Volvo Ingersoll Rand SD-116 TF Series User manual

Ref. No. VOE21A1004871
CPN 43816586
English
Printed in Sweden 2008-06
Volvo, Shippensburg
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

California
Legal Statement
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
California
Proposition 65 Warning
Battery posts, terminals and other related accessories
contain lead and lead compounds, chemicals known
to the State of California to cause cancer 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 maintenance and accuracy of the information
contained in this manual as it relates to applications
for the referenced equipment manufactured exclusively
under the Ingersoll-Rand brand.

CPN 43816586 November 6, 2006
Read and understand this manual before operating or servicing this equipment.
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
021402AATM
C
VOE21 1004871h.pdf

SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX i
TABLE OF CONTENTS
TITLE PAGE
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
IDENTIFICATION DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
MACHINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
ENGINE IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
INSTRUCTION MANUAL STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
MACHINE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 1-7
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
VIBRATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
VIBRATION FREQUENCY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
OPERATOR’S STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
GRADEABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
SERVICEABILITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
ROPS/FOPS/SEAT BELT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
IDENTIFICATION 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
HAZARDOUS SUBSTANCE PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
SAFETY RELATED DECALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
U.S. DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
INTERNATIONAL DECALS WITH INTERPRETATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
SECTION 2 - SYMBOL IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SYMBOL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
INGERSOLL RAND MACHINE SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
INTERNATIONAL ROAD MACHINE SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

ii SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX
TABLE OF CONTENTS
TITLE PAGE
SECTION 3 - