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Volvo Ingersoll Rand SD-116 TF Series, Operator'S Manual

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Volvo Ingersoll Rand SD-116 TF Series Operator'S Manual Download Page 101

MAINTENANCE INSTRUCTIONS

SECTION 5

SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX

5-3

5. Thoroughly wash all fittings, caps, plugs, etc. with nonflammable, nontoxic

cleaning solution before servicing, to prevent dirt from entering while
performing the service.

Handling Fluids and Oil, Fuel Filters

1. When draining fluids, ensure that adequate sealable containers are available

and that every care is taken to prevent spillage.

2. Always ensure waste fluids are disposed of in an environmentally safe manner.

3. Always ensure that used filters are stored in secure containers and disposed of

in an environmentally safe manner. 

INITIAL BREAK-IN MAINTENANCE - 50 HOURS

New equipment requires the following initial one time break-in maintenance after 50 hours of 
operation. After this initial phase, the intervals listed in the following pages should be followed.

1. Torque the horizontal and vertical swivel pins to the following values.

•

SD-116, SD-122 and SD-160 TF Series - (540 N-m) (400 lb-ft)

•

SD-190 and SD-200 TF Series - (1080 N-m) (800 lb-ft.)

2. Change the axle wheel ends oil. Refer to Page 5-59 for procedures.

3. Change the axle differential and brake assembly oil. Refer to Page 5-60 for

procedure.

4. Change the eccentric oil. Refer to Page 5-63 or procedures.

5. Change the carrier oil. Refer to Page 5-64 for procedures.

6. Add hydraulic oil to level of sight glass on hydraulic tank. Refer to Page 5-34.

7. Remove particles from the (optional) pre-cleaner located on the air intake.

Remove the cover and tip the pre-cleaner to remove particles. 

8. Inspect and surface clean the breather located on the carrier assembly. Refer

to Page 5-43.

9. Grease the carrier assembly. Refer to Page 5-43.

10. Grease the horizontal and the vertical swivel pins. Refer to Page 5-41.

INITIAL BREAK-IN MAINTENANCE - 150 HOURS

New equipment requires the following initial one time break-in maintenance after 150 hours of 
operation. After this initial phase, the intervals listed in the following pages should be followed.

1. Change the torque hub (drum drive) oil. Refer to Page 5-71.

Summary of Contents for Ingersoll Rand SD-116 TF Series

Page 1: ...g CST SD116DX SD116F SD122D SD122DX SD122F SD160F SD190DX SD200 Serial No SD116DX SD116F All SD122D SD122DX SD122F Serial No 177814 Incl 177108 SD160DX SD160F Serial No 180042 SD190DX Serial No All SD200DX SD200F Serial No 180684 SD116DX SD116F SD122D SD122DX SD122F SD160F SD190DX SD200 ...

Page 2: ... and other reproductive harm Wash hands after handling This manual and its contents are produced and maintained by Volvo Construction Equipment in accordance with an agreement with Ingersoll Rand regarding the depiction and use of its exclusive trademarks in support of equipment originally manufactured under the Ingersoll Rand brand Volvo Construction Equipment is fully responsible for the mainten...

Page 3: ...uipment 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 021402AA TMC VOE21 1004871h pdf ...

Page 4: ......

Page 5: ...DENTIFICATION OF MAJOR COMPONENTS 1 10 SECTION 1 SAFETY 2 1 SAFETY 2 2 BE AWARE OF SAFETY INFORMATION 2 2 UNDERSTAND SIGNAL WORDS 2 2 OVERVIEW 2 3 GENERAL 2 4 SELECTION AND QUALIFICATION OF PERSONNEL 2 4 ORGANIZATIONAL MEASURES 2 5 PRE START INSPECTION 2 5 SAFETY INSTRUCTIONS 2 6 STARTING 2 7 OPERATING 2 8 STOPPING 2 9 MAINTENANCE 2 9 TRANSPORTING TOWING AND ROADING 2 11 WARNING OF SPECIAL DANGERS...

Page 6: ...SELECTOR SWITCH 4 5 PARKING BRAKE SWITCH 4 6 PARK BRAKE TEST SWITCH 4 6 PROPULSION CONTROL RELEASE PUSHBUTTON 4 6 VIBRATION ON OFF SWITCH 4 6 PROPULSION CONTROL 4 7 EMERGENCY STOP SWITCH 4 7 TILT STEERING RELEASE LEVER OPTIONAL 4 7 WORK LIGHT SWITCH OPTIONAL 4 7 AUTO MANUAL VIBRATION SWITCH 4 8 VIBRATION AMPLITUDE SWITCH 4 8 INSTRUMENT CLUSTER 4 8 ALTERNATOR CHARGE INDICATOR 4 8 LOW OIL PRESSURE I...

Page 7: ... ENGINE COMPARTMENT 5 9 ROUTINE MAINTENANCE AS REQUIRED 5 10 Check Air Cleaner Connections and Ducts For Leaks 5 10 Checking and Removing the Air Cleaner Primary Element 5 10 Cleaning the Primary Air Cleaner Element 5 12 Replacing the Air Cleaner Elements 5 14 Cleaning Washing The Machine 5 16 Torque Loose Bolted Connections 5 18 Check All Shock Mounts 5 18 10 HOUR OR DAILY ROUTINE MAINTENANCE 5 1...

Page 8: ...el Filter Water Separator Element SD 116 SD 122 TF 155 HP Electronic Engine SD 122 SD 160 TF 173 HP Mechanical Engine 5 51 Change Fuel Filter SD 116 SD 122 TF 155 HP Electronic Engine SD 122 SD 160 TF 173 HP Mechanical Engine 5 52 Change Fuel Filter SD 190 and SD 200 TF 205 HP Tier II Electronic Engine 5 53 Change Fuel Filter Water Separator Element SD 190 and SD 200 TF Tier III 203 HP Electronic ...

Page 9: ...ACTORS 7 6 SD 190DX 200 F DX TERRA FIRMA SERIES VIBRATORY SOIL COMPACTORS 7 7 PHYSICAL SPECIFICATIONS 7 8 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 D...

Page 10: ...HINES 10 3 SD 116 Series Schematics 10 3 SD 122 Series Schematics 10 3 SD 160 Series Schematics 10 3 SD 190 Series Schematics 10 3 SD 200 Series Schematics 10 3 ELECTRICAL SCHEMATICS FOR THE SD 116F DX SD 122D F DX COMPACTORS W ELECTRONIC ENGINES 13309711 10 5 ELECTRICAL SCHEMATICS FOR THE SD 116F DX SD 122F D D SD 190DX AND SD 200F DX COMPACTORS W ELECTRONIC ENGINES 13375696 10 8 ELECTRICAL SCHEM...

Page 11: ... RECOMMENDED SPARE PARTS 11 2 SD 116TF SERIES RECOMMENDED SPARE PARTS 11 2 SD 122TF SERIES RECOMMENDED SPARE PARTS 11 8 SD 160TF SERIES RECOMMENDED SPARE PARTS 11 15 SD 190TF SERIES RECOMMENDED SPARE PARTS 11 22 SD 200TF SERIES RECOMMENDED SPARE PARTS 11 28 RECOMMENDED LUBRICANTS FOR ALL MODELS 11 34 WORD INDEX 12 1 ...

Page 12: ......

Page 13: ...SD 116F DX 122D F DX 160F DX 190DX 200F DX 1 INTRODUCTION ...

Page 14: ...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 SECTIO...

Page 15: ...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 R...

Page 16: ...0DX 200F DX MACHINE IDENTIFICATION The machine identification plate 1 Figure 1 is located on the forward left side of the rear frame Figure 1 ENGINE IDENTIFICATION The Cummins engine number can be found on the engine data plate 1 Figure 2 Figure 2 ...

Page 17: ...ust 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 c...

Page 18: ...a a 156 horsepower electronic Tier II fuel injected Cummins diesel engine An optional 173 horsepower mechanical engine standard on the SD 160 TF is available for the SD 122 SD 190 and 200 models prior to Serial Number 185573 are powered via a 205 horsepower electronic Tier II fuel injected Cummins diesel engine SD 190 and 200 models effective with Serial Number 185573 are powered by a 203 horsepow...

Page 19: ...opulsion direction speed and braking controls plus vibration On Off control and emergency stop push pull control are located to the right of the operator The control console includes the following controls supplied as standard or optional equipment dependent on model The controls and indicator lights include vibration frequency control engine coolant temperature gauge tachometer hourmeter engine s...

Page 20: ...gine rpm selection Low rpm selection is for idling only The low machine speed range is recommended for compacting and the high speed range for traveling BRAKES The standard mechanical braking components located in the drum drive motor assembly and the axle assembly are designed for use as a parking brake emergency brake The mechanical brake s are spring applied and hydraulically released Loss of e...

Page 21: ...red if the following are not complied with DO NOT operate this machine if the Rollover Protection Structure ROPS or Falling Objects Protection Structure FOPS is structurally damaged shows cracks is not properly secured as originally installed or has been involved in a rollover DO NOT repair modify drill weld on or add attachments to the ROPS FOPS unless authorized in writing by the manufacturer DO...

Page 22: ...INTRODUCTION 10 SD 116F DX 122D F DX 160F DX 190DX 200F DX IDENTIFICATION OF MAJOR COMPONENTS Figure 4 ...

Page 23: ...perator Control Console 4 Articulation Pin 5 Universal Drum Scraper 6 Drum Smooth Padfoot 7 Drum Drive and Brake 8 Hydraulic Tank 9 Propulsion Speed Vibration Control 10 Fuel Tank Fill Point 11 Lifting Lug 12 Axle and Brake Assembly 13 Batteries Jack Controls 14 Batteries Master Switch 15 Isolators 16 Eccentric Drive 17 Emergency Stop Switch ...

Page 24: ...INTRODUCTION 12 SD 116F DX 122D F DX 160F DX 190DX 200F DX ...

Page 25: ...SD 116F DX 122D F DX 160F DX 190DX 200F DX 1 1 SECTION 1 SAFETY ...

Page 26: ...STAND SIGNAL WORDS A signal word DANGER WARNING or CAUTION is used with the safety alert symbol DANGER identifies the most serious hazard DANGER WARNING or CAUTION safety labels are located near specific hazards NOTICE labels are for general information SAFETY ALERT SYMBOL DANGER RED BACKGROUND DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious ...

Page 27: ...eople of installation operation or maintenance information which is important but not hazard related OVERVIEW BEFORE YOU OPERATE MAINTAIN OR IN ANY OTHER WAY USE THIS COMPACTOR READ and STUDY this manual KNOW how to safely use the compactor s controls and what you must do for safe maintenance ALWAYS wear or use the proper safety items required for your personal protection If you have ANY QUESTIONS...

Page 28: ...other vehicles equipment is considered contrary to its designated use The manufacturer supplier cannot be held liable for any damage resulting from such use The risk of such misuse lies entirely with the user Operating the machine within the limits of its designated use also involves compliance with the inspection and maintenance directives contained in the operating manual SELECTION AND QUALIFICA...

Page 29: ...in the machinery USE protective equipment wherever required by the circumstances or by law OBSERVE all safety instructions and warnings attached to the machine BE SURE all safety instructions and warnings attached to the machine are complete and perfectly legible STOP the machine immediately in the event of any malfunction REPORT the malfunction to the proper authority person NEVER provide service...

Page 30: ...ble condition OPERATE the machine only if all protective and safety oriented devices such as removable safety devices emergency shut off equipment soundproofing elements and exhausts are in place and fully functional START the machine from the driver s seat only and always wear the seat belt WATCH the indicators during start up and shutdown procedures in accordance with the operating instructions ...

Page 31: ...ntrol is in the STOP position BEFORE starting the engine ENSURE that the parking brake control is in the Applied position START the engine from the operator s position only WARNING Never jump start the compactor directly to the starter or starter solenoid Severe injury or death could result from the compactor lurching forward or backward and running over the person s attempting to jump start the c...

Page 32: ...E EXTREME CAUTION and be very observant when operating in close quarters or congested areas NEVER carry passengers CLOSE all sound baffles during operation KNOW the area in which you are working Familiarize yourself with work site obstructions and any other potential hazards in the area KNOW and USE the hand signals required for particular jobs and know who has the responsibility for signaling DO ...

Page 33: ...aintenance work ENSURE that the maintenance area is adequately secured If the machine is completely shut down for maintenance and repair work it must be secured against inadvertent starting by locking the principal control elements and removing the ignition key and or attaching a warning sign to the ignition or main switch CARRY OUT maintenance and repair work only if the machine is positioned on ...

Page 34: ...ance to the compactor unless the drum and wheels are adequately chocked the articulation lock bar lock pin is in the locked position and parking brake is applied NEVER fill the fuel tank with the engine running while near an open flame or while smoking ALWAYS wipe up any spilled fuel DO NOT alter the engine governor settings from those indicated in the engine manual and the engine option plate ALW...

Page 35: ...lieved WAIT for fluid to cool down before disconnecting Hot hydraulic fluid will cause severe burns NEVER use your hands to check for leaks when inspecting an hydraulic system Use a piece of cardboard and always wear gloves and safety glasses GET immediate attention if fluid has been injected under your skin Fluid penetration from a pin hole leak can cause severe injury or death ENSURE hydraulic l...

Page 36: ...r on public access roads KNOW your approximate stopping distance at any given speed NEVER turn corners at excessive speeds Look in all directions before reversing your direction of travel POSITION the compactor on the transporter or hauling vehicle centered from side to side and apply the brake REFER to Section 4 of this manual for proper towing instructions WARNING OF SPECIAL DANGERS When working...

Page 37: ...machine and may be hazardous to health Table 2 SUBSTANCE PRECAUTION Antifreeze Water Cooled Engine Avoid ingestion skin contact and breathing fumes Hydraulic Oil Avoid ingestion skin contact and breathing fumes Engine Lubricating Oil Avoid ingestion skin contact and breathing fumes Preservative Grease Avoid ingestion skin contact and breathing fumes Rust Preventative Avoid ingestion skin contact a...

Page 38: ...ollover 1 Left Side Console 4 WARNING Improper Operation 2 Both Sides of Cowling 5 WARNING Hot Pressurized Fluid 2 Left Side of Frame 6 WARNING Rotating Fan Blade 1 Top of Cowling Near Radiator Cap 7 Checklist 1 ROPS Support 8 WARNING Use Of Ether 1 Shroud or Air Cleaner 9 WARNING Towing Tag OPTIONAL BRAKE RELEASE VALVE ONLY 1 Tow Valve in Battery Box OPTIONAL BRAKE RELEASE VALVE ONLY 10 WARNING R...

