SANY SPR160C-8 User manual
Quality Changes the World
Pneumatic Tire Roller
SPR160C-8
SPR200C-8
Operation and Maintenance Manual
Operation and Maintenance Manual-Oct. 2018
SPR160/200C-8 Pneumatic Tire
Roller
Operation and Maintenance Manual
WARNING
Read and follow the safety precautions and instructions in this manual and on the machine dec-
als. Failure to do so can cause serious injury, death or property damage. Keep this manual with
the machine for reading and future reference.
SPR160/200C-8 Pneumatic Tire Roller
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Operation and Maintenance Manual-Oct. 2018
SPR160/200C-8 Pneumatic Tire Roller
Sany Group
SANY Automobile Manufacturing CO.,LTD
Sany Industry Zone
Economic & Technical Development Zone
Changsha, Hunan, China 410100
http://www.sanyglobal.com
Tel: 0086-4006098318
Scan here to download the GCP APP
APP for Android & iOS
©2018 by Sany Group. All rights reserved. No part of this publication may be reproduced, used, distributed
or disclosed except for normal operation of the machine as described herein. All information included within
this publication was accurate at the time of publication. Product improvements, revisions, etc., may result in
differences between your machine and what is presented here. Sany Group assumes no liability. For more
information, contact Sany Group.
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Operation and Maintenance Manual-Oct. 2018 1
RESPONSIBILITY
SPECIFIC DECLARATION
Pneumatic tire roller is used to compact sand soil and sand gravel in the construction of roads and
foundations, which is suitable for most types of road construction, airfields, dam construction and
harbor projects. Any other use or any operation beyond the specified working range is not author-
ized use. SANY expressly bears no liability for any consequence due to any unauthorized use.
Information in this manual is used to guide qualified operators to operate and maintain rollers cor-
rectly. SANY expressly bears no liability for any consequence due to any use not observing the in-
formation in this manual.
It is forbidden to convert the roller without authorization. SANY expressly bears no liability for any
consequence. When crack or electrical malfunction on the roller occurs, please contact the suppli-
er, and don’t conduct welding or make changes without permission, or else, for any consequence
due to such contravention, SANY shall not bear any liability.
Use genuine spare parts from SANY. SANY expressly bears no liability for any machine damage
or accident due to the use of untested or unauthorized spare parts or tools.
Operate and maintain parts (such as engine, a/c) on the roller, and observe related regulations in
Users' guide supplied from their manufacturer.
SANY expressly bears no liability for any machine failure or damage due to force majeure of natu-
ral disasters (earthquake, typhoon) and wars.
SANY cannot predict every circumstance that might involve a potential hazard in operation or
maintenance. Operators and owners should highly attach importance to safety. Local specific
safety rules of the countries may be stricter. If they differ from the regulations in this manual, ob-
serve the stricter one.
Duty of Sany
•Be responsible for providing qualified products and correct documents.
•Fulfill their promises on after-sales service, and document all maintenance and repair working
done by after-sales service personnel.
•Train the operation and maintenance personnel based on their needs.
Duty of owners or other authorized personnel
•Only after each person involved in the product’s operation, maintenance and repair is trained
and fully understands the Parts Book and Safety, Operation and Maintenance Manual, can they
operate and maintain the roller.
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2Operation and Maintenance Manual-Oct. 2018
•Ensure the operation and maintenance personnel are qualified and know their related
responsibilities.
•Periodically check related personnel's safety consciousness during working.
•If any fault which will lead to unsafety occurs, stop the roller immediately.
•If necessary SANY service personnel have the right to check the roller for safety.
•Besides check items regulated by SANY, observe local laws and regulations to check the roller.
•Ensure timely maintenance and repair on the roller.
•Carefully plan the use of the roller.
Duty of All Working Personnel
•If there is any abnormal symptom which may cause abnormal working of the roller or potential
hazard, report to your leader. If possible, correct fault in time.
•All personnel working around the roller must observe all warning signals and take care of their
own and others' safety.
•All personnel should know their working tasks and procedures.
•Watch something like high voltage wire, unrelated personnel and poor ground for potential dan-
ger, and report to the operators and signalmen.
