Troubleshooting Issues with the Benford TV1200: A Comprehensive Guide

[MikePhua]

The Benford TV1200 is a popular ride-on tandem roller, known for its compact size and ability to deliver high-quality compaction in tight spaces. It is commonly used in construction, roadwork, and landscaping projects. However, like all machinery, the TV1200 is not immune to operational issues. In this article, we will explore some of the most common problems users face with the Benford TV1200, how to troubleshoot these issues, and practical solutions for keeping the machine running smoothly.
Overview of the Benford TV1200 Roller
The Benford TV1200 is a dual-drum, diesel-powered compactor designed for smaller-scale compaction jobs, such as working on narrow roads, footpaths, and confined spaces. It uses two smooth steel drums for efficient compaction of granular materials, asphalt, and other construction surfaces. The roller is equipped with features like a hydrostatic drive system, adjustable drum vibrations, and a user-friendly control panel.
Key components that play a crucial role in the TV1200's performance include:

• Hydrostatic Drive System: The drive system powers the rollers and provides forward and reverse motion.
  
• Vibration System: The drums are equipped with a vibration system to enhance compaction performance.
  
• Diesel Engine: Provides the necessary power for the roller, including driving the system and powering hydraulic functions.
  
• Control Panel: Allows the operator to adjust settings like vibration, speed, and engine power.
  

Despite its strong reputation, the TV1200 can experience several issues, which we'll address below.
Common Issues with the Benford TV1200

1. Engine Starting Issues
   

One of the most common problems faced by operators of the Benford TV1200 is difficulty starting the engine. If the engine won’t start, it could be caused by several factors, ranging from simple issues like a dead battery to more complex electrical or fuel system problems.

• Symptoms: The engine turns over but doesn’t start, or it struggles to start, requiring multiple attempts.
  
• Possible Causes:
  • Weak or Dead Battery: A weak battery may fail to provide enough power to start the engine.
    
  • Fuel Issues: Contaminated or old fuel can clog the fuel system, making it difficult for the engine to start.
    
  • Faulty Fuel Injectors: If the injectors are clogged or malfunctioning, the engine won’t receive the proper amount of fuel, making it hard to start.
    
  • Electrical Problems: Issues with the ignition switch, starter motor, or wiring can prevent the engine from starting.
    

Solution:

• Check the Battery: If the battery is weak or dead, charge or replace it. Ensure the battery connections are clean and tight.
  
• Inspect the Fuel System: Check for water or dirt in the fuel tank and filter. Replace the fuel filter if it’s clogged. Consider draining and replacing old fuel.
  
• Examine Fuel Injectors: Clean or replace any clogged fuel injectors to ensure proper fuel delivery.
  
• Check Electrical Connections: Inspect the wiring, ignition switch, and starter motor for faults. Repair or replace any damaged components.
  

1. Loss of Compaction Power
   

A common complaint from operators is that the TV1200 is not delivering its usual compaction force. This can result in an unsatisfactory finish to the surface being compacted, leading to rework and delays.

• Symptoms: The compaction seems weak, even when the vibration system is engaged, or the roller is not producing enough pressure.
  
• Possible Causes:
  • Low Hydraulic Pressure: Insufficient hydraulic pressure can affect the roller’s ability to generate compaction force.
    
  • Worn Vibration System: Over time, the vibration system may become worn or malfunction, causing the drums to fail in providing the proper compaction force.
    
  • Incorrect Settings: The vibration system or drum speed settings might not be properly adjusted for the material being compacted.
    

Solution:

• Check Hydraulic Fluid Levels: Ensure the hydraulic fluid levels are correct, as low levels can impact performance. If necessary, top up or replace the fluid.
  
• Inspect the Vibration System: Test the vibration system and replace any worn components, such as the vibration motor or springs.
  
• Adjust Settings: Review and adjust the vibration and drum speed settings based on the type of material being compacted. Follow the manufacturer's manual for guidance on setting adjustments.
  

