BRIAN BULINDA

DRUM ROLLER MACHINE REPORT

Introduction
A drum roller machine is commonly used in construction for compacting soil, asphalt, or other materials.
It consists of one or more cylindrical drums that roll over the surface to compress and smooth it. These
machines come in different sizes and configurations depending on the specific applications.
Types of drum roller machines used in construction
1. Smooth wheeled Rollers:
Also known as static rollers
These have a smooth surface and compact the surface by applying static pressure evenly across the drum.
They are effective for compacting granular materials like gravel and sand.
They are further classified into;
Single drum roller/pad-foot/sheep foot roller: These rollers have pad feet or "feet" attached to the drum
surface, which penetrate and compact cohesive or semi-cohesive soils more effectively.
Double drum roller/tandem roller: These have two drums, one in front of the other, which provide better
compaction and stability, especially for larger projects.
Advantages of static rollers:
- Simple operation
- High compaction efficiency
- Suitable for large-scale projects
- Disadvantages:
- Limited mobility
- Not ideal for cohesive or asphalt materials
2. Pneumatic tire Rollers: These rollers have rubber tires instead of steel drums. They are often used for
finishing surfaces and compacting hot mix asphalt.
- Advantages:
- Good traction on uneven surfaces
- Versatile for different types of materials
- Reduced risk of surface damage
- Disadvantages:
- Lower compaction density compared to vibratory rollers
- Limited effectiveness on cohesive materials
3. Vibratory Rollers: These rollers have vibrating drums, which help increase compaction efficiency,
especially in dense or difficult-to-compact materials.
They are effective for compacting asphalt and other cohesive materials.
Advantages:
- High compaction density
- Versatile for different types of materials
- Faster compaction rates
Disadvantages:
- Higher maintenance costs
- More complex operation compared to static rollers
4. Combination Rollers:
Combination rollers combine the features of both vibratory and pneumatic tire rollers to provide versatile
compaction capabilities. They are ideal for various types of projects.
Advantages:
- Versatile for different materials and surfaces
- Efficient compaction performance
- Reduced need for multiple machines
Disadvantages:
- Higher initial investment
- Complex maintenance requirements
Functions of a drum roller machine in construction
1. Compaction: The drum roller compacts soil, gravel, asphalt, or other materials by applying pressure
and rolling over the surface. This reduces voids, increases density, and improves the load-bearing
capacity of the ground.
2. Smoothing: The roller's weight and movement help smooth out uneven surfaces, creating a level and
uniform finish.
3. Surface Finish: Depending on the type of drum roller, it can provide different surface finishes, ranging
from smooth to textured, suitable for various applications such as roads, parking lots, and building
foundations.
4. Density Control: By controlling factors like drum pressure, vibration intensity, and roller speed,
operators can achieve the desired level of material compaction and density.
5. Efficiency: Drum rollers are designed to efficiently cover large areas, speeding up the construction
process and reducing labor requirements.
Generally, drum roller machines play a crucial role in ensuring the quality and longevity of construction
projects by providing effective compaction and surface finishing.
Systems of a drum Roller Machine.
Drum roller machines typically consist of several systems working together to perform their functions
effectively. Here are the main systems found in a drum roller machine:
1.Engine system
The engine of a road roller machine operates on the principles of internal combustion to generate power
for driving the roller and operating its various systems. Key working principles of the engine in a road
roller:
a) Internal Combustion: The engine uses the internal combustion process to generate power. In an
internal combustion engine, fuel (usually diesel) from the fuel tank is pumped by the fuel
injection pump via the fuel filters, injected into the combustion chamber via injector nozzles,
mixed with air, compressed, and then ignited. This controlled explosion produces high-pressure
gases that drive the piston, converting the chemical energy of the fuel into mechanical energy.
b) Four-Stroke Cycle: Most road roller engines operate on a four-stroke cycle, which includes
intake, compression, power, and exhaust strokes. During the intake stroke, the intake valve opens,
allowing the air-fuel mixture to enter the cylinder. The compression stroke compresses this
mixture, leading to ignition and expansion in the power stroke. Finally, the exhaust stroke expels
the burnt gases from the cylinder.