Duty of Managers
•Ensure the operators are trained and fully understand the Safety, Operation and Maintenance
Manual supplied by SANY. Ensure the operators are in physical fitness and have the certification
of operation. Otherwise, it is forbidden to operate the roller .
•Ensure the operators have good judgement ability, teamwork consciousness and psychological
quality. Otherwise, it is forbidden to operate or repair the roller.
•Ensure the signalmen have good vision and acoustic judgement, master standard command sig-
nals. At the same time, they should have enough experience in recognizing danger factors cor-
rectly, and inform the operators of danger factors to avoid them in time.
•Ensure assistant workers can identify the model and working condition to choose a proper roller.
•Publicize safety consciousness to working personnel, and make them aware of safety preca-
tions and their related responsibilities.
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Operation and Maintenance Manual-Oct. 2018 I
Table of Contents
1 Introduction........................................................................................................................1-1
1.1 Overview.................................................................................................................................1-3
1.2 Your Documentation Package.............................................................................................1-4
1.2.1 Your Documentation Package ...................................................................................1-4
1.2.2 Recommendations on Using the Documentation ....................................................1-4
1.2.3 Documentation Storage...............................................................................................1-4
1.2.4 Organization of this Manual ........................................................................................1-4
1.3 Your SANY Machine .............................................................................................................1-5
1.3.1 Machine Directions.......................................................................................................1-5
1.3.2 Breaking in a New Machine .......................................................................................1-6
1.3.3 Machine Information ....................................................................................................1-6
1.3.4 Serial Number and Distributor Information ...............................................................1-7
1.4 Contact Information ..............................................................................................................1-8
1.5 Abbreviations .........................................................................................................................1-8
1.6 Glossary .................................................................................................................................1-8
2 Safety.....................................................................................................................................2-1
2.1 General ...................................................................................................................................2-3
2.1.1 Introduction....................................................................................................................2-3
2.1.2 Intended Use.................................................................................................................2-4
2.1.3 Unintended Use ............................................................................................................2-5
2.1.4 Qualifications of Operators and Maintainers ...........................................................2-5
2.1.5 Conversions and Alterations to the Machine............................................................2-5
2.2 Safety Message.....................................................................................................................2-6
2.2.1 Introduction....................................................................................................................2-6
2.2.2 Safety Message Introduction ......................................................................................2-6
2.2.3 Safety Message Locations..........................................................................................2-6
2.2.4 Signal Alerts ..................................................................................................................2-7
2.2.5 An Example of Signal Alerts .......................................................................................2-8
2.2.6 Safety Decals ................................................................................................................2-8
2.3 General Precautions.......................................................................................................... 2-12
2.3.1 Safety Rules ............................................................................................................... 2-12
2.3.2 Abnormal Case .......................................................................................................... 2-13
2.3.3 Safety Equipment ...................................................................................................... 2-13
2.3.4 Protective Equipment for Personal Safety............................................................. 2-14
2.3.5 Precautions Against Emergency............................................................................. 2-15
2.4 Precautions During Operation.......................................................................................... 2-20
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II Operation and Maintenance Manual-Oct. 2018
2.4.1 Safe Starting............................................................................................................... 2-20
2.4.2 Safe Operation........................................................................................................... 2-23
2.4.3 Safe Parking............................................................................................................... 2-27
2.5 Precautions For Maintenance .......................................................................................... 2-30
2.5.1 Basic Rules................................................................................................................. 2-30
2.5.2 Lockout/Tagout Procedures..................................................................................... 2-30
2.5.3 Working Area Preparation........................................................................................ 2-31
2.5.4 Cleaning the Equipment ........................................................................................... 2-31
2.5.5 Self-preparation ......................................................................................................... 2-32
2.5.6 Use Tools Correctly ................................................................................................... 2-32
2.5.7 Maintenance with Engine Running ......................................................................... 2-33
2.5.8 Working under the Roller.......................................................................................... 2-34
