

number of passes

Once the specified number of passes are done, stop rolling work on the current

section and move on to the next section – over compaction is detrimental to the

compaction effort and the machine

Always ensure that the material to be compacted is at or near its Optimum

Moisture Content – not too dry and not too wet

+++ Dry or wet materials cannot be compacted effectively +++

Always overlap the machine about 10% to the previously compacted pass

When compacting black-top materials (asphalt) switch the Water Sprinkling

System ON to avoid material sticking to the drums

Never run machine with vibration ON over hard materials, (e.g. concrete, hard

asphalt, etc.) – for travelling longer distances always switch Vibration OFF and

do not exceed normal walking speed

When working inside narrow Trenches, always start the engine before lifting the

Roller into the trench (trench walls will make it difficult to start the engine, in

particular machines with crank start system)


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3.2 Layer thickness / number of passes guide

As a rule-of-thumb for normal layers (5 – 10cm) of material to be compacted allow the following number of passes, depending on weight class of the Roller:

Roller weight 600 – 750kg : 5 – 6 passes

Roller weight 750 – 950kg : 4 – 5 passes at approx. ‘half walking speed’ Roller weight >950kg : 3 – 4 passes

Increase number of passes for thicker layers or for difficult materials For further guidance on specific materials, please refer to the annex. ‘Machine Application / Selection Guide’ at the back of this Manual.

3.3 Working on slopes and near embankments that can collapse

Always operate machine UP and DOWN slopes or hills – never from side to side

Always work your Roller TOWARDS the edge of the embankment – with the operator out

of the danger zone; see below

max. max.


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4. Daily Maintenance checks / actions

The listing below shows the routine Daily Maintenance items, which may be performed by

the operator

Clean the machine, in particular any build-up of soil in the area of the Scrapers

Refuel the machine – preferably this is done at the end of the shift to avoid entry of

water into the fuel tank due to overnight condensation

Check the engine oil level – must be between the MIN and MAX marks of the

dipstick, when machine is parked on level ground

Check the hydraulic oil level at the sight glass on the hydraulic tank – must be

at least ¾ full when machine is cold

Check the Airfilter element, and clean as required – handle and re-install with

absolute care!

Check for any loose bolts or nuts, oil leaks and any unusual noises – report any

unusual findings to Foreman

Every week: check Water Trap (if fitted) and drain water sediment, as required

“CLEAN MACHINES ALWAYS WORK BETTER”


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1. Servicing – General, and Servicing the Roller

1.1 General

Due to the inherent nature of danger during the servicing / adjustments to Construction

machinery, all servicing should be performed by suitably qualified persons only, and with

the use of suitable tools and in appropriate locations with required facilities.

Should specific details or advice be required, this should be obtained from STAMPEDE’s

Service Centre personnel.

Service items and spare parts should always be obtained from STAMPEDE, where they

are guaranteed for consistent quality and fitness for purpose.

1.2 Roller Servicing Schedule

The following table lists all regular Service / Routine Adjustment items that need to be

performed at the specified intervals and with the specified servicing consumables

Item #

Service item Service Interval

Service Consumable

Quantity / Spec.

1 Change of oil in the Vibrator Assy. 6 months Engine Oil *) SAE15W40

See table below

2 A Hydraulic oil change 12 months Hydraulic Oil *) grade 68-ISO

See table below

2 B Replacement of return line Hydraulic Filter Cartridge (top of hydraulic tank)

12 months Part No. CRO91 1

3 Replacement of Breather on Hydraulic tank (top of hydraulic tank)

2 years Part No. TRM-1-14M

1

4 Strainers in the hydraulic tank: a) Cleaning b) Replacement

12 months 2 years

Pt. No. RR0120550121

1 or 2

5 Lubrication of Drive Bearings 3 months EP2 grease 4 nipples 6 Lubrication of Final Drive Gears and

Cleaning thereof / grease replenishing 1 month 6 months

EP2 grease EP2 grease

2 nipples

7 Fine adjustment of neutral position of the Control Cable / Hydr. Pump

when required

8 Check/Adjustment of Scraper Bars 6 months 9 Check and re-set of vibrator frequency

(rpm), if required 6 months

Table of Oil fill quantities in litres

Service compartment Oil Type: PR39 PR60 PR62 PR75 PR90 Vibrator Assembly Oil Engine Oil

15W40 0,1 0,16 0,16 0,2 0,25

Hydraulic Oil Hydraulic Oil 68ISO

23 35 27 45 55

*) All oils must be virgin oils from reputable

manufacturers; recycled oils are not approved


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#1 - Change of oil in the Vibrator Assy.