c) Power Generation: The mechanical energy produced by the expansion of gases during
combustion is transmitted to the crankshaft through the movement of pistons. The crankshaft
converts this linear motion into rotational motion, which is then used to drive the road roller's
wheels or drum(s) through a transmission system.
The transmission system of a road roller machine plays a crucial role in transferring power generated by
the engine to the wheels or drum(s) for propulsion and compaction operations. Here are the key working
principles of the transmission system in a road roller:

o Power Transfer: The transmission system is responsible for transferring power from the
engine to the wheels or drum(s) of the road roller. This process involves converting the
rotational motion of the engine's crankshaft into the linear motion needed to drive the
roller forward or backward. Transmission may be hydrostatic or mechanical. In a
hydrostatic transmission, hydraulic pumps and motors are used to control the speed and
direction of the roller by varying the flow of hydraulic fluid. Mechanical transmissions,
on the other hand, use gears and clutches to change speed and direction mechanically.
 o Speed Control: The transmission system allows the operator to control the speed of the
road roller by adjusting the transmission settings. This can be done through a lever, pedal,
or electronic controls, depending on the type of transmission used.
o Direction Control: In addition to speed control, the transmission system enables the
operator to change the direction of travel of the road roller. By engaging different gears
or hydraulic circuits, the operator can switch between forward and reverse motion as
needed for compaction operations.
o Torque Conversion: The transmission system also plays a role in converting the engine's
high-speed, low-torque output into lower-speed, higher-torque output required for
effective compaction

d) Cooling System: The engine incorporates a cooling system to regulate its operating temperature. This
typically involves a radiator, coolant, water pump, and cooling fan. As the engine operates, coolant
circulates through the engine block, absorbing heat and carrying it to the radiator where it is dissipated
into the surrounding air.

e) Lubrication: Proper lubrication is essential for reducing friction and wear between moving parts within
the engine. The engine is equipped with an oiling system that delivers oil to critical components such as
bearings, pistons, and camshafts to ensure smooth operation and prevent damage.

