SANY SSR120 User manual

Full Hydraulic
Single Drum Roller
Operation and Maintenance Manual
SSR120
Quality Changes the World
SSRD120
SSRP120

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Full Hydraulic Single Drum Roller
Operation and Maintenance Manual
SSR120/SSRD120/SSRP120
Read and follow the safety precautions and instructions in this manual and on the machine
decals. Failure to do can cause serious injury, death or property damage. Keep this manual
with the machine for reading and future reference.
WARNING
线粗：1pt
SSR120 SSRD120 SSRP120
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SSR120/SSRD120/SSRP120
© 2010 by Sany Group. All rights reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during 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.
Sany Group
Sany Heavy Industry CO.，LTD
Sany Industry Town,
Economic & Technical Development Zone
Changsha, Hunan, China 410100
http://www.sanygroup.com
Tel: [phone]
Fax: [phone]
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公司名称和地址写各自事业部，电话、传真、邮箱统一用以下三一海外联系方式
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SSR120/SSRD120/SSRP120
Ｄｅｌｉｎｅａｔｉｏｎ ｏｆ ｒｅｓｐｏｎｓｉｂｉｌｉｔｙ
Ｓｐｅｃｉｆｉｃ ｄｅｃｌａｒａｔｉｏｎ
Single drum roller is used to compact sand soil and sand gravel in the construction of
roads and foundations, which are suitable for most types of road construction, airfields, dam
construction and harbor projects. Any other use or any operation beyond the specied working
range is not authorized use. SANY expressly bears no liability for any consequence due to any
unauthorized use.
Information on this manual is used to guide qualified operators to operate and maintain
graders correctly. SANY expressly bears no liability for any consequence due to any use not
observing the information on this manual.
It is forbidden to convert the grader without authorization.Sany expressly bears no liability
for any consequence. When crack or electrical malfunction on the grader occurs, please contact
the supplier, 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 grader, and observe related
regulations on Users' guide supplied from their manufacturer.
SANY expressly bears no liability for any machine failure or damage due to force majeure of
natural 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 specic
safety rules of the countries may be stricter. If they differ from the regulations on this manual,
observe the stricter one.
Duty of SANY
• Be responsible for providing qualied products and correct documents.
• Fulll 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 anthorized personnel
• Only after each person involved in the product’s operation, maintenance and repair is trained
and fully understands the Parts Book and Operation and Maintenance Manual, can they operate
and maintain the grader.
• Ensure the operation and maintenance personnel are qualified and know their related
responsibilities.
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SSR120/SSRD120/SSRP120
• Periodically check related personnel's safety consciousness during working.
• If any fault which will lead to unsafety occurs, stop the grader immediately.
• If necessary SANY service personnel have the right to check the grader for safety.
• Besides check items regulated by SANY, observe local laws and regulations to check the
grader.
• Ensure timely maintenance and repair on the grader.
• Carefully plan the use of the grader.
Duty of all working personnel
• If there is any abnormal symptom which may cause abnormal working of the grader or
potential hazard, report to your leader. If possible, correct fault in time.
• All personnel working around the grader 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
danger, and report to the operators and signalmen.
Duty of managers
• Ensure the operators are trained and fully understand the Operation and Maintenance Manual
supplied by SANY. Ensure they are in physical tness and have the certication of operation.
Otherwise, it is forbidden to operate the grader.
• Ensure the operators have good judgement ability, teamwork consciousness and
psychological quality. Otherwise, it is forbidden to operate or repair the grader.
• Ensure the signalmen have good vision and acoustic judgement, master standard command
signals. At the same time, they should have enough experience in recognizing danger factors
correctly, 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
grader.
• Make each working person take their related responsibilities, and require them to report
unsafe factors to their leader in time.
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SSR120/SSRD120/SSRP120
Table of Contents
1 Introduction
1.1 Overview 1-1
1.2 Your Documentation Package 1-2
1.2.1 Recommendations on using the documentation 1-2
1.2.2 Documentation storage 1-2
1.2.3 Organization of this manual 1-2
1.2.3.1 Introduction 1-3
1.2.3.2 Safty 1-3
1.2.3.3 System functions 1-3
1.2.3.4 Operation 1-3
1.2.3.5 Maintenance 1-3
1.2.3.6 Troubleshooting 1-4
1.2.3.7 Technical specications 1-4
1.3 Your SANY Equipment 1-4
1.3.1 Equipment directions 1-4
1.3.2 Breaking in a new equipment 1-4
1.3.3 Equipment information 1-5
1.3.4 Serial number and distributor information 1-6
1.4 Contact Information 1-7
2 Safety
2.1 General 2-1
2.1.1 Intended use 2-3
2.1.2 Unintended use 2-3
2.1.3 Qualications of operators and maintainers 2-3
2.1.4 Unauthorized modication 2-4
2.2 Safety Message 2-4
2.2.1 Safety message introduction 2-4
2.2.2 Safety message locations 2-5
2.2.3 Signal words 2-6
2.2.4 An example of signal words 2-6
2.2.5 Safety decals 2-7
2.2.5.1 Safety words 2-7
2.2.5.2 Safety symbols 2-7
2.3 General Precautions 2-11
