DOWNLOAD OPERATOR MANUAL
Operation and Maintenance Manual
SD-116 TF Series Effective All Serial Numbers
SD-122 TF Series Effective S/N 177814 including S/N 177108
SD-160 TF Series Effective S/N 180042
SD-190 TF Series Effective All Serial Numbers
SD-200 TF Series Effective S/N 180684
TITLE
INTRODUCTION.
INTRODUCTION.
OVERVIEW.
IDENTIFICATION DATA.
MACHINE IDENTIFICATION
ENGINE IDENTIFICATION.
INSTRUCTION MANUAL STORAGE.
GENERAL INFORMATION.
MACHINE DESCRIPTION
MAIN FRAME
CONTROLS
VIBRATION SYSTEM.
VIBRATION FREQUENCY.
OPERATOR’S STATION
GRADEABILITY
BRAKES
SERVICEABILITY.
ROPS/FOPS/SEAT BELT.
IDENTIFICATION OF MAJOR COMPONENTS.
SECTION 1 - SAFETY
BE AWARE OF SAFETY
UNDERSTAND SIGNAL WORDS
SELECTION AND QUALIFICATION OF PERSONNEL.
ORGANIZATIONAL MEASURES.
PRE START INSPECTION.
MAINTENANCE
TRANSPORTING, TOWING AND ROADING
WARNING OF SPECIAL DANGERS
HAZARDOUS SUBSTANCE PRECAUTION
SAFETY RELATED DECALS.
U.S. DECALS
INTERNATIONAL DECALS WITH INTERPRETATION.
SECTION 2 - SYMBOL IDENTIFICATION.
SYMBOL IDENTIFICATION
INGERSOLL RAND MACHINE SYMBOLS
INTERNATIONAL ROAD MACHINE SYMBOLS
OPERATING CONTROLS AND INSTRUMENTS
VIBRATION FREQUENCYCONTROL
VOLTMETER
STEERING WHEEL
ENGINE COOLANT TEMPERATURE GAUGE
TACHOMETER/HOURMETER.
FUEL GAUGE.
HORN BUTTON
ENGINE OIL PRESSURE GAUGE.
HYDRAULIC OIL TEMPERATURE GAUGE
SPEEDOMETER.
IGNITION SWITCH.
HIGH/LOW ENGINE SPEED SWITCH (THROTTLE)
SPEED RANGE SELECTOR SWITCH.
PARKING BRAKE SWITCH
PARK BRAKE TEST SWITCH
PROPULSION CONTROL RELEASE PUSHBUTTON.
VIBRATION ON/OFF SWITCH.
PROPULSION CONTROL
EMERGENCY STOP SWITCH
TILT STEERING RELEASE LEVER (OPTIONAL).
WORK LIGHT SWITCH (OPTIONAL)
AUTO/MANUAL VIBRATION SWITCH.
VIBRATION AMPLITUDE SWITCH
INSTRUMENT CLUSTER.
ALTERNATOR CHARGE INDICATOR.
LOW OIL PRESSURE INDICATOR
AIR FILTER RESTRICTED INDICATOR
GRID HEATER INDICATOR (REF. ONLY)
TURN SIGNAL INDICATORS.
CHECK ENGINE LIGHT (AMBER).
STOP ENGINE LIGHT (RED).
HYDRAULIC OIL TEMPERATURE INDICATOR
BATTERY MASTER SWITCH
SUSPENSION SEAT
FUSE BLOCK.
FUSE IDENTIFICATION.
FUSE RATINGS/CIRCUIT
RELAYS AND DIODES.
TITLE
SECTION 4 - OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS.
GENERAL INFORMATION
PRE-START CHECKS / VERIFICATIONS
PROPELLING MACHINE AND OTHER CHECKS/VERIFICATIONS WHILE ENGINE IS RUNNING.
OPERATING THE MACHINE
DAILY PRECAUTIONS AFTER WORK.
MOVEMENT OF MACHINE BETWEEN WORK SITES.
LOWERING THE OPERATOR PLATFORM
TOWING THE MACHINE - WITHOUT TOW VALVE. .
BYPASSING THE PROPULSION PUMP AND RELEASING THE BRAKES
RESTORING OPERATION OF THE PROPULSION PUMP AND APPLYING THE BRAKE.
TOWING THE MACHINE - WITH TOW VALVE
RESTORING OPERATION OF THE PROPULSION PUMP AND APPLYING THE BRAKE.
SECTION 5- MAINTENANCE INSTRUCTIONS
MAINTENANCE INSTRUCTIONS
GENERAL MAINTENANCE INFORMATION.
INITIAL BREAK-IN MAINTENANCE - 50 HOURS.