2.5.9 Working in Noisy Environment ................................................................................ 2-34
2.5.10 Removing Paint before Welding or Heating ........................................................ 2-35
2.5.11 Correct Welding ....................................................................................................... 2-35
2.5.12 Do Not Heat beside Hydraulic Pipeline................................................................ 2-36
2.5.13 Do Not Heat the Pipes with Combustible Liquid ................................................ 2-36
2.5.14 Correctly Operating the Hydraulic System .......................................................... 2-36
2.5.15 Being Aware of High-pressure Liquid................................................................... 2-37
2.5.16 Regularly Replacing the Rubber Hoses............................................................... 2-38
2.5.17 Avoiding Scald by High-temperature Liquid ........................................................ 2-39
2.5.18 Preventing Battery from Explosion ....................................................................... 2-40
2.5.19 Preventing Components from Flying out ............................................................. 2-41
2.5.20 Safe Storage of Parts ............................................................................................. 2-41
2.5.21 Safe Treatment of Liquid ........................................................................................ 2-42
2.5.22 Safe Treatment of Chemicals ................................................................................ 2-42
2.5.23 Appropriate Disposal of Wastes............................................................................ 2-43
2.6 Precautions of Lubricant Selection.................................................................................. 2-43
2.7 Safe Transportation ........................................................................................................... 2-44
2.7.1 Load/unload the Roller.............................................................................................. 2-44
2.7.2 Lift and Tie Down the Roller..................................................................................... 2-44
2.7.3 Transport the Roller................................................................................................... 2-45
3 System Functions...........................................................................................................3-1
3.1 General Overview .................................................................................................................3-3
3.1.1 Introduction....................................................................................................................3-3
3.1.2 Overall Structure...........................................................................................................3-3
3.1.3 Main Technical Features .............................................................................................3-4
3.2 Display and Control Console...............................................................................................3-4
3.2.1 Introduction....................................................................................................................3-4
3.2.2 Dashboard .....................................................................................................................3-5
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Operation and Maintenance Manual-Oct. 2018 III
3.2.3 Electrical Control Switches in Cab (optional) ........................................................ 3-12
3.2.4 Other Switches........................................................................................................... 3-14
3.2.5 Display ........................................................................................................................ 3-15
3.2.6 A/C (optional) ............................................................................................................. 3-34
3.2.7 Radio (optional) ......................................................................................................... 3-35
3.3 Safety Protection Device................................................................................................... 3-39
4 Operation.............................................................................................................................4-1
4.1 General Notes........................................................................................................................4-3
4.2 Check Before Start the Engine............................................................................................4-3
4.2.1 Introduction....................................................................................................................4-3
4.2.2 Inspection (walk-around).............................................................................................4-3
4.2.3 Inspection before Starting ...........................................................................................4-4
4.3 Adjustment Prior to Operation.............................................................................................4-6
4.3.1 Operator Seat................................................................................................................4-6
4.3.2 Rearview Mirror ............................................................................................................4-7
4.4 Engine Start-up......................................................................................................................4-7
4.4.1 Normal Engine Start-up ...............................................................................................4-7
4.4.2 Engine Start-up Under Low Temperature .................................................................4-9
4.4.3 Jump-start the Engine............................................................................................... 4-10
4.5 Inspection after Engine Start-up .......................................................................................4-11
4.6 Operation of Working Devices ......................................................................................... 4-12
4.6.1 Introduction................................................................................................................. 4-12
4.6.2 Engine Speed Control............................................................................................... 4-12
4.6.3 Travel Control............................................................................................................. 4-13
4.6.4 Braking Operation During Traveling ....................................................................... 4-15
4.6.5 Water Spraying System Operation ......................................................................... 4-17
4.6.6 Oil Spraying System Operation (Optional) ............................................................ 4-22
4.6.7 Auxiliary Equipment Operation................................................................................ 4-29
4.6.8 Operating the Parking Brake ................................................................................... 4-37
4.6.9 Shutting Down the Engine and Parking the Machine........................................... 4-38