I
Table of Contents
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Table of Contents
SSR120/SSRD120/SSRP120
2.3.1 Safety rules 2-11
2.3.2 Abnormal case 2-11
2.3.3 Safety devices 2-11
2.3.4 Protective measures for personal safety 2-12
2.3.5 Precautions against emergency 2-13
2.3.5.1 Use the emergency stopping button correctly 2-13
2.3.5.2 Evacuation in re accident 2-14
2.3.5.3 Touching high-voltage lines 2-14
2.3.5.4 Falling object protection 2-15
2.4 Precautions During Operation 2-15
2.4.1 Safe starting 2-15
2.4.1.1 Safe mounting 2-15
2.4.1.2 Seat adjusting 2-15
2.4.1.3 Seat belt 2-16
2.4.1.4 Before starting the engine 2-16
2.4.1.5 Engine starting 2-17
2.4.1.6 After starting the engine 2-18
2.4.2 Safety operation 2-19
2.4.2.1 Surveying the worksite in advance 2-19
2.4.2.2 Before operation 2-20
2.4.2.3 Safe traveling 2-21
2.4.2.4 Safe turning 2-24
2.4.2.5 Safe vibrating 2-24
2.4.3 Safe parking 2-25
2.4.3.1 Requirements for parking area 2-25
2.4.3.2 Parking rules 2-25
2.5 Maintenance Precautions 2-26
2.5.1 Basic rules 2-26
2.5.2 Lockout/Tagout procedures 2-26
2.5.3 Working area preparation 2-27
2.5.4 Washing the equipment 2-28
2.5.5 Self-preparation 2-28
2.5.6 Proper tool 2-29
2.5.7 Maintenance with engine running 2-29
2.5.8 Working under the roller 2-30
2.5.9 Working in noisy environment 2-31
2.5.10 Removing paint before welding or heating 2-31
2.5.11 Correct welding 2-31
II
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SSR120/SSRD120/SSRP120
Table of Contents
2.5.12 No heating beside hydraulic pipeline 2-32
2.5.13 No heating the pipes with combustible liquid 2-33
2.5.14 Correctly operating the hydraulic system 2-33
2.5.15 Being aware of high-pressure liquid 2-34
2.5.16 Regularly replacing the rubber hoses 2-35
2.5.17 Avoid scald by high-temperature liquid 2-35
2.5.18 Preventing battery from explosion 2-36
2.5.19 Preventing components from ying out 2-37
2.5.20 Safe storage of parts 2-37
2.5.21 Safe treatment of liquid 2-37
2.5.22 Safe treatment of chemicals 2-38
2.5.23 Proper disposal of wastes 2-38
2.6 Safe Transportation 2-39
2.6.1 Load/Unload the roller 2-39
2.6.2 Transport the roller 2-40
2.6.3 Lift the roller 2-40
3 System Functions
3.1 General Description 3-1
3.1.1 Front frame 3-2
3.1.2 Center articulation frame 3-3
3.1.3 Rear frame 3-3
3.1.4 Rear axle 3-3
3.1.5 Covering part 3-4
3.1.6 Engine 3-4
3.1.7 Vibratory drum 3-4
3.1.8 Control system 3-5
3.2 Control Devices 3-6
3.2.1 Steering wheel 3-7
3.2.2 Hand brake switch 3-7
3.2.3 Front working lamp switch 3-8
3.2.4 Switch for washer and front wiper 3-8
3.2.5 SYLD display 3-9
3.2.6 Rear wiper switch 3-10
3.2.7 Rear working lamp switch 3-10
3.2.8 Turning lamp switch 3-11
3.2.9 Ignition switch 3-12
3.2.10 Throttle control lever 3-13
III
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SSR120/SSRD120/SSRP120
3.2.11 Emergency stopping button 3-13
3.2.12 Gear select switch 3-14
3.2.13 Warning lamp switch 3-14
3.2.14 Compaction mode select switch 3-15
3.2.15 Frequency select switch 3-15
3.2.16 Vibration button 3-16
3.2.17 Traveling control lever 3-16
3.2.18 Horn button 3-16
3.2.19 Master switch of power supply 3-17
3.2.20 Driver's seat 3-17
3.2.21 Cab lamp switch 3-18
3.2.22 A/C control panel 3-18
3.2.23 Radio control panel 3-21
3.3 Monitoring Device 3-25
3.3.1 Left turning indicator lamp 3-26
3.3.2 Parking brake indicator lamp 3-26
3.3.3 Crab-walk indicator lamp 3-26
3.3.4 Neutral position indicator lamp 3-27
3.3.5 Battery indicator lamp 3-27
3.3.6 Preheating indicator lamp 3-27
3.3.7 Right turning indicator lamp 3-28
3.3.8 Air lter indicator lamp 3-29
3.3.9 Oil water separator indicator lamp 3-29
3.3.10 High-frequency vibration indicator lamp 3-29
3.3.11 Low-frequency vibration indicator lamp 3-30
3.3.12 Tachometer 3-30
3.3.13 Fuel level indication 3-30
3.3.14 Engine oil pressure indication 3-31
3.3.15 System calendar/time/working hours 3-31
3.3.16 Engine coolant temperature indication 3-31
3.3.17 Water level indication 3-32
3.3.18 Speedometer 3-32
3.3.19 Functional buttons (F1-F6) 3-32
3.3.20 Functional pages 3-33
3.3.20.1 Parameter setting page 3-33
3.3.20.2 Clock setting page 3-33
3.3.20.3 Hour meter setting page 3-34
3.3.20.4 Debugging page 3-34
IV
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SSR120/SSRD120/SSRP120
Table of Contents
3.3.20.5 Model conguration page 3-35
3.3.20.6 GPS information page 3-35
3.3.20.7 Language selection page 3-37
3.3.20.8 System information page 3-37
3.3.20.9 Password input page 3-37
3.4 Other Functions 3-38
3.4.1 Lifting points of the roller 3-38
3.4.2 Lifting points of the cab 3-38
3.4.3 Fixing points of the roller 3-38
3.4.4 Rear mirrors 3-39
4 Operation
4.1 Checking before Starting the Engine 4-1
4.1.1 Inspection (walk-around) 4-1
4.1.2 Inspection before starting 4-2
4.1.2.1 Check the engine oil level 4-2
4.1.2.2 Check the coolant level of the engine 4-3
4.1.2.3 Check the oil water separator 4-3
4.1.2.4 Check the hydraulic oil level 4-4
4.1.2.5 Check the washer 4-5
4.1.2.6 Check the air lter 4-5
4.1.2.7 Check the tyre pressure 4-6
4.1.2.8 Check the position of limit plate 4-6
4.1.2.9 Check the vibratory drum and dampers 4-6
4.1.2.10 Check the electric wires 4-7
4.2 Adjustments Prior to Startup 4-7
4.2.1 Seat adjustment 4-7
4.2.2 Rear mirror adjustment 4-7
4.3 Equipments Checking Prior to Startup 4-8
4.3.1 Electrify the control system 4-8
4.3.2 Check the fuel level 4-9
4.3.3 Check the traveling control lever 4-10
4.3.4 Check the emergency stopping button 4-11
4.3.5 Check the hand brake switch 4-11
4.3.6 Check the switches 4-11
4.4 Engine starting 4-13
4.4.1 Normal start 4-13
4.4.2 Jump-start 4-14
V