f) Exhaust System: After combustion, exhaust gases are expelled from the engine through an exhaust
system. This system includes components such as a muffler and catalytic converter to reduce noise and
emissions before releasing the exhaust into the environment. It also consists of the turbo charger which is
a forced induction device that is powered by the flow of exhaust gases.It uses this energy to compress the
intake air, forcing more air into the engine in order to produce more power for a given displacement.
2.Hydraulic system
The hydraulic system of a road roller machine is a critical component that enables various functions, such
as steering, vibration, and drum movement. Here are the key working principles of the hydraulic system
in a road roller:
1. Hydraulic Fluid: The hydraulic system uses hydraulic fluid, typically oil, to transmit power and control
functions within the road roller. The hydraulic fluid is pressurized by a pump to create the necessary force
for operating hydraulic cylinders, motors, and other components.
2. Hydraulic Pump: The hydraulic pump is responsible for generating hydraulic pressure by converting
mechanical energy from the engine or electric motor into fluid flow. The pump supplies pressurized
hydraulic fluid to the system to power different hydraulic functions.
3. Hydraulic Cylinders: Hydraulic cylinders are essential components that convert hydraulic pressure into
linear motion. In a road roller, hydraulic cylinders are used to control the movement of the drum(s),
steering mechanisms, and other functions. When pressurized fluid enters the cylinder, it pushes a piston,
causing the cylinder to extend or retract.
4. Control Valves: Control valves regulate the flow and direction of hydraulic fluid within the system. By
opening and closing specific pathways, control valves enable operators to control the speed, direction, and
intensity of hydraulic functions, such as drum vibration or steering.
5. Hydraulic Motors: Hydraulic motors convert hydraulic pressure into rotational motion. In a road roller,
hydraulic motors are often used to drive the drum(s) for compaction operations. By controlling the flow
of hydraulic fluid to the motor, operators can adjust the speed and direction of drum rotation.
6. Hydraulic Reservoir and Filters: The hydraulic system includes a reservoir to store hydraulic fluid and
filters to remove contaminants that could damage components. The reservoir ensures an adequate supply
of fluid for the system, while filters help maintain the cleanliness of the fluid to prevent damage and
ensure optimal performance.
7. Safety Features: Hydraulic systems in road rollers often include safety features such as pressure relief
valves to prevent overloading and protect components from damage. These safety mechanisms help
maintain system integrity and protect against potential hazards during operation.
3.Compaction system
The compaction system of a road roller machine plays a vital role in achieving proper density and
uniformity in the construction of roads, highways, and other infrastructure projects. The working
principle of the compaction system involves the application of mechanical force to the soil or asphalt
surface to reduce air voids and increase material density. Key components and principles of operation in
the compaction system of a road roller machine are:
1. Drum: The drum is the primary compaction component of a road roller machine. It can be a single
drum (smooth or pad-foot) or tandem drums (double drum). The drum's weight, size, and surface type
(smooth or pad-foot) determine the compaction efficiency and effectiveness. The drum exerts pressure on
the ground surface to compress the material and achieve the desired compaction level.
2. Vibration System: Some road rollers are equipped with a vibration system that adds dynamic force to
the compaction process. The vibration system generates high-frequency vibrations that help in settling the
material and reducing air voids more effectively. Vibration can be controlled and adjusted based on the
type of material being compacted.
3. Water Spray System: In certain cases, road rollers may have a water spray system to moisten the
material being compacted. Moisture content plays a crucial role in achieving proper compaction,
especially for granular materials like soil or aggregates. The water spray system ensures optimal moisture
levels for effective compaction.
4. Control Systems: Modern road rollers may feature advanced control systems that allow operators to
adjust parameters such as vibration frequency, drum pressure, and speed to optimize compaction
performance based on the specific requirements of the project. These control systems enhance precision
and efficiency during the compaction process.
4.Steering system
The steering system of a road roller machine is crucial for maneuvering the vehicle and controlling its
direction during operation. The working principle of the steering system involves the coordination of
various components to enable the driver to steer the road roller effectively. Key components and
principles of operation in the steering system of a road roller machine are:
a. Steering Wheel: The steering wheel is the primary control interface that allows the
operator to change the direction of the road roller. By turning the steering wheel left or
right, the operator can adjust the angle of the front wheels to steer the machine in the
desired direction.
b. Front Axle: The front axle of the road roller machine is connected to the steering
mechanism, allowing for the rotation of the front wheels when the steering wheel is
turned. The front axle plays a critical role in transmitting the steering input from the
operator to the front wheels, enabling directional control.
c. Steering Mechanism: The steering mechanism consists of various components such as tie
rods, steering knuckles, and steering arms that work together to translate the steering
input into movement of the front wheels. When the operator turns the steering wheel, the
steering mechanism transfers this input to the front wheels, causing them to pivot and
change direction.
d. Hydraulic Steering System: Modern road roller machines are equipped with hydraulic
steering systems that use hydraulic fluid to assist in steering operations. The hydraulic
system provides power assistance to make steering easier and more responsive.
e. Steering Control Valve: The steering control valve regulates the flow of hydraulic fluid to
the steering cylinders, which actuate the movement of the front wheels. By adjusting the
flow of hydraulic fluid based on the steering wheel input, the steering control valve
enables precise and efficient steering control.
5.Braking system
The braking system of a road roller machine is essential for controlling and stopping the vehicle safely
during operation. The working principle of the braking system involves the coordination of various
components to slow down or stop the road roller efficiently. Key components and principles of operation
in the braking system of a road roller machine are:
1. Brake Pedal: The brake pedal is the primary control interface that allows the operator to
apply the brakes. By pressing the brake pedal, the operator activates the braking system
to slow down or stop the road roller.
2. Brake System Components: The braking system of a road roller typically consists of
multiple components, including brake drums, brake shoes, brake calipers, brake discs,
hydraulic lines, brake fluid reservoir, and master cylinder. These components work
together to generate friction and force to slow down the road roller.
3. Hydraulic Brake System: Many road roller machines are equipped with hydraulic brake
systems that use hydraulic fluid to transmit force from the brake pedal to the brake
components. When the operator presses the brake pedal, hydraulic pressure is generated
in the system, causing the brake components to engage and slow down the road roller.
4. Drum Brakes or Disc Brakes: Road roller machines may be equipped with drum brakes
or disc brakes, depending on the model and design. Drum brakes use brake shoes that
press against the inside of a rotating drum to generate friction and slow down the vehicle.
Disc brakes use brake pads that clamp onto a rotating disc to achieve the same effect.
5. Parking Brake: In addition to the main braking system, road roller machines are also
equipped with a parking brake that locks the wheels in place when the vehicle is
stationary. The parking brake prevents the road roller from rolling unintentionally and
provides an additional safety measure during parking.
6. Anti-lock Braking System (ABS): Some modern road roller machines may be equipped
with an anti-lock braking system (ABS) that helps prevent wheel lock-up during sudden
braking. ABS sensors monitor wheel speed and modulate brake pressure to maintain
traction and stability, enhancing safety and control during braking.
6.Electrical system
The electrical system of a road roller machine plays a crucial role in powering various components and
systems, providing lighting, control functions, safety features, and communication capabilities. The
power is often provided by a diesel engine, which drives a generator to produce electricity for the
electrical system.