4.7 Equipment Cleanup ........................................................................................................... 4-40
4.8 Transportation..................................................................................................................... 4-41
4.8.1 Transport Vehicle....................................................................................................... 4-41
4.8.2 Driving on to the Transport Vehicle Independently via a Slope .......................... 4-41
4.8.3 Loading and Unloading by a Crane ........................................................................ 4-42
4.8.4 Winch Traction ........................................................................................................... 4-43
4.8.5 Shipping ...................................................................................................................... 4-43
5 Maintenance.......................................................................................................................5-1
5.1 General ...................................................................................................................................5-3
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IV Operation and Maintenance Manual-Oct. 2018
5.1.1 Notes on Maintenance.................................................................................................5-3
5.1.2 Notes on Engine Performance ...................................................................................5-3
5.1.3 Notes on Fuel System..................................................................................................5-3
5.1.4 Notes on Hydraulic System.........................................................................................5-4
5.2 Functional Fluids ...................................................................................................................5-4
5.2.1 Fuel.................................................................................................................................5-4
5.2.2 Engine oil .......................................................................................................................5-5
5.2.3 Hydraulic Oil ..................................................................................................................5-5
5.2.4 Coolant...........................................................................................................................5-5
5.2.5 Grease ...........................................................................................................................5-6
5.2.6 Requirements of Oil and Fluids ..................................................................................5-6
5.2.7 Fuel/lubricant Filling Capacities .............................................................................. 5-10
5.3 Test Run Instructions ..........................................................................................................5-11
5.4 Maintenance Schedule.......................................................................................................5-11
5.4.1 Introduction..................................................................................................................5-11
5.4.2 Routine Maintenance................................................................................................ 5-12
5.4.3 Short-time Storage of Machine................................................................................ 5-13
5.4.4 Long-time Storage-Maintain ................................................................................... 5-13
5.4.5 Post Maintenance-Check ......................................................................................... 5-14
5.4.6 Machine in Freezing Condition-Maintain ............................................................... 5-15
5.4.7 Regular Technical Maintenance Intervals.............................................................. 5-15
5.5 Maintenance for the Power System ................................................................................ 5-17
5.5.1 Oil Tank and Oil Lines-Check .................................................................................. 5-17
5.5.2 Air Filter-Clean/Replace ........................................................................................... 5-18
5.5.3 Engine Oil-Check/Refill/Change ............................................................................. 5-23
5.5.4 Engine Oil Filter-Replace ......................................................................................... 5-27
5.5.5 Oil Water Separator-Check/Drain/Replace ........................................................... 5-28
5.5.6 Radiator-Clean/Clean ............................................................................................... 5-33
5.5.7 Coolant-Check/Refill/Change .................................................................................. 5-34
5.5.8 Engine Belt-Check/Replace..................................................................................... 5-36
5.5.9 Engine Air Intake Pipeline-Check ........................................................................... 5-39
5.5.10 Fuel-Check/Refill..................................................................................................... 5-39
5.5.11 Fuel Filter-Replace.................................................................................................. 5-41
5.5.12 Crankcase Vent Line-Check .................................................................................. 5-42
5.5.13 Fuel Tank-Clean ...................................................................................................... 5-42
5.6 Maintenance for the Hydraulic System ........................................................................... 5-43
5.6.1 Hydraulic Oil-Check/Refill/Change ......................................................................... 5-43
5.6.2 Hydraulic Oil Filter-Replace ..................................................................................... 5-46
5.7 Maintenance for the A/C ................................................................................................... 5-47
5.7.1 A/C-Check/Maintain(Optional) ................................................................................ 5-47
5.7.2 Compressor V-belt-Check/Tighten/Replace.......................................................... 5-51
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Operation and Maintenance Manual-Oct. 2018 V
5.8 Maintenance for the Electric System............................................................................... 5-52
5.8.1 Battery-Check ............................................................................................................ 5-52
5.8.2 Fuse-Replace............................................................................................................ 5-54
5.9 Maintenance for the Machanical Structure..................................................................... 5-56
5.9.1 Washer-Check ........................................................................................................... 5-56
5.9.2 Damper-Check/Replace........................................................................................... 5-57