Table of Contents
SSR120/SSRD120/SSRP120
VI
4.4.3 Engine start in cold weather 4-14
4.5 After Engine Starting 4-16
4.6 Test Running 4-17
4.7 Travel Operation 4-18
4.7.1 Travel forward 4-18
4.7.2 Travel backward 4-19
4.7.3 Make turning 4-19
4.7.4 Switching the speed gear 4-19
4.8 Compaction Operation 4-20
4.8.1 Compaction mode and switching 4-20
4.8.1.1 Manual mode 4-20
4.8.1.2 Auto mode 4-20
4.8.1.3 Switching the compacting mode 4-20
4.8.2 Compacting frequency and switching 4-21
4.8.2.1 High frequency 4-21
4.8.2.2 Low frequency 4-21
4.8.2.3 Switching the compacting frequency 4-21
4.8.2.4 Selecting frequency according to the road condition 4-22
4.8.3 Vibration 4-22
4.8.3.1 Vibrating in manual mode 4-22
4.8.3.2 Vibrating in auto mode 4-24
4.9 Parking Operation 4-24
4.9.1 Service brake 4-24
4.9.2 Parking brake 4-25
4.9.3 Emergency brake 4-26
4.10 Check after Each Work Day 4-27
4.11 Correct Driving According to the Road Condition 4-27
4.11.1 Working near ditch edge and road shoulder 4-27
4.11.2 Working near buildings vulnerable to vibration 4-28
4.11.3 Working on the slope 4-28
4.12 Other Auxiliary Equipments 4-29
4.12.1 Wiper and washer 4-29
4.12.2 Working lamps 4-30
4.13 Transportation 4-30
4.13.1 Transport vehicle 4-30
4.13.2 Using a slope 4-30
4.13.3 Shipping 4-32
4.13.3.1 Container shipping 4-32