Here are the key components and functions of the electrical system in a road roller machine:
 a) Battery: The battery is a primary component of the electrical system that stores electrical energy
and provides power to start the engine, operate electrical components, and systems. Road roller
machines typically use lead-acid batteries that are rechargeable and designed to withstand the
rugged conditions of construction sites.
b) Alternator/Generator: The alternator or generator is responsible for charging the battery and
supplying electrical power to the vehicle's systems while the engine is running. It converts
mechanical energy from the engine into electrical energy to keep the battery charged and
maintain power to electrical components.
c) Starter Motor: The starter motor is used to crank the engine and start the road roller machine.
When the operator turns the ignition key, the starter motor engages with the engine's flywheel to
initiate the engine's combustion process.
d) Lighting System: Road roller machines are equipped with various lighting components, including
headlights, taillights, turn signals, and work lights. These lights provide visibility and safety
during operation, especially in low-light conditions or at night.
e) Instrument Cluster: The instrument cluster displays essential information to the operator, such as
speed, engine RPM, fuel level, temperature, and warning indicators. It helps the operator monitor
the road roller's performance and status while operating the machine.
f) Control Systems: The electrical system includes control systems that manage various functions of
the road roller machine, such as engine speed control, hydraulic system operation, steering
control, and braking systems. These control systems ensure smooth operation and efficiency
during construction activities.
g) Safety Features: The electrical system may incorporate safety features such as seat belt sensors,
emergency stop buttons, reverse alarms, and warning indicators to enhance operator safety and
prevent accidents on construction sites.
h) Fuse Box/Relays: The electrical system includes fuse boxes and relays that protect electrical
components from overloading or short circuits. Fuses break the circuit when overloaded, while
relays control high-current circuits by using low-current signals.
These systems work together to ensure the efficient and effective operation of the drum roller machine
during compaction and surface finishing tasks.

I attended the daily sessions and gained valuable insights into heavy machinery maintenance. I had the
opportunity to work with the operators and mechanic team, assisting in various tasks such as conducting
routine maintenance checks, handling repairs which enabled me gain practical experience and develop a
deeper understanding of various aspects of mechanical and transport division. More over , I had the
opportunity to gain hands on experience in servicing and maintaining various heavy machinery
components.

Problem statement
The issue of dark smoke emissions from the drum roller and insufficient strength to climb up a hill and
leakage of engine oil from the crankshaft was reported by the operator of the drum roller. The dark smoke
not only indicates potential environmental non-compliance but also raises concerns about the efficiency
and performance of the equipment. This problem poses a risk to the company’s reputation, regulatory
compliance and health of workers. The insufficient strength of the drum roller to climb up a hill hinders
the equipments ability to perform essential task efficiently. Engine oil leakage from the crankshaft may
lead to damage of the engine. The purpose of this report is to investigate the root causes of the dark
smoke emissions from the drum roller and propose effective solutions to mitigate this issue ensuring
environmental compliance, operational efficiency and safety of personnel.

Work done
I worked alongside skilled mechanics in this department and assisted in replacing the rear crankshaft seal
of a road roller machine. It involved removing the hydraulic pump, flywheel housing and the fly wheel.
The function of seal is to prevent engine oil from leaking out of the crankshaft. Seals are made of rubber
or silicone and they wear out because of age corrosion from road salt or rotational forces of the
crankshaft.
I also assisted in the removal of faulty injector nozzles of the road roller machine. This was to reduce the
smoke produced by the drum roller machine since a bad fuel injector can cause smoke in a vehicle.

