Op y Mant Xs203j

XCMG Construction Machinery CO., LTD.
Foreword
Thanks for you trust and recognition of XCMG brand and use of XSJ series roller!
Please operate and maintain in strict accordance with Product Operation Instructions to make sure the roller is
under the optimal working status.
The Product Operation Instructions and other attached technical documents are a part of the roller that must
be kept properly within life cycle of the product and used jointly as the necessary basis for using the roller.
We reserve the right of constantly modifying the Operation Instructions with technical improvement. Please
kindly understand that these modifications will not be noticed.
This manual includes:
1 safety manual, 2 operation manual, 3 maintenance and repair, 4 transportation and storage, 5 technical
specification.
This manual will help you
• Understand this machine
• Avoid damage caused by unprofessional operation
Obeying the maintenance instructions will:
• Improve the reliability of machines in the field
• Increase the life of the machine
XCMG do not undertake any responsibility for the safe operation of machine in following cases, where:
• The operation doesn’t comply with the disposition of normal usage pattern
• Beyond a predetermined range
• For the injury and damage caused by force majeure
No compensation will be given in the following cases:
• improper operation
• insufficient maintenance
• misuse of fuel and lubricants
This manual is an important part of the machine. Before operation, maintenance and repair of the machine, it
is important to read the content of this manual carefully and operate as required, especially the safety matters;
Any modification without the manufacturer’s permission can be dangerous!
We reserve the right to make technical changes without prior notice.
You can also get instructions from the manufacturer or dealer on how to use the machine correctly.
XCMG, For Your Success!
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Content
1 Safety manual
1.1 General rules
1.2 Safety Command
1.3 Safety Operation Regulations
1.4 Safety Regulations on Start
1.5 Safety regulations on driving
1.6 Transport safety requirements
1.7 Refueling safety procedures
1.8 Maintenance and repair regulations
2 Operation Manual
2.1 General rules
2.2 Overview and Illustration
2.3 Display, control components graphic chart and function introduction
2.4 Operation rules
3 Maintenance and repair

3.1 General rules
3.2 Service position diagram
3.3 The maintenance interval
3.4 Maintenance Works
3.5 Other Maintenance Description
3.6 Common fault remedies
4 Transport and storage

4.1 Transportation
4.2 Storage
5 Technical specification
XS203JXS203JPD
1 Safety Manual
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1.1 General rules
1.1.1 Safety is absolute important for you！
In order to ensure the machine you acquired from XCMG is safe and reliable and for the sake of your
personal safety and safety of others, the roller is manufactured according to the latest technical standards and
existing technical specifications and rules. However, the most important safety factor is you.
The Safety Manual is used for reminding you possible safety issues in daily use of the machine. Use under
following conditions could endanger personal safety:
• The machine is used for non-designated occasions;
• The machine is operated by authorized personnel never attended professional training;
• The machine is refitted and altered without written authorization of XCMG;
• Requirements of the manual are not observed;
Following rules and regulations are just as valid as requirements in the manual:
• Applicable rules on prevention of accidents;
• Public recognized safety and road traffic rules;
• Local safety rules;
• Local laws and regulations;
The operator has the responsibility of understanding and observing these rules. When those introduced in the
manual are different from laws and regulations of the user country, then laws and regulations of the user country
shall prevail.
1.1.2 Remember!
Requirements for operation of the machine:
• The machine must be operated by authorized operators who shall be at least 18 plus years old and have
attended professional training. Responsibilities related to operation of the machine must be made clear;
• The machine can never be operated, maintained and repaired by any personnel under the effect of
alcohol, drug and stimulant or narcotic;
• Maintenance and repair must be performed by personnel qualified in training as professional knowledge
is required.
Designated purposes
The machine can be used only for:
• Compaction of highway base course and secondary base course;
• Compaction of earthwork base course;
• The machine can be operated when its safety device is complete and valid;
• The machine must be checked by professional service personnel at least once per year.
Non-designated purposes
The machine cannot be used for:
• Vibration operation is not allowed on hard cement pavement, compacted pavement, severely frozen
pavement and all other hard pavements;
• Inflammable and explosive environment;
• Vibration operation is not allowed on hard cement pavement, compacted pavement, severely frozen
pavement and all other hard pavements;
• Surroundings of dangerous buildings.
1.1.3 Particular care should be taken for the contents marked by the safety marks in reading this Manual
Description of safety mark
The safety mark defines important safety information in the manual. When you see such
safety mark, please read carefully information below, observe strictly and inform
surrounding personnel.
Description of safety marks of different grades
Indicate the hazard of high risk level that could lead to death or severe
Danger injury if not avoided.
Indicate the hazard of medium risk level that might lead to death or severe
Warning injury if not avoided.
Caution injury if not avoided.
1.2 Safety Command

1.2.1 Before using rollers, operators must be familiar with the contents of
this manual (Fig.1-1).
1.2.2 Operate in strict accordance with Operation Manual, regulations on
maintenance and repair, and transportation and storage regulation.
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1.2.3 Do not carry passengers during traveling.
1.2.4 Do not maintain or repair the roller during traveling.
1.2.5 Getting on or getting off the roller is allowed only when the roller stops by holding handrail and handle on
the roller. While getting on and getting off the roller. You need to keep contact of your body, hands and feet with
the machine.
1.2.6 Slow down while the roller is turning.
1.2.7 Running across the slope is forbidden. Running upward or downward along the slope is allowed.
Running over a slope beyond the maximum inclination specified for the machine
Warning is not allowed. Getting on and off a slope must be always at slow speed.
1.2.8 While compacting close to roadside or at the depression, make sure at least 2/3 steel drum is running over the
pavement already compacted.
1.2.9 Make sure there are no obstacles in the driving direction, on the pavement or ahead.
1.2.10 Drive with particular care on uneven roads.
1.2.11 Use the provided safety equipment and fasten the safety belt (if equipped)
1.2.12 Keep the roller clean. Remove dirt and oil from the operating platform and steps, and keep instructions and
marks complete and clear.
1.2.13 Safety measures before fueling
• Shut down the engine;
• No smoking;
• Keep away from open fire;
• Place filler pipe at the port of fuel tank for fear of sparks.
1.2.14 Before maintenance and repair
• Use wood wedge block the front and rear drum;
• Make sure that the front and rear frame locking mechanism is in the locking state.
1.2.15 If the roller has no cab, it is recommended to wear ear protectors when the noise is greater than 85 db.
1.2.16 Please do not refit and alter the roller as it could affect its safety. Any refitting and alteration requires written
authorization of XCMG.
1.2.17 Start the machine as per its Operation Manual. To start and drive a cold engine, make its engine idle for
8-10 minutes before start.
Only when the compressed air in the air bag reaches 800kPa can the road roller
Danger start traveling. Otherwise, the malfunction of brake could result in serious
consequence.
1.2.18 The roller cannot be towed unless under instructions of a professional.
1.3 Safety Operation Regulations

1.3.1 Preparations before driving the machine
1.3.1.1 Familiar with all kinds of rules and precautions at work site (Fig.1-2).
1.3.1.2 Carefully read and understand this Manual prior to starting machine or
operating the machine for the first time.
1.3.1.3 The operator cannot drink alcohol and take stimulant or other drugs
when driving the roller or performing pavement compacting operation.
1.3.1.4 Find out the place of fire extinguisher, first-aid equipment and alarm
telephone (Fig.1-3).
1.3.1.5 Use common sense to avoid the accidents. When something unexpected
happens, don’t panic. The first and most important thing is to protect life safety,
followed by avoiding loss of property.
1.3.1.6 For self-safety, must wear personal safety protection (Fig.1-4).
• Helmet
• Working boots with steel header
• Protective goggles
• Reflective clothes
• Work gloves
• Ear protector
• Mask (dust environment)
1.3.2 Machine check
1.3.2.1 Machine is free from damage such as looseness,
rupture or loss of component. In case of any damage, do not
use the roller before repair (place a warning mark on the roller
to prevent use of the damaged machine).
1.3.2.2 Windshield and reflective glass must be clean
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1.3.2.3 Mark and pattern must be clean, complete, clear and distinguishable.
1.3.2.4 All hand or foot control elements, steps, anti-slip device and handle cannot be covered by ice or polluted by
oil or impurities.
1.3.2.5 No tool or other object is placed in operation space of the machine.
1.3.2.6 All kinds of necessary liquids are located at correct level. Fill the liquid when necessary
1.3.2.7 To fill fuel, refer to refueling section.
1.3.2.8 Pay attention to keep away from open flame whiling check oil and liquid level and filling the machine with
oil. Smoking is forbidden!
1.3.2.9 If you find any problem or doubt that the roller is damaged, contact equipment manager, machine owner or
site manager to repair the faulty equipment immediately.
1.3.2.10 It is necessary to keep good ventilation under whatever circumstances. Do not start the machine in a
confined environment and be aware that the engine has the possibility of emitting dangerous smoke. Do not work
at narrow and poorly ventilated underground place.
1.3.2.11 It is necessary to install ventilation facility, water the pavement or wear mask if the pavement material is
likely to cause dust.
1.3.3 Skills of the operator
1.3.3.1 The operator shall accept professional training and be
familiar with the machine, including its control devices, marks
and symbols (Fig.1-5)
1.3.3.2 The operator shall be aware of capacity and limitation of the
roller, including speed limit, lateral inclination limit, brake and
steering limit, etc.
1.3.3.3 The operator must know the location and methods of
emergency parking and avoiding danger.
1.3.4 Personal safety
1.3.4.1 Make sure the roller is free from any mark indicating the machine
cannot be driven or needs to be repaired.
1.3.4.2 Confirm that the machine is not being repaired.
1.3.4.3 Only start the machine from the main control penal.
1.3.4.4 Fasten your seat belt (if configured).
1.3.4.5 It is only allowed to get on and off when the roller stops, and hold the
armrest to get on and off correctly (figure 1-6). Carrying passengers is
forbidden.
1.3.4.6 Do not adjust seat while driving the machine as the seat may
move towards undesired direction. Make sure the seat backrest is fixed
while adjusting it. The operator must sit in the seat while driving the
machine. Make sure the seat backrest is fixed while adjusting it. The
operator must sit in the seat while driving the machine.
1.3.5 Working area
1.3.5.1 Check front and rear, top and bottom of the machine in the
working area and confirm there is no person or obstacle around.
1.3.5.2 Check for crack and depression on the pavement that may
cause damage of the machine (Fig.1-7).
1.3.5.3 Make sure vibration of the roller will not damage surrounding
buildings and equipment. Remember that vibration of the roller will
be transmitted through pavement material by some distance.
1.4 Safety Regulations on Start

1.4.1 Preparation work before stating
1.4.1.1 Make sure the emergency brake works normally.
1.4.1.2 Make sure all control devices work normally.
1.4.1.3 Start the machine as per its Operation Manual. Only when the
compressed air in the air bag reaches 800kPa can the road roller start traveling. Otherwise, the malfunction of
brake could result in serious consequence.
1.4.2 Post-start operation
1.4.2.1 Confirm the normal response of each instrument.
1.4.2.2 Confirm if all control devices respond normally, especially brake control devices.
1.4.2.3 If any problem is found, the engine shall be shut down. Warning signs shall be placed on the machine
when leaving the machine.
1.4.3 Start under low temperature weather
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When low-temperature starting device is used under low temperature weather, operate as per the regulation
provided by its Manufacturer.
1.5 Safety Regulations on Driving

1.5.1 Remember!
• Do not leave the operation positions after the engine is started;
• The doors and windows of the cab should be closed during
driving;
• Drive the roller carefully;
• Always observe the working pavement, especially during
reversing;
• Make sure the roller is in good condition through your
vision, hearing and smell;
• Be aware of the potential risk for inhalation of exhaust emitted
from the roller;
• Slow down while turning, especially during sharp turning;
• Nobody could enter the collision risk area when the engine is
operating(Fig.1-8).
1.5.2 Driving on a slope
Running across the slope is forbidden. Running upward or downward along the slope is allowed(Fig.1-9,
1-10). Do not shift gear on slope and shall drive with low speed. Do not use working mode (vibration operation)
while driving on a slope with large gradient.
1.5.3 Driving
on uneven
roads
• Avoid driving on road edges, trenches or places that could impair the stability of the machine. Please
also be aware that wet and loose soils considerably reduce the adhesion of the roller. Always keep a
sufficient distance when passing through under bridges, tunnels, branches, electric power lines etc
(Fig.1-11).
• Shall use the ROPS and fasten the safety belt (if equipped) when driving on uneven roads.
• In case the machine gets approaching the road edges or hollow holes during compacting the
ground, make sure that 2/3 of the machine drums should be supported by the compacted ground
area.
Running over a slope beyond the maximum inclination specified for the
Warning machine is not allowed. Getting on and off a slope must be always at slow speed.
1.5.4 Drive on public roads

• Read carefully vehicle driving rules of local public roads.
• While driving over public roads, always observe traffic rules; do not exceed the speed allowed in traffic
rules and pay attention to running distance after braking (Figure 1-12).
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• Cross the rails stably and never allow steel drum to touch both tracks at the same time. Also, make sure
not to contact the high-voltage cable on the road. If the obstacle is very close and the roller is trapped,
shall pass through the obstacle instead of staying in the original place.
1.5.5 Shut down the engine
• Stop the engine following the instructions in the manual.
Never stop the engine while the roller is running.
• Remove the key and prohibit unauthorized personnel from
operating the machine.
• It is only allowed to get on and off when the roller stops, and
hold the armrest, step on the foot plate to get on and off
correctly. Never jump off a machine (figure 1-13).
1.6 Transport safety requirements

1.6.1 Personal safety
• When loading/unloading the roller onto/off a transport vehicle,
don’t stand under or around it. Never attempt to move or tow
the machine by hand.
• Shall be aware of the danger of squashing when
loading/unloading the machine.
Be careful of possible dangers when loading and unloading the
Warning rollers!
1.6.2 Transport vehicle

• The truck must accord with the requirements of such transport
vehicles, such as maximum load, engine power, brake
performance, etc.; transportation truck should be especially
dedicated to transport rollers; use a slope for loading /
unloading!
• The best way to move the roller for a longer distance is to use a
trailer.
• The loading and unloading of roller should make use of the
metal inclined plane, which should be in the best condition.
Never use a deteriorated inclined plane. Make sure the slope is
correctly placed between transportation truck and road surface.
Make sure the slope is free of oil, dirt, snow, ice and silt etc.
• Make sure the truck hits the ground, and make sure the drag rod
is underlaid with wood. Attach the chain cable to the roller and
load the winch on the carrier vehicle. Shall use chain and steel wire of right size, do not use thick string.
• Start the winch and pull the roller into the trailer. Turn on the emergency braking on the roller. Ensure
that the roller is safely loaded onto the vehicle in accordance with the operation manual. Make sure all
parts of the roller are not loose.
1.6.3 Loading/Unloading the Machine with a Crane
As for small size rollers, cranes can be used to transport them onto transportation truck. All small rollers are
installed with hoisting holes. Roller’s weight is marked on its nameplate. Operations should follow rollers’ safety
regulations.
1.6.4 Towing
Warning The roller cannot be towed unless under instructions of a professional.
• Never tow the roller with long-distance (greater than 300 meters). Shall obey the traffic rules. Never
travel with the speed that not allowed in the operation manual. Don’t allow anyone sitting on the roller
when towing.(Fig.1-15).
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• For specific towing measures, please carefully read the chapter content of operation manual.
1.7 Refueling Safety Procedures
Take the following safety measures when refueling:
• Shut down the engine;
• No smoking;
• Keep away from open fire;
• Let fuel mouth contact oil tank, avoid to produce sparks;
• Make sure adding the qualified fuel oil to proper position of fuel tank;
• Shall remove the oil residue before starting the machine;
• Tighten the fuel tank cap, to avoid accidents when the fuel flows out.
Don’t fill fuel to the machine in an enclosed are with poor ventilation.
When filling the fuel should be away from flame and hazardous sources that
Warning may cause the risk.
The oil pipe is grounded by locating it on the oil tank neck point, so as to avoid
generating electrical spark.
No smoking! No mobile phones during oil filling!
1.8 Maintenance and repair regulations
Danger Never use damaged or dangerous roller!
• Only trained personnel can repair or maintain the roller.

• Know well the location of fire extinguisher, first-aid box and telephone number used to call the police
before repair the roller(see Fig.1-3).
• Use common sense to avoid the accidents. When something unexpected happens, don’t panic. The first
and most important thing is to protect life safety, followed by avoiding loss of property.
• For self safety, must wear personal safety protections(see Fig.1-4).
• No smoking at work, keep away from the flame. For welding operation, refer to 1.8.1 preparation before
maintenance and repair.
1.8.1 Preparatory work before maintenance and repair
• Stick a mark to the roller to indicate the roller is under repair. Shut off the electricity, and take away the
switch key(Fig.1-16).
• Keep front and rear frame locking mechanism under locking status(Fig.1-17).
• When welding or doing other operation which will produce large amounts of heat or open flames, must
drain the oil tank, and dry it.
• Never weld near a plastic or rubber material, such as a polyurethane scraper. Toxic smoke is produced if
these materials are heated.
• Make sure the battery and power source disconnected before using the electro welding.
• Never use the gasoline (flammables) for cleaning. Seal the unused flammable or harmful materials and
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handle properly. When using hazardous materials on your body shall use a gas mask.
• Shall use upholder to prevent the roller from falling or inclining when lifting the roller. Only jack up
the roller is not allowed(Fig.1-18).
• Do not repair the roller when it is running. One of the
principles is that the hood should be well covered when
the engine is on. Make sure forward/reverse control
handle is in the center and apply emergency brake. When
starting the engine indoors, the additional dust remover
shall be connected to direct the exhaust gas out.
Caution Only XCMG spare parts can be used.
1.8.2 Repair of the engine
Caution Read the engine maintenance manual carefully.
• Shall be careful when the engine is started, if possible, shut it down before repairing.
• Shouldn’t wear loose clothes when repairing the engine.
• Pay attention to the hidden problems mentioned in the engine operation manual.
• Let the engine cooling down before repairing the engine.
1.8.3 Repair of cooling system
Caution Turn off the engine before checking the machine.
Shall let the engine cooling down if possible.

Be especially careful when removing the radiator top cover when the engine
is still hot.
It is a must to wear work gloves, work uniform and goggles and stay with
some distance from the top cover. Do not remove the top cover when the cooling
system still has pressure and be especially careful when adding coolant into the
hot water tank (Figure 1-19).
1.8.4 Repair of the hydraulic system
Caution Regular maintenance of the hydraulic system is very important.
• When the roller works under high oil pressure, minor damage or crack of the rubber hose and at the joint
could result in severe consequence. Please note that the hydraulic pipe is made of rubber that might have
crack after used for some time. The new rubber hose should be provided by XCMG if you are unclear of
its endurance degree. Do not store the rubber hoses for a long time as they are easy-corrosive product !
• Please note that the hydraulic system might have pressure even when the machine stops. Must work
under no pressure.
• When checking the hydraulic system should wear protective
goggles and gloves. Should use paper board to check the
leakage, do not contact directly by hand (Fig.1-20). If the
hydraulic oil permeates into your skin or eyes, should be
treated timely.
• When filling the hydraulic oil, be especially careful to
remove the oil tank cover, forbid smoking or use of open
flame and remove residual oil. No smoking or open flames.
Residual oil should all be removed.
• Make sure pressure stop valve is correctly set. Overpressure
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will result in rupture of rubber hose and consequent injury while under pressure will bring about difficult
control of the roller.
1.8.5 Repair of battery
The battery contains corrosive sulphuric acid. Wear gloves during maintenance to avoid sulfuric acid sticking
to the skin, clothes or machinery. If you have sulfuric acid stuck to your body, remove all contaminated clothing
and quickly rinse your skin with water for at least 15 minutes. If sulfuric acid is splashed in the eyes, flush eyes
with water for at least 15 minutes and then immediately require medical aid. Continue wiping with sponges and
flannel on the way to the doctor.
The gas formed in the battery is explosive and may explode if an open fire
Danger approaches.
Be especially careful while replacing the battery to prevent short circuit of battery terminal. To disconnect the
battery, first disconnect its negative terminal.
When using the charger to recharge, shall disconnect the charger power supply before connecting the charger
and battery cable.
1.8.6 Repair of tire
• Shall repair the tires in the repair office. Repair the tire at tire repair place and replace the tire with
special tools and devices as it is filled with compressed gas (Figure 1-21).
• For inflation pressure of the tire, refer to descriptions in technical specification. Pay attention to that
sunshine and friction could boost tire pressure.
• Do not exhaust by opening the tire deflation valve manually (Figure 1-22) but gradually reduce tire
pressure with air needle.
Warning Regular check of tire wear status is very important.
1.8.7 Operation in cabin

• Check for damage of cab and its connection. Fasten
connecting bolts of cab with an adjustable
wrench on a regular basis (for fastening torque, refer to
maintenance instructions) (Figure 1-5).
• Check working status of seat belt (if
equipped). It should be replaced if damaged or
overdrawn.
1.8.8 Air conditioning system and pressure
vessel
If the roller is installed with air conditioning
system, do not perform welding operation around
the air conditioner or at its inlet. All repair
operations to the system, including replacement
of antifreeze, must be performed in a workshop
with special equipment (Figure 1-24).
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Engine radiator must be filled with antifreeze when the roller is installed with
Warning an air conditioning system.
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2 Operation Manual
2.1 General rules

2.1.1 The roller can be operated by operators who have attended professional training, hold a driving license and
are qualified to operate the roller only.
2.1.2 For the sake of your personal safety, wear personal protective equipment (see figure 1-4) when operating the
machine.
• Helmet
• Working boots with steel header
• Protective goggles
• Reflective clothes
• Work gloves
• Ear protector
• Mask (dust environment)
2.1.3 Carefully read and understand this Manual prior to starting machine or operating the machine for the first
time. The manual should be placed in a place available at any time. If the instruction manual is lost, damaged or
unclear, exchange with new ones immediately.
2.1.4 Understand every part of the roller before driving it, master its working performance, and be familiar with all
operations and operating systems.
2.1.5 Safety is absolute important for you！ Particular care should be taken for the contents marked by the safety
marks in reviewing this Manual
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Indicate the hazard of high risk level that could lead to death or severe injury
Danger if not avoided.
2.2 Overview and Illustration