5.9.3 Connections and Tightness-Check......................................................................... 5-57
5.9.4 Lubricant for Drive Axle-Change ............................................................................. 5-58
5.9.5 Lubricant-Fill............................................................................................................... 5-58
5.10 Maintenance for the Working Device ............................................................................ 5-59
5.10.1 Oil/water Spraying System-Check........................................................................ 5-59
5.10.2 Tires and Rims-Check ............................................................................................ 5-60
5.10.3 Filter Element for Oil Spraying-Replace(optional).............................................. 5-60
5.10.4 Mud Scraper-Check/Replace ................................................................................ 5-61
6 Troubleshooting ..............................................................................................................6-1
6.1 Diesel Engine.........................................................................................................................6-3
6.2 Running System ....................................................................................................................6-5
6.3 Water Spraying System........................................................................................................6-5
6.4 Electrical Parts.......................................................................................................................6-6
6.4.1 Electrical Parts ..............................................................................................................6-6
6.4.2 Electrical System ..........................................................................................................6-6
6.4.3 Fuses..............................................................................................................................6-6
6.5 A/C System ............................................................................................................................6-7
6.5.1 Introduction....................................................................................................................6-7
6.5.2 Abnormal Noise in Cooling System ...........................................................................6-7
6.5.3 Faults of Heating Device .............................................................................................6-8
6.5.4 Other Faults...................................................................................................................6-8
7 Specifications ...................................................................................................................7-1
7.1 Specifications of the Equipment..........................................................................................7-3
SPR160/200C-8 Pneumatic Tire Roller Table of Contents
VI Operation and Maintenance Manual-Oct. 2018
SPR160/200C-8 Pneumatic Tire Roller
Operation and Maintenance Manual-Oct. 2018 1-1
Introduction
1.1 Overview.................................................................................................................................1-3
1.2 Your Documentation Package.............................................................................................1-4
1.2.1 Your Documentation Package..................................................................................1-4
1.2.2 Recommendations on Using the Documentation...................................................1-4
1.2.3 Documentation Storage .............................................................................................1-4
1.2.4 Organization of this Manual.......................................................................................1-4
1.3 Your SANY Machine .............................................................................................................1-5
1.3.1 Machine Directions .....................................................................................................1-5
1.3.2 Breaking in a New Machine ......................................................................................1-6
1.3.3 Machine Information ...................................................................................................1-6
1.3.4 Serial Number and Distributor Information..............................................................1-7
1.4 Contact Information ..............................................................................................................1-8
1.5 Abbreviations .........................................................................................................................1-8
1.6 Glossary .................................................................................................................................1-8
SPR160/200C-8 Pneumatic Tire Roller Introduction
Operation and Maintenance Manual-Oct. 2018 1-3
1.Introduction
1.1 Overview
•SANY-built equipment offers high-quality performance and excellent after-sales service support.
•SANY-built equipment is widely used throughout the industry for various types of applications.
•SANY is a leading manufacturer of heavy construction equipment worldwide.
Fig 1-1
This operator’s manual provides safety, sys-
tem functions, operation, maintenance, trou-
bleshooting and specifications. In order to
properly use your equipment, it is important to
read and understand this manual before using
the equipment.
Items addressed in this manual are designed
to help you:
•Understand the structure and performance
of your equipment.
•Reduce improper operation and point out
possible hazardous situations when using
your equipment.
•Increase efficiency during operation.
•Prolong the service life of your equipment.
•Reduce maintenance costs.
Always keep this manual nearby and have all
personnel involved with any operations read it
periodically. If this manual become damaged
or lost and cannot be read, it is advised to re-
quest a replacement copy from your SANY
distributor as soon as possible.
If you sell the equipment, be sure to give this
manual to the new owner.
Continuing improvements in the design can
lead to changes in details which may not be
reflected in this manual. Always consult your
SANY distributor for the latest available infor-
mation on your equipment or if you have
questions regarding information in this
manual.
SPR160/200C-8 Pneumatic Tire Roller Introduction
1-4 Operation and Maintenance Manual-Oct. 2018
1.2 Your Documentation Package
1.2.1 Your Documentation Package
The documentation includes:
•Safety,Operation and Maintenance Manual.
•Parts Book– including the Parts List and the Drawings needed for ordering parts. If the Parts
Book is not attached with the equipment, contact SANY.
1.2.2 Recommendations on Using the Documentation
•The documents only apply to this machine, and should not be used with any other machines.
•Ensure that the documents are complete and up to date.
•Put all data in a folder (if including leaflets).
•Print and replace the lost, damaged and blotted pages.
•Add the latest SANY data in time and destroy the inapplicable old documents.
1.2.3 Documentation Storage
•Always keep the Operation and Maintenance Manual in the net pocket behind the operator
cabin’s seat.