INITIAL BREAK-IN MAINTENANCE - 150 HOURS.
MAINTENANCE SCHEDULE.
ACCESS ENGINE COMPARTMENT .
ROUTINE MAINTENANCE - AS REQUIRED
Check Air Cleaner Connections and Ducts For Leaks
Checking and Removing the Air Cleaner Primary Element.
Cleaning the Primary Air Cleaner Element
Replacing the Air Cleaner Elements
Cleaning / Washing The Machine
Torque Loose Bolted Connections
Check All Shock Mounts
10 HOUR OR DAILY ROUTINE MAINTENANCE
Check Engine Oil Level.
Check Engine Coolant Level, Clean Radiator and Oil Cooler.
Check Fuel Level.
Drain Water from Fuel Filter/Water Separator - SD-116, -122 (155 HP Electronic Engine) & SD-122, -160 (173 HP Mechanical Engine).
5-12
5-21
5-22
5-26
5-14
5-16
5-18
5-18
5-18
5-18
5-20
5-21
5-23
Drain Water from Fuel Filter/Water Separator - SD-116, -122 (155 HP Electronic Engine) . . . 5-24
Drain Water from Fuel Filter/Water Separator - SD-190 & SD-200 (205 HP Electronic Tier II Engine). .
Drain Water from Fuel Filter/Water Separator - SD-190 & SD-200 (203 HP Electronic Tier III Engine)
5-25
5-27 Inspect Cooling Fan Drive Belts
5-28 Check Parking Brake Using The Parking Brake Test Switch
5-28 Check Condition of Drum and Clean
Check Drum Scraper Setting
Check Seat Belt.
SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX
TABLE OF CONTENTS TITLE
50 HOUR OR WEEKLY ROUTINE MAINTENANCE
Check Batteries, Cables and Grease Terminals
Check Tire Air Pressure.
Torque Wheel Nuts.
Check Air Cleaner Integrity and Filter Elements.
Check Hydraulic Oil Level
Check Eccentric Oil Level.
Check Wheel Ends Oil Levels
Check Carrier Oil Level
Check Axle Transfer Case Oil Level.
Check Axle Differential / Brake Oil Level
Check Drum Drive (Torque Hub) Oil Level - SD-116, -122, -160, and -190 TF.
Check Drum Drive (Torque Hub) Oil Level - SD-200 TF
Grease Horizontal / Vertical Swivel Pins - SD-116, -122 & -160 TF.
Grease Horizontal / Vertical Swivel Pins - SD-190 & -200 TF
Clean the Carrier Breather. .
Grease the Carrier Seal
500 HOURS OR SEMI-ANNUAL MAINTENANCE.
Grease Steering Cylinder Pins.
Change Engine Oil and Filter.
Change Three Hydraulic Oil Filters
Replace In-Line Fuel Filter - Tier 2 Engines.
Replace In-Line Fuel Filter - Tier 3 Engines.
Change Fuel Filter Water Separator Element - SD-116, SD-122 TF 155 HP Electronic Engine, SD-122, SD-160 TF 173 HP Mechanical Engine
Change Fuel Filter SD-116, SD-122 TF 155 HP Electronic Engine, SD-122, SD-160 TF 173 HP Mechanical Engine
Change Fuel Filter SD-190 and SD-200 TF - 205 HP Tier II Electronic Engine.
Change Fuel Filter Water Separator Element SD-190 and SD-200 TFTier III 203 HP Electronic Engine.
Clean Axle Breathers
Grease the Ratchet Jack
Check Cooling System Integrity.
1000 HOUR OR ANNUAL MAINTENANCE.
Torque the Horizontal Swivel Pin - SD-116, -122 and -160 TF
Torque The Vertical Swivel Pin - SD-116, -122 and -160 TF.
Torque the Horizontal Swivel Pin - SD-190 and -200 TF.
Torque the Vertical Swivel Pin - SD-190 and -200 TF
Change Axle Wheel Ends Oil.
Change Axle Differential Brake Oil.
Change Axle Transfer Case Oil
Change Eccentric Oil
Change Carrier Oil
Drain and Flush Radiator, Replace Engine Coolant.
Drain and Clean Hydraulic Tank and Three Hydraulic Suction Strainers.
Check Engine Belt and Tensioner
Adjust and Set Valve Clearance.
Change Drum Drive (Torque Hub) Oil Level - SD 116, 122, 160 and 190.
Change Drum Drive (Torque Hub) Oil Level - SD 200.
TROUBLESHOOTING
FUSE BLOCK.
FUSE RATINGS/CIRCUIT
RELAYS AND DIODES.
ENGINE WILL NOT START
ENGINE WILL NOT START
DIFFICULT STARTING & POOR / IRREGULAR PERFORMANCE. .
