I. Typical Overload Signs in the Engine
1. Power Loss: Slow acceleration, lack of power when climbing hills, and even a sudden drop in engine speed during normal operation.
2. Abnormal Smoke: Continuous black or blue smoke from the exhaust pipe may indicate incomplete fuel combustion or oil involvement in combustion, suggesting excessive load.
3. Overheating: Water and oil temperatures continuously rise, exceeding normal ranges (water temperature > 95°C), requiring immediate shutdown and inspection.
4. Significantly Increased Fuel Consumption: A significant increase in fuel consumption per unit time is a direct economic indicator of overload operation.
II. Abnormal Pressure in the Hydraulic System
1. Oil Temperature Increase of 15–20°C: Overload causes a sharp increase in hydraulic system pressure, exacerbating internal leakage, decreasing oil viscosity, and hindering heat dissipation.
2. Slow or Weak Movement: Unresponsive start/stop of the vibratory roller, heavy steering, and slow lifting indicate insufficient output torque from the hydraulic motor.
3. Increased Risk of Hydraulic Pipeline Burst: When system pressure approaches or exceeds the relief valve's set value, pipeline rupture and other safety accidents are more likely to occur during emergency braking.
III. Changes in Overall Machine Structure and Control Characteristics
1. Braking Distance Increased by 1.5–2 Times: Overload alters the equipment's center of gravity, slowing braking response during slope operations and highlighting safety hazards.
2. Steering Delay of 0.5–1 Second: Delayed control response affects construction accuracy and safety.
3. Microscopic Cracks Appear in Steel Wheel Welds: Long-term overload operation leads to metal fatigue, increasing the risk of sudden structural failure.
4. Vibration Bearing Life Reduced by 30%–50%: High loads accelerate bearing wear, significantly increasing maintenance costs.
IV. Instrument and Intelligent System Alarms Modern road rollers are mostly equipped with electronic monitoring systems that can display the following in real time:
1. Engine load percentage (over 90% continuous operation indicates overload)
2. Hydraulic system pressure value (exceeding the rated pressure by 16–25 MPa is abnormal)
3. Vibration frequency and amplitude deviating from the set range
4. ECU fault code indication (e.g., P0234 "Boost pressure too high")