Page 39: ...SAFETY SECTION 1 SD 116F DX 122D F DX 160F DX 190DX 200F DX 1 15 U S Decals 1 Do Not Sit On Rail 2 Crush Area 3 Rollover ...

Page 40: ... 4 Improper Operation 5 Hot Pressurized Fluid 6 Rotating Fan Blade WARNING Hot pressurized fluid Can cause severe burns Do not open radiator while hot 59246660 WARNING 5 9 0 5 1 1 5 1 U P I Rotating fan blade Can cause severe injury Do not operate with guard removed ...

Page 41: ...TION Select Vibration modes or Vibration Frequency Select required Frequency Operation Operating STAY SEATED ALLOW NO PASSENGERS ALLOW NO BYSTANDERS Downhill and Uphill Travel GO SLOWLY Machine ON LEVEL SURFACE AND PROPULSION CONTROL LEVER IN STOP POSITION Water Emulsion Spray Switch OFF Vibration Mode Selector OFF Parking Brake APPLY Engine Speed LOW IDLE For 3 4 mins Ignition Switch OFF Hauling ...

Page 42: ...DX 8 Use Of Ether 9 Towing Tag WARNING UPI 59087452 U s e o f e t h e r m a y c a u s e e x p l o s i o n a n d s e v e r e i n j u r y T h i s e n g i n e i s e q u i p p e d w i t h a n e l e c t r i c h e a t e r s t a r t i n g a i d D o n o t u s e e t h e r ...

Page 43: ...ause serious injury or death Install lock pin before servicing WARNING Runaway machine can cause severe injury or death Manually releasing brakes and shunting propulsion pump will allow machine to roll freely Chock tires and or drums before starting towing procedures Carefully follow towing instructions in the Operation and Maintenance Manual Prior to manually releasing brakes transfer Tagout tag ...

Page 44: ...otating Fan and Belt Rotating Blade Can cause severe injury Do not operate with guards or shields removed Stop machine before performing maintenance 5 Rollover Rollover of this machine can cause severe injury or death Do not operate this machine near or on an inclined surface A rollover can occur If this machine has a Rollover Protective Structure ROPS seat belts must be worn to avoid severe injur...

Page 45: ...ng the radiator cap Steam or fluid escaping from the radiator can burn Inhibitor contains alkali Avoid contact with skin and eyes Always shut down the engine and allow to cool before removing the radiator cap Remove the cap slowly to relieve pressure Avoid contact with steam or escaping fluid UPI 59050948 ...

Page 46: ...TION Select Vibration modes or Vibration Frequency Select required Frequency Operation Operating STAY SEATED ALLOW NO PASSENGERS ALLOW NO BYSTANDERS Downhill and Uphill Travel GO SLOWLY Machine ON LEVEL SURFACE AND PROPULSION CONTROL LEVER IN STOP POSITION Water Emulsion Spray Switch OFF Vibration Mode Selector OFF Parking Brake APPLY Engine Speed LOW IDLE For 3 4 mins Ignition Switch OFF Hauling ...

Page 47: ...SD 116F DX 122D F DX 160F DX 190DX 200F DX 2 1 SECTION 2 SYMBOL IDENTIFICATION ...

Page 48: ...bols shown in this section may not appear on your machine Table 1 IR Machine Symbols 1 Drum Vibration 9 Anti Drum Spin 2 Drum Vibration Control 10 Manual Vibration Control 3 High Amplitude 11 Automatic Vibration Control 4 Low Amplitude 12 Vibration Control Mode 5 Frequency Vibration 13 Caution 6 Tiedown Point 7 Ignition Switch 8 Anti Wheel Spin ...

Page 49: ...SYMBOL IDENTIFICATION SECTION 2 SD 116F DX 122D F DX 160F DX 190DX 200F DX 2 3 INTERNATIONAL ROAD MACHINE SYMBOLS NOTE Some symbols shown in this section may not appear on your machine ...

Page 50: ... Inject Cold Start 53 Hydraulic Oil Temperature 10 Linear 32 Engine Air Filter 54 Fuel Diesel 11 Rotational 33 Engine Air Filter Failure 55 Fuel Level 12 Volume Empty 34 Fan Belt Failure 56 Fuel Filter 13 Volume Half Full 35 Emergency Engine Stop 57 Work Light 14 Volume Full 36 Engine Start 58 Flashing Beacon 15 Grease 37 Engine On Run 59 Control Lever Dual Direction 16 Oil Lubrication Point 38 St...

Page 51: ...SD 116F DX 122D F DX 160F DX 190DX 200F DX 3 1 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS ...

Page 52: ... this section before operating the machine ARTICULATION LOCK PIN WARNING During shipment and before performing any checks or service operations place the articulation lock pin in the locked position The articulation lock pin 1 Figure 3 1 is used to prevent accidental articulation of the compactor The lock pin must be in the locked position prior to shipment and before performing any checks or serv...

Page 53: ...e Test Switch 4 Steering Wheel 17 Propulsion Cont Release Pushbutton 5 Engine Coolant Temp Gauge 18 Vibration ON OFF Switch 6 Tachometer Hourmeter 19 Propulsion Control 7 Fuel Gauge 20 Emergency Stop Switch 8 Horn 21 Operator s Seat 9 Engine Oil Pressure Gauge 22 Tilt Steering Release Lever 10 Hyd Oil Temp Gauge Opt Optional 23 Work Lights Switch 11 Speedometer Optional 24 Auto Manual Vib Switch O...

Page 54: ...gnition switch is at the On position The normal green operating range is 12 to 15 5 volts STEERING WHEEL The steering wheel 4 is used to steer the machine ENGINE COOLANT TEMPERATURE GAUGE The temperature gauge 5 indicates engine coolant temperature The gauge includes a blue cool range and a red high temperature range with normal operating temperatures occupying the range between them TACHOMETER HO...

Page 55: ...STOP position RUN position START position Once the engine starts release the switch immediately and it automatically returns to the Run position If the engine does not start attempt to restart NOTICE Starter may overheat if operated longer than 30 seconds Allow the starter to cool for 2 to 3 minutes before trying again HIGH LOW ENGINE SPEED SWITCH THROTTLE This two position switch 13 is used to se...

Page 56: ...ake Apply the parking brake by pressing the switch at the end marked as below When the brake is On the parking brake red warning light switch will be illuminated except following an e stop Release by pressing the switch at the other end and the red warning light will extinguish NOTE Brakes can only be released by this switch when the engine is running PARK BRAKE TEST SWITCH The park brake test swi...

Page 57: ...is in the STOP position EMERGENCY STOP SWITCH The Emergency Stop Switch 20 is a latching type switch that when pressed shuts down the engine and all other machine functions in the event of an emergency and applies the parking brake To restart the machine after the e stop has been activated pull out on the switch and proceed with the start up procedure DO NOT USE THE EMERGENCY STOP CONTROL FOR NORM...

Page 58: ...elect high amplitude vibratory compaction depress the top of switch To select low amplitude depress the bottom of the switch INSTRUMENT CLUSTER In addition to Engine Coolant Temperature Gauge 5 Tachometer Hourmeter 6 and Fuel Level Gauge 7 the following indicator lights may appear on instrument cluster Figure 3 3 Figure 3 3 Table 2 ALTERNATOR CHARGE INDICATOR The alternator charge indicator light ...

Page 59: ... Starting aids are extremely flammable and can explode The illuminated light indicates that the grid heater is heating the air in the engine air intake chamber The indicator will go out when the air intake temperature is high enough to assist in starting the engine TURN SIGNAL INDICATORS The turn signal indicators 30 show the direction in which the machine is going to turn on machines equipped wit...

Page 60: ...features several adjustments The armrest can be tilted by rotating adjustment 1 Figure 3 5 The back of the seat can be tilted by lifting adjustment handle 2 and positioning the back as desired The entire seat can be rotated horizontally by lifting handle 3 and rotating seat as desired The seat cushion can be positioned forward and reverse and be tilted by handles located at 4 Operator comfort resi...

Page 61: ... while machine is moving FUSE BLOCK The fuses 1 Figure 3 6 for the compactor are located under the seat as shown Fuse identification rating and circuit are illustrated below and on a decal located on the fuse compartment cover not shown Figure 3 6 FUSE IDENTIFICATION Fuse identification and physical position are shown in Figure 3 7 This information is identified on a decal on the inside of the fus...

Page 62: ...WITCH PARK BRAKE F2 10 AMPS HORN AIR FILTER HYD OIL TEMP F3 10 AMPS TWO SPEED BACK UP F4 15 AMPS LIGHTS BEACON TURNSIGNAL HAZARD F5 5 AMPS AUTO VIB IMPACT METER F6 5 AMPS TRACTION CONTROL F7 10 AMPS POWER PORT F8 30 AMPS THROTTLE SOLENOID PULL IN F9 10 AMPS INSTRUMENT CLUSTER F10 10 AMPS GAUGE OPTIONS F11 10 AMPS CAB OPTIONS F12 15 AMPS SPARE F13 25 AMPS HEATER VALVE BLOWER A C F14 10AMPS FRONT WI...

Page 63: ...160F DX 190DX 200F DX 3 13 RELAYS AND DIODES The relays and diodes illustrated in Figure 3 8 are contained in a harness assembly housing Figure 3 9 located adjacent to the air cleaner mounting bracket Relay C AND F are for ELECTRONIC engine only Figure 3 8 Figure 3 9 ...

Page 64: ...SECTION 3 OPERATING CONTROLS AND INSTRUMENTS 3 14 SD 116F DX 122D F DX 160F DX 190DX 200F DX ...

Page 65: ...SD 116F DX 122D F DX 160F DX 190DX 200F DX 4 1 SECTION 4 OPERATING INSTRUCTIONS ...

Page 66: ... Always chock the drum wheels when parking the machine Do not grease the machine while the engine is running Always perform safety checks prior to starting using the machine Do not control travel speed using the High Low engine speed switch Do not shift speed range selector at speeds above 5 km h 3 mph Always operate the machine at full engine speed when compacting or traveling the unit Never oper...

Page 67: ...ssure caps drum muffler engine safety shrouds and area under the machine for any signs of leakage WARNING Injury can occur when removing the radiator cap Steam or fluid escaping from the radiator can burn Rust inhibitor contains alkali Avoid contact with skin and eyes Always shut down the engine and allow it to cool down before removing the radiator cap Remove cap slowly to relieve pressure Avoid ...

Page 68: ...4 3 Use only 2 diesel fuel Figure 4 2 Figure 4 3 8 Check engine oil level on dipstick 1 Figure 4 4 If required add motor oil through fill area 2 Figure 4 4 for Tier II engines 1 Figure 4 4 for Tier III engines to bring to Full level on dipstick Refer to the Section 8 for lube oil type If no oil is showing on the dipstick call for service assistance to investigate the cause of oil loss ...

Page 69: ...sh clean anti wear hydraulic oil through the fill area 2 Figure 4 5 Install the fill plug Refer to Section 8 for hydraulic oil specs Figure 4 5 10 Check wear condition of mounting pins and bushings on the steering cylinders 1 Figure 4 6 Any wear in the pins and bushings should be noted and proper personnel notified TIER II ENGINES TIER III ENGINES ...

Page 70: ... machine controls must be performed prior to operating the machine 1 Mount the compactor maintaining a three point contact as shown in Figure 4 7 below Figure 4 7 NOTE The machine contains a circuit that will allow machine to start only if the propulsion control 19 Figure 4 7 is in neutral the brakes are applied and the Emergency Stop 20 switch is reset 2 Securely fasten seat belt across hips ...

Page 71: ...p Figure 4 8 5 Place engine speed control switch 13 Figure 4 9 to Low idle position Figure 4 9 6 Apply parking brake by placing the parking park brake switch 15 Figure 4 9 in the On position 7 Turn ignition switch 12 Figure 4 10 to the ON RUN position and verify that the following occurs a The park brake switch 15 Figure 4 10 indicator light turns On b The control console Alternator Not Charging l...

Page 72: ...fying that the machine will not start with the propulsion control lever in a position other than the STOP position 11 Return ignition switch 12 Figure 4 10 to the STOP position 12 Place the propulsion control lever 19 Figure 4 8 in the STOP center position PROPELLING MACHINE AND OTHER CHECKS VERIFICATIONS WHILE ENGINE IS RUNNING NOTE If any controls or devices do not function correctly do not oper...

Page 73: ... 13 Figure 4 12 to Low idle position Figure 4 12 3 If applied reset the emergency stop switch STOP 20 Figure 4 11 by pulling upward on the switch Engine will not crank if emergency stop switch is depressed 4 Be sure Park Brake switch 15 Figure 4 12 is in the Applied position The engine will not crank if Park Brake is in the Off position ...

Page 74: ...rect operation of the steering system with the engine running Turn the steering wheel fully to the left and then to the right The movement of the steering should be smooth and without hesitation If not do not operate the machine until the condition is corrected 8 With engine running release the parking brake control 15 Figure 4 12 and ensure Brake Light goes out Observe area around machine for per...

Page 75: ... the emergency stop While the propulsion control 19 Figure 4 13 is in the STOP position depress the red emergency STOP 20 NOTE The engine should immediately shut down and the parking brake apply After resetting the emergency brake returning the ignition switch to the STOP position and then turning it ON the parking brake light will illuminate to indicate the brakes are applied A restart of the mac...

Page 76: ...e the machine until the condition s is corrected 3 Monitor and ensure horn and back up alarm functions and ensure that optional lights properly illuminate the working area 4 Monitor working area for obstacles and persons 5 Always move the steering wheel slowly and monitor the steering action 6 Always apply the parking brake turn off the engine and remove the ignition key before leaving the operato...

Page 77: ...s 5 The High or Low speed range must be selected on the speed range selector switch 14 Figure 4 16 prior to moving the machine The High speed range should only be used when traveling between work sites The Low speed range should always be used when compacting or traveling inclined surfaces Do not shift speed range switch at speeds above 5 km h 3 m p h 6 Press and hold release pushbutton 17 Figure ...

Page 78: ...tion by depressing switch end marked Select low amplitude for final or thin layer of soil and when soil is loose and granular by depressing switch end marked Figure 4 18 Drum Vibration Frequency Selection 1 Select frequency by rotating the selector switch 2 Figure 4 18 to the desired frequency The dial is marked with the ranges of vibration frequency for high and low amplitude Refer to Table below...

Page 79: ...ection Drum Vibration On Off Selection 1 Press button switch 14 Figure 4 19 on the propulsion control lever to turn On drum vibration Press again to turn drum vibration Off Figure 4 19 Only switch on drum vibration while unit is in motion Always switch off vibration before machine comes to a halt and never allow machine to vibrate when stationary TYPES OF SOIL NATURAL FREQUENCY Sand Uniformly Grad...