1. Hydraulic Leaks
   

Hydraulic systems in compactors are essential for operation, as they control the movement of the drums, vibration system, and other critical components. If hydraulic leaks occur, it can lead to a loss of pressure, reducing overall performance.

• Symptoms: Visible fluid leaks around the hydraulic lines or under the machine. The machine may operate at reduced power or not at all if the hydraulic system is compromised.
  
• Possible Causes:
  • Damaged Hydraulic Hoses: Hoses can become cracked or worn over time, leading to fluid leakage.
    
  • Faulty Seals: Seals around the hydraulic cylinders or pumps can deteriorate, causing leaks.
    
  • Loose Connections: Loose or improperly tightened hydraulic fittings can also result in leaks.
    

Solution:

• Inspect Hydraulic Hoses: Check all hydraulic hoses for signs of wear, cracks, or damage. Replace any damaged hoses immediately.
  
• Examine Hydraulic Seals: Inspect the seals around hydraulic cylinders and pumps. Replace any that are worn or damaged.
  
• Tighten Fittings: Ensure that all hydraulic connections are securely tightened and free of leaks.
  

1. Overheating Issues
   

Overheating is a potential problem for many diesel-powered machines, including the Benford TV1200. If the engine or hydraulic system overheats, it can cause the machine to stop working or lead to long-term damage.

• Symptoms: The temperature gauge shows a high reading, or the engine begins to lose power or shut down due to heat.
  
• Possible Causes:
  • Clogged Radiator: Dust and debris can accumulate in the radiator, causing poor airflow and inefficient cooling.
    
  • Low Coolant Levels: If the coolant levels are low, the engine may not cool effectively, leading to overheating.
    
  • Faulty Thermostat: A malfunctioning thermostat can cause the engine to overheat by not regulating coolant flow correctly.
    

Solution:

• Clean the Radiator: Ensure the radiator is free from debris and dirt. Use compressed air or a cleaning solution to clean it.
  
• Check Coolant Levels: Regularly check the coolant level and top it up if needed. Replace any coolant that is old or contaminated.
  
• Test the Thermostat: If the thermostat is faulty, replace it with a new one to ensure proper temperature regulation.
  

1. Poor Drivability and Handling
   

Occasionally, operators report that the Benford TV1200 is difficult to drive or control. This can lead to problems during operation, especially when precise movements are required.

• Symptoms: The machine may jerk or hesitate when accelerating or decelerating. The drive system may also respond poorly to throttle inputs.
  
• Possible Causes:
  • Hydrostatic Drive Issues: Problems within the hydrostatic transmission can cause uneven or unresponsive drive performance.
    
  • Worn or Damaged Bearings: Worn bearings or parts in the drive system can create excessive friction, causing handling issues.
    
  • Incorrect Calibration: The drive system may need recalibration to ensure smooth operation.
    

Solution:

• Inspect the Hydrostatic Drive: Check the drive system for leaks, worn components, or signs of damage. Perform any necessary repairs or replacements.
  
• Lubricate Bearings: Ensure that all bearings in the drive system are adequately lubricated. Replace any worn bearings.
  
• Recalibrate the Drive System: If necessary, recalibrate the hydrostatic drive system according to the manufacturer’s instructions.
  

Case Study: Benford TV1200 Starting Problems
A construction company encountered a starting issue with their Benford TV1200, where the engine would not start on the first attempt, though it would eventually turn over after multiple tries. After inspecting the machine, it was discovered that the battery was old and had difficulty providing enough power to the starter motor. The battery was replaced, and the problem was resolved.
Conclusion: Keeping the Benford TV1200 in Peak Condition
The Benford TV1200 is a reliable machine, but like all heavy equipment, it requires regular maintenance and troubleshooting to ensure optimal performance. By addressing common issues like starting problems, loss of compaction power, hydraulic leaks, overheating, and drivability issues, operators can prolong the lifespan of the roller and improve job site efficiency. Regular inspections, timely repairs, and proper calibration can keep the TV1200 running smoothly and avoid costly downtime.