2.2.1 General introduction (figure 2-1)
Fig.2-1 Machine structure

1 Frame 2 Drum 3 Sticker 4 Control system 5 Scraper plate 6 Cabin 7 Gas circuit system
8 Air conditioning system 9 Electrical system 10 Hydraulic 11 Transmission system 12 Hood 13 Powertrain system
The main features of the machine are hydraulic vibration, power gear shift, power reverse, full hydraulic
articulated steering and maintenance-free battery. Meanwhile, air conditioner and compactness meter can be
equipped according to the requirements of users.
Shanghai China-3 diesel engine, water cooling, turbocharging, large power reserve, low oil consumption, low
noise.
The front inner-cylinder chamber structural drum is simple and robust; dual frequency and dual vibration
function, big static pressure and exciting force enables high working efficiency; special vibration bearing of
international well-known brand has long lifetime and high reliability.
There are two kinds of hydraulic vibration system, one is closed-loop hydraulic system, the other is open-loop
hydraulic system.
The closed-loop hydraulic system, consists of variable piston pump and quantitative piston motor, double
frequency, double amplitude, scientific and reasonable static load and excitation force configuration to ensure
effective compaction of different types of materials and different thicknesses of layers.
Open-loop hydraulic system adopts domestic advanced open double-frequency and double-amplitude
hydraulic system, scientific and reasonable static load and vibration force configuration, to ensure the effective
compaction of different types of materials, different thickness of the layer.
The transmission device of the machine is composed of three-gear electrically controlled gearbox and rear
axle, which can realize the forward and backward three-speed control. The drive axle has the automatic differential
function, which can automatically realize the torque distribution according to the road condition, ensuring the high
mobility and climbing performance of the machine.
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Full-hydraulic steering system improves the steering operation convenience and flexibility.
The machine adopts articulated beam frame, which is convenient for maintenance;
The electrical system of the machine mainly includes starting, generator system, control system, lighting
system and instrument signal system. It is easy to operate and observe. The audible and visual alarm device on the
dashboard provides maintenance and repair information, preventing equipment from damage and shorten the
downtime.
Based on the ergonomic design concept, all kinds of instruments, indicators and operation buttons are
integrated on the adjustable dashboard of the control box, and the throttle lever and the propel lever are placed at
right side to improve the comfort of operation.
The cabin with three-stage damping and air conditioning has good sealing performance, large internal space,
large area of glass and wide visibility, providing comfortable and safe working conditions for operators.
2.2.2 Overview of components
2.2.2.1 Front/rear frame
Front frame (Fig.2-2) connects the front wheel and acts as an important part for compaction. First
removed the connecting bolt at the front beam, which can be
separated from the frame, then remove the connecting bolt
of front wheel, the front wheel is separated from the frame
and can roll out from the front. The weight of the front
frame of the XSJ series roller is about 1/3 of the total weight
of the machine.
At the left and right side of the end of rear frame
(Fig. 2-3) are respectively the storage battery box, diesel
tank, the middle part is welded with drive axle installation
plate, the front hinged plate is welded with joint plate, diesel
engine mounting plate, steering cylinder plate, cabin
mounting plate, etc.
Front and rear frame (Fig. 2-4) is connected by
hinged mechanism. The articulated mechanism acts as the
articulation steering and frame swing function. Articulated
steering is used to achieve small turning radius.
2.2.2.2 Front wheel

Front wheel (Fig. 2-5) is not only the walking
wheel, but also the main working device of the roller.
The shock absorber seat is connected with the
front frame. The right side is connected by splines to
transfer the torque of the vibration motor to the left
and right exciters.
The left and right exciters are connected
and supported on the amplitude plate through the
drive shaft. The left and right vibration chamber is
filled with a certain capacity of gear oil, when the
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front drum is moving, gear oil is dripping along the inwall from top to bottom, thus to lubricate the bearing.
Another form of front drum is padfoot drum (figure 2-6), also known as PD drum. The drum above
mentioned is also called smooth drum. Padfoot drum, as the name implies, means welding padfoot in a certain
order on the surface of the smooth drum. Normally 10 rows of 150 padfoots. Padfoot shell segment is also
available, realizing double application for one machine.
The padfoot drum also can be used for rolling, impacting and mixing of soil, crushing and compaction of
the cohesive soil.
2.2.2.3 Rear wheel
Rear drum is driven by tires, mainly composed of tire, rim and driving axle (Fig.2-7).
Wide base tires with wavy pattern and plum flower pattern are used for different road surface (wavy pattern
has bigger adhesion force, plum blossom pattern has shallow indentation).
The drive axle is equipped with automatic differential function and
wide base tire to ensure that the
roller has good driving
performance and higher
climbing ability.
2.2.2.4 Power system (figure

2-8)
The engine is powered
by Shangchai diesel engine,
which attenuates the
vibration of the engine
through a shock absorber, mainly including the following
subsystems:
• Power output
The power of the engine is transferred to the driving
tire by the clutch separating the bearing to the
transmission and other components, and the power is
transferred to the vibration pump and steering pump
through the split-box at the other end.
• Air inlet system
Two-stage filtration is adopted. The rain cap filters
large particles and prevents rain into piping. Air filter
further purifies the air for engine.
Compared with natural air intake engine,
turbocharged engine has larger air inflow, also higher
power.
• Fuel system
Diesel stored in the diesel tank can support
one-workday operation.
• Exhaust system
The acoustic attenuation of muffler is higher than 20db.
• Cooling system
Water radiator is used for cooling the engine body, under hydraulic
oil cooler there is a tank for cooling cycled engine oil. Suction type fan is
used.
• Starting and electric system
Voltage of starter is 24V, voltage of generator is 28v.
2.2.2.5 Hydraulic system
Hydraulic diagram is as follows (figure 2-9)
• Hydraulic vibration system
Closed-loop hydraulic vibration system consists mainly hydraulic
pump (Fig. 2-10a) and hydraulic motor(Fig. 2-11a). Hydraulic pump outlet
oil flow can be adjusted, through the double displacement output, so as to
achieve the hydraulic motor output shaft of different speeds, namely double
frequency. The forward/reverse output of the motor can be achieved by
adjustment, and the eccentric moments of the left and right exciters of the front
17
wheels are different, which leads to different vibration amplitude of the front wheels, namely, double amplitude.
Dual vibration frequencies and amplitudes allow the machine to deliver excellent performance during the
compaction of different materials and layer thicknesses.
• Hydraulic steering system
Use the open type hydraulic system consisting of gear pump, full hydraulic steering unit and steering
cylinder. The steering operation is convenient and flexible.
2.2.2.6 Operating system
The instrument box (Fig. 2-12) integrates such elements as steering
wheel, indicators, meters, switches. It is artistic and practical.
The control box is located on the right side of the seat for easy
operation.
Hand brake flexible shaft is arranged between seat and operation
panel, so that limited space is maximally used.
2.2.2.7 Brake device
Brake device include hand brake and foot brake. For
foot brake, see air circuit system.
Hand brake adopts hub brake (figure 2-13), which is
installed on the output shaft of transmission box. Its control
handle is located in the middle of control box and driver’s
seat. It is designed to provide parking brake for road roller,
avoid unexpected accidents and ensure safety of person and
machine.
2.2.2.8 Cab (figure 2-14)
Large glass is equipped in the cab. Clear sight is available
from all angles.
Comfortable feeling due to big operation space.
Anti-vibration pad is installed between the driver’s cabin
and car frame, so as to reduce the impact of vibration on the operator and
improve the driving comfort.
Air conditioner prevents dust into the cab, good sealing effect.
Sound insulation function reduces noise hazards.
2.2.2.9 Air conditioning system (Optional)
Adopt horizontal air conditioner (cold and warm); the warm wind is
generated through the cycling water of engine. The evaporator of air
conditioner is installed under the seat. The condenser is set up in front of the
water radiator. The compressor is connected to the V shaped groove of the
front end of engine (fan end) via belt.
2.2.2.10 Electrical system
Electrical principle diagram is shown in the following page (Fig. 2-15)
The electrical system supplies power to the whole machine, including the starting circuit, power circuit,
stopping circuit, working status indication of key components, fault warning systems, etc. Sound and light warning
indicators on the instrument panel provide instant information on service and maintenance, preventing the machine
from working with fault and avoid disastrous damages for minimum on-site downtime.
2.2.2.11 Gas circuit system
Air circuit system is an auxiliary unit to facilitate the operation of clutch and braking. Air compressor 2
stores the compressed air in the air bag 1 and outputs it through two channels: one is to clutch boosting system; the
other is to foot brake system. （Figure2-9） (Fig. 2-16)
1. Clutch servo system
Clutch booster system
is a kind of oil-push-gas
booster system, in the
absence of compressed air,
press the clutch pedal, the
clutch can still be removed,
but will be very strenuous.
2. Foot brake system
Foot brake adopts
clamp disc brake and is
mounted on drive axle. This
power system is a kind of
booster system combining
18
gas-over-oil mode.
Adjustment and precautions:
A. Air reservoir
Open the drainage valve at the bottom of the air reservoir after usage, drain the water from the reservoir
before closing the drainage valve.
B. Air exhaust operation
When the pipe of oil pressure system is damaged or dismantled, air in the oil circuit system must be
discharged Two persons should work together to discharge the air. One adds brake fluid to the oil cup and step the
pedal repeatedly to charge the oil circuit system with brake fluid; the other person performs the air exhaust as per
the following procedures (start the engine and enable the air compressor, the pressure gauge should reach over
600kPa)
Discharge the clutch servo system: step on the pedal 7 repeatedly to charge the oil circuit and add brake fluid
to the oil cup 4 continuously, which connects to main clutch cylinder 6; Open the vent plug of clutch servo cylinder
5; step on the pedal to discharge the air and then tighten the vent plug. Repeat the above procedures until there is
no air bubble.
(2) Air bleeding of brake system: Step on the pedal 8 to connect the air circuit, add brake oil to the oil cup 4
that is connected to the brake booster cylinder 9 frequently. Remove brake fluid on the brake caliper gently, tighten
the screw plug while step on the pedal to discharge the oil and gas; Repeat the action until there is no more air
bubble.
2.2.2.12 Covering parts
Covering parts include rear engine hood, scraper, etc.
The rear hood is made of thin sheet casting for weight reduction purpose and supported by the linear driver.
High lifting power and simple operation.
Two kinds of scraper plates for use of smooth drum and padfoot drum.
2.2.3 Application and range of use
• Compaction of highway base course and secondary base course;
• Compaction of earthwork base course.
19
20
21
22
23
24
25
26
27
2.2.4 Safety sign and auxiliary sign
2.2.4.1 Distribution schematic of safety signs an auxiliary signs (Fig. 2-17)
Figure 2-17 Mark installation position diagram
28
2.2.4.2 Description of safety and auxiliary signs (Fig. 2-1)
Table 2-1
No. Graphic Name Description
Check the amount of brake fluid and clutch fluid

1 Brake oil level alarm
to make sure the liquid level is in the right range
This is the power main switch socket, when

Main disconnect starting the whole machine, you need to use the
2
switch power switch key to connect the power supply
from this place
3 Nameplate Identify the main parameters of the machine
This is the hydraulic oil feeding port, if

4 Diesel filling port
necessary; add hydraulic oil through this port.
This is the lifting hole of the road roller. It is

5 Lifting place sign
used for lifting the complete machine.
Check the tire pressure regularly to reach the

6 Tyre pressure
marked value.
7 Model mark Model mark of roller
Lubricating grease This is the filler for grease, add in grease

8
filler sign according to maintenance requirement.
29
Drain the water from air tank regularly to ensure
9 Water discharging
the safety of braking.
Safety sign Danger of squeezing when the hinge

Danger sign in
10 connection of front/rear frame is reversing!
impact zone
Keep off!
11 Trademark XCMG(Xuzhou Construction Machinery Group)
Hydraulic oil filling This is the hydraulic oil feeding port, if

12
mark necessary; add hydraulic oil through this port.
Maintenance layout Identify the location and maintenance cycle of

13
plan the whole machine
Cold water drainage

14 Indicating low temperature water drainage
mark
2.2.4.3 Requirements for sign protection

• Keep decals clear; clean it with clean fabric strip and soap water when necessary; don’t use detergent or
gasoline.
• The sign must be free from damage or loss. In case of loss, damage or unclear graphics, should be
exchanged in time.
• Safety signs are more important. They should be checked daily.
30
2.3 Display, control components graphic chart and function introduction
2.3.1 Display, control components graphic chart
Instrument box component (figure 2-18), control box component (figure 2-19) and switch components in cab
(figure 2-20)
Table 2-18 Table 2-19
Table 2-2
Front
1 9 washer
switch
Combination instrument
2 Rocker switch combination 10 Front wiper switch
3 Key switch 11 Rear washer switch
4 Throttle control knob 12 Rear wiper switch
5 Gear control lever 13 Radio-cassette player
6 Combination switch 14 Ceiling lamp
7 Main disconnect switch 15 Machine control box
8 Rotary alarm light switch
31
2.3.2 Instrument box control panel function introduction
Table 2-3
No. Name Symbol Function
Instrument display and warning (see the 2.3.2.1