Page 80: ...ction 1 Safety Loading the machine under its own power drive on for transporting 1 Choose level ground which will solidly support the vehicle 2 Clean the trailer surface and loading ramps 3 Before loading machine chock the wheels of the trailer 4 A signalman must assist the operator with any necessary warnings 5 Approach the transporter loading ramps squarely to make sure machine does not drop off...

Page 81: ...llowing procedure to raise the operator s platform WARNING Crush area Can cause severe injury or death Stay clear when raising or lowering the operator platform 1 Shut off the engine 2 Remove thumb screws 1 Figure 4 20 from each side of the step assembly 2 Figure 4 20 3 Lift up on the step assembly 2 Figure 4 20 until the pins in the step assembly can be disengaged from the slots in the battery bo...

Page 82: ...nd attach with pin 5 and clip 6 7 Adjust ratchet mechanism 8 Figure 4 21 to the raise position Move lever 1 in the appropriate direction to raise the operator platform enough to remove force from ROPS support bolts 1 Figure 4 22 Figure 4 22 8 Remove bolts from the hydraulic tank side of the frame Then remove the bolts from the jack side of the ROPS support 1 9 Continue raising the platform using j...

Page 83: ...ove jack lever 1 Figure 4 21 install it in the jack then and secure it with the pin 2 Figure 4 21 2 Adjust ratchet mechanism 8 Figure 4 21 to the lowering position Move lever 1 in the appropriate position to lower the operator platform until the bolt holes in the ROPS support are aligned with the bolt holes in the frame Install bolts 1 Figure 22 in the hydraulic tank side of the frame Item 2 Figur...

Page 84: ...0F DX 190DX 200F DX Figure 4 24 4 Torque all four ROPS support bolts to 895 N m 660 lb ft 5 Disconnect jack 3 Figure 4 25 from clevis plate 4 by removing clip 6 and pin 5 6 Reposition jack to mounting lug 7 Figure 4 25 and attach with pin 5 and clip 6 Figure 4 25 ...

Page 85: ... system has been disabled the towing machine is the only means of restraining the compactor while being towed Tow only on level ground or up a slight grade Since the compactor braking system has been disabled the towing machine is the only means of restraining the compactor while being towed Chock the disabled compactor whenever towing has stopped Refer to Transporting Towing and Roading in Sectio...

Page 86: ...re that the Parking BRAKE Control 15 Figure 4 26 is in the Applied position Figure 4 26 3 Raise the operator s platform per instructions on Page 4 17 to gain access to SD 116 and SD 122 propulsion pump 1 Figure 4 27 and multi function valves 2 The propulsion pump shown in Figure 4 28 is supplied on the SD 160 SD 190 and the SD 200 The procedures are similar Figure 4 27 ...

Page 87: ...to the full Forward or Reverse position 6 Lower the operator s platform See page 4 19 NOTE If the engine will not run a portable hydraulic pressure source Porta Power is required to release the brakes prior to towing the compactor NOTICE Dirt in the hydraulic system will lead to premature component failure A clean contaminant free system is extremely important to the machine s proper function Take...

Page 88: ... 8 Thread a tee fitting into drum drive motor and connect brake line to the tee NOTICE Do not exceed 24 bar 350 psi Excessive pressure may result in seal damage 9 Connect a Porta Power to the tee and pressurize the system to 24 bar 350 psi to release the brakes 10 Secure the Porta Power to the drum frame ...

Page 89: ...m RESTORING OPERATION OF THE PROPULSION PUMP AND APPLYING THE BRAKE 1 Chock the wheels and drum 2 Relieve the Porta Power hydraulic pressure 3 Disconnect the Porta Power remove the tee and connect the brake line 4 Move the Propulsion Travel Control to the NEUTRAL position 5 Raise the operator s platform per instructions on Page 4 17 to gain access to SD 116 and SD 122 propulsion pump 1 Figure 4 31...

Page 90: ...ition pull the emergency stop up and verify the park brake switch is illuminated to indicate the parking brake is applied 9 Check the parking brake using the parking brake test switch procedures identified in Section 5 of these instructions 10 Close the hood of the engine compartment TOWING THE MACHINE WITH TOW VALVE WARNING Machine runaway condition could occur Always chock the drum and wheels of...

Page 91: ...er malfunction it may become necessary to tow your compactor Towing the compactor requires bypassing the propulsion pump and releasing the spring applied brakes Procedures to do so are described below NOTE The propulsion pump is designed with a bypass function that consists of two multi function valve cartridges used to disengage the propulsion system In order to tow the compactor the propulsion p...

Page 92: ...RNING Return this tag to its storage position only after the brakes and propulsion pump have been returned to their normal conditions NOTE Hydraulic pressure to release the brake is supplied via a machine mounted hand pump 1 Figure 4 35 equipped with a pressure gauge 2 It is located in the battery compartment 6 Access the battery compartment ...

Page 93: ...il you feel the knob drop into retracted detent 9 Using the hand pump 1 Figure 4 35 pressurize the system to 24 bar 350 psi registered on the gauge to release the brakes Figure 4 35 10 Raise the operator s platform per instructions on Page 4 17 to gain access to SD 116 and SD 122 propulsion pump 1 Figure 4 36 and multi function valves 2 The propulsion pump shown in Figure 4 37 is supplied on the S...

Page 94: ...ex 4 to prevent cartridge rotation rotate the middle size hex three revolutions counter clockwise CCW to open the bypass valve Do not rotate more than three revolutions as additional rotation will generate external leakage 12 Lower the operator s platform See page 4 24 13 Move the propulsion control to the full forward or reverse position 14 Remove the chocks and tow the machine 15 Chock the wheel...

Page 95: ...the parking brake is applied only if power is available to the electrical system the ignition key is in the ON position and the E STOP control has not been actuated or has been actuated and returned to the normal operating position 1 Chock the drum and wheels 2 Move the propulsion Travel control to the neutral position 3 Raise the operator s platform per instructions on Page 4 17 to gain access to...

Page 96: ...5 Lower the operator s platform 6 Access the battery compartment 7 Pull and rotate the knob on valve 3 Figure 4 40 90 degrees from the retracted detent position to the extended detent Figure 4 40 8 PRESS and twist the knob on valve 1 Figure 4 40 to return knob to lock position 9 Verify the emergency control is pulled up turn the key to the ON position to verify the brake is applied 10 Check the pa...

Page 97: ...urn this tag to its storage position only after the brakes and propulsion pump have been returned to their normal conditions 12 Remove the Warning tag from the steering wheel 13 Return the Warning tag to its stored position in the battery compartment 14 Close the hood of the engine compartment ...

Page 98: ...SECTION 4 OPERATING INSTRUCTIONS 4 34 SD 116F DX 122D F DX 160F DX 190DX 200F DX ...

Page 99: ...SD 116F DX 122D F DX 160F DX 190DX 200F DX 5 1 SECTION 5 MAINTENANCE INSTRUCTIONS ...

Page 100: ...r checks is to ensure the uninterrupted and safe operation of the unit by revealing the need for adjustment caused by normal seat belt wear Prior to conducting any maintenance work ensure that the following instructions are observed 1 Park the machine on firm level ground 2 Shut down the engine and allow it to cool NOTE Replacement of engine oil planetary wheel end gear oil carrier gear oil differ...

Page 101: ...ng values SD 116 SD 122 and SD 160 TF Series 540 N m 400 lb ft SD 190 and SD 200 TF Series 1080 N m 800 lb ft 2 Change the axle wheel ends oil Refer to Page 5 59 for procedures 3 Change the axle differential and brake assembly oil Refer to Page 5 60 for procedure 4 Change the eccentric oil Refer to Page 5 63 or procedures 5 Change the carrier oil Refer to Page 5 64 for procedures 6 Add hydraulic o...

Page 102: ...DULE Function Specification Interval A As Required B 10 Hours Daily C 50 Hours Weekly D 500 Hours Semi Annual E 1000 Hours Annual A B C D E Page Ref Check Air Cleaner Connections and Ducts For Leaks correct as required X 5 10 Checking and Removing the Air Cleaner Primary Element indicator light X 5 10 Checking and Removing the Air Cleaner Primary Element X 5 12 Replacing the Air Cleaner Elements X...

Page 103: ...rive Belts x 5 27 Lamp Indicator Lights Check X 5 28 Check Parking Brake Using the Parking Brake Test Switch X 5 28 Check Condition Of Drum and Clean X 5 29 Check Drum Scraper Setting X 5 30 Check Seat Belt X 5 30 Check Batteries Cables and Grease Terminals X 5 31 Check Tire Air Pressure 1 1 bar 16 psi X 5 32 Torque Wheel Nuts 550 Nm 407 lb ft X 5 34 Check Air Cleaner Integrity and Filter Elements...

Page 104: ...ion 8 X 5 39 Check Drum Drive Torque Hub Oil Level SD 200 Refer to Section 8 X 5 40 Grease Horizontal Vertical Swivel Pins SD 116 122 160 Refer to Section 8 X 5 41 Grease Horizontal Vertical Swivel Pins SD 190 200 Refer to Section 8 x 5 42 Clean The Carrier Breather x 5 43 Grease The Carrier Seal Refer to Section 8 x 5 43 Grease Steering Cylinder Pins Refer to Section 8 x 5 44 Change Engine Oil an...

Page 105: ... Change Fuel Filter SD 190 and 200 205 HP Tier 2 Electronic Engine x 5 53 Change Fuel Filter Water Separator Element SD 190 and 200 203 HP Tier 3 Electronic Engine 5 54 Clean Axle Breathers X 5 55 Grease The Ratchet Jack Refer to Section 8 X 5 56 Check Cooling System Integrity X 5 56 Torque The Horizontal Swivel Pin SD 116 122 and 160 X 5 57 Torque The Vertical Swivel Pin SD 116 122 and 160 5 58 T...

Page 106: ...ier Oil Refer to Section 8 X 5 63 Drain and Flush Radiator Replace Engine Coolant x 5 66 Drain and Clean Hydraulic Tank and Three Hydraulic Suction Strainers X 5 69 Check Engine Belt and Tensioner X 5 70 Adjust and Set Valve Clearance X 5 71 Change Drum Drive Torque Hub Oil SD 116 122 160 and 190 Refer to Section 8 x 5 71 Change Drum Drive Torque Hub Oil Level SD 200 Refer to Section 8 x 5 72 MAIN...

Page 107: ... to open the fiberglass hood Figure 5 1 1 Open and remove the lock 1 Figure 5 1 from the draw latch 2 Figure 5 1 2 Pull down the draw latch 2 Figure 5 1 on both sides of the machine Figure 5 2 3 To open the hood pull up the handle 3 Figure 5 2 away from you until it catches inside the prop pin 4 To close the hood pull the prop pin handle 1 Figure 5 3 outwards ...

Page 108: ...ine are tight and sealed Checking and Removing the Air Cleaner Primary Element Maintenance of the air cleaner is due only when the air cleaner restriction indicator light located on the operator s console is illuminated This indicates that the air cleaner is plugged and requires attention The air cleaner is a dry type with two elements A primary element that is replaceable or can be cleaned and a ...

Page 109: ...e Never service the air cleaner while the engine is running 1 Open clip 1 Figure 5 4 and remove air filter housing cover 2 to access the filter elements Check evacuator valve 3 to see that it is not inverted damaged or plugged Figure 5 4 2 Gently remove primary filter element 1 Figure 5 5 Figure 5 5 TIER II ENGINES TIER III ENGINES ...

Page 110: ...tective clothing is worn to protect eyes and exposed parts of the body NOTICE Excessive air pressure can damage the primary air element Air pressure should not exceed 6 89 bar 100 psi from a 3 cm 1 8 inch diameter nozzle located 5 cm 2 in away from the filter Excessive water pressure can damage the primary air element Pressure should not exceed 2 75 bar 40 psi from a water hose Do not use a nozzle...

Page 111: ...s with the air nozzle Inspect for holes and tears by looking through the primary air cleaner element toward a bright light Check for damaged gaskets or dented metal parts DO NOT REUSE DAMAGED AIR CLEANER ELEMENTS WARNING Never use gasoline or solvents to clean the elements Gasoline and solvents are extremely flammable and may cause serious injury or death 2 To clean the primary air cleaner element...

Page 112: ... filter element before reusing Circulate warm air at LESS than 71 C 160 F DO NOT USE A LIGHT BULB TO DRY THE PRIMARY FILTER ELEMENT Inspect for holes and tears by looking through the primary filter element toward a bright light Check for damaged gaskets or dented metal parts DO NOT REUSE DAMAGED FILTER ELEMENTS Protect the filter from dust damage while drying Replacing the Air Cleaner Elements 1 E...

Page 113: ...orn or perforated pleats are present Records indicate the primary element has been replaced three times or 1 year duration has passed since the last replacement 5 Carefully install the replacement safety element 1 Figure 5 10 by pushing it straight into housing 6 Carefully install the cleaned or replacement primary element 1 Figure 5 9 7 Ensure the evacuator valve 3 Figure 5 11 is clear 8 Install ...

Page 114: ...These areas include the vertical and horizontal swivel pins and bushings and cylinder pins if the fittings are not plugged with a pipe plug Plugs indicate a maintenance free bearing Refer to Section 8 for complete lubrication specifications The complete machine must be given a weekly cleaning Daily cleaning will be required if material is adhering to the drum NOTICE Protect all electrical componen...

Page 115: ... 2 Clean the evacuator valve 3 Figure 5 11 and inspect the rubber for cracks Replace as required After cleaning 1 Remove all material added for protection from water entry 2 Grease fittings immediately with the exception of the optional self lubricating bearings 3 Check for defects in the air cleaner ducts and correct as required 4 Check air intake for accumulation of debris that could restrict ai...

Page 116: ... if they have been loosened Check All Shock Mounts 1 Check all shock mounts 1 Figure 5 14 periodically for looseness or deterioration Figure 5 14 2 Replace shock mounts one at a time that have torn or excessively cracked rubber Torque all capscrews and nuts as necessary 10 HOUR OR DAILY ROUTINE MAINTENANCE Check Engine Oil Level 1 Park machine on stable level surface and shut down engine 2 Wait at...

Page 117: ...el The oil level must be between the full top mark and low bottom mark 5 If oil level is low add oil through the fill area 2 Figure 5 15 for Tier 2 engines 1 Figure 5 16 for Tier 3 engines to bring oil to the proper level Refer to Section 8 for oil specifications 6 Start engine allow to run for one minute and recheck oil level Add oil as necessary ...