Dark smoke
Dark smoke coming from the exhaust system of a road roller machine can indicate various issues with the
engine or fuel system. Common reasons for dark smoke and their potential solutions:
1. Incomplete Combustion: Dark smoke can be a result of incomplete combustion of fuel in the engine,
which may be caused by a clogged air filter, dirty fuel injectors, or incorrect fuel-to-air ratio.
Solution: Replace the air filter, clean or replace the fuel injectors, and ensure proper fuel and air mixture
by adjusting the carburetor or fuel injection system.
2. Excessive Fuel: If the engine is receiving more fuel than it can burn efficiently, it can lead to dark
smoke emissions. This could be due to a faulty fuel injector, a malfunctioning carburetor, or a problem
with the fuel pump.
Solution: Check and repair or replace faulty fuel injectors, carburetor, or fuel pump to ensure the correct
amount of fuel is being delivered to the engine.
3. Dirty or Worn-out Engine Components: Accumulation of carbon deposits on engine components like
valves, pistons, or cylinders can also cause dark smoke emissions.
Solution: Perform regular maintenance, including cleaning and inspecting engine components, and
replace any worn-out parts to improve combustion efficiency.
4. Overheating: Engine overheating can lead to poor combustion and dark smoke emissions. This could
be caused by a malfunctioning cooling system, low coolant levels, or a blocked radiator.
Solution: Check and repair the cooling system, ensure proper coolant levels, clean the radiator, and
address any issues causing the engine to overheat.
5. Excessive Load: Operating the road roller machine under heavy loads for extended periods can put
strain on the engine and lead to dark smoke emissions.
Solution: Avoid overloading the machine and allow it to cool down periodically during heavy-duty
operations to prevent overheating and inefficient combustion.
Insufficient strength to climb up a hill
If a drum roller is unable to climb up a hill, it could be due to various reasons related to the engine,
transmission, or mechanical components of the machine. Common causes and possible solutions for a
drum roller struggling to climb hills are:
1. Engine Power Issues:
Cause: Insufficient engine power due to low fuel pressure, clogged fuel filters, or worn-out engine
components can make it difficult for the drum roller to climb hills.
Solution: Check and replace clogged fuel filters, inspect the fuel pump for proper pressure, and ensure the
engine is well-maintained with regular servicing.
2. Transmission Problems:
Cause: Issues with the transmission, such as low transmission fluid levels, worn-out clutch plates, or a
malfunctioning transmission pump, can affect the roller's ability to climb hills.
Solution: Check and top up the transmission fluid if low, inspect and replace worn-out clutch plates, and
have a professional mechanic diagnose and repair any transmission-related issues.
3. Hydraulic System Malfunction:
Cause: Problems with the hydraulic system, such as low hydraulic fluid levels, leaks in the hydraulic
lines, or a faulty hydraulic pump, can impact the roller's performance on inclines.
Solution: Check and refill hydraulic fluid levels, inspect for leaks in the hydraulic lines and repair as
needed, and troubleshoot the hydraulic pump for any faults.
4. Traction Issues:
Cause: Poor traction due to worn-out tires, insufficient tire pressure, or damaged drive components can
hinder the roller's ability to climb hills.
Solution: Check and inflate tires to the recommended pressure, inspect tires for wear and replace if
necessary, and examine drive components like chains or belts for damage or wear.
5. Maintenance Neglect:
Cause: Lack of regular maintenance, including servicing engine components, checking fluid levels, and
inspecting mechanical parts, can lead to performance issues when climbing hills.
Solution: Implement a routine maintenance schedule for the drum roller, including regular inspections,
fluid checks, and component servicing to prevent breakdowns and ensure optimal performance.
Conclusion
In summary, the attachment has been an enlightening and transformational experience that has equipped
me with the competencies required to make a meaningful impact within my field. I am grateful for the
opportunity, and I am confident that the knowledge and experience gained will be valuable in my future
career endeavor’s.
I gained practical skills, insights, and a deeper appreciation for the importance of teamwork, safety, and
precision during work.
Recommendations
I highly recommend the mechanical department. This department offer an exceptional opportunity for
anyone interested in pursuing a career in engineering or related fields, providing valuable experience in
sustainability, quality workmanship, and customer satisfaction. The skills and knowledge gained in these
department will be highly beneficial in any industry or organization where attention to detail and
sustainability are essential.
Reference
Attachment logbook