1 Combination instrument
combination instrument function description)
Rocker switch
2
combination
Switch on power supply of the whole machine,
Horn button
press the horn button.
Press the switch, background light of instrument and
Instrument lamp switch
rocker switch are on.
Three-gear switch Up is high amplitude, down
Amplitude selective
is low amplitude, middle position is stopping
switch
vibration
Vibration switch Press to switch vibration/no vibration operation.
Three-gear switch（automatic reset). Lift/lower the

Hood lifting switch
rear hood, rising and falling.
Insert the key and turn clockwise, I position connect

3 Key switch the whole power supply, II position is starting. Turn
the key anti-clockwise, the engine stops.
Change the engine throttle, turn from left to right to

4 Throttle control knob
increase the throttle.
Place the joystick in the neutral position, roller

stops. Different speeds can be obtained when the
5 Gear control lever lever is operated as indicated (see 2.3.2.2 manual
transmission instructions and fault diagnosis for
details).
Control the steering lights and work lights of cabin

6 Combination switch
(see 2.3.2.3 operation of combination switch)
7 Main disconnect switch To turn on/off the battery power supply
Rotary alarm light

8 Turn on/off the rotating lamp.
switch
9 Front washer switch Spray water to front glass
10 Front wiper switch Control the front windscreen wiper
11 Rear washer switch Spray water to rear glass
32
12 Rear wiper switch Control the rear windscreen wiper
13 Radio-cassette player Radio-cassette player operation interface.
14 Ceiling lamp Internal lighting in the cab.
15 Machine control box Integrated vehicle circuit fuse and relay circuit.
2.3.2.1 Combination instrument function description
Table 2-4
No. Name Symbols Function
1 Voltage display Display the voltage of the machine
2 Primary engine failure In case of primary fault alarm given by the engine, should
alarm light stop the machine for inspection.
3 This lamp is on, indicating that the engine lubricating oil

Low engine oil pressure
pressure is too low, shall stop the machine and inspect.
4 The light is on, indicating that the air filter is clogged,

Air filter clog alarm
immediately stop the machine for inspection.
33
5 Engine oil compaction

Display the engine oil pressure value.
indicator
6 This lamp flashes when the combination switch is turned

Left steering
up (optional).
7 Display engine speed, white area is safe area, red area is

Tachometer rpm×100
alarm area.
8 This lamp flashes when the combination switch is turned

Right steering
down (optional).
9 Water-thermometer Display the engine water temperature.
10 Always press the function switch button for 5 seconds.

Buzzer shield
The light is on to shield the alarm sound.
When the diesel engine is running, this lamp is on,

11 Charge indication indicating that the engine does not generating electricity,
shall stop the machine and inspect.
Water level warning of oil-water separator, indicating that
12 Oil –water separator
excess moisture in the oil-water separator needs to be
warning light
drained.
13 Oil level gage Display the diesel level of fuel tank
14 When the engine DM1 signal is in position 1, the engine

Engine start wait alarm
start waiting alarm light lights up. Check the engine.
15 Gearbox oil filter clog This light is on, indicating that the gearbox oil filter is
alarm blocked. Stop immediately for inspection.
When the ambient temperature is low, the engine will

16 Preheating automatically turn on the preheating switch and the
indicator light will be on.
17 This lamp is on, indicating that the engine water is too hot,
Water temperature alarm
18 When the water level of the tank is low, this light flashes
Low water level alarm
(optional).
19 Neutral gear alarm light Control lever is in the neutral gear stroke.
20 Centralized lubrication
This car does not have this function.
alarm
34
Engine running time is displayed in the upper right corner

of the display (engine speed is bigger than 100rpm,
calculation starts); For the display area of the central
meter, it can be switched through the functional display
21 Display button. According to needs, the air pressure value of the
airbag, battery voltage value, fuel oil level value and time
can be displayed. When switching to the transmission oil
temperature, transmission box oil pressure, engine oil
pressure, "----” is displayed.
22 Function display switch Press this button to switch machine parameters in the LED
button screen.
23 The light is on, indicating that the hydraulic oil filter has
Hydraulic filter element
problems, stop immediately for inspection.
24 This lamp is on, indicating that the hydraulic oil is too hot,
Hydraulic oil temperature
25 This lamp is on, indicating the vehicle is in service brake

Service brake alarm light
state.
26 This lamp is on, indicating that the air pressure of the air
Low air pressure alarm
bag is too low, shall stop the machine and inspect.
27 When the fuel level is lower than 1/8, the alarm light will
Fuel low level alarm
be on.
28 It indicates the vehicle is in parking state if this lamp is

Parking brake
on.
29 Engine middle level fault In case of intermediate fault alarm given by the engine,
alarm should stop the machine for inspection.
30 In case of highest fault alarm given by the engine, should

Engine stop alarm light
stop the machine for inspection.
During welding operation must disconnect the positive and negative electrode
Warning simultaneously, otherwise will cause serious damage to the combination
instrument.
35
2.3.2.2 Lever transmission instructions and fault diagnosis
2.3.2.2.1 Operating instruction

(1) Confirm the wiring is correct.
(2) 24V power supply, system initialization buzzer rings shortly, digital tube display 00, neutral gear
outputs 24V
(3) Step the clutch (input 24V or floating) and the clutch indicator light will be on.
(4) Step on clutch, put the lever in forward/backward position, press the button of increase/decrease gear,
shift gear is effective, the buzzer beeps shortly when the gear shift is successful. During gear shift, the
output signal of solenoid valve M1, M2, M3 and M4 is 0V. The selected gear position is displayed in the
digital tube.
(5) Release clutch and indicator light goes out. Any selected position takes effect, the output of the
corresponding digital tube will be as follows:
1) F1 Forward gear 1: solenoid valve M1, M2, M3, M4 output signals;
2) F2 Forward gear 2: solenoid valve M1, M3, M4 output signals;
3) F3 Forward gear 3: solenoid valve M1, M3 output signals;
4) Neutral gear: neutral signal output; Solenoid valve M1, M2, M3, M4 output 0V.
5) R1 Reverse gear 1: solenoid valve M2, M3, M4 signal output; Reverse gear outputs signal;
6) R2 Reverse gear 2: solenoid valve M3, M4 output signal; Reverse gear outputs signal;
7) R3 Reverse gear 3: solenoid valve M3 outputs signal; Reverse gear outputs signal;
(6) When the lever is latched in the neutral position, the gear will automatically change into neutral
position, without clutch operation, and take effect immediately. The output signal is 0V from solenoid
valve M1, M2, M3 and M4.
(7) When the system is in a gear output, if the braking signal input is effective and the gear display remains
unchanged, the gearshift controller of the handle performs the neutral signal output; When the brake
36
signal input fails, the gear output of the gearshift controller will automatically recover.
2.3.2.2.2 Fault diagnosis

In case of abnormal operation of the system, the engine must be shut down and the following steps shall be
followed to eliminate possible faults. The display priority of fault code is E4 → -8 from high to low:
(1) After the lever controller is powered on, the Nixie tube displays 00, indicating that the system is normally
powered, otherwise, the system power supply is abnormal.
(2) Press and hold the +/- gear button at the same time for 5S, the nixie tube displays EE (press the +/- gear
button at the same time), and the buzzer rings, indicating that the +/- gear button is effective and enters the
diagnosis mode.
(3) After EE is displayed (keep the +/- gear button pressed at the same time), the clutch is pressed/released, the
brake is pressed / released, the handle is pushed forward, the handle is pulled back, and then the handle is
returned to the middle position. At this time, the +/- gear button is released. If the nixie tube displays 00, it
indicates that there is no following fault. If the following code is displayed, it indicates that the system has
faults. The meaning of the fault code is as follows:
Fault code Implication Possible fault

1. Break of conductor between brake and controller
E4 Invalid input of brake 2. Brake failure
3. Brake input point failure of lever controller

1. Invalid clutch input between clutch and controller
E3 Invalid clutch input 2. Clutch failure
3. Clutch input point failure of lever controller

1. Poor contact between lever and controller, loose/fall
off
E1 Invalid entry of forward gear
2. Hall component is damaged
3. Failure of forward input point of lever controller

1. Poor contact between lever and controller, loose/fall
off
E2 Invalid entry of reverse gear
2. Hall component is damaged
3. Failure of forward input point of lever controller

Short-cut of solenoid valve M1 Short circuit between solenoid valve M1 and direct
E5
conductor of controller
Short-cut of solenoid valve M2 Direct conductor short circuit between solenoid valve M2
E6
and controller
E7
and controller
E8
and controller
Open circuit of solenoid valve M1 Direct conductor break between solenoid valve M1 and
-5
controller
-6
controller
-7
controller
-8
controller
Warning Entering diagnostic mode while the engine is running is likely to cause danger.
37
2.3.2.3 Combination switch operation instruction
Combination switch control the on and off of work light,
and is divided in to four gears, gear 0, gear 1, gear 2 and gear 3,
when select the gear 0, the work lights of roller are not work;
gear 1, only the front headlamp works; gear 2, the front and
rear headlamp works together; gear 3, only the rear headlight
works; at the meanwhile, the combination switch can control
steering light, when the combination switch is turned upward, the
left steering light is on; when it is turned downward, the right
steering light is on.
2.4 Operation rules

This section describes the starting, operation, stop and the
proper procedures before starting and after stop and the safety precautions. It also contains the measures to prevent
and remove dangers while working in a dangerous area and special issues that should be taken into consideration
while working in special circumstances etc.
2.4.1 Preparation work before stating
Before starting the engine, please make sure that every preparation work has been in place.
2.4.1.1 Operator’s preparation
• You have passed professional training and with a driving license;
• Not under impact of alcohol, drug, cordial or narcotic drug;
• Familiar with surrounding of job site, working conditions and work object;
• Familiar with all kinds of rules and precautions at work site.
• Have read carefully the Operation Manual and master operation regulations;
• Personnel protective devices have been worn;
• The place where the fire extinguisher and first aid bag are placed is found out;
• No smoking;
• Operators are requested to inspect the machine personally and confirm the safety.
2.4.1.2 Site inspection and preparation
• Check whether the site is suitable for roller working, avoid operation on damaged pavement;
• Whether the pavement layer material, thickness, hardness meet the construction technology
requirements;
• Check if there are people or obstacles before and after the machine, to ensure construction safety.
While the roller is working, keep away from civil buildings. For operations
with high amplitude, the exiting force has large effect over buildings within
Warning the scope of 50m; for operations with low amplitude, the exiting force has
large effect over buildings within the scope of 30m.
38
2.4.1.3 Machine check and preparation
• No damaged parts;
• Each fastener is not loose;
• No oil leakage, water leakage or gas leakage exists;
• Tyre pressure gauge is normal;
• Lamps, rearview mirrors, cab glasses without damage, dirt;
• All parts are lubricated (for lubricating oil/grease used for the machine, refer to Table 3-1);
• Hydraulic oil level, fuel level, brake fluid and cooling water level are proper (for oils used for the
machine, refer to Table 3-1);
• The safety warning signs are complete and clear;
• Armrest, ladder is reliable, and no oil pollution;
• Front and rear frame locking mechanism in separate state
(Fig.2-24).
2.4.1.4 Getting on/off the cab and inspecting/preparing the interior of
cab
• Open the cabin door, step on the stair and get on/off the
cabin by holding the handrail;
• When getting on/off the machine, please face the machine,
hold the handrail, step on the stair and keep three contact points
with the machine (two feet, one hand or two hands one foot)
(figure 2-25);
Getting on and getting off the roller