Page 118: ...llow it to cool down before removing the radiator cap Remove cap slowly to relieve pressure Avoid contact with steam or escaping fluid 1 Check engine coolant level by observing the level in the coolant recovery bottle 1 Figure 5 17 Coolant level should be at the COLD level mark if the engine is cold or at the HOT level if the engine is at operating temperature If required add a 50 50 mixture of an...

Page 119: ...ng fins If dry dust is present use compressed air to clean 4 In case of severe clogging due to fluid leaks apply diesel fuel or a commercial cleaning detergent Let it soak in then wash it off with a water jet Check Fuel Level WARNING Fuel is flammable May cause severe injury or death Shut down the engine extinguish all open flames and do not smoke while filling the tank Always wipe up any spilled ...

Page 120: ... DX 160F DX 190DX 200F DX Figure 5 19 Figure 5 20 NOTICE Never allow fuel tank to completely empty otherwise the entire fuel system will require bleeding The fuel tank should always be filled with 2 diesel fuel at the end of the shift to prevent condensation ...

Page 121: ...or Figure 5 21 Figure 5 21 Filter water separator Figure 5 21 must be drained of accumulated water and sediment daily To drain the water follow the steps listed below 1 Park machine on stable level surface and shut down engine 2 Open the hood 3 Place a container under the drain valve to catch any liquid 4 Inspect the see thru spin on bowl 1 Figure 5 21 5 Open the containment drain valve 2 Figure 5...

Page 122: ...t be drained of accumulated water and sediment daily To drain the water follow the steps listed below 1 Park machine on stable level surface and shut down engine 2 Open the hood 3 Open the containment drain valve 1 Figure 5 22 by turning counterclockwise sufficiently to allow contaminants and water to drain If more than 59 mL 2 ounces are removed the fuel filter must be refilled with fuel 4 Close ...

Page 123: ...d of accumulated water and sediment daily To drain the water follow the steps listed below Figure 5 23 1 Park machine on stable level surface and shut down engine 2 Place a container under the drain valve to catch any liquid 3 Open the hood 4 Lift the containment drain valve 1 Figure 5 23 sufficiently to allow contaminants and water to drain If more than 59 mL 2 ounces are removed the fuel filter ...

Page 124: ...ted water and sediment daily To drain the water follow the steps listed below Figure 5 24 1 Park machine on stable level surface and shut down engine 2 Place a container under the drain valve to catch any liquid 3 Open the hood 4 Open the containment drain valve 1 Figure 5 24 by turning counterclockwisesufficiently to allow contaminants and water to drain If more than 59 mL 2 ounces are removed th...

Page 125: ...re 5 25 for cracks 4 Verify the fan is securely mounted 5 Replace fan if damaged and tighten mounting hardware Inspect Cooling Fan Drive Belts 1 Park machine on stable level surface and shut down engine 2 Open machine hood 3 Inspect the drive belt Figure 5 26 for damage Transverse across the belt width cracks are acceptable Longitudinal direction of the belt length are not acceptable and the belt ...

Page 126: ... parking brake is capable of holding the machine from moving with the parking brake applied engine running propulsion lever release pushbutton depressed and the propulsion control moved forward or reverse This must be done with the parking brake switch 15 ON and the light illuminated When the parking brake switch is ON it disables the propulsion control 19 Figure 5 28 Pushing the test switch 16 on...

Page 127: ... If the parking brake is working correctly the machine will not move If the parking brake is not working correctly and movement is observed contact service personnel immediately and do not use machine until corrected Check Condition of Drum and Clean 1 Park the machine on a level surface and turn off the engine 2 Perform a visual inspection of the drum assembly 1 Figure 5 29 and remove all adherin...

Page 128: ...ow the scraper drum clearance to be less than 20 mm 0 79 in or more than 25 mm 0 98 in Check Seat Belt CHECK the seat belt regularly for wear or damage Inspect belt hardware and fabric Replace if hardware is damaged or if strap is nicked frayed or loose sticking is found Seat belt assemblies should be replaced every 3 years regardless of appearance Seat belt strength degrades over time and use due...

Page 129: ... can ignite and explode Skin and eye contact with the battery fluid can cause injury Do not smoke when observing battery fluid level Avoid skin and eye contact with the battery fluid If contact occurs flush area immediately with water The standard batteries 1 Figure 5 30 require the following for machine use Figure 5 30 Keep connections tight Clean terminals and apply a small amount of grease to p...

Page 130: ...qualified person should Ensure the rim is clean and rust free GENEROUSLY lubricate both tire and rim with rubber lubricant NEVER inflate the tire to OVER 2 4 bar 35 psi to seat beads Excessive inflation pressure when seating beads may cause tire and rim assembly to burst and cause severe injury CHECK to ensure normal operating pressure is not above 1 1 bar 16 psi WARNING The tires on this machine ...

Page 131: ...tires are cold using an appropriate pressure gauge Normal tire pressure is 1 1 bar 16 psi Placing water in tires is an economical means of adding weight to the wheels of the compactor The addition of calcium chloride to the water is recommended to prevent the water from freezing If a tire with ballast is replaced the replacement tire must also contain an equal amount of ballast Contact your Ingers...

Page 132: ... checks until they are properly seated Check Air Cleaner Integrity and Filter Elements To verify the air cleaner system is functioning properly refer to pages 5 10 through 5 16 for checks and procedures Check Hydraulic Oil Level NOTICE Dirt in the hydraulic system will lead to premature component failure A clean contaminant free system is extremely important to the machine s proper function Take e...

Page 133: ...ion 8 Be sure to install fill plug Figure 5 33 Check Eccentric Oil Level 1 Park the machine on a level surface with the drum index at the 12 o clock position and shut off engine This will place the eccentric fill plug 1 Figure 5 34 in the 12 o clock position This will also locate the drain plug 2 in the 6 o clock position and the sight gauge 3 Figure 5 34 and Figure 5 35 in the 4 o clock position ...

Page 134: ...ection 8 for oil specifications Figure 5 35 3 Install plug 1 Figure 5 34 and wipe up excess oil Check Wheel Ends Oil Levels 1 Park the machine on a level surface with the wheel end oil level check plug 1 Figure 5 36 located in the 9 o clock 2 or the 3 o clock 3 position and shut off engine Figure 5 36 2 Allow wheel end to cool if necessary 3 Clean around plug and remove 4 Verify oil level is at th...

Page 135: ...o cool if necessary 3 Clean around level check plug 1 Figure 5 37 on the lower side of the carrier and remove Drain plug 2 is located at 6 o clock Figure 5 37 4 Check oil level Oil should be level with the bottom of level check plug hole 1 Figure 5 37 5 If necessary remove breather 1 Figure 5 38 and add oil until oil runs out of hole 1 Figure 5 37 Refer to Section 8 for oil specifications Figure 5...

Page 136: ... oil level check plug 1 Figure 5 39 Figure 5 39 4 Verify oil is to the bottom of hole 5 If not add oil until level with hole Refer to Section 8 for oil specifications 6 Clean insert and tighten plug Wipe up excess oil Check Axle Differential Brake Oil Level 1 Park the machine on a level surface and shut off engine 2 Allow axle differential case to cool if necessary 3 Remove oil fill level check pl...

Page 137: ...um Drive Torque Hub Oil Level SD 116 122 160 and 190 TF 1 Park machine on level ground apply park brake 2 Allow drive motor case to cool if necessary Figure 5 41 3 Remove the allenhead oil level check plug 1 Figure 5 41 located at the 4 o clock position 4 Verify oil is to the bottom of the hole 5 If filled correctly replace plug and clean up any excess oil 6 If not filled correctly remove fill loc...

Page 138: ...ition to drain oil with the use of a clear standpipe supplied with the SD 200 Access to the spring loaded can is thru access holes in the drum drive mounting bracket 1 Park the machine on a level surface with the single drain fill port on the drive aligned with access hole 1 Figure 5 43 2 Allow drive motor case to cool if necessary Figure 5 43 3 Remove one of the two hex allen head oil fill level ...

Page 139: ...ring loaded cap Add oil until oil runs out of level check hole 2 Figure 5 43 Refer to Section 8 for lubrication information 6 Clean insert and tighten plug 7 Wipe up any excess oil Grease Horizontal Vertical Swivel Pins SD 116 122 160 TF 1 Clean the vertical pin fittings 1 Figure 5 45 and horizontal swivel pin 2 grease fittings Figure 5 45 2 Apply five shots of MPG EP2 grease to each fitting ...

Page 140: ...2D F DX 160F DX 190DX 200F DX Grease Horizontal Vertical Swivel Pins SD 190 200 TF 1 Clean the vertical pin 1 Figure 5 46 and horizontal swivel pin 1 Figure 5 47 grease fittings Figure 5 46 Figure 5 47 2 Apply five shots of MPG EP2 grease to each fitting ...

Page 141: ...e left side of the drum Figure 5 48 2 Remove the hex head breather 3 Cover the breather port to avoid contaminants entering the carrier 4 Thoroughly clean the breather in solvent and dry 5 Replace the breather Grease the Carrier Seal 1 Grease the carrier grease seal 1 Figure 5 49 by greasing the carrier grease seal fitting 2 with grease until it exits the seal 1 Refer to Section 8 lubricant specif...

Page 142: ...rain into the ground Dispose of properly Grease Steering Cylinder Pins 1 Clean the two grease fittings 1 Figure 5 50 and apply three shots of MPG EP2 grease Figure 5 50 2 Refer to Section 8 for lubricant specification Change Engine Oil and Filter 1 Park the machine on a level surface after allowing the water to reach operating temperature then shut off the engine 2 Place a container with a capacit...

Page 143: ...0F DX 5 45 Figure 5 51 3 Remove the engine oil drain plug 4 Clean the area around the head of oil filter 1 Figure 5 52 for Tier 2 engines 1 Figure 5 53 for Tier 3 engines and remove the filter using a 90 95 mm filter wrench Catch any escaping oil in a container Figure 5 52 ...

Page 144: ...s 8 Install the filter as specified by filter manufacturer Mechanical overtightening may distort the threads or damage the filter element seat 9 Clean drain plug install and torque to 80 N m 59 lb ft 10 Tier 3 Engines Remove the dipstick 1 Figure 5 54 Figure 5 54 11 All Engines Fill crankcase with motor oil through the fill area 2 Figure 5 55 for Tier 2 engines 1 Figure 5 54 for Tier 3 engines unt...

Page 145: ...3 Dispose of used oil in accordance with local regulations 14 Run machine and check for leaks Change Three Hydraulic Oil Filters This machine is equipped with three hydraulic oil filters The filters are located behind the cover 1 Figure 5 56 directly above the hydraulic oil tank 2 Figure 5 56 They include the charge pressure filter 1 Figure 5 57 the suction filter 2 and the return filter 3 ...

Page 146: ... system is extremely important to the machine s proper function Take extra care when working around or on the hydraulic system to ensure its complete cleanliness 1 To change the hydraulic oil filters position the machine on a stable level surface and shut off engine 2 Remove bolt and lower cover 3 Unscrew the three filters and discard in accordance with local guidelines 4 Clean the sealing surface...

Page 147: ...y spilled fuel The in line fuel filter will eventually clog from accumulated sediment To prevent this the in line fuel filter must be replaced at the same time that the primary fuel filter is changed Perform the steps outlined below to replace the in line fuel filter 1 Park machine on a stable level surface and shut down the engine 1 Figure 5 58 Figure 5 58 2 Open the hood and locate the filter 3 ...

Page 148: ...severe injury or death Shut down the engine extinguish all open flames and do not smoke while filling the tank Always wipe up any spilled fuel The in line fuel filter will eventually clog from accumulated sediment To prevent this the in line fuel filter must be replaced at the same time that the primary fuel filter is changed Perform the steps outlined below to replace the in line fuel filter 1 Pa...

Page 149: ...If necessary refer to engine manufacturer s manual for information on bleeding the system 9 Check for any leaks Change Fuel Filter Water Separator Element SD 116 SD 122 TF 155 HP Electronic Engine SD 122 SD 160 TF 173 HP Mechanical Engine WARNING Fuel is flammable May cause severe injury or death Shut down the engine extinguish all open flames and do not smoke while filling the tank Always wipe up...

Page 150: ...tighten DO NOT OVERTIGHTEN 9 With vent plug 1 Figure 5 60 loosened operate primer pump 5 until fuel purges the vent plug 1 10 Close vent plug 1 Figure 5 60 start the engine and check for leaks Change Fuel Filter SD 116 SD 122 TF 155 HP Electronic Engine SD 122 SD 160 TF 173 HP Mechanical Engine WARNING Fuel is flammable May cause severe injury or death Shut down the engine extinguish all open flam...

Page 151: ...sealing gasket 6 Fill the element with clean fuel 7 Spin the element onto the filter head according to instructions on element 8 Start the engine and check for leaks Change Fuel Filter SD 190 and SD 200 TF 205 HP Tier II Electronic Engine WARNING Fuel is flammable May cause severe injury or death Shut down the engine extinguish all open flames and do not smoke while filling the tan Always wipe up ...

Page 152: ... engine and check for leaks Change Fuel Filter Water Separator Element SD 190 and SD 200 TF Tier III 203 HP Electronic Engine WARNING Fuel is flammable May cause severe injury or death Shut down the engine extinguish all open flames and do not smoke while filling the tank Always wipe up any spilled fuel The engine fuel water separator filter removes water rust particles dust and other particles fr...

Page 153: ...instructions printed on the side 7 If fuel filter is changed according to these instructions no manual bleeding of fuel lines should be required If necessary refer to engine manufacturers manual for information on bleeding the system 8 Check for any leaks Clean Axle Breathers 1 Thoroughly clean the area around the single axle breathers 1 Figure 5 64 located on the top of the axle Figure 5 64 2 Rem...

Page 154: ... Section 8 for oil specifications 3 Close the battery access door Check Cooling System Integrity 1 Park the machine on a level surface and shut off engine 2 Verify coolant level is normal for engine temperature 3 Inspect radiator and oil cooler hoses for leaks 4 Inspect radiator cap for leaks 5 Check drain petcock and attached hose for condition 6 Inspect radiator fan and belts for damage 7 Check ...

Page 155: ... are not identical on all machines Torque the Horizontal Swivel Pin SD 116 122 and 160 TF 1 Position the machine on stable level surface shutdown the engine 2 Clean area around the horizontal swivel pin 1 Figure 5 66 Figure 5 66 3 Remove mounting hardware 2 and 3 Figure 5 66 4 Torque the horizontal swivel pin 1 Figure 5 66 to 540 Nm 400 lb ft 5 Replace mounting hardware and torque as required ...