Park machine slightly tilted to the LH side

Place suitable catching pan

underneath area of the Drain Plug (1)

Open Filler Plug (2) (Allen key)

Open Oil Drain Plug (1) and let all oil run

out into the catch pan – Access to plug is

from below with hex. socket and extension

Replace Drain Plug tightly – check

condition of copper washer

Fill in fresh oil through Filler Plug (2)

using a suitable clean funnel -

for oil type and quantity refer to table above – DO NOT OVER-FILL!

Check condition of Breather (3) and clean if necessary

#2 A/B – Hydraulic oil and Filter change

Open the Hydr. Oil Filter cap by removing

the 3 screws (1) – Lid is spring-loaded!

Drain all the oil through the Drain Plug at

the bottom of the Hydraulic Tank

Lift out Filter Element (2) and replace

with new one (Part # CRO91)

Fill in fresh oil through open filler cap,

- for oil type and quantity refer to table

above

Insert the Filter Element (2) and the spring

(3) and replace filter cap

Check oil level at oil sight glass (4) -

level should be near top of gauge when

correct oil quantity has been filled in

#3 – Replacement of Breather on hydraulic tank

Disconnect return-line hose at filter housing

Remove Filter Body by undoing 2 screws (5)

Screw out the now exposed Breather (6) and

replace with new one (Part # TRM-1-14M)

Re-assemble in reverse order, ensure O-rings

are in good condition and in place

2

2

3

1

3 4

5

6

6

Right-hand side of machine

Left-hand side of machine 1


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#4 – Cleaning / Replacement of hydraulic oil suction strainer/s (located inside Hydraulic Tank –

therefore this job is best done at time of hydraulic oil change, ref. #2 above)

Disconnect return-line hose from filter body

Remove the entire filter housing from hydraulic tank

by undoing 6 screws (1)

Put your hand inside empty tank and unscrew the suction

filter/s by hand inside tank

Clean out the suction element/s in petrol, using compressed

air from inside to outside – or replace if any damage is seen

Check inside of tank for any dirt / debris and remove

Re-install suction filter/s, hand tight

Re-install filter housing and check for tightness

Re-fill tank with Hydraulic Oil, see item #2 above

#5 - Lubrication of Drive Bearings

A - Non-drive side (LH side of machine)

Clean area of the 2 grease nipples (1)

on LH side of lower frame side plate

Apply grease pump nozzle to both

nipples and inject 4 – 5 shots to each

B - Drive side (RH side of machine)

Remove Gear Cover


nipples (2) on outer gears and

inject 4 – 5 shots to each

Replace Gear Cover, make sure Seal is

in good condition

1

1

1

2


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# 6 – Lubrication and

cleaning / replenishing of Final Drive Gears

A - Regular Lubrication

Clean up area of the 2 grease nipples

(1) on the gear cover


nipples and inject 5 – 10 shots to each

Use EP2 Grease (eg. Shell Alvania EP2)

B - Cleaning / replenishing of Final Drive Gears

Remove Gear Cover on RH side

Clean out grease/oil and dust/soil

deposits on inside of Gear Cover

and in the area of the Gears with

Hi-Pressure washer and let dry

Re-apply grease generously to all gears

Use EP2 Grease (eg. Shell Alvania EP2)

Re-install Gear Cover, check condition

of gasket and replace if necessary,

or apply small strip of Silicone to sealing

surfaces

# 7 - Fine adjustment of ‘neutral position’ of the Hydraulic Drive Pump / Control Cable

(only required if the machine is ‘creeping’ when Forw/Rev lever is in neutral)

With the engine switched OFF, check

movement of the Control Cable

Ensure that the Control Cable is moving freely,

if not, service the cable and/or control lever /

rack & pinion area

For adjustment of the ‘neutral position’ of the

pump actuation lever loosen both nuts (1) on

the Control Cable at the mounting bracket

Do adjustment by turning both nuts forward

or backwards until proper ‘neutral position’ is

achieved, then lock both nuts again in this position

Note: only small adjustments are required!

Start engine and check, repeat if necessary

1

1


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# 8 - Adjustment of Scraper Bars

(only when clearance to drums is excessive)

A – Outer Scrapers (front & rear)

Loosen Scraper Holding Bolts (1)

Slide Scraper towards the drum,

leaving a gap of approx. 1mm

(the thickness of a hex saw blade)

Replace Scrapers if worn or bent

Tighten Scraper Holding Bolts

B – Inner Scrapers

Loosen Scrapers by undoing Scraper

Holding Bolts (2) at both Side Plates

Adjust the Scrapers towards the drum,

by turning the edge closer to the drum,

leaving a gap of approx. 1mm

Replace Scrapers if worn or bent

Tighten Scraper Holding Bolts

# 9 - Check and re-set of vibrator frequency (rpm), if required

To perform this test, place machine on a Rubber Test Mat or on soft ground

Start engine and switch vibration ON

Use a ‘Sirometer’ (1) or Strobe Light to check

vibration Frequency of the drums/bottom frame

- it should be 3.500rpm (58Hz) with a tolerance

of +/- 50rpm

If the hydraulic system is in good order, this

should correspond to approx. 2.700rpm on the

HATZ, YANMAR and KOHLER Diesel engines

(under load)

(3.400 – 3.500 rpm on the HONDA petrol engine)

If the Frequency is not to above spec, the engine

revs may need re-adjustment or look for reason

within the machine’s hydraulic system (vibration

circuit) – see Hydraulic Diagram in the Annex.

Section of this Manual

NB: The ‘Sirometer’ test instrument is available from

STAMPEDE and can be used on many other

rev. counting applications

1

2

1

Alternate

position

to hold

Sirometer


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2. Servicing – HATZ engine

The servicing information below is a reproduced extract from the published material of the

engine manufacturer (HATZ), from whom further details can be obtained.

When operating in areas with high dust loading, maintenance intervals should be reduced

(halved), in particular Air Filter servicing/replacement, replacement of Fuel Filter and

change of Engine Oil


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Recommended

for RSA

In view of our local operating

conditions it is good practice

to change Engine Oil and

Filter every 3 months,

irrespective of hours worked

It is good practice to

change Fuel Filter every 6 months,

irrespective of hours worked.

Airfilter servicing / replacement more

frequently, depending on job conditions,

latest every 6 months


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3. Servicing – KOHLER Diesel engine

The servicing information below is an extract from the published material of the engine

manufacturer (Kohler), from whom further details can be obtained. An electronic or hard

copy of the manufacturer’s Manual is also available from STAMPEDE

Daily Checks (usually performed by the machine operator)

Check the engine oil level on the dip stick

Level must be between the MIN and MAX marks,

when machine is parked on level ground

Re-fuel the machine as required, fill up tank preferably at the end of the shift

Check condition of Starter Rope

Routine Maintenance

a) Servicing every 250 hours or every 3 months *)

Change engine oil (SAE 15W40)

Change Engine Oil Filter element

Change Fuel Filter

Change Air Filter element

b) Servicing every 500 hours or at least once a year *)

Adjust Tappet clearance

Detailed inspection of Airfilter assembly, replace any worn/broken/cracked parts

Inspect bottom of fuel tank for any sediments and clean out

Remove Air Shroud and Rope Starter, inspect Cooling Fins on flywheel and cylinder

and clean with compressed air and brush

Inspect Rope Starter Assembly and replace any worn/broken/damaged parts

Check condition and tightness of Engine Mounting rubbers

*) When operating in areas with high dust loading, maintenance intervals should be

reduced (halved), in particular Air Filter servicing/replacement, replacement of Fuel

Filter and change of Engine Oil


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4. Servicing – HONDA engine

The servicing information below is a reproduced extract from the published material of the

engine manufacturer (HONDA), from whom further details can be obtained.


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Recommended

for RSA


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Annex: Hydraulic Diagram

Imp

ort

ant

No

te:

On

all

HO

ND

A-p

ow

ered

mac

hin

es

the

Vib

rati

on

Pu

mp

(it

em 9

) is

a

6cc

/rev

pu

mp

an

d t

he

engi

ne

spee

d

sett

ing

is 3

.450

– 3

.50

0rp

m u

nd

er

load

(h

igh

idle

sp

eed

is 3

.550

rpm

)

Hyd

rau

lic D

iagr

am f

or

sin

gle

-sh

aft

Vib

rato

r sy

stem

s

Ap

plic

able

to

STA

MP

EDE

Ped

estr

ian

Ro

llers

M

od

el P

R3

9, P

R6

0, P

R6

2, P

R7

5, P

R9

0

(cu

rren

t as

per

Jan

uar

y 2

01

7)


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Page

25


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26


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Annex: Layer Thickness / No. of Passes Application Guide


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Notes:

R-SERIES WALK-BEHIND ROLLERSstampede.africa/wp-content/uploads/2018/04/Oper... · 3. Tips for...

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