ENGINE MAKING EXCESSIVE FUMES .
ENGINE OVERHEATS - STOP ENGINE IMMEDIATELY
LOW ENGINE OIL PRESSURE - RED WARNING LIGHT ILLUMINATES
VOLTMETER INDICATES LOW OR NEGATIVE VALUE
FUSE FAILURE .
CONTROL MODULE DESCRIPTION. .
POWER MUST BE ON.
TRACTION CONTROL.
CAUSE OF FAULTS.
VARIABLE VIBRATION CONTROL
CAUSE OF FAULTS.
AUTO VIBE / IMPACT METER.
SECTION 7- TECHNICAL SPECIFICATIONS.
TECHNICAL SPECIFICATIONS.
MACHINE WEIGHTS, ENGINE DATA, EQUIPMENT DESCRIPTIONS, AND SELECTED
PERFORMANCE DATA FOR THE SD-116 DX/F COMPACTOR (TERRA FIRMA SERIES).. .7-8
MACHINE WEIGHTS, ENGINE DATA, EQUIPMENT DESCRIPTIONS, AND SELECTED PERFORMANCE DATA FOR THE SD-122 D/DX COMPACTORS (TERRA FIRMA SERIES).7-10
MACHINE WEIGHTS, ENGINE DATA, EQUIPMENT DESCRIPTIONS, AND SELECTED PERFORMANCE DATA FOR THE SD-122F COMPACTOR (TERRA FIRMA SERIES). . . . . .7-12
MACHINE WEIGHTS, ENGINE DATA, EQUIPMENT DESCRIPTIONS, AND SELECTED PERFORMANCE DATA FOR THE SD-160DX COMPACTOR (TERRA FIRMA SERIES).. . . .7-14
MACHINE WEIGHTS, ENGINE DATA, EQUIPMENT DESCRIPTIONS, AND SELECTED PERFORMANCE DATA FOR THE SD-160F COMPACTOR (TERRA FIRMA SERIES). . . . . .7-16
MACHINE WEIGHTS, ENGINE DATA, EQUIPMENT DESCRIPTIONS, AND SELECTED
PERFORMANCE DATA FOR THE SD-190DX COMPACTOR (TERRA FIRMA SERIES).. . . .7-18
MACHINE WEIGHTS, ENGINE DATA, EQUIPMENT DESCRIPTIONS, AND SELECTED PERFORMANCE DATA FOR THE SD-200DX COMPACTOR (TERRA FIRMA SERIES).. . . .7-20
MACHINE WEIGHTS, ENGINE DATA, EQUIPMENT DESCRIPTIONS, AND SELECTED PERFORMANCE DATA FOR THE SD-200F COMPACTOR (TERRA FIRMA SERIES).. . . . .7-22
MACHINE DIMENSIONS
TITLE
SECTION 8- FUEL AND LUBE SPECIFICATIONS.
FUEL AND LUBE SPECIFICATIONS.
LUBRICATION CHART.
PERIODIC LUBRICATION SCHEDULE.
FLUID CAPACITIES.
HAZARDOUS SUBSTANCE PRECAUTION
SECTION 9 - TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
SAE TORQUE CHARTS.
ISO METRIC TORQUE CHART.
SAE TORQUE CHART - SD 116/122/160/190/200 TF SERIES
SAE TORQUE CHART - SD 116/122/160/190/200 TF SERIES
SAE TORQUE CHART - SD 116/122/160/190/200 TF SERIES
SECTION 10 - SCHEMATICS
SCHEMATICS.
SD-116 Series Schematics
SD-122 Series Schematics
SD-160 Series Schematics
SD-190 Series Schematics
SD-200 Series Schematics
ELECTRICAL SCHEMATICS FOR THE SD-116F/DX & SD-122D/F/DX COMPACTORS
W/ELECTRONIC ENGINES (13309711)
ELECTRICAL SCHEMATICS FOR THE SD-116F/DX, SD-122F/D/D, SD-190DX AND SD-200F/DX COMPACTORS W/ELECTRONIC ENGINES (13375696)
ELECTRICAL SCHEMATICS FOR THE SD-122F/D/DX COMPACTORS
W/MECHANICAL ENGINES (13304852)
ELECTRICAL SCHEMATICS FOR THE SD-122F/D/DX & SD160F/DX COMPACTORS W/MECHANICAL ENGINES (13375704)
HYDRAULIC SCHEMATICS FOR THE SD-116F/DX COMPACTORS (13238902) .
HYDRAULIC SCHEMATICS FOR THE SD-116F/DX & SD-122F/D/DX COMPACTORS (13463336)
HYDRAULIC SCHEMATICS FOR THE SD-116F/DX & SD-122F/D/DX COMPACTORS (13375670)
HYDRAULIC SCHEMATIC FOR THE SD-160F/DX COMPACTORS (13365374).