Page 156: ...an area around the vertical swivel pin 1 Figure 5 67 Figure 5 67 3 Remove mounting hardware 2 and 3 Figure 5 67 4 Torque the horizontal swivel pin 1 to 540 Nm 400 lb ft 5 Replace mounting hardware and torque as required Torque the Horizontal Swivel Pin SD 190 and 200 TF 1 Position the machine on stable level surface shutdown the engine 2 Clean area around the horizontal swivel pin 1 Figure 5 68 Fi...

Page 157: ...ition the machine on stable level surface shutdown the engine 2 Clean area around the vertical swivel pin 1 Figure 5 69 Figure 5 69 3 Remove mounting hardware 2 and 3 Figure 5 69 4 Torque the horizontal swivel pin 1 Figure 5 69 to 1080 Nm 800 lb ft 5 Replace mounting hardware and torque as required Change Axle Wheel Ends Oil WARNING Hot oil or components can burn Oil must be at normal operating te...

Page 158: ... oil until oil is level with the bottom of the hole Refer to Section 8 for oil specifications 4 Clean and replace level plug 1 Figure 5 70 and tighten 5 Repeat procedure for the other wheel end unit Change Axle Differential Brake Oil WARNING Hot oil or components can burn Oil must be at normal operating temperatures when draining Avoid contact with hot oil or components Do not allow oil to drain i...

Page 159: ...hree drain plugs 1 Figure 5 71 located on the bottom of the axle Remove the three drain plugs Figure 5 71 6 Remove the fill level plug 1 or 2 Figure 5 72 and allow axle to drain completely Discard oil according to local guidelines and environmental regulations Figure 5 72 7 Clean all three drain plugs 8 Replace all three drain plugs and tighten ...

Page 160: ...be at normal operating temperature when draining Avoid contact with hot oil or components Do not allow oil to drain into the ground 1 Position the compactor on level ground allowing machine to run sufficiently so axle transfer case oil reaches operating temperature 2 After properly positioning the machine shut down the engine and apply brake 3 Remove keys 4 Chock tires and drum 5 Remove the fill l...

Page 161: ...l or components can burn Oil must be at normal operating temperature when draining Avoid contact with hot oil or components Do not allow oil to drain into the ground 1 Allow eccentric oil to reach operating temperature and park the machine on a level surface with the drum index angle mounted on the inside of the drum at the 12 o clock position NOTE This positioning will place the eccentric fill pl...

Page 162: ...low oil to drain 4 Clean and replace drain plug 5 Fill eccentric with oil until visible on level gauge 3 Figure 5 75 Figure 5 75 6 Clean and replace fill plug 7 Wipe up any excess oil Change Carrier Oil WARNING Hot oil or components can burn Oil must be at normal operating temperature when draining Avoid contact with hot oil or components Do not allow oil to drain into the ground ...

Page 163: ...fill breather plug 1 Figure 5 76 3 Place a container under drain plug 1 Figure 5 77 Figure 5 77 4 Remove drain plug and allow carrier to drain 5 Clean and replace drain plug 6 Remove level check plug 2 Figure 5 77 7 Add oil until oil runs out of level check plug mounting hole Refer to Section 8 for lubricant instructions 8 Replace level check plug 9 Clean in solvent dry and replace fill breather p...

Page 164: ...llow to cool down before removing radiator cap Remove cap slowly to relieve pressure Avoid contact with steam or escaping fluid The coolant system of any vehicle should be drained and flushed out at least once a year Unless coolant has a corrosion preventive in it rust and scale will eventually clog up the system Any effective commercial flushing agent should be used at least once or twice a year ...

Page 165: ... drain plug 2 Figure 5 80 located on the bottom of the engine water inlet hose connection point Remove the plug and drain the coolant from the engine 4 for damaged hoses and loose or damaged hose clamps Replace as required Check radiator for leaks damage and buildup of dirt Clean and repair as required 5 Clean the cooling system using a commercial radiator flushing product Follow the manufacturers...

Page 166: ...ual for the manufacturer s recommendation for proper ratio of antifreeze to water mixture The addition of a separate lubricant and corrosion inhibitor will guard against internal corrosion and freezing 7 Refill the coolant system 8 Drain and clean overflow bottle 2 Figure 5 81 Refill the overflow bottle with a 50 50 mixture of antifreeze and water Do not fill past the Full mark on the overflow bot...

Page 167: ...lead to premature component failure A clean contaminant free system is extremely important to the machine s proper function Take extra care when working around or on the hydraulic system to ensure its complete cleanliness 1 Position the compactor on level ground allowing machine to run sufficiently so hydraulic oil reaches operating temperature 2 After properly positioning the machine shut down th...

Page 168: ... using procedures previous described in these instructions See Page 5 47 9 Clean and replace the drain plug 10 Fill the hydraulic oil tank to level gauge with clean hydraulic oil from an unopened container Refer to Section 8 Fuel and Lubricant Specifications for details on proper oil NOTE When filling the hydraulic oil tank be sure to filter the oil through a 10 micron filter 11 Run machine and al...

Page 169: ... on level ground apply park brake 2 Allow drive motor case to cool if necessary Figure 5 84 3 Remove the allenhead oil level check plug 1 Figure 5 84 located at the 4 o clock position 4 Position a container under the torque hub 5 Remove drain plug at the 6 o clock location and allow oil to drain 6 Clean and replace drain plug 7 Remove fill plug 1 Figure 5 85 and add oil until oil is level with bot...

Page 170: ...f a clear standpipe supplied with the SD 200 Access to the spring loaded can is thru access holes in the drum drive mounting bracket 1 Park the machine on a level surface with the single drain fill port on the drive located at the 6 o clock location 2 Allow drive motor case to cool if necessary 3 Remove one of the two hex allen head oil fill level check plugs located at the 9 o clock position or 1...

Page 171: ...location the spring loaded fill and drain cap at the 12 o clock position Stop engine and apply brake 7 Insert standpipe into drum drive and fill torque hub with oil until it is level with the bottom of level check hole 1 Figure 5 86 Refer to section 8 for lubrication information 8 Replace level check location plug and clean up any excess oil ...

Page 172: ...SECTION 5 MAINTENANCE INSTRUCTIONS 5 74 SD 116F DX 122D F DX 160F DX 190DX 200F DX ...

Page 173: ...SD 116F DX 122D F DX 160F DX 190DX 200F DX 6 1 SECTION 6 TROUBLESHOOTING ...

Page 174: ...ailures and problems In the event of a failure it is recommended that you read through this manual If you are unable to determine the cause of the problem when following the troubleshooting charts in this section contact your local Ingersoll Rand service office FUSE BLOCK The fuses 1 Figure 6 1 for the compactor are located under the seat as shown Fuse identification rating and circuit are illustr...

Page 175: ...H PARK BRAKE F2 10 AMPS HORN AIR FILTER HYD OIL TEMP F3 10 AMPS TWO SPEED BACK UP F4 15 AMPS LIGHTS BEACON TURNSIGNAL HAZARD F5 5 AMPS AUTO VIB IMPACT METER F6 5 AMPS TRACTION CONTROL F7 10 AMPS POWER PORT F8 30 AMPS THROTTLE SOLENOID PULL IN F9 10 AMPS INSTRUMENT CLUSTER F10 10 AMPS GAUGE OPTIONS F11 10 AMPS CAB OPTIONS F12 15 AMPS SPARE F13 25 AMPS HEATER VALVE BLOWER A C F14 10AMPS FRONT WIPER ...

Page 176: ...elays and diodes illustrated in Figure 6 3 are contained in a harness assembly housing Figure 6 4 located adjacent to the air cleaner mounting bracket Relay C AND F are for ELECTRONIC engine only A decal illustrated as Figure 6 3 is located in the inside of the housing cover Figure 6 3 Figure 6 4 ...

Page 177: ...lace Batteries discharged Charge Batter master switch OFF Turn ON Battery cable connections loose or disconnected Tighten or connect In line fuse link faulted Call for service to replace Starter relay faulted Call for service to replace Defective ignition switch Call for service to replace Starter or starter solenoid defective Call for service to replace Starter Does Rotate Empty fuel tank Fill De...

Page 178: ...er change fuel water separator elements ensure use of correct fuel bleed fuel system Air cleaner element blocked Clean or replace Loose or badly adjusted throttle control cable Adjust or replace cable Incorrect valve clearance Call for specialist service to correct Defective fuel injectors Call for specialist service to correct Fuel pump failure Call for specialist service to correct Defective tur...

Page 179: ...ed air flow Clean cooling fins or clear blockage Radiator cap defective Call for specialist service to correct Thermostat defective Call for specialist service to correct Injector nozzles defective Call for specialist service to correct Incorrect fuel pump calibration Call for specialist service to correct Engine oil level low Add oil to correct level Lubrication system leak Stop engine and check ...

Page 180: ...rake Replace fuse F1 Horn air filter restrictor indicator hydraulic oil temp gauge Replace fuse F2 Two speed control back up alarm Replace fuse F3 Lights beacon turn signals hazard lights Replace fuse F4 Auto vib impact meter Replace fuse F5 Traction control Replace fuse F6 Power port Replace fuse F7 Throttle solenoid pull in Replace fuse F8 Instrument cluster Replace fuse F9 Gauge options Replace...

Page 181: ...cessor and it is operating properly MODE Yellow LED which will blink at a fast six cycles per second rate to indicate software has not been loaded into the control or blink at a slow two cycles per second rate to indicate software has been loaded and no errors have been found by the microprocessor STATUS Red LED will indicate specific faults by an ON OFF blinking four bit code with the time ON ide...

Page 182: ...dicate the length of time the red LED is lit SHORT SHORT LONG SHORT indicates the front coil on the traction control valve controlling the drum drive is outside allowable preset limits LONG SHORT LONG SHORT indicates the rear coil on the traction control valve controlling the drum drive is outside allowable preset limits SHORT LONG LONG SHORT indicates the controller is receiving a signal from the...

Page 183: ...PRESET LIMITS LONG LONG LONG SHORT indicates NO SIGNAL IS BEING RECEIVED FROM THE ECCENTRIC DRIVE MOTOR SPEED SENSOR CAUSE OF FAULTS The Variable Vibration Control faults may be caused by one or more areas of concern Contact Ingersoll Rand for an analysis of fault indication AUTO VIBE IMPACT METER This control which operates in the AUTO MODE only is designed to activate the vibration system when t...

Page 184: ...SECTION 6 TROUBLESHOOTING 6 12 SD 116F DX 122D F DX 160F DX 190DX 200F DX ...

Page 185: ...SD 116F DX 122D F DX 160F DX 190DX 200F DX 7 1 SECTION 7 TECHNICAL SPECIFICATIONS ...

Page 186: ...on is divided into the following sections Machine Identification Environmental Specifications Physical Specifications Machine Dimensions MACHINE IDENTIFICATION Name Address of Manufacturer Ingersoll Rand Construction Technologies Road Development Division 312 Ingersoll Drive Shippensburg Pennsylvania 17257 Phone 717 532 9181 Main Switchboard Phone 1 800 227 0573 Customer Service Parts Name and Typ...

Page 187: ... of Compactors covered in this manual is outlined below Compactor Series Effective with Serial Number SD 116F SD 116DX All initial production SD 122F SD 122D and SD 122DX Effective with S N 172719 including S N 172423 S N 172437 SD 160F SD 160DX Effective with S N 180042 SD 190DX All initial production SD 200F Effective with S N 181198 SD 200DX Effective with S N 180684 ...

Page 188: ...83 dB A with Vibration On A weighted sound power level of the machine Lw 112 0 dB A Vibration On These measurements were recorded in accordance with the requirements of ISO 6394 ISO 6395 and ISO 6396 with the engine running at manufacturer s rated speed Operator s Exposure to Vibration In accordance with the requirements of Clause 3 6 3 a of Annex 1 of Council Directive Relating to Machinery 98 37...

Page 189: ...ith Vibration On A weighted sound power level of the machine Lw 112 0 dB A Vibration On These measurements were recorded in accordance with the requirements of ISO 6394 ISO 6395 and ISO 6396 with the engine running at manufacturer s rated speed Operator s Exposure to Vibration In accordance with the requirements of Clause 3 6 3 a of Annex 1 of Council Directive Relating to Machinery 98 37 EC the f...

Page 190: ...d 85 dB A with Vibration On A weighted sound power level of the machine Lw 112 0 dB A Vibration On These measurements were recorded in accordance with the requirements of ISO 6394 ISO 6395 and ISO 6396 with the engine running at manufacturer s rated speed Operator s Exposure to Vibration In accordance with the requirements of Clause 3 6 3 a of Annex 1 of Council Directive Relating to Machinery 98 ...

Page 191: ...A with Vibration On A weighted sound power level of the machine Lw 113 0 dB A Vibration On These measurements were recorded in accordance with the requirements of ISO 6394 ISO 6395 and ISO 6396 with the engine running at manufacturer s rated speed Operator s Exposure to Vibration In accordance with the requirements of Clause 3 6 3 a of Annex 1 of Council Directive Relating to Machinery 98 37 EC th...

Page 192: ...kg cm 173 lb in PROPULSION Transmission Type of System Hydrostatic 2 speed motors on planetary axle and drum drive w No Spin differential Travel Speed Low Range 4 8 km High 3 0 mph Low High Range 12 5 km High 7 8 mph High ENGINE Model Standard Diesel Cummins QSB5 9 30T Turbo 6 Cyl Tier II EPA Rated Power 2200 rpm 115 6 kW 155 HP Maximum torque 1300 rpm 608 8 N m 449 ft lb Idle High Low 2350 rpm Hi...

Page 193: ... lb in 5876 kg mm 510 lb in MISCELLANEOUS Electrical System 12 Volt DC Negative gnd 95 Amp Alternator Cooling System Capacity 26 5 Liters 28 Quarts Fuel Tank Capacity 257 L 68 Gallons Hydraulic Oil Tank Capacity 84 L 22 2 Gallons Engine Crankcase Capacity 14 2 L 15 Quarts Gear Housing Axle 9 5 L 10 Quarts Transfer Case Axle 1 8 L 1 9 Quarts Planetary Each 2 0 L 2 1 Quarts Drum Eccentrics Capacity ...

Page 194: ...2 lb in PROPULSION Transmission Type of System Hydrostatic 2 speed motors on planetary axle and drum drive w No Spin differential Travel Speed Low Range 4 3 km Low 2 7 mph Low High Range 12 1 km High 7 5 mph High ENGINE Model Standard Diesel Cummins QSB5 9 30T Turbo 6 Cyl Tier II EPA Rated Power 2200 rpm 116 3 kW 156 HP Maximum torque 1300 rpm 608 8 N m 449 ft lb Idle High Low 2457 rpm High 950 rp...