Danger while it is running is forbidden.
• Adjust the position of seat (figure 2-26), meter box angle(Fig.2-27) for a comfort drive;
Adjust the seat as follows:
(1) Front and back adjustment: operate front and back adjustment handle to move the seat back and forth to a
proper position;
(2) Backrest adjustment: operate backrest adjustment lever to make the backrest have a proper angle;
(3) Height adjustment: directly lift the seat so that its height is adjusted to the appropriate height.
It is not allowed to adjust the seat
Warning while driving the road roller.
Regulate angle adjustment lever, operate the instrument box in the proper angle for better steering wheel
operation and gauge observation.
• Check if the rear mirror can provide a clear visibility;
• Check if the instrument is eligible;
• Turn on the main power switch(Fig.2-28), insert the
key and turn clockwise to connect the complete machine.
• Check the quality of electricity of power supply;
• Check the reading of fuel oil gauge;
• Observe if all the alarm lights are in order;
• Check if the switch components in cab are in order.
2.4.2 Start the engine
39
Only after good preparation, can start the engine.
(1) Shift control lever shall be in the neutral position, otherwise the
engine cannot be started. 2. The throttle control lever in the low speed position; 3.
Amplitude selector switch should be in neutral position. Make sure the hand brake is
in brake position (Fig. 2-29).
(2) Turn on the main disconnect switch, insert the key and turn clockwise to
connect the complete machine.
(3) Check that all the instruments are normal. Press the starting button to start
the engine.
The starting time should not exceed 15 seconds, if need second start, the
interval time should not be less than 2 minutes.
(4) Engine idle speed (700 ~ 1000 RPM) running for about 3 ~ 5 minutes, if
the environment temperature is low, extend the idling time.
Engine used fluids refer to the following table.
Refer to the Operation and Maintenance Manual for specific methods and
precautions for starting the engine.
2.4.3 Motion of the roller
Make sure there is no person or obstacle surrounding the road roller; honk to
give a warning.
(1) Push forward throttle control handle to accelerate, let engine run at rating
speed (1800rpm);
(2) Rotate steering wheel to right and left; check if the steering mechanism
can work normally;
When the road roller is working, any person in the steering hinge area
Danger (impact zone at the two sides) is prohibited (figure 2-30)!
(3) Step on the main clutch pedal to disconnect the power. Set the shifting
control lever to the needed speed and driving direction. Press brake handle down
and release the hand brake; slowly release the pedal of main clutch pedal to let
the road roller take off, at the same time, slightly step on the foot brake pedal to
check if it is in good order.
Shift I is designed for operation of road roller, shift III is designed to move from
work site to work site.
Only when the compressed air in the air bag reaches 800kPa can the road
Danger roller start traveling. Otherwise, the malfunction of brake could result in
serious consequence.
When selecting the speed, it is not allowed to apply the shift 3 (the highest
Warning speed) from stop to the take off. The speed must be shifted from shit 1 to shit 2
and then shit 3.
(4) For reverse driving, place the shift control lever to the required gear, make sure
there is no people or other obstacle material behind the machine, the buzzer will make a
sound as configuration(Fig.2-31).
When reversing the road roller, operators should observe the circumstance in
the rear direction and work on it at low speed.
Warning Confirm the site satisfies the minimum turning diameter (13m) before turning
and slow down.
(5) In case steering required, turn on the steering light and make sure no person or obstacle in the rear
direction before reversing.
(6) Traveling on the slope (figure 2-32)
Theoretical grade ability of this road roller series is 30% (α≈16.7°), and slope in actual construction is
generally ≤20% (α≈11.3°), so it is very important for operator to correctly operate the road roller while going up
and down the slope.
40
Fig. 2-32
While traveling on the slope, it is only allowed to climb up or go down the slope
along the direction indicated by the arrow (see figure 2-32). It is not allowed to
Danger drive the road roller crosswise on the slope.
Drive the road roller slowly on slope. No gear shifting! No steering! It is not
allowed to slide out of gear while going down from a slope.
41
2.4.4 Vibration of the roller
As is required by construction process requirements, the road roller always works in a reciprocating way.
(1) Operate the amplitude selection switch, where the lower corresponds to low amplitude, upper high
amplitude.
(2) Turn on the roller vibration switch, the roller will vibrate.
(3) According to the construction process requirements, high and low amplitude vibration operation is
adopted. When the soil density meets the requirements, the vibration switch is closed. After stopping the operation,
the amplitude selection switch is returned to the middle position.
The roller cannot vibrate under non-running status (in situ), or otherwise the
machine could be damaged (the vibration bearing cannot be lubricated in this
case).
To change amplitude, first stop vibration, or otherwise you may damage the
machine.
Amplitude cannot be shifted directly from large (or small) to small (or large),
but has to stay in the neutral for 1-2 minutes.
Warning When performing vibration operation, always observe whether reading
displayed on the instrument is normal and if abnormal, please stop operation
immediately.
It is forbidden to vibrate over hard roads, or otherwise you may damage the
machine.
Gear I is used for operation, gear Ⅱ and Ⅲ are forbidden to be used for
operation.
2.4.5 Braking of the roller
The brake system of this series of road roller includes service braking, parking brake and secondary braking.
(1) Service brake
Normally, on a straight road, the roller can be brought to a slow stop by resetting the gear shift lever and then
gently step the brake pedal.
(2) Parking brake
After the roller stops, adjust the throttle to idle speed, make the engine run at idle speed for about 3~5
minutes, pull up the flameout cable to make the engine flameout. Turn the key switch anticlockwise to disconnect
the power supply of the complete machine. Pull up the hand brake; disconnect the power supply of battery.
(3) Service emergency braking
In a dangerous situation, when the emergency brake is needed when driving, the main clutch pedal must be
pressed first to cut off the power, and the brake pedal must be quickly pressed down to make the roller stop
immediately. After stopping, reset the shift control handle in time.
2.4.6 Parking of roller
(1) When the road roller finishes working, park it on smooth road surface with stopping braking. If it needs to
park it on the slope, please block its front and rear wheels with wooden wedge to prevent wheels from moving(Fig.
2-33).
(2) Make sure the rear engine hood has been lowered.
Lifting/lowering operation of the rear hood: switch on the
power supply of the whole machine, turn the up/down button of
the hood, to lift or lower the rear hood. The hood lifting switch
is three position switch with automatic reset function, release it
after turn up/down to the appropriate location, the hood stops
moving up/down.
When the operator leaves the road roller, please disconnect
the power master switch and key switch and close window and
door of the cab to prevent unknown person from operating the
machine.
(4) To park for a long time, cushion steel drum or wheel
foundation with bolster.
2.4.7 Use of air conditioner(Optional)
Refer to the Operation and Maintenance Manual of Air Conditioners for specific methods and precautions of
using the air conditioner.
The air conditioner switch control the working state of air conditioning system, can realize the cooling and
warming function. The left side knob of air condition switch (Fig. 2-34) control the wind speed, the right side knob
control the temperature, air conditioning evaporator is installed under the seat.
If the cooling system is needed, must close the warm water valve(see Fig.2-35);
Caution otherwise, should open it.
42
Fig. 2-34 air conditioning switch
Fig 2-35 warm water valve position
43
3 Maintenance and Repair
44
3.1 General rules
3.1.1 Maintenance and repair of the roller in strict accordance with regulations are of great importance to prolong
its service life and ensure its normal working.
3.1.2 The roller can be maintained and repaired only by the personnel who has attended professional training and
obtained authorization.
3.1.3 For the sake of your personal safety, wear personal protective equipment (see figure 1-4) when repair or
maintain the machine.
3.1.4 Read carefully and master the manual before its maintenance and repair. The manual should be placed in a
place available at any time. If the instruction manual is lost, damaged or unclear, exchange with new ones
immediately.
3.1.5 Safety is absolute important for you！ Particular care should be taken for the contents marked by the safety
marks in reviewing this Manual
Indicate the hazard of high risk level that could lead to death or severe injury
Danger if not avoided.
3.1.6 Care for the environment! Avoid oil polluting the environment.
3.1.7 Record maintenance and repair of the machine and keep it properly for future reference.
3.1.8 Good ventilation conditions shall be ensured if the engine operations indoor.
3.1.9 The machine shall be kept clean to facilitate finding of such fault as leakage, loose bolt or loose connection.
3.1.10 Impurities on the surface of working area shall be cleaned before every time filling of fluid, checking of oil
level and lubrication.
45
3.2 Service position diagram
3.2.1 Distribution of main maintenance positions (Figure 3-1)
1 Rear hood 16 Mounting bolts of front beam
2 Air conditioning condenser 17 Battery box(left side)

3 Diesel refueling port, oil-water separator 18 Drain plug of diesel
4 Hydraulic oil radiator 19 Air condition compressor
5 Radiator 20 Inflating valve
6 Level of engine oil 21 Drive axle, drive shaft
7 Power box filler 22 Rim joint ball nut
8 Air filter 23 Drain plug of hydraulic oil
9 Rear hood hinge 24 Air reservoir
10 Hydraulic oil filling port 25 Articulation
11 Seat 26 Steering cylinder
12 Brake fluid level 27 Level bolt of front drum
13 Front drum refueling (drain) plug 28 Rubber damping block
14 Vent plug of front drum 29 Scraper plate
15 Mounting bolts of front drum
3.2.2 Oils used for the machine (Table 3-1)

The following is the lubricating oil, hydraulic oil, coolant and fuel used in the machine. Using the same oil or
higher level of oil is recommended, please refer to Chapter 3.5 in case of special environment.
Table 3-1
46
Model and
Name Filling Part Filling Mark
Specification
Drum
XCMG dedicated
Lubricating oil
85W/90 gear oil
Drive axle
XCMG dedicated Engine

Engine oil Summer CF 15W /40
Winter CF 10W /30 Power transmission box
XCMG dedicated
Hydraulic oil Hydraulic system
40-1
0# or -10#(ambient
temperature -10℃～
40℃)
Diesel Diesel tank
-35# (ambient
temperature of -35℃
to -10℃)
XCMG dedicated
Coolant Cooler
-45# antifreeze
Automobile XCMG dedicated

Brake fluid oiler
brake fluid HZY3
Knuckle bearing of steering oil cylinder,

Lubricating Automobile general oil cup at articulated mechanism, frame
grease lithium base bearing of front wheel, splines inside
vibration chamber of front wheel
When the roller is used under extremely high temperature or particularly cold
Caution conditions that require use of special lubricant, it is recommended to contact
contact dealer or After-sales Service Department of XCMG.
When above lubricant requirement is hardly met, please contact dealer or
Caution After-sales Service Department of XCMG.
47
3.2.3 Recommended fastening torque
For the fastening torque of dry bolts fastened with a torque wrench, please refer to Table 3-2 (unless there is
special requirement). Fastening torque of lubricated bolt is generally 90% the recommended value.
Table 3-2
Recommended fastening torque table（N.m）
Performance level 8.8 10.9 12.9
M6 10~12 14~17 17~20
M8 25~30 34~41 41~48
M10 49~59 68~81 81~96
M12 86~103 119~141 141~167
M12×1.25 90~108 124~147 147~174
M14 137~164 189~224 224~265
M14×1.5 149~179 206~243 243~289
Thread
M16 214~256 295~350 350~414
M16×1.5 228~273 314~372 372~441
Specification
M18 294~353 406~481 481~570
M20 417~500 576~683 683~808
M20×1.5 463~555 640~758 758~897
M24 722~864 998~1195 1167~1397
M24×2 785~940 1086~1300 1269~1520
M27 1056~1264 1461~1749 1707~2044
M30 1434~1717 1984~2375 2318~2775
48
3.3Maintenance interval
3.3.1 Daily maintenance (every 10 hours) list
Table 3-2
Maintenance Points Maintenance Works
3 3.4.1.1 Addition of diesel
10 3.4.1.2 Hydraulic oil level check
6 3.4.1.3 Engine oil level check
5 3.4.1.4 Inspect level of coolant
29 3.4.1.5 Regulation on spacing between scrapers
14 3.4.1.6 Vent plug check
12 3.4.1.7 Brake fluid level check
15、16、22、28 3.4.1.8 Check and fasten bolts and nuts
8 3.4.1.9 Dust discharging of air filter
24 3.4.1.10 Air reservoir drainage

3.3.2 Maintenance works within 50 hours after initial operation
Table 3-3
- 3.4.4.9 Replace the machine oil and filter
- 3.4.5.1 Replace diesel oil filter
3 3.4.5.2 replace the water oil separator
- 3.4.5.3 Replacement of hydraulic oil filter
7 3.4.4.6 Replace gearbox lubrication oil and filter element
21 3.4.5.5 Replacement of lubricant on driving axle