HYDRAULIC SCHEMATIC FOR THE SD-190DX AND SD-200F/DX COMPACTORS (13414289)10-25
TABLE OF CONTENTS
TITLE
SECTION 11 - RECOMMENDED SPARE PARTS.
RECOMMENDED SPARE PARTS.
SD-116TF SERIES RECOMMENDED SPARE PARTS.
SD-122TF SERIES RECOMMENDED SPARE PARTS.
SD-160TF SERIES RECOMMENDED SPARE PARTS.
SD-190TF SERIES RECOMMENDED SPARE PARTS.
SD-200TF SERIES RECOMMENDED SPARE PARTS.
RECOMMENDED LUBRICANTS FOR ALL MODELS.
WORD INDEX
INTRODUCTION
INTRODUCTION
OVERVIEW
CONGRATULATIONS! You have just acquired an Ingersoll Rand compactor, an applicationdesigned product built with your needs in mind.
The primary purpose of this manual is to provide the operator and site maintenance personnel with knowledge of the fundamental rules and criteria to be followed for the on-site use and maintenance of the following Terra Firma series compactors.
•SD-116 DX
•SD-116 F
•SD-122 D
•SD-122 DX
•SD-122 F
•SD-160 DX
•SD-160 F
•SD-190 DX
•SD-200 DX
•SD-200 F
This instruction manual must have been read and fully understood by the operator before operating the machine. The instruction manual consists of
•INTRODUCTION
•SECTION 1 - SAFETY
•SECTION 2 - SYMBOL IDENTIFICATION
•SECTION 3 - CONTROLS AND INSTRUMENTS
•SECTION 4 - OPERATING INSTRUCTIONS
•SECTION 5 - MAINTENANCE INSTRUCTIONS
•SECTION 6 - TROUBLESHOOTING
•SECTION 7 - TECHNICAL SPECIFICATIONS
•SECTION 8 - FUEL AND LUBRICATION SPECIFICATIONS
•SECTION 9 - TORQUE SPECIFICATIONS
•SECTION 10 - SCHEMATICS
•SECTION 11 - RECOMMENDED SPARE PARTS LISTS
2SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX
INTRODUCTION
Always keep the Operation and Maintenance Manual on the machine and within reach of the operating position.
If any part of this manual cannot be understood, contact your supervisor or local Ingersoll Rand Distributor. This is an essential condition for working safely with this machine.
The correct machine operation, use and regular maintenance are also essential elements to provide the highest performance and safety.
The present manual is accompanied with an engine instruction manual. You are therefore advised to follow the operation and maintenance instructions as specified in both the engine and the machine instruction manuals.
Some illustrations in this manual may show machines with optional equipment installed. This optional equipment maybe purchased from your local Ingersoll Rand Road Machinery Equipment Distributor.
Each manual is reviewed and revised regularly to include all necessary changes. Ingersoll Rand reserves the right to modify or make changes within a specific model group without notice, and without incurring any liability to retrofit machines previously shipped from the factory. Contact your Ingersoll Rand Road Machinery Equipment Distributor for non-routine maintenance that is not covered in this manual.
IDENTIFICATION DATA
An exact description of the model type and serial number of your machine will facilitate fast and efficient response from our parts and service support operations.
Always provide the model of your machine and it's serial number when you contact the local Ingersoll Rand service or parts office.
We advise you to enter your machine data in the following lines to maintain machine and engine information:
Model............................
Serial No..................................
Year of manufacture..............
Engine Serial No. and type of engine..............................
INTRODUCTION
MACHINE IDENTIFICATION
The machine identification plate (1, Figure 1) is located on the forward left side of the rear frame.
ENGINE IDENTIFICATION
The Cummins engine number can be found on the engine data plate (1, Figure 2).
2
Figure 1
Figure
INTRODUCTION
INSTRUCTION MANUAL STORAGE
A storage pouch (1, Figure 3) provides space for the machine manuals. The manuals are located to the right side of the operator’s seat and provides space for the operation and Maintenance Manual.
GENERAL INFORMATION
All safety rules in Section 1 must be observed. If further information is required concerning the recommended use on soil applications, contact your local Ingersoll Rand Distributor.
Ingersoll Rand Construction Technologies Road Development Division 312 Ingersoll Drive
Shippensburg, PA 17257 USA
Tel:717-532-9181
Fax:717-530-3402 (Service and Warranty)
717-530-3403 (Customer Service Parts)
Ingersoll Rand reserves the right to make any changes or modifications without prior notice and without incurring any liability to retrofit machines previously shipped from the factory.