•The Parts Book is best left either shelved in the workshop area or office. It should always be
available to the maintenance and service personnel as required.
1.2.4 Organization of this Manual
This operator's manual covers safety, operation and maintenance of your machine. Get familiar
with it before performing any operations. Put this manual within easy reach for your reference and
replace it if it is lost or damaged. Due to improvement and updating of products, some information
may differ from your machine. If you have any question on the use and maintenance of your ma-
chine, contact your SANY distributor.
1. Introduction
This section provides an overview of what is covered in the rest of this manual, including machine
label information and SANY contact information.
2. Safety
This section covers basic safety information relating to this equipment. Make sure you fully under-
stand all the precautions described in this manual and the safety labels on the machine before op-
erating or maintaining this machine. Failure to do so may result in serious injury or death.
3. System functions
Introduction SPR160/200C-8 Pneumatic Tire Roller
Operation and Maintenance Manual-Oct. 2018 1-5
This section provides an overview of all the controls and prompt & operating systems on your ma-
chine. Only when you are familiar with all systems, can you operate and maintain the machine
safely.
4. Operation
This section provides the basic operating procedures for the machine. It is important to study and
become familiar with all procedures before performing any operations with the machine.
5. Maintenance
This section provides all general maintenance and repair procedures. It is important to study and
become familiar with all the maintenance and repair procedures before performing any mainte-
nance or repair operations on the machine.
6. Troubleshooting
This section includes common malfunctions and fault diagnostic procedures for the operating sys-
tem of this pneumatic tire roller. The basic troubleshooting methods for mechanical, hydraulic and
electrical systems are included.
7. Specifications
This section provides the general information about this machine. Some information may change
as design modification.
1.3 Your SANY Machine
1.3.1 Machine Directions
1
2
3
4
SPR160/200C-8 Pneumatic Tire Roller Introduction
1-6 Operation and Maintenance Manual-Oct. 2018
Fig 1-2
1. Front 2. Right 3. Back 4. Left
1.3.2 Breaking in a New Machine
Your machine has been well adjusted and tested before delivery. However, initial operation on the
machine in severe conditions will seriously affect the performance or reduce the service life of the
machine. Thus SANY recommends you to perform a 100-hour test run before putting the machine
into production use.
During the break-in period:
•Let the machine warm up prior to any operation.
•Avoid operating or running the equipment at a high speed in overload working conditions.
•Avoid sudden starting, rapid movement or abrupt stop of the equipment.
•Cool down the system of the equipment at the end of every working day.
1.3.3 Machine Information
The serial numbers and model numbers on the components are the only numbers that your SANY
distributor will need when ordering replacement parts or requiring assistance for your machine.
You can find the related information on the name plate. It is a good idea to record these information
in this manual for future use.
Fig 1-3
On the front right plate of frame locates the
name plate.
Introduction SPR160/200C-8 Pneumatic Tire Roller
Operation and Maintenance Manual-Oct. 2018 1-7
1.3.4 Serial Number and Distributor Information
This location is for you to record information relating to your equipment. It is advised that you
keep this manual with your equipment at all times for reference.
Model No.
Serial No.
Build Date
Truck V.I.N. No.
Distributor Name:
Address:
Phone Numbers:
SPR160/200C-8 Pneumatic Tire Roller Introduction
1-8 Operation and Maintenance Manual-Oct. 2018
1.4 Contact Information
Thank you for purchasing a SANY product. In the event that you should need to contact us for any
reason, you can reach us as follows.
Our address: SANY Industry Town, Economic and Technological Development Zone, Changsha,
Hunan, China
Tel: 0086-4006098318
Post code: 410100
Email: crd@sany.com.cn
1.5 Abbreviations
•SYCD – Sany control display
•ISO – International Organization for Standardization
•A/C – Air condition
•rpm – Revolutions per minutes
•OAT –Organic Acid Technology
1.6 Glossary
•Pneumatic Tire Roller – A machine that compacts by using the characteristics of an inflatable
tire.
•Serial Number – Unique machine designation. On machine nameplate.
•Refrigerant – The intermediary substance used in various heat engines to complete energy
conversion.
•Cab – The small cabin where the operator stays in and control the equipment.
Introduction SPR160/200C-8 Pneumatic Tire Roller
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