3.3.3 Daily maintenance (Every 50 hours) list
Table 3-4
8 3.4.3.1 Check and cleaning works on air filter
25 3.4.3.2 Lubrication on hinge joint structure parts
21、26 3.4.3.3 Lubrication on steering cylinder and drive shaft parts
20 3.4.3.4 Check on pressure within tyres
7 3.4.3.5 Lubrication on separate bearing
7 3.4.4.6 Check on gearbox oil level and lubrication oil level

3.3.4 Monthly maintenance (Every 200 hours)
Table 3-5
13、27 3.4.4.1 Check front drum oil level
49
28 3.4.4.2 Check rubber isolator of front drum
25 3.4.4.3 Check on oil level of driving axle
2、4、5 3.4.4.4 Check and clean radiator

8 3.4.4.5 Check on air intake pipe
12 3.4.4.7 Check braking system
19 3.4.4.8 Air-conditioner maintenance
- 3.4.4.9 Replace the machine oil and filter
- 3.4.4.10 Replace diesel oil filter
5 3.4.4.11 replace the water oil separator
3.3.5 Quarterly maintenance (Every 500 hours)
Table 3-6
- 3.4.5.1 Replacement of hydraulic oil filter
1、9 3.4.5.2 Lubrication on rear hood hinge and other parts
21 3.4.5.3 Replacement of lubricant on driving axle
17 3.4.5.4 Battery maintenance

3.3.6 Maintenance list of every six months (Every 1000 hours)
Table 3-7
3.4.6.1 Drainage of condensed water and sediments in hydraulic
10、23
oil tank
3.4.6.2 Drainage of condensed water and sediments in diesel
3、18
tank
- 3.4.6.3 Exhaust the air of fuel system
- 3.4.6.4 Check the valve clearance of engine
- 3.4.6.5 Check on tension on engine belt

3.4.6.6 Change main filter element and safety filter element
-
inside air filter
7 3.4.4.6 Replace gearbox lubrication oil and filter element
3.3.7 Yearly maintenance list (every 2000 hours)
Table 3-8
10、23 3.4.7.1 Replacement of hydraulic oil
13、27 3.4.7.2 Replace front drum lubricating oil

3.4.7.3 Maintenance and adjustment on clearance between friction
21
plate of drive axle brake
12 3.4.1.7 Replace the braking liquid (at least every two years)
3.4Maintenance contents and works
3.4.1 Daily maintenance(Every 10 hours)
3.4.1.1 Addition of diesel (Fig.3-2)
The design volume for diesel tank is 310L, fulfills exactly the daily
demand for normal working conditions, shall add diesel to the diesel tank
everyday before work. The amount of addition can be judged according to the
50
workload, normally top up.
(1) Unscrew the oil cap and add diesel fuel with the oil gun.
Judge whether it is filled up according to the fuel gun display value or the diesel fuel level gage reading.
(2) Screw the filler cap.
Before filling diesel, shut down the engine and
put oil filler gun nozzle close to filler pipe
Warning journal of the diesel tank to prevent spark.
Smoking and open flame are strictly
forbidden.
Fully fill the diesel tank with diesel oil before
everyday work and use winter diesel oil in
Caution winter to prevent thickening as a result of
sedimentation of wax.
3.4.1.2 Check oil level of hydraulic oil tank(Fig.3-3)
Check the hydraulic level meter display window. When the oil level is lower than the middle of the window,
add the hydraulic oil timely.
Warn Mixture use of hydraulic oils
with two different brand no. is
ing strictly forbidden.
3.4.1.3 Check the oil level of lubricant of engine(Fig.3-4)
(1) open the rear cover;
(2) pull out the oil dipstick and wipe it clean, then place it again as originally.
(3) pull out the oil dipstick again, check the oil level which should be between
the highest and lowest scale. Add oil timely if the level is below lowest scale.
Caution Check oil level at least 5 minutes after engine shuts down.
Starting of the diesel engine is never allowed if oil is lower than “L” (low oil
Warning level) mark on the oil gauge or higher than “H” (high oil level) mark.
3.4.1.4 Inspect level of coolant(Fig. 3-5)
(1) Rotate the radiator filler cap for about 1/4 turns, wait for pressure inside
the radiator drops, with stable pressure unscrew the cap, check the liquid level
position, please add when lack of coolant. Use coolant of same brand.
(2) Tighten the filling cap.
Do not open the filler cap when the radiator is too hot, avoid scalding hands
Warning with hot air.
3.4.1.5 Regulation on spacing between scrapers(Fig.3-6)

Before adjusting scraper plate, park the roller on the level road pavement,
apply the hand brake.
Check the distance between front and rear scraper and front drum surface, the
recommend value should be 20-30 mm. Too big or small space needs to be
adjusted.
Release the scraper bolt, adjust the space then retighten it.
3.4.1.6 Vent plug check(Fig. 3-7)
The vent plug is located at the left side of front drum, used to exchange
internal and external air.
Check whether the vent plug is blocked. If cleaning is required, use the
51
following methods:
(1) Loosen the thread, remove the air plug, and clean it;
(2) Return to the original place after drying.
3.4.1.7 Brake fluid level check(Fig. 3-8)
The fluid level should be between upper and lower scale of the dipstick.
Add brake fluid timely if the level is below lowest scale. Please add well for
exhaust operation (see 2.2.2.11), to ensure the clutch and brake system timely
and effective.
Replace the brake liquid at least every two years.
The recommended brake fluid of the same grade must be used for addition
Warning and replacement. To avoid braking and clutch failure, do not mix other
fluids.
3.4.1.8 Check and fasten bolts and nuts(Fig.3-9)

Check and tighten bolts and nuts in key parts. These key parts
including the connecting ball nut between driving axle and
rim(graphic A), connecting bolt between cab and rear frame (graphic
B), articulation bolts (graphic C), left, right rubber damping block
bolt of front drum (graphic D) etc.
3.4.1.9 Dust discharging of cartridge of air filter (Fig.3-10)
Just pinch the dust accumulator with your hand and
release dust.
3.4.1.10 Air reservoir drainage(Fig. 3-11)
Open the drainage valve at the bottom of the air
reservoir, drain the water from the reservoir before
closing the drainage valve.
3.4.2 Maintenance works within 50 hours after initial
operation
Specific maintenance methods please refer to
monthly and quarterly maintenance.
3.4.3 Weekly maintenance (Every 50 hours)
3.4.3.1 Check and cleaning works on air filter(Fig.
3-12)
This series uses turbocharger engine which
rotates at extremely high speed. Highly sensitive to
dust, it is very important to check and clean the air
filter.
Start the engine and run at rated speed to
check the air filter alarm light on the meter box. If
the indicator light is on, the main filter element
should be cleaned or replaced timely.
(1) Open the end cover and remove the main
filter element (do not move the safety filter
element);
(2) Clean the main filter element with
compressed air, and the maximum pressure of
compressed air shall not exceed 500 Kpa. The compressed air moves up and down in the main filter element along
the folded line of the filter paper, keeping the minimum distance between the nozzle and the filter paper at
20-30mm;
Caution Be careful to wear protective goggles when using compressed air.
(3) clean the outer shell, end cover and inner cover;
(4) after each component is dry, the assembly is completed;
(5) check whether the connecting bracket between air filter and engine is loose and whether the inlet pipe is
sealed well.
The main filter element can be cleaned up to 5 times and must be replaced later. When replacing the main
filter element, the safety filter element should be exchanged at same time.
52
3.4.3.2 Lubrication on articulated parts(Fig.3-13)
There are 4 oil cups in the articulated mechanism, all of which must be lubricated.
（1） Turn the steering wheel to left and right to expose the oil cup;
If the lubricating grease cannot go into the bearing, need to reduce the bearing
Caution load with jack before filling.
Notice the safety mark (Fig. 3-14). When lubricating, shut off tthe engine and
Danger apply the hand brake.
(2) Wipe clean around the oil cup;
(3) Add grease to 4 oil cups through the grease gun and the soft hose nozzle (see the attached tools), and
add about 5 times (or fill until the grease overflow).
(4) Leave small amount of lubricating grease on the grease fitting, in order to prevent the dust.
3.4.3.3 Lubrication on steering cylinder and drive shaft parts(Fig. 3-15)
The steering cylinder has four oil cups, two of which are located
on both sides of the rear frame (open the air storage cylinder box
door to reach the right side cup, open the ladder box door, use special oil pipe to draw out the left side oil cup, as
shown in the figure), and the other two cups are on both sides of the steering coupling plate (below the cabin).
There are three oil cups in the steering cylinder, one in the middle section and two in the cross shafts of
two sections.
(1) Wipe clean around the oil cup;
(2) Add grease to oil cups through the grease gun and the soft hose
nozzle (see the attached tools), and add about 5 times (or fill until the
grease overflow).
(3) Leave small amount of lubricating grease on the grease fitting, in
order to prevent the dust.
3.4.3.4 Check on pressure within tyres(Fig.3-16)
The tire pressure was measured by a tire pressure gage (see attached
tool).
20.5-25 The normal operating range of tire pressure is 250~350 kpa.
23.1 -26 Normal operating range of tire pressure is 130~150 kpa.
If the tire is filled with liquid, and when inflated, the valve should be
in the top position.
53
3.4.2.5 Lubrication on separate bearing
The refueling port is located on the right cover plate below the hydraulic tank (Figure 3-17).
3.4.4 Monthly maintenance(Every 200 hours)
3.4.4.1 Check front drum oil level (Fig.3-18)
(1) Drive the roller onto a level road (to be operated by two persons,
where one person drives the roller and the other person observes standing at
the left side of the front wheel). When the filler plug locates just on the top,
pull up the handbrake;
(2) Loose oil level bolt and check whether any oil comes out of the bolt
hole. It not, it indicates the oil level is low and you need to fill clean gear oil
through the filler plug hole until oil comes out of the bolt hole.
The vibration bearing will suffer

Caution from overheat when oil is too much
or too little.
3.4.4.2 Checking front wheel rubber isolator(Fig.3-19)

(1) Make sure the rubber shock isolator is not damaged, correctly fasten
fastening bolts and replace immediately in case of obvious crack;
(2) When 10-15mm deep crack occurs on more than 3 rubber cushion blocks at
one side (check depth of the crack with blade or other sharp tool), replace all rubber
cushion blocks at the side.
3.4.4.3 Check on oil level of driving axle (Fig.3-20)
(1) Park the roller on the horizontal road surface, make the arrow of the
end cover of the driving axle wheel point vertically to the ground, and pull up
the hand brake after stopping;
(2) First clean and unscrew the oil plug, if the oil level does not reach the
lower edge of the oil level plug hole, should fill oil until the oil spills from the oil
level hole;
(3) Clean the metal particles on the plug, screw oil level plug on;
Danger Working under the roller is strictly forbidden while the engine is operating!
Caution The oil level check port is also oil filler.
54
3.4.4.4 Checking and cleaning of radiator (Figure 3-21)
Periodically or when the cooling effect is not good, check whether the surface of the radiator is clean, clean
the radiator with compressed air if necessary, and the maximum pressure of compressed air shall not exceed 500
kpa. Use of steam injection washing machine could bring about better effect.
3.4.4.5 Check on intake pipes (Fig.3-22)
Check whether the inlet pipe is cracked, damaged, and securely attached, and exchange the inlet pipe or
tighten the joint if necessary.
3.4.4.6 Check(replace) lubricating oil of gearbox (as shown in Fig. 3-23)
Check gearbox and lubricating oil level: check at least once a week. Follow the
following steps.
1） Park the vehicle on even areas;
2） Latch the gearbox shift lever in neutral position;
3） Gearbox operating temperature is within the normal range;
4） The engine speed is about 1000r/min.
5） Rotate the pine oil dipstick counterclockwise, remove and wipe clean;
6） Insert the oil ruler into the filling tube and tighten it, then loosen it after it is in
place.
7） Steps 5 and 6 should be performed at least twice to ensure the accuracy of the test;
8） At 40℃, the oil level should be between the lower and middle scale;
9） At 60℃, the oil level should be between the upper scale and the middle scale;
10） Check whether the fasteners in each part of the gearbox are loose and whether there
is leakage in the sealing joint surface;
11） Check and adjust the control mechanism of the gearbox to ensure normal operation.
Replace the gearbox lubricating oil: replace oil after first 50 hours and every 1000
hours thereafter. Make sure to replace oil at least once a year. When replacing oil, the
vehicle should be parked in a flat area, unscrew the oil plug, drain the old oil as far as
possible. When discharging oil, not only should the oil in the gearbox be cleaned, but
also the oil in the radiator and tubing be cleaned. Oil drainage should be operated with 40℃ oil temperature, never
in cold state. Filter element must be replaced at the same time, and clean the transmission oil sump and the primary
filter screen.
Please refer to the Gearbox Operation Manual for other maintenance requirements and matters needing
attention.
3.4.4.7 Check the braking system (Figure 3-24)
Inspect brake tubing and joints for leakage with soapy water.
Check if brake fluid oil is enough, always ensure that adding the brake fluid
to the correct position;
Check each gas line element for oil leakage.
Check all tubing and fittings for