Page 195: ...draulic Oil Tank Capacity 84 L 22 2 Gallons Engine Crankcase Capacity 14 2 L 15 Quarts Gear Housing Axle 9 5 L 10 Quarts Transfer Case Axle 1 8 L 1 9 Quarts Planetary Each 2 0 L 2 1 Quarts Drum Eccentrics Capacity 7 6 L 8 Quarts Drum Drive 3 8L 4 Quarts Carrier Capacity 0 1 L 0 1 Quarts Articulation Angle 38 Oscillation Angle 17 Gradeability Theoretical 68 SD 122D 75 SD 122DX Tire Size 23 1 26 R3 ...

Page 196: ...peed motors on planetary axle and drum drive w No Spin differential Travel Speed Low Range 4 5 km Low 2 8 mph Low High Range 12 7 km High 7 9 mph High ENGINE Model Standard Diesel Cummins 6BT 5 9C T1 Turbo 6 Cyl Tier I EPA Rated Power 2200 rpm 116 3 kW 156 HP Maximum torque 1300 rpm 608 8 N m 449 ft lb Idle High Low 2457 rpm High 950 rpm Low Oil Capacity Crankcase 14 2 L 15 Quarts Oil Filtration S...

Page 197: ...0 kg mm 552 lb in MISCELLANEOUS Electrical System 12 Volt DC Negative gnd 95 Amp Alternator Cooling System Capacity 20 8 Liters 22 Quarts Fuel Tank Capacity 257 L 68 Gallons Hydraulic Oil Tank Capacity 83 3 L 22 Gallons Engine Crankcase Capacity 14 2 L 15 Quarts Gear Housing Axle 9 5 L 10 Quarts Transfer Case Axle 1 8 L 1 9 Quarts Planetary Each 2 0 L 2 1 Quarts Drum Eccentrics Capacity 7 6 L 8 Qu...

Page 198: ...tatic 2 speed motors on planetary axle and drum drive w No Spin differential Travel Speed Low Range 4 5 km Low 2 8 mph Low High Range 12 5 km High 7 7 mph High ENGINE Model Standard Diesel Cummins B5 9 TAA 6 Cyl CAC Rated Power 2200 rpm 129 0 kW 173 HP Maximum torque 1300 rpm 718 6 N m 530 ft lb Idle High Low 2457 rpm High 1000 rpm Low Oil Capacity Crankcase 14 2 L 15 quarts Oil Filtration Spin on...

Page 199: ... in 9044 kg mm 785 lb in MISCELLANEOUS Electrical System 12 Volt DC Negative gnd 95 Amp Alternator Cooling System Capacity 26 5 Liters 28 Quarts Fuel Tank Capacity 257 L 68 Gallons Hydraulic Oil Tank Capacity 104 L 27 5 Gallons Engine Crankcase Capacity 14 2 L 15 Quarts Gear Housing Axle 11 4 L 12 Quarts Transfer Case Axle 1 8 L 1 85 Quarts Planetary Each 3 6 L 3 8 Quarts Drum Eccentrics Capacity ...

Page 200: ...tic 2 speed motors on planetary axle and drum drive w No Spin differential Travel Speed Low Range 4 7 km Low 2 9 mph Low High Range 13 1 km High 8 1 mph High ENGINE Model Standard Diesel Cummins B5 9 TAA 6 Cyl CAC Rated Power 2200 rpm 129 0 kW 173 HP Maximum torque 1300 rpm 718 6 N m 530 ft lb Idle High Low 2457 rpm High 1000 rpm Low Oil Capacity Crankcase 14 2 L 15 quarts Oil Filtration Spin on F...

Page 201: ...747 lb in 11349 kg mm 985 lb in MISCELLANEOUS Electrical System 12 Volt DC Negative gnd 95 Amp Alternator Cooling System Capacity 26 5 Liters 28 Quarts Fuel Tank Capacity 257 L 68 Gallons Hydraulic Oil Tank Capacity 104 L 27 5 Gallons Engine Crankcase Capacity 14 2 L 15 Quarts Gear Housing Axle 11 4 L 12 Quarts Transfer Case Axle 1 8 L 1 85 Quarts Planetary Each 3 6 L 3 8 Quarts Drum Eccentrics Ca...

Page 202: ...4 6 km h Low 2 8 mph Low High Range 12 4 km h High 7 7 mph High ENGINE Prior to S N 185573 Model Standard Diesel Cummins QSB5 9 44 TAA Electronic 6 Cyl Tier II Rated Power 2200 rpm 152 9 kW 205 HP Maximum torque 1500 rpm 928 7 N m 685 ft lb Idle High Low 2350 rpm High 1000 rpm Low Oil Capacity Crankcase 14 2 L 15 quarts Oil Filtration Spin on Fuel Filtration 2 Filters Spin on and in line Fuel Syst...

Page 203: ...ed 344 kN 77400 lb 463 kN 104100 lb Nominal Amplitude Eccentric 1 28 mm 0 050 in 1 97 mm 0 078 in Eccentric Moment 5876 kg mm 510 lb in 9044 kg mm 785 lb in MISCELLANEOUS Electrical System 12 Volt DC Negative gnd 95 Amp Alternator Cooling System Capacity 27 Liters 28 5 Quarts Fuel Tank Capacity 257 L 68 Gallons Hydraulic Oil Tank Capacity 104 L 27 5 Gallons Engine Crankcase Capacity 14 2 L 15 Quar...

Page 204: ...e 4 4 km Low 2 7 mph Low High Range 12 7 km High 7 9 mph High ENGINE Prior to S N 185573 Model Standard Diesel Cummins QSB5 9 44 TAA Electronic 6 Cyl Tier II Rated Power 2200 rpm 152 9 kW 205 HP Maximum torque 1500 rpm 928 7 N m 685 ft lb Idle High Low 2350 rpm High 1000 rpm Low Oil Capacity Crankcase 14 2 L 15 quarts Oil Filtration Spin on Fuel Filtration 2 Filters Spin on and in line Fuel System...

Page 205: ... kN 83700 lb 502 kN 112800 lb Nominal Amplitude Eccentric 1 14 mm 0 045 1 76 mm 0 069 Eccentric Moment 6360 kg mm 552 lb in 9816 kg mm 852 lb in MISCELLANEOUS Electrical System 12 Volt DC Negative gnd 95 Amp Alternator Cooling System Capacity 27 Liters 28 5 Quarts Fuel Tank Capacity 257 L 68 Gallons Hydraulic Oil Tank Capacity 104 L 27 5 Gallons Engine Crankcase Capacity 14 2 L 15 Quarts Gear Hous...

Page 206: ...e 4 6 km Low 2 9 mph Low High Range 13 5 km High 8 4 mph High ENGINE Prior to S N 185573 Model Standard Diesel Cummins QSB5 9 44 TAA Electronic 6 Cyl Tier II Rated Power 2300 rpm 152 9 kW 205 HP Maximum torque 1500 rpm 928 7 N m 685 ft lb Idle High Low 2350 rpm High 1000 rpm Low Oil Capacity Crankcase 14 2 L 15 quarts Oil Filtration Spin on Fuel Filtration 2 Filters Spin on and in line Fuel System...

Page 207: ...04 kN 90800 lb 491 kN 110300 lb Nominal Amplitude Eccentric 1 51 mm 0 059 1 99 mm 0 078 Eccentric Moment 8607 kg mm 747 lb in 11349 kg mm 985 lb in MISCELLANEOUS Electrical System 12 Volt DC Negative gnd 95 A Alternator Cooling System Capacity 27 Liters 28 5 Quarts Fuel Tank Capacity 257 L 68 Gallons Hydraulic Oil Tank Capacity 104 L 27 5 Gallons Engine Crankcase Capacity 14 2 L 15 Quarts Gear Hou...

Page 208: ... SPECIFICATIONS 7 24 SD 116F DX 122D F DX 160F DX 190DX 200F DX MACHINE DIMENSIONS Figure 7 1 provides a dimensional outline of the SD 116F DX SD 122D DX Compactors the values of which are defined in Table 7 8 Figure 7 1 ...

Page 209: ...ngth Overall 5895 232 I Front Hub to Bumper 1069 42 1 J Wheel Drum Base 3100 122 K Rear Hub to Bumper 1726 67 9 L Articulation to Front Hub 1475 58 M Articulation to Rear Hub 1625 63 9 N Platform Height 2379 93 6 O Deck Height 1466 57 7 P Curb Clearance 483 19 Q Angle Q 28 28 R Ground Clearance 375 14 8 S Angle S 19 19 T Rolling Radius Tire 683 26 9 U Rolling Radius Drum SD 116DX 752 5 29 6 U Roll...

Page 210: ... 7 TECHNICAL SPECIFICATIONS 7 26 SD 116F DX 122D F DX 160F DX 190DX 200F DX Figure 7 2 provides a dimensional outline of the SD 160DX SD 160F Compactors the values of which are defined in Table 7 9 Figure 7 2 ...

Page 211: ...ront Hub N A N A M Articulation to Rear Hub N A N A N Platform Height 2386 2431 93 9 95 7 O Deck Height 1476 58 1 P Curb Clearance 528 20 8 Q Angle Q 25 25 R Ground Clearance 506 19 9 S Angle S 20 20 T Rolling Radius Tire 683 703 26 9 27 7 U Rolling Radius Drum 800 703 31 5 27 7 V Drum Radius SD 160F 876 34 5 W Turning Radius Inside 3463 136 X Articulation Angle 38 38 Y Oscillation Angle 15 15 NOT...

Page 212: ...TION 7 TECHNICAL SPECIFICATIONS 7 28 SD 116F DX 122D F DX 160F DX 190DX 200F DX Figure 7 3 provides a dimensional outline of the SD 190DX Compactor the values of which are defined in Table 7 11 Figure 7 3 ...

Page 213: ...ht 193 5 7 6 H Length Overall 6280 247 2 I Front Hub to Bumper 1205 47 4 J Wheel Drum Base 3214 126 5 K Rear Hub to Bumper 1862 73 3 L Articulation to Front Hub 1588 62 5 M Articulation to Rear Hub 1626 64 0 N Platform Height 2386 93 9 O Deck Height 1476 58 1 P Curb Clearance 443 17 4 Q Angle Q 19º R Ground Clearance 455 17 9 S Angle S 15º T Rolling Radius Tire 683 26 9 U Rolling Radius Drum 800 3...

Page 214: ... 7 TECHNICAL SPECIFICATIONS 7 30 SD 116F DX 122D F DX 160F DX 190DX 200F DX Figure 7 4 provides a dimensional outline of the SD 200DX SD 200F Compactors the values of which are defined in Table 7 12 Figure 7 4 ...

Page 215: ...o Front Hub 1588 62 5 M Articulation to Rear Hub 1626 64 N Platform Height 2386 2442 93 9 96 1 O Deck Height 1482 1554 58 3 61 2 P Curb Clearance 468 547 18 4 21 5 Q Angle Q 20 20 R Ground Clearance 465 18 3 S Angle S 15 15 T Rolling Radius Tire 683 722 26 9 28 4 U Rolling Radius Drum 825 32 5 V Drum Radius SD 200F 938 36 9 W Turning Radius Inside 3463 136 3 X Articulation Angle 38 38 Y Oscillatio...

Page 216: ...SECTION 7 TECHNICAL SPECIFICATIONS 7 32 SD 116F DX 122D F DX 160F DX 190DX 200F DX ...

Page 217: ...SD 116F DX 122D F DX 160F DX 190DX 200F DX 8 1 SECTION 8 FUEL AND LUBE SPECIFICATIONS ...

Page 218: ... under each interval These intervals are based on average operating conditions In the event of extremely severe dusty or wet operating conditions more frequent lubrication than specified may be necessary All oil levels are to be checked with the machine parked on a level surface and while the oil is cold unless otherwise specified On plug type check points the oil levels are to be at the bottom ed...

Page 219: ...ng 3 During regular lubrication service visually check the entire unit to ensure that capscrews nuts and pins are properly secured 4 Spot check several capscrews and nuts for proper torque If any are found loose a more thorough investigation must be made 5 If a defect is detected which requires special maintenance service stop the machine operation until the defect has been corrected If necessary ...

Page 220: ...SPECIFICATIONS 8 4 SD 116F DX 122D F DX 160F DX 190DX 200F DX LUBRICATION CHART LUBRICATION SCHEDULE CHART Grease Synthetic Trans Oil Engine Oil Fuel Filter s Engine Coolant Engine Oil Filter Hydraulic Oil Hydraulic Oil Filter ...

Page 221: ... 2 IR Multi Purpose Premium Engine Oil SAE 15W 40 3 IR All Season Premium Hydraulic Oil ISO VG 46 VI 140 MIN IR All Season Premium Hydraulic Oil meets specifications for use at temperatures above 12 C 10 F use ISO VG 32 4 IR Synthetic Component Lubricant Synthetic Hydrocarbon w Phosphorus ISO VG 220 5 IR Premium Limited Slip Component Lubricant SAE 80W 90 LS API GL5 Service Legend A Add S Check G ...

Page 222: ...NTER OF SIGHT GLASS 17 ECCENTRIC OIL SA SEEITEM 4 CENTER OF SIGHT GLASS 18 AXLE WHEEL ENDS 2 SA SEEITEM 5 BOTTOM OF LEVEL HOLE 19 AXLE DIFFERENTIAL SA SEEITEM 5 BOTTOM OF LEVEL HOLE 21 CARRIER OIL SA SEEITEM 4 BOTTOM OF LEVEL HOLE 22 AXLE TRANSFER CASE SA SEEITEM 5 BOTTOM OF LEVEL HOLE 23 TORQUE HUB DRUM DRIVE SA SEEITEM 5 BOTTOM OF LEVEL HOLE 24 HORI VERT SWIVEL PINS G MPG EP2 3 SHOTS 25 CARRIER ...

Page 223: ...e Specs Comments 500 HOURS OR SEMI ANNUALLY 30 STEERING CYLINDER PINS G MPG EP2 3 SHOTS EACH 31 ENGINE OIL DF See Item 5 B5 9 C 14 2 L 15 QUARTS QSB5 9 C14 2 L 15 QUARTS 32 ENGINE OIL FILTER C QTY OF 1 33 HYDRAULIC OIL FILTERS 3 C QTY OF 3 36 AXLE BREATHER CL QTY OF I 38 CARRIER BREATHER CL CLEAN WITH SOLVENT 39 RATCHET JACK GR MPG EP2 ...