SSR120/SSRD120/SSRP120
Table of Contents
4.13.3.2 Non-container shipping 4-36
5 Maintenance
5.1 General 5-1
5.1.1 Notes on maintenance 5-1
5.1.2 Notes on fuel system 5-1
5.1.3 Notes on engine performance 5-2
5.1.4 Notes on hydraulic system 5-2
5.1.5 Notes on cooling system 5-3
5.2 Fluids 5-3
5.2.1 Engine oil 5-3
5.2.2 Fuel 5-4
5.2.3 Mineral hydraulic oil 5-4
5.2.4 Lubricant 5-5
5.2.5 Lubricating grease 5-5
5.2.6 Coolant 5-5
5.3 Test Run Instructions 5-6
5.4 Maintenance 5-7
5.4.1 Routine maintenance 5-8
5.4.2 Regular maintenance 5-8
5.4.2.1 Every 50 service hours 5-8
5.4.2.2 Every 100 service hours 5-9
5.4.2.3 Every 250 service hours 5-9
5.4.2.4 Every 500 service hours 5-10
5.4.2.5 Every 1000 service hours 5-10
5.4.2.6 Replacing intervals for key parts 5-11
5.4.3 Maintenance for long-time stored roller 5-12
5.4.4 Maintenance for the engine 5-13
5.4.4.1 Engine oil - check/rell/change 5-13
5.4.4.2 Change the engine oil lter 5-14
5.4.4.3 Fuel - check/rell/change 5-15
5.4.4.4 Oil water separator - check/oil draining/exhaust 5-17
5.4.4.5 Change the oil water separator 5-18
5.4.4.6 Change the duplex fuel lter 5-19
5.4.4.7 Clean the radiator 5-20
5.4.4.8 Change the coolant 5-21
5.4.4.9 Engine belt - check/tension/replace 5-22
5.4.4.10 Change the air lter 5-24
VII