Caution leakage.
3.4.4.8 Air-Conditioner Maintenance

Do regular maintenance to refrigeration system, compressor, and electrical circuit system according to table
3-9. Refer to the Operation and Maintenance Manual of Air Conditioners for detailed maintenance requirements of
the air conditioner.
Table 3-9
Maintenance intervals
System parts Action
Half of
Month Yearly
year
Refrigeration tube Check for wear and chafing ※
Cooling
Connector Check the leakage ※
System
Condenser Check for heat sink status ※
55
Reservoir Check for use or replacement ※
Refrigerating fluid Check for refrigerant condition ※

Air conditioner Check the connection status of main
※
main body fastening parts
System sealing Check each sealing parts, exchange timely ※
Electromagnetic
Check the clutch off state ※
clutch
Belt Check the belt and tensity ※
Compressor
Check the installation status to ensure no
Fixed support ※
looseness
Compressor Check the abnormal sound of the running ※
Electric wire Check the condition of the line ※

Gas circuit
Connector clip Check the condition of the plug ※
system
Control switch Check the condition of the control parts ※
3.4.4.9 Replace the machine oil and filter

See engine operation and maintenance instruction for details.
3.4.4.10 Replace diesel oil filter
See engine operation and maintenance instruction for details.
3.4.4.11 replace the water oil separator(Fig.3-25)
Use a tool to remove the old oil-water separator and install a new one.
Pay attention to tightening the fuel pipe joint and relevant fasteners during
replacement to prevent fuel leakage.
56
3.4.5 Quarterly maintenance (Every 500 hours)
3.4.5.1 Change hydraulic oil filter element (Fig. 3-26)
Two filters are used in the hydraulic system. The steps to replace the filters
are as follows:
(1) clean the surrounding area of the filter (especially the threaded
connection), screw off the filter and throw it into the waste box;
(2) Wipe clean the sealing surface of the filter seat;
(3) Apply a thin layer of hydraulic oil to the surface of the rubber seal pad
of the new hydraulic oil filter;
(4) rotate the filter and install it. After connecting the rubber sealing pad
with the filter seat, tighten it for half a circle more.
(5) Start the engine and check whether the filter is leaking. Also check the
oil level of the hydraulic oil tank. Add hydraulic oil if needed.
Do not leave old seal ring at the filter, or there will be oil leakage between new
Caution sealing and old sealing.
Caution Be careful not to tighten it too much, otherwise will damage the seal.
3.4.5.2 Lubricate the hinge of rear engine hood(Figure 3-27)

Fill grease to the oil cup at hinge part(Picture A) of the rear hood with grease
gun, grease gun hose nozzle(see attached tools) for three strokes (or until the
overflowing of grease).
3.4.5.3 Change lubrication oil in driving axle(Figure 3-20)
For the first 50 hours of use, the drive axle oil shall be replaced every 500
hours.
(1)Park the roller on a horizontal road, pull up the handbrake shaft;
(2) Place small barrel below each oil outlet. Wipe clean around the oil drain
plug, screw down the oil drain plug, and tighten the oil drain plug immediately after the oil is fully drained (the
sealing ring needs to be replaced).
(3) add clean gear oil from the oil inlet, add it until the oil outlet overflow, and tighten each oil plug (the
sealing ring needs to be replaced).
3.4.5.4 Battery maintenance
This machine uses maintenance free imported accumulator, only need to check the binding post and charge in
time. Corrosion on the binding post must be removed in time, after cleaning the components,do not assembly
before drying.
Do not smoke; Keep away from open fire.
Warning Do not put any metal tools onto the battery.
If short circuit occurs, cut off the circuit immediately with insulated material. Do not
touch it with hands.
Caution Keep great ventilation while charging the battery under normal temperature.
3.4.6 Maintenance every six months (Every 1000 hours)
3.4.6.1 Drainage of condensed water and sediments in hydraulic oil
tank(Fig.3-28)
(2) Unscrew oil drain plug (put a 25L container under it), discharge
condensate water and sediment inside the oil tank, remove impurities on the
screw plug (magnetic) until the extent clean hydraulic oil comes out and then
install oil drain plug.
This operation shall be carried out more than 10 hours after the roller
stops working
3.4.6.2 Drainage of condensed water and sediments in diesel
tank(Fig 3-29)
(1)Park the roller on a horizontal road, pull up the handbrake
shaft;
(2) Unscrew oil drain plug (put a 15L container under it),
discharge condensate water and sediment inside the oil tank, remove
impurities on the plug (magnetic) until the extent clean diesel oil comes
out and then install oil drain plug.
57
This operation shall be carried out more than 10 hours after the roller stops working
3.4.7.5 Exhaust fuel system(Fig. 3-30)
After replacing the fuel filter, the diesel engine may stop working for some days, and the air will enter the fuel
system. Exhaust shall be carried out according to the following steps:
（1） Park the roller on a horizontal road, pull up the handbrake shaft;
（2） Loosen the fuel oil return joint bolts on the fuel pump;
（3） Repeatedly press the overhand lift pump to exhaust the oil until there is no air bubble in the diesel
coming from the vent bolt;
（4） Tighten the bleed bolts.
3.4.6.4 Check the valve clearance of engine
Refer to Engine operation and maintenance manual.
3.4.6.5 Check on tension on engine belt
Refer to Engine operation and maintenance manual.
3.4.6.6 Replacement of main filter element and safety filter element
of air filter (as shown in Figure 3-12)
See 3.4.3.1 Check and clean air filter
3.4.7 Yearly maintenance (Every 2000 hours)
3.4.7.1 Replace hydraulic oil (see Fig. 3-3, 3-25, 3-27)
All the hydraulic oil in the hydraulic system needs to be
replaced for annual maintenance. The replacement steps are as
follows:
(1)Park the roller on a horizontal road, pull up the handbrake
shaft;
(2) Unscrew oil drain plug (put a 240L container under it), discharge all the hydraulic oil from the oil tank;
(3) Clean the iron chips and oil stains on the magnetic body of the oil drain plug, and reinstall the oil drain
plug;
(4) Replacement of hydraulic oil filter;
(5) Open the oil filler cap and add the clean hydraulic oil to the correct position.
(6) Start up the engine and test performance of the hydraulic system.
(7) Double check oil level and fill oil to correct position if necessary.
Caution Strictly ensure brand no., quality and cleanliness of the hydraulic oil.
Warning Use of oil with other brand no. is not allowed unless allowed by the Manufacturer.
Warning Mixture use of hydraulic oils with two different brand No. is strictly forbidden.
3.4.7.2 Replace front drum lubricating oil (as shown in Figure 3-18)
All lubricating oil inside vibration chamber of the front drum must be replaced during annual maintenance in
the following steps:
(1) Drive the roller onto a level road (to be operated by two persons, where one person drives the roller and
the other person observes standing at the left side of the front drum). When one of the oil drain plug (also as oil
filler plug) just locates at the bottom and the oil level bolt locates at the side bottom, stop the roller and pull up the
hand brake;
(2) Loosen oil drain (filling) plug, drain all gear oil inside the vibration chamber (put a 70L container under
it), wipe the iron filings and oil stains on the oil plug;
(3) Add gear oil, loosen the oil level bolt, add oil through the upper oil plug hole to the oil level bolt hole, and
then tighten the oil filling (drain) plug. The filling volume is around 50l.
3.4.7.3 Maintenance and adjustment on clearance between friction plate of drive axle brake
(2) Measure the gap between the two driven plates and the active plates of the friction plate with
micrometer(see Fig. 3-20).
(3) If is greater than 5mm, turn the adjusting bolt until the clearance is suitable.
Check the friction plate gap every year, especially any of the following
Caution conditions happen, should timely check and adjust the clearance: brake with
abnormal voice, braking ability falls, and change of brake pressure.
Danger Working under the roller is strictly forbidden while the engine is operating!
58
3.5 Other Maintenance Description
3.5.1 Oil recommended under special environment
The roller is filled with oils listed in Table 3-1 before delivery to meet the operation demand for the
temperature scope of -10℃-40℃. Please consult XCMG for oil selection under other special circumstances.
3.5.2 High-pressure washing
Do not spray high-pressure water column directly at fuel tank cover and hydraulic oil tank cover while using
high-pressure cleaner! Cover the oil tank cover with a plastic bag and seal it with a rubber cover to prevent
humidity.
Do not spray water directly to electrical elements and instrument panel.
3.6. Common fault remedies

Table 3-10
Failure
Part Cause Remedies
Characteristics
Insufficient fuel Refueling
Oil way clog Clean or replace filter
Difficulty in Pump failure Overhaul or replace
starting Injector fault Overhaul or replace
Low battery Charge or replace
Electrical wiring fault Overhaul or replace
Overcharge Select the right gear
Air in the oil way Air exhaust
Water in the diesel Replace diesel
Abnormal
fuming Air filter clog Inspect and repair or replace
Too much oil supply Check and adjust oil supply
Check thermostat and cooling
Engine Engine temperature too low
system
Broken or loose belt Inspect, check or replace
Too high environment temperature Inspect or stop machine for rest
Oil level too high or too low Reduce or add
Engine
overheating or Not sealed air inlet pipe Inspect, adjust or replace
alarm
Engine water tank cooler is broken or clogged Replace or clean
Air filter or supercharger fault Inspect, adjust or replace
Vent clog Inspect and adjust
Lubrication system outside leakage Check and seal
Oil cooler leaks Inspect, repair or replace
Increased oil
consumption Supercharger fault Repair or replace
Air compressor failure (oil pumping of air
Repair or replace
compressor)
Low oil Too low/high oil level Inspect oil level, add or exhaust
pressure Pressure gauge or sensor not operate properly Inspect and replace
Table 3-10
Failure
Part Cause Remedies
Characteristics
Engine Engine oil filter clog Inspect, clean or repair
Low oil
pressure Pressure regulating valve does not work Overhaul or replace
59
Not sealed oil inlet pipe Overhaul or replace
Pressure gauge or sensor not operate
Inspect and replace
properly
Oil pressure too Engine working temperature too low Check cooling system, repair or replace
high Replace the oil according to the
Incorrect oil specification
specification
Pressure regulating valve broken Overhaul or replace
Water or dirts in the diesel Drain the dirty water, replace the filter
Engine stalling Air in the oil supply system Check fuel system leakage, exhaust air
Fuel pump has failure Replace fuel pump
Electrics fault Inspect and repair
Hydraulic vibration system fault Inspect and repair
Transmission spline sleeve or shaft wear Inspect and replace
No vibration
Vibrating bearing burned Inspect and replace
Front
Hydraulic vibration system fault Inspect and repair
Drum The movable eccentric block is stuck or
Inspect and replace
torn
Overheating Too little or too much cooling oil Proper lubricating oil volume
Vibration motor shaft end seal failure Inspect and replace
Oil leakage
Fastening screws Tighten
Clutch disengaged not completely Inspect and adjust
Difficult to
Power engage gears Gear selector fault Inspect and replace
box
Oil leakage Power tank has production defects Replace
Note: For failures of engine and power box, refer to their operation and maintenance instruction.
Table 3-10
Failure
Part Cause Remedies
Characteristics
The fuel tank oil level is too low Fill the oil to moderate amount
System does not
Pump overflow valve has defects Repair or replace
Hydraulic vibrate
Motor or pump is damaged Replace
Vibration Vibrational The fuel tank oil level is too low Fill the oil to moderate amount
frequency too The output flow rate of pump is not
System low Adjust the flow set value
normal
Solenoid valve stuck or damaged Repair or replace
Vibration fails
Orifice clogged Cleaning and washing
Insufficient oil supply by pump Check pump
Steering wheel
The fuel tank oil level is too low Fill the oil to moderate amount
difficulty
Steering Oil viscosity too high Use oils as recommended.
System Easy to steer Low pressure of steering overflow valve Adjust