Page 224: ...22 160 TOTAL 11 8 L 12 5 QT SD 160 190 200 TOTAL 45 CARRIER OIL DF SEEITEM 4 FILL TO LEVEL HOLE 46 ECCENTRIC OIL DF SEEITEM 4 FILL TO CENTER OF SIGHT GLASS 48 HYDRAULIC OIL DF SEEITEM 3 84 L 89 QT SD 116 122 109 L 110 QT SD 160 190 200 49 HYDRAULIC OIL STRAINERS CL QTY OF 3 53 AXLE TRANSMISSION CASE DF SEEITEM 5 1 8 L 1 9 QT 54 TORQUE HUB DRUM DRIVE DF SEEITEM 5 3 7 L 4 QT SD 116 122 160 190 4 L 4...

Page 225: ...ethod of checking for accurate fluid levels is used Table 3 Fluid Oil Approximate Capacity SD 116 155 HP SD 122 155 HP SD 122 173 HP SD 160 173 HP SD 190 205 HP SD 200 205 HP Diesel Fuel 257 Liters 68 Gallon Hydraulic Oil 84 Liters 23 Gallon 104 Liters 28 Gallon Engine Oil 14 2 Liters 15 Quart Engine Coolant 21 Liters 22 Quart 27 Liter 28 Quart Axle Differential Oil 9 5 Liter 10 Quart 11 5 Liter 1...

Page 226: ...le 4 SUBSTANCE PRECAUTION Engine Exhaust Fumes Avoid breathing fumes Engine Exhaust Fumes Avoid buildup of fumes in confined spaces Antifreeze Water cooled engine Avoid ingestion skin contact and breathing fumes Hydraulic Oil Avoid ingestion skin contact and breathing fumes Engine Lubricating Oil Avoid ingestion skin contact and breathing fumes Preservative Grease Avoid ingestion skin contact and ...

Page 227: ...SD 116F DX 122D F DX 160F DX 190DX 200F DX 9 1 SECTION 9 TORQUE SPECIFICATIONS ...

Page 228: ... than 5 16 inch NOTE Use Loctite 242 on bolts 5 16 inch and smaller to fill all gaps between the engaged bolt and nut threads Bolt Coarse Torque Bolt Fine Torque Lbs Ft N m Lbs Ft N m 1 4 20 9 12 1 4 28 11 15 5 16 18 19 26 5 16 24 21 28 3 8 16 37 50 3 8 24 42 57 7 16 14 59 80 7 16 20 66 89 1 2 13 90 122 1 2 20 100 136 9 16 12 130 176 9 16 18 145 197 5 8 11 180 244 5 8 18 205 278 3 4 10 320 434 3 4...

Page 229: ... required they will be indicated in the text Table 2 NOTE Use Loctite 271 on all bolts larger than M8 NOTE Use Loctite 242 on M8 bolts and smaller Apply enough Loctite to fill all gaps between the engaged bolt and nut threads All thread fasteners will have Loctite applied except the following 1 Nylon insert nuts 2 Whizlock bolts and nuts 3 Fasteners less than 1 4 inch diameter 4 If specifically in...

Page 230: ...80 1313 Elbow Flange to Axle Motor M12 105 79 Axle To Rear Frame M20 730 540 Axle Motor To Axle M14 170 125 Hood Spring Angle to Rear Frame M10 61 45 Hood Cowling to Rops Support M8 28 21 Hood Hinges To Hood M8 28 21 Spring Pins To Hinges M12 105 79 Railing to Rops Support M12 105 79 Grill To Hood M8 28 21 Isolators to Rear Frame M12 105 79 Rops To Rops Support Platform M24 635 470 Isolator to Rop...

Page 231: ... 130 Pump Stack Support Bracket To Pump Mounting Plate 173 HP Engine M10 55 41 Vibration Pump To Propulsion Pump 1 2 105 79 Vibration Pump To Propulsion Pump 173 HP Engine 1 2 105 79 Hood Hinge To Rear Frame M16 130 100 Striker To Striker Plate N A 105 79 Rops To Rops Support Platform M24 470 635 Striker Plate To Rops Support M10 61 45 Pedestal Assy To Rops Support Platform M10 61 45 Eyebolt To Ro...

Page 232: ...00 M10 61 45 Spacer To Rear Frame M12 150 110 Bumper To Rear Frame SD 190 and 200 M16 265 195 Cover To Spindle Bearing Housing M8 29 21 Eccentric Motor To Carrier Assy M12 107 79 Drive Motor Assembly To Shock Mount M16 264 195 Drum Shock Mount To Carrier Plate M12 149 110 Shock Mounting Plates To Shock M16 373 275 Wheel To Axle M22 550 407 Drum Drive Motor To Drive Motor Mounting Plate M20 515 380...

Page 233: ...SD 116F DX 122D F DX 160F DX 190DX 200F DX 10 1 SECTION 10 SCHEMATICS ...

Page 234: ...rs with Electronic Engines Drawing No 13309711 pages 10 3 through 10 5 Electrical schematics for the SD 116 SD 122 SD 190 SD 200 Series of Compactors with Electronic Engines Drawing No 13375696 pages 10 6 through 10 8 Electrical schematics for the SD 122 F D DX Compactors with Mechanical Engines Drawing No 13304852 pages 10 9 through 10 11 Electrical schematics for the SD 122 and SD 160 Series of ...

Page 235: ...ing on the type of engine in the machine Electrical Schematic 13309711 Use with Electronic Engine Electrical Schematic 13304852 Use with Mechanical Engine Effective with S N 179959 use one of the Electrical Schematics listed below depending on the type of engine in the machine Electrical Schematic 13375696 Use with Electronic Engine Electrical Schematic 13375704 Use with Mechanical Engine SD 160 S...

Page 236: ...SECTION 10 SCHEMATICS 10 4 SD 116F DX 122D F DX 160F DX 190DX 200F DX ...

Page 237: ...SCHEMATICS SECTION 10 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX 10 5 Electrical Schematics for the SD 116F DX SD 122D F DX Compactors w Electronic Engines 13309711 ...

Page 238: ...SECTION 10 SCHEMATICS 10 6 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX ...

Page 239: ...SCHEMATICS SECTION 10 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX 10 7 ...

Page 240: ... 10 SCHEMATICS 10 8 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX Electrical Schematics for the SD 116F DX SD 122F D D SD 190DX and SD 200F DX Compactors w Electronic Engines 13375696 OM13375696_0B01 ...

Page 241: ...SCHEMATICS SECTION 10 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX 10 9 OM13375696_0B02 ...

Page 242: ...SECTION 10 SCHEMATICS 10 10 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX OM13375696_0B03 ...

Page 243: ...SCHEMATICS SECTION 10 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX 10 11 Electrical Schematics for the SD 122F D DX Compactors w Mechanical Engines 13304852 OM13304852_0C01 ...

Page 244: ...SECTION 10 SCHEMATICS 10 12 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX OM13304852_0C02 ...

Page 245: ...SCHEMATICS SECTION 10 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX 10 13 OM13304852_0C03 ...

Page 246: ...SECTION 10 SCHEMATICS 10 14 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX Electrical Schematics for the SD 122F D DX SD160F DX Compactors w Mechanical Engines 13375704 OM13375704_0B01 ...

Page 247: ...SCHEMATICS SECTION 10 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX 10 15 OM13375704_0B02 ...

Page 248: ...SECTION 10 SCHEMATICS 10 16 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX OM13375704_0B03 ...

Page 249: ...SCHEMATICS SECTION 10 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX 10 17 Hydraulic Schematics for the SD 116F DX Compactors 13238902 ...

Page 250: ...SECTION 10 SCHEMATICS 10 18 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX ...

Page 251: ...SCHEMATICS SECTION 10 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX 10 19 Hydraulic Schematics for the SD 116F DX SD 122F D DX Compactors 13463336 ...

Page 252: ...SECTION 10 SCHEMATICS 10 20 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX ...

Page 253: ...SCHEMATICS SECTION 10 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX 10 21 ...

Page 254: ...SECTION 10 SCHEMATICS 10 22 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX Hydraulic Schematics for the SD 116F DX SD 122F D DX Compactors 13375670 ...

Page 255: ...SCHEMATICS SECTION 10 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX 10 23 ...

Page 256: ...SECTION 10 SCHEMATICS 10 24 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX Hydraulic Schematic for the SD 160F DX Compactors 13365374 ...

Page 257: ...SCHEMATICS SECTION 10 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX 10 25 Hydraulic Schematic for the SD 190DX and SD 200F DX Compactors 13414289 SD 160 SD 190 ...

Page 258: ...SECTION 10 SCHEMATICS 10 26 SD 116F DX SD 122D F DX SD 160F DX SD 190DX SD 200F DX ...

Page 259: ...SD 116F DX 122D F DX 160F DX 190DX 200F DX 11 1 SECTION 11 RECOMMENDED SPARE PARTS ...

Page 260: ...hese spare parts may actually be used depending on how your machine is equipped how frequently your machine is used and how well it is cared for The recommended spare parts are tabulated below grouped by major assemblies and the service interval operating hours Table 11 1 Spare Parts for SD 116 TF Series Compactors Service Interval Hours Component Description CPN 0 1000 1000 3000 3000 Air Cleaner ...

Page 261: ...965377 1 Battery Hold Down 19295492 1 Potted Diode Pack 19281419 1 Diode Assembly 58892449 1 Seat Switch Harness 13165071 1 Switch 58878562 1 Backup Alarm 13236203 Engine 2 2 2 Engine Oil Filter 13360706 2 2 2 Primary Fuel Filter 13284708 1 1 1 In Line Fuel Filter 58827932 1 1 1 Fuel Filter 13217609 1 1 1 Radiator Cap 59498790 1 Solenoid 58875196 1 Coolant Recovery Bottle 58802851 1 Drive Coupling...

Page 262: ...sc Brake 54705447 6 Axle Intermediate Disc Brake 59153759 1 Axle Drive Motor 13321351 1 Bearing 13245337 2 Cable 59436741 1 Cable 59607861 1 Cable Sleeve 59214775 1 Dust Seal 13238423 1 Dust Seal 13238431 1 Ferrule 59607853 1 Fuel Cap 13213574 1 Fuel Sender 13213582 1 Lock 13349212 1 Hood Draw Latch 59162149 1 T Handle 13299581 Hydraulics 1 Hose 40 in 13255179 1 Vibration Pump 13289947 1 Steering ...

Page 263: ...anel 13309521 1 1 1 Horn 13469010 1 1 Horn Button 59159558 1 1 1 Ignition Key 58917261 1 Ignition Switch 54461090 1 Manual Case 59185074 1 1 1 Park Brake Switch 54666094 1 Spacer Steel Platform 13412648 1 Hi Low Travel Switch 54666086 1 Hi Low RPM Switch 54666078 1 Hi Low Amplitude Switch 54666060 1 1 1 Brake Test Switch 54666102 1 Washer Bottle Cap 13228242 1 Spinner Kit 59199141 Side Console 1 E...

Page 264: ...ctric Service Repair Kit 13852009 1 Propulsion Pump Seal Kit 59360384 1 Vibration Pump Seal Kit 58813791 1 Steering Valve Seal Kit 54747340 1 Axle Drive Motor Seal Kit 59019679 1 Drum Drive Motor Seal Kit Gearbox 13462205 Optional Equipment 1 1 1 Beacon Light Lamp 13176797 Air Pre cleaner Option 1 Spring 13460365 1 Air Pre cleaner 59081323 Audible Alarm 1 Audible Alarm 58870294 1 Timer 58870932 Wo...

Page 265: ...13375548 1 Speed Sensor 59249284 Variable Frequency Dual Amplitude 1 Vibration Frequency Knob 59047019 1 Speed Sensor 13254503 1 Vibration Sensor Harness 13493523 Scraper Options 1 1 Scraper Tooth 59175661 1 Scraper Bar 13213913 Cab with Heater and Air Conditioning 1 Heater Valve 13200027 1 Front Wiper Switch 59196451 1 Rear Wiper Switch 59196444 1 Washer Switch 59195925 1 Block Heater 59118521 St...

Page 266: ...y be used depending on how your machine is equipped how frequently your machine is used and how well it is cared for The recommended spare parts are tabulated below grouped by major assemblies and the service interval operating hours Table 11 2 Spare Parts for SD 122 TF Series Compactors Service Interval Hours Component Description CPN 0 1000 1000 3000 3000 Air Cleaner 2 2 2 Primary Filter Element...

Page 267: ...r Diode 59020065 1 Diode Assembly 58892449 1 Potted Diode Pack 19281419 1 1 1 Fuse 5 Amp 59465591 1 1 1 Fuse 10 Amp 59325712 1 1 1 Fuse 15 Amp 59483339 1 1 1 Fuse 30 Amp 58893249 1 Seat Switch Harness 13165071 1 Switch 58878562 1 Audible Alarm 58870294 1 Timer 58870932 1 Backup Alarm 13236203 Engine 2 2 2 Engine Oil Filter Standard 13360706 2 2 2 Primary Fuel Filter Standard 13284708 1 1 1 In Line...

Page 268: ...1 Temperature Sender 59816322 1 Seal Clamp 13093075 1 U Clamp 59534313 1 Muffler 13169537 2 Muffler Clamp 59179218 1 Radiator Hose Bottom 13279666 1 Radiator Hose Top 13168851 1 Starter 13360516 1 Solenoid 58875196 1 Alternator 13852256 Frame 1 Articulation Oscillation Pin 13276795 6 Axle Disc Brake 54705447 6 Axle Intermediate Disc Brake 59153759 1 Axle Drive Motor 54678636 1 Axle Drive Motor Sol...

Page 269: ...action Control Valve 13165659 1 Loop Flushing Valve 59077602 1 Brake Shunt Two Speed Manifold 13205133 1 Hose 40 in 13255179 2 2 2 Pressure Filter Element 13408240 1 1 1 Return Filter Element 13190723 Pedestal Assembly 1 Eyebolt 13214804 1 Instrument Panel 13309521 1 Horn 13469010 1 1 Horn Button 59159558 1 1 1 Ignition Key 58917261 1 Ignition Switch 54461090 1 Manual Case 59185074 1 1 1 Park Brak...

Page 270: ...lternate Action Switch Kit 13382445 1 Top Dust Boot 59108100 1 Bottom Dust Boot 59108605 Rear Wheels 2 2 2 Valve Caps 59929711 2 2 Air Valve 59524447 Kits 1 SD 122 TF Decal Kit U S 13263116 1 SD 122 TF Decal Kit E U 13302633 1 Steering Pump Seal Kit 58898677 1 Propulsion Pump Seal Kit 59360384 1 Vibration Pump Seal Kit 58813791 1 Steering Valve Seal Kit 54747340 1 Electric Service Repair Kit 13852...