Table of Contents
SSR120/SSRD120/SSRP120
5.4.4.11 Change engine base mounts 5-26
5.4.5 Maintenance for hydraulic system 5-27
5.4.5.1 Hydraulic oil - check/rell/change 5-27
5.4.5.2 Change the hydraulic oil lter 5-29
5.4.6 Maintain the A/C 5-29
5.4.6.1 Instructions for using the A/C 5-29
5.4.6.2 Maintaining intervals for the A/C 5-31
5.4.6.3 V-belt for compressor - check/tension/replace 5-34
5.4.7 Maintaining the electric system 5-36
5.4.7.1 Maintaining the batteries 5-36
5.4.7.2 Maintaining the electric box 5-37
5.4.7.3 Maintaining the fuse 5-38
5.4.8 Maintaining the vibratory drum 5-39
5.4.8.1 Maintaining the reducer 5-39
5.4.8.2 Change lubricant in vibration excitation chamber 5-39
5.4.8.3 Maintaining the dampers 5-40
5.4.9 Maintaining the rear axle 5-41
5.4.10 Maintaining the brake 5-42
5.4.10.1 Check the clearance of the brake disc 5-42
5.4.10.2 Adjust the clearance of the brake disc 5-43
5.4.10.3 Release the brake manually 5-44
5.4.11 Filling the windshield washing uid 5-45
5.4.12 Adjust the mud scraper 5-45
5.4.13 Oil and auxiliary materials 5-46
5.4.14 Check the bolts 5-46
5.5 Repair 5-48
5.5.1 General 5-48
5.5.1.1 Basic principle 5-48
5.5.1.2 Basic maintenance methods 5-48
5.5.2 Vibratory drum disassembly 5-49
5.5.3 Replace the oil cylinder 5-55
5.5.4 Maintaining the tyre 5-59
5.5.3.1 Removing the tyre 5-59
5.5.3.2 Fitting the tyre 5-60
5.5.3.3 Inating the tyre 5-61
VIII

SSR120/SSRD120/SSRP120
Table of Contents
6 Troubleshooting
6.1 Mechanical Parts 6-1
6.1.1 Engine 6-1
6.1.2 Vibratory drum 6-3
6.1.3 Traveling system 6-4
6.1.4 Brake 6-5
6.2 Typical Hydraulic Elements 6-6
6.2.1 Axial plunger pump 6-6
6.2.2 Axial plunger motor 6-10
6.2.3 Change valve 6-12
6.2.4 Overow valve 6-16
6.2.5 Steering cylinder 6-20
6.2.6 Oil lter 6-25
6.2.7 Sealing elements 6-26
6.2.8 Hydraulic steering gear 6-28
6.3 Electrical Parts 6-30
6.3.1 Basic electrical system 6-30
6.3.2 Electrical system of working devices 6-32
6.3.3 Fuses 6-33
6.4 Air Conditioning System 6-34
6.4.1 System with poor refrigeration 6-34
6.4.2 Insufcient system refrigeration 6-35
6.4.3 Abnormal noise caused by refrigerating system 6-37
6.4.4 Air heating device fault 6-38
6.4.5 Other faults 6-38
6.5 Troubleshooting Examples 6-40
7. Specications
7.1 Dimension of the Equipment 7-1
7.2 Specications of the Equipment 7-2
VII

SSR120/SSRD120/SSRP120
Introduction
1 Introduction
1.1 OverView 1-1
1.2 Your Documentation Package 1-2
1.3 Your SANY Machine 1-4
1.4 Contact Information 1-7
Introduction

SSR120/SSRD120/SSRP120
Introduction
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.
This operator’s manual provides safety,
operation, maintenance, troubleshooting and
technical 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
equipment.
• Increase equipment 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 work operations
read it periodically. If this manual should
become damaged or lost and cannot be read, it
is advised to request 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 detail which may not
be reflected in this manual. Always consult
your SANY distributor for the latest available
information on your equipment or if you have
1-1
Fig.1-1

Introduction
SSR120/SSRD120/SSRP120
questions regarding information in this manual.
1.2 Your Documentation Package
The documentation includes:
• Operation and Maintenance Manual.
• Parts Book– including the Parts List and
the drawings needed when ordering parts.
If the Parts Book is not attached with the
equipment, contact SANY.
1.2.1 Recommendations on using the
documentation
• The documents only apply to this
equipment, and should not be used with
any other equipments.
• Ensure that the documents are complete
and up to date.
• Put all data in a folder (if including leaets).
• Print and replace the lost, damaged and
blotted pages.
• Add the latest SANY data in time and
destroy the inapplicable old documents.
1.2.2 Documentation storage
Always keep the operator manual with the
equipment in the operator cab.
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.
1.2.3 Organization of this manual
This operator's manual covers operation and
maintenance of your equipment. 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
1-2