under no load
difficult to steer Overflow valve blocked Repair or replace
under heavy load
No steering Steerer does not work normally Repair or replace
60
Lack of brake fluid Add brake fluid to desired position
Pipeline clogged Check and dredge the pipes
Check and replace the corresponding
Hose crack or leakage
hose and joints
Brake fluid deteriorates or mixed into Cleaning and washing brake system
Braking not work
other oils components and replace brake fluid
Brake fluid is mixed with air Refer to 2.2.2.11 for exhaust method
Brake
Air cylinder does not reset or reset Replace the corresponding components
slowly or replace the air cylinder assembly
The friction plate is badly worn Replace
Brake over pressure Check, troubleshoot
Excessive clearance between friction
No brake Adjustment
plates
Brake spring damaged Replace
Table 3-10
Failure
Part Cause Remedies
Characteristics
Incorrect clearance between the
Adjustment
disengage bearing and the disengage disc
Friction plate is too thick Repair or replace
Steel disc deformation Replace
disengaged not Big free stroke of pedal Adjustment
Clutch
completely
Whether the height of the inside end of
Adjust the height of the inside end of the
the separation lever is in the same plane
separation lever on the same plane with
or the inside end face of the separation
certain height
lever is too low
Bearing damaged Replace
61
4Transportation and Storage
62
4.1Transportation
For short-distance transportations, drive the roller with gear 2 or 3 to the site according to road conditions.
Shift gear step by step, do not allow to jump gear or start from the parking with
Caution gear 3.
Shall use platform trailer for long-distance transport of the roller.
The crane can be used to unload a small sized roller onto the transportation vehicle. Please refer to 4.1.2 for
loading & unloading of large-sized roller. All rollers are designed with hoisting holes. Roller’s weight is marked on
its nameplate. Operations should follow rollers’ safety regulations.
4.1.1 Transportation Vehicle
The following conditions shall be taken into consideration in case using a transport vehicle: maximum load,
rated engine power, brake performance, etc.; it’s better to use vehicles exclusive for transporting roller. Pull up the
hand brake flexible shaft when the roller is loaded on vehicle and ensure that all parts of the roller are tightened
without looseness.
4.1.2 Loading/Unloading the Machine with slope
Drive the roller onto a carrier vehicle as the figure 4-1. The ramp angle should be less than 20%
(α≈11.3°). The incline can be made of rock and concrete or metal surface.（the surface is like the washboard）.
Any deteriorated or rusty incline can not be
used! （Fig. 4-2）

Make sure the ramp is correctly placed
between transportation truck and road
Danger surface.
Make sure the ramp is free of oil, dirt, snow,
ice, silt etc.
4.1.3 Fixing roller in transportation

Attach the chain cable to the roller and load the
winch on the carrier vehicle, as shown in Fig.4-3. Shall
use chain and steel wire of right size, do not use thick
string. (Anchor the transporters), to avoid excessive
stretching of the rubber damping block, do not over
tighten it. At the same time, put chocks under front and
rear drums to ensure that the roller will not move or slip.
63
Keep front and rear frame locking mechanism under locking status(Fig4-4) .
4.1.4 Hoisting the roller
Lift the machine with hoist tool according to the figure 4-5.
After hoisting the roller, must loosen the locking device of hinge joint frame to the home position
before starting the engine.
Lock the front and rear chassis before lifting

Danger the roller (Figure 4-4).
4.1.5 Towing Machine

First with the use the hard drag bar to fix the roller and trailer. Release the brake before towing the machine,
the braking is realized by trailer during towing.
In downhill traction operation of the roller without braking capacity, the traction device must have
enough strength, and capabilities against inertial impact of the machine.
Running over a slope beyond the maximum

inclination specified for the machine is not
Warning allowed. Getting on and off a slope must be
always at slow speed.
Caution The maximum traction speed is 1 km/h, the maximum distance is 300m.
Danger Only can use the hard drag bar to toe the roller.
4.2Storage
4.2.1 Daily Machine Storage and Protection
• At the end of daily work, park the machine onto a flat ground. If it
is just a case of having to leave the machine onto a slope, then block the
machine’s both front and rear drums (Fig.4-6) with stones or wood wedges, so
as to prevent any accident happening
• Before leaving the machine unattended, please have its braking
system engaged and shut off the engine.
• Before leaving the machine unattended, please have its braking
system engaged and shut off the engine.
• Switch off the power system and have the parts with locking-key
securely locked (such as cabin door, engine hood, etc.), pull out the key and keep it carefully.
64
4.2.2 Short-time Storage（Within Three Months）
• Clean the machine to keep it free of dirt and dust, especially clean the engine, generator, injecting pump
of start motor, injector, hydraulic pump and motor as well as hydraulic hoses. After cleaning, wipe them with dry
and soft cloth.
• Drain our all the coolant of the water tank cooler
• Clean every lubrication point with coal oil and fill lubrication grease.
4.2.3 Long-term Storage
4.2.3.1 Storage site
• Normally, the machine should be placed in a storage room with
nice ventilation.
• If the machine has to be placed outdoor, park it on a concrete road,
which has a sewerage system. Cover the machine with some plastic sheets
(Figure 4-7). In addition, the storing place should not be exposed to natural
disaster, corrosive and hazardous substance and gas.
4.2.3.2 Storage
• Start the machine every month and rotate it at low speed about half
an hour to make all systems lubricate, at the same time, grease all points.
• Regularly check the protective cover and anti-corrosion substance on the machine.
• In the winter, before storing the roller for a long time, you must drain out the coolant in the radiator to
avoid the radiator being damaged due to frozen water.
4.2.4 Preparations for restarting after long time storage
• Remove the covering things.
• Clean the protective substance coated on the uncover area of the machine;
• Charge the battery and connect its wires;
• Drain out the dirty oil from the crankshaft tank， reducer and drive axle.
• Replace the lubricating oil in vibrating drum.
• Drain out the sediments and water mixed in hydraulic oil tank and fuel tank.
• Grease each articulation joints.
• Before operating the machine, carry out inspection
65
5 Technical Specification
66
XS203J/ XS203JPD
Unit：mm
Dimensions A B C D E F G H K β
XS203J 6320 2300 3200 3230 2130 1600 40 440 2230 33°
XS203JPD 6320 2300 3200 3230 2130 1721 30 440 2230 33°
The swing angle of the front and rear frame is ±11°
67
Technical parameters Unit XS203J XS203JPD
Weight
Operating weight kg 20-000 20-600
Distributed mass of
kg 10-000 10-600
front drum
Distributed mass of
kg 10-000 10-000
front drum
Compaction performance
Static linear load N/cm 470 /
Nominal amplitude mm 1.9/0.95 1.6/0.8
Vibration frequency Hz 28/33 28/33
Exciting force kN 353/245 316/219
Range of speed
Gear I speed km/h 2.95 2.95
Gear Ⅱ speed km/h 5.78 5.78
Gear Ⅲ speed km/h 9.4 9.4
Theoretical
% 30 30
gradeability
Minimum turning
mm 6-500 6-500
radius
Power system
Model SC8D175.2G2B1 SC8D175.2G2B1
Cooling mode Water-cooled Water-cooled
Number of cylinder 6 6
Rated power kW 128 128
Rated speed rpm 1–800 1–800
Voltage V 24 24
Rated pressure of hydraulic system
Vibration system MPa 35 35
Steering system MPa 16 16
Volume
Engine oil L 20 20
Fuel tank L 310 310
Hydraulic oil tank L 215 215
Power box lubrication
L 20 20
oil
Radiator L 34 34
Vibration chamber L 40 40
Drive axle main
L 18 18
reducer
Drive axle rim L 9 9
Brake fluid L 3 3
68
69
.
XCMG CONSTRUCTION MACHINERY CO., LTD.

Add：NO.1 Industry District, Jinshanqiao Developing zone, Xuzhou, Jiangsu, China
销售电话（Sale Tel）：+86-516-87928888
销售传真（Sale Fax）：+86-516-87638888
服务电话（Service Tel）：+86-516-87932222
服务传真（Service Fax）：+86-516-85857433
备件电话（Spare Parts Tel）：+86-516-87938878
备件传真（Spare Parts Fax）：+86-516-83363922
技术支持（Technical Service）：0516-87938756
邮编（Post Code）：221004
服务热线（Service Hotline）：400-110-9999
网址（Web Sites）：http://www.xcmg.com/xgdl
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XCMG Construction Machinery CO., LTD.

3 Maintenance and repair

4 Transport and storage

1.2 Safety Command

1.3 Safety Operation Regulations

1.4 Safety Regulations on Start

1.5 Safety Regulations on Driving

1.5.4 Drive on public roads

1.6 Transport safety requirements

1.6.2 Transport vehicle

Warning The roller cannot be towed unless under instructions of a professional.

Danger Never use damaged or dangerous roller!

• Only trained personnel can repair or maintain the roller.

Caution Only XCMG spare parts can be used.

1.8.2 Repair of the engine

Caution Read the engine maintenance manual carefully.

Caution Turn off the engine before checking the machine.

Shall let the engine cooling down if possible.

1.8.4 Repair of the hydraulic system

Caution Regular maintenance of the hydraulic system is very important.

Warning Regular check of tire wear status is very important.

1.8.7 Operation in cabin

2.1 General rules

2.2 Overview and Illustration

Fig.2-1 Machine structure

2.2.2.2 Front wheel

2.2.2.4 Power system (figure

Figure 2-17 Mark installation position diagram

Check the amount of brake fluid and clutch fluid

This is the power main switch socket, when

3 Nameplate Identify the main parameters of the machine

This is the hydraulic oil feeding port, if

This is the lifting hole of the road roller. It is

Check the tire pressure regularly to reach the

7 Model mark Model mark of roller

Lubricating grease This is the filler for grease, add in grease

Safety sign Danger of squeezing when the hinge

11 Trademark XCMG(Xuzhou Construction Machinery Group)

Hydraulic oil filling This is the hydraulic oil feeding port, if

Maintenance layout Identify the location and maintenance cycle of

Cold water drainage

2.2.4.3 Requirements for sign protection

Table 2-18 Table 2-19

3 Key switch 11 Rear washer switch

4 Throttle control knob 12 Rear wiper switch

5 Gear control lever 13 Radio-cassette player

6 Combination switch 14 Ceiling lamp

7 Main disconnect switch 15 Machine control box

8 Rotary alarm light switch

No. Name Symbol Function

Instrument display and warning (see the 2.3.2.1

Vibration switch Press to switch vibration/no vibration operation.

Three-gear switch（automatic reset). Lift/lower the

Insert the key and turn clockwise, I position connect

Change the engine throttle, turn from left to right to

Place the joystick in the neutral position, roller

Control the steering lights and work lights of cabin

7 Main disconnect switch To turn on/off the battery power supply