Page 271: ...Temperature Gauge 58893983 1 Hydraulic Oil Temperature Sender 58913856 Variable Frequency Dual Amplitude 1 Vibration Frequency Knob 59047019 1 Speed Sensor 13254503 1 Speed Sensor 59249284 1 Vibration Sensor Harness 13493523 Traction Enhancement 1 Speed Sensor 13365325 1 Sensor Assembly 13375548 Scraper and Bolt On Shell Options 1 1 Scraper Tooth 59175661 1 Scraper Bar 13213913 Cab with Heater and...

Page 272: ...73 HP Mechanical Engine 1 Delay Timer 13313655 1 Oil Filter 35387489 1 Primary Fuel Filter 59477570 1 In Line Fuel Filter 58827932 1 Alternator 13852256 1 Starter 59816520 1 Solenoid 58875196 1 Fan Belt 13852272 1 Oil Pressure Switch 59971457 Strike Off Blade 1 Steering Pump 13205497 Seal Kit 13461033 1 Blade Cylinder 13515283 1 Seal Kit 13515770 1 Bearing 50273986 1 Pivot Pin 59683805 1 Dump Swit...

Page 273: ... used depending on how your machine is equipped how frequently your machine is used and how well it is cared for The recommended spare parts are tabulated below grouped by major assemblies and the service interval operating hours Table 11 3 Spare Parts for SD 160 TF Series Compactors Service Interval Hours Component Description CPN 0 1000 1000 3000 3000 Air Cleaner 2 2 2 Primary Filter Element 132...

Page 274: ...ch Harness 13165071 1 1 Alternator Diode 59020065 1 Diode Assembly 58892449 1 Potted Diode Pack 19281419 1 Switch 58878562 1 Water Switch 59636738 1 Audible Alarm 58870294 1 Timer 58870932 1 Backup Alarm 13236203 Engine 2 2 2 Engine Oil Filter 35387489 1 1 1 Fuel Filter 58827932 1 1 1 Radiator Cap 59498790 1 1 Fuel Throttle Solenoid 59009134 1 Solenoid Stop 54651088 1 Coolant Recovery Bottle 58802...

Page 275: ...875196 1 Alternator 13852256 Frame 1 Articulation Oscillation Pin 13276795 1 Axle Drive Motor 13254701 1 Axle Drive Solenoid Valve 59155739 1 Cable 59436741 2 Cable 59607861 1 Cable Sleeve 59214775 1 Dust Seal 13238423 1 Dust Seal 13238431 1 Ferrule 59607853 1 Fuel Cap 13213574 1 Fuel Sender 13213582 1 Lock 13349212 1 Hood Draw Latch 59162149 1 T Handle 13299581 Hydraulics 1 Vibration Pump 1325465...

Page 276: ...sure Filter Element 13467774 1 1 1 Return Filter Element 59764498 Pedestal Assembly 1 Eyebolt 13214804 1 Instrument Panel 13309521 1 1 1 Horn 13469010 1 1 Horn Button 59159558 1 1 1 Ignition Key 58917261 1 Ignition Switch 54461090 1 Manual Case 59185074 1 1 1 Park Brake Switch 54666094 1 Spacer Steel Platform 13412648 1 Hi Low Travel Switch 54666086 1 Hi Low RPM Switch 54666078 1 Hi Low Amplitude ...

Page 277: ... 2 2 2 Valve Caps 59929711 2 2 Air Valve 59524447 Kits 1 SD 160 TF Decal Kit U S 13309190 1 SD 160 TF Decal Kit E U 13446596 1 Horn Field Kit 13483193 1 Throttle Solenoid Linkage Kit 13501408 1 Steering Pump Seal Kit 58898677 1 Propulsion Pump Seal Kit 59360384 1 Vibration Pump Seal Kit 59399253 1 Steering Valve Seal Kit 54747340 Optional Equipment 1 1 1 Beacon Light Lamp 13176797 Air Pre cleaner ...

Page 278: ...83 1 Hydraulic Oil Temperature Sender 58913856 Variable Frequency Dual Amplitude 1 Vibration Frequency Knob 59047019 1 Vibration Sensor Harness 13493523 1 Speed Sensor 13254503 1 Speed Sensor 59249284 Traction Enhancement 1 Speed Sensor Assembly 13375548 Scraper and Bolt On Shell Options 1 1 Scraper Tooth 59175661 1 Scraper Bar 13213913 Strike Off Blade 1 Blade Pump 13323027 1 Blade Valve 13289814...

Page 279: ...l Filter 35387489 1 Primary Fuel Filter 59477570 1 In Line Fuel Filter 58827932 1 Alternator 13852256 1 Starter 59816520 1 Solenoid 58875196 1 Fan Belt 13852272 1 Oil Pressure Switch 59971457 Cab with Heater and Air Conditioning 1 Heater Valve 13200027 1 Front Wiper Switch 59196451 1 Rear Wiper Switch 59196444 1 Switch Blank 58835398 1 Washer Switch 59195925 Block Heater 1 Block Heater 59118521 ...

Page 280: ... how your machine is equipped how frequently your machine is used and how well it is cared for The recommended spare parts are tabulated below grouped by major assemblies and the service interval operating hours Table 11 4 Spare Parts for SD 190 TF Series Compactors Service Interval Hours Component Description CPN 0 1000 1000 3000 3000 Air Cleaner 2 2 2 Primary Filter Element Tier II 13284591 1 1 ...

Page 281: ...9020065 1 Diode Assembly 13322912 1 Audible Alarm 58870294 1 Timer 58870932 1 Backup Alarm 13236203 Engine 2 2 2 Engine Oil Filter Tier II 13284617 2 2 2 Primary Fuel Filter Tier II 13284625 1 1 1 In Line Fuel Filter Tier II 58827932 2 2 2 Engine Oil Filter Tier III 13284617 2 2 2 Fuel Filter Tier III 19295872 1 1 1 Filter 25 Micron Tier III 19280205 1 Fan Belt Tier III 19295914 1 1 1 Radiator Cap...

Page 282: ...rnator 13852256 Frame 1 Axle Drive Motor 13254701 1 Cable 59436741 1 Cable 59607861 1 Cable Sleeve 59214775 1 Ferrule 59607853 1 Fuel Cap 13213574 1 Fuel Sender 13213582 1 Latch 59162149 1 Spring 13460365 1 T Handle 13299581 Hydraulics 1 Vibration Pump 13527965 1 Steering Pump 58859380 1 Propulsion Pump 13254669 1 Propulsion Pump Neutral Start Switch 13228994 1 Steering Valve 13277116 1 Traction C...

Page 283: ... 59159558 1 1 1 Ignition Key 58917261 1 Ignition Switch 54461090 1 Manual Case 59185074 1 1 1 Park Brake Switch 54666094 1 Hi Low Travel Switch 54666086 1 Hi Low RPM Switch 54666078 1 Hi Low Amplitude Switch 54666060 1 1 1 Brake Test Switch 54666102 1 1 Dual Switch Seat Kit 13167945 1 Spinner Kit 59199141 Side Console 1 Emergency Stop Switch 59111450 1 FSR Cable 13320841 1 1 FSR Control 13289921 1...

Page 284: ...tion Pump Seal Kit 59399253 1 Steering Valve Seal Kit 54747340 1 Vibration Motor Seal Kit 59480681 Optional Equipment 1 1 1 Beacon Light Lamp 13176797 Air Pre cleaner Option Air Pre cleaner 59081323 1 1 1 Worklights Bulb 13406764 Worklights 1 Front Rear Worklights Switch 13197108 1 Bulb 13406764 1 Worklights Rework 13359815 Tow Valve Option 1 Three Section Valve 13304878 Gauge Installation 1 Voltm...

Page 285: ...d Sensor 13254503 1 Vibration Sensor Harness 13493523 1 Vibration Pump 13483698 1 Vibration Pump Seal Kit 59985044 Scraper and Bolt On Shell Options 1 1 Scraper Tooth 13294632 1 Scraper Bar 13881040 Cab with Heater and Air Conditioning 1 Heater Valve 13200027 1 Front Wiper Switch 59196451 1 Rear Wiper Switch 59196444 1 Washer Switch 59195925 1 Block Heater 59118521 1 Washer Bottle Cap 13228242 1 S...

Page 286: ...parts may actually be used depending on how your machine is equipped how frequently your machine is used and how well it is cared for The recommended spare parts are tabulated below grouped by major assemblies and the service interval operating hours Table 11 5 Spare Parts for SD 200 TF Series Compactors Service Interval Hours Component Description CPN 0 1000 1000 3000 3000 Air Cleaner 2 2 2 Prima...

Page 287: ...l 1 Oil Pressure Sender 58878000 1 Battery Master Switch 13209648 1 Battery Hold Down 19295492 1 1 1 Fuse 5 Amp 59465591 1 1 1 Fuse 10 Amp 59325712 1 1 1 Fuse 15 Amp 59483339 1 1 1 Fuse 30 Amp 58893249 1 1 1 Relay 58965377 1 1 Alternator Diode 59020065 1 Potted Diode Pack 19281419 1 Diode Assembly 58892449 1 Audible Alarm 58870294 1 Timer 58870932 1 Backup Alarm 13236203 Engine 2 2 2 Engine Oil Fi...

Page 288: ...mp 59495028 1 Insert Clamp 59583468 1 U Clamp 59534313 1 1 1 Radiator Cap 59498790 1 1 Fuel Throttle Solenoid 59009134 1 Coolant Recovery Bottle 58802851 1 Drive Coupling 59286336 1 Oil Pressure Switch 59971457 1 Muffler 13169537 2 Muffler Clamp 59179218 1 Radiator Hose Bottom 13279666 1 Radiator Hose Top 13417894 1 Starter 19295856 1 Alternator 13852256 Frame 1 Axle Drive Motor 13254701 1 Cable 5...

Page 289: ...8994 1 Steering Valve 13277116 1 Traction Control Valve 13165659 1 Loop Flushing Valve 59077602 1 Brake Shunt Two Speed Manifold 13205133 1 Hose 40 in 13255179 1 Speed Sensor 59249284 2 2 2 Pressure Filter Element 13408240 1 1 1 Return Filter Element 13190723 Pedestal Assembly 1 Eyebolt 13214804 1 Instrument Panel 13309521 1 1 1 Horn 13469010 1 1 Horn Button 59159558 1 1 1 Ignition Key 58917261 1 ...

Page 290: ...FSR Control 13289921 1 Switch Alternate Action Kit 13382445 1 Top Dust Boot 59108100 1 Bottom Dust Boot 59108605 Rear Wheels 2 2 2 Valve Caps 59929711 2 2 Air Valve 59524447 Kits 1 SD 200 TF Decal Kit U S 13309190 1 SD 200 TF Decal Kit E U 13446596 1 Steering Pump Seal Kit 58898677 1 Horn Field Kit 13483193 1 Propulsion Pump Seal Kit 59360384 1 Vibration Pump Seal Kit 59985044 1 Steering Valve Sea...

Page 291: ...ree Section Valve 13304878 Gauge Installation 1 Voltmeter 58877796 1 Engine Oil Pressure Gauge 58822313 1 Hydraulic Oil Temperature Gauge 58893983 1 Hydraulic Oil Temperature Sender 58913856 Traction Enhancement 1 Sensor Assembly 13375548 Variable Frequency Dual Amplitude 1 Vibration Frequency Knob 59047019 1 Vibration Sensor Harness 13493523 1 Speed Sensor 13254503 1 Speed Sensor 59249284 Scraper...

Page 292: ...and Air Conditioning 1 Heater Valve 13200027 1 Front Wiper Switch 59196451 1 Rear Wiper Switch 59196444 1 Washer Switch 59195925 1 Switch Blank 58835398 Block Heater 1 Block Heater 59118521 1 Qt 1 Gal 5 Gal 55 Gal IR All Season Premium Hydraulic Oil N A N A 59045179 59045187 IR Multi Purpose Premium Engine Oil 59022343 59023507 57022327 59022335 IR Premium Limited Slip Component Lubricant 13248455...

Page 293: ...moving the Air Cleaner Primary Element 5 10 Cleaning the Primary Air Cleaner Element 5 12 Cluster Indicator Light 3 3 Contact information 5 Control Module Description 6 9 Controls 7 D Daily Precautions After Work 4 16 Danger 1 2 Difficult Starting Poor Irregular Performance 6 6 Dimensions SD 100 7 24 Drain and Clean Hydraulic Tank and Three Hydraulic Suction Strainers 5 69 Drain and Flush Radiator...

Page 294: ...rature Indicator 3 9 Hydraulic Schematics 10 2 I Identification 3 Identification Data 3 Ignition Switch 3 5 Impactmeter 3 4 Indicator Light Cluster 3 3 Ingersoll Rand Machine Symbols 2 2 Initial Break in Maintenance 150 Hours 5 3 Initial Break in Maintenance 50 Hours 5 3 Inspection Pre Start 1 5 Instruction Manual Storage 5 Instructions Safety 1 6 Instrument Cluster 3 8 International 2 3 Interatio...

Page 295: ...ating Suggestions and Checks while Operating Machine 4 12 Operating the Machine 4 12 Organizational 1 5 Organizational Measures 1 5 Overhead Electric Lines 1 12 P Park Brake Test Switch 3 6 Parking Brake Switch 3 6 Periodic Lubrication Schedule 8 5 Power Green LED 6 9 Power Must Be On 8 9 Pre Start Inspection 1 5 Pre Start Checks Verifications 4 3 Propelling Machine and other Checks Verifications ...

Page 296: ... 22 SD 200TF Series Recommended Spare Parts 11 22 11 28 Selection and Qualification of Personnel 1 4 Serial Number and Product Range 10 3 Signal Words 2 2 Special Dangers 1 12 Speed Range Selector Switch 3 5 Speedometer 1 5 Standard International Symbols 2 4 Starting 1 7 Status Red LED 6 9 Steering Wheel 3 4 Stopping 1 9 Storage Pouch 5 Suspension Seat 3 10 System Green LED 6 9 T Tachometer Hourme...

Page 297: ...WORD INDEX SD 116F DX 122D F DX 160F DX 190DX 200F DX 12 5 W Warning 1 2 1 12 Warning of Special Dangers 1 12 Work Light Switch 3 7 ...

Page 298: ......

Page 299: ...ing and maintenance publications This warranty does not cover replacement of scheduled service items such as oil filters and wear items This warranty does not apply to engines including engine electrical components and tires or other accessories and equipment furnished by IR but manufactured by others The initial user shall rely solely on the warranty if any of the respective manufacturers thereof...

Page 300: ... 2006 Ingersoll Rand Company Printed in Sweden Road Development Ingersoll Rand Construction Technologies 312 Ingersoll Drive Shippensburg PA 17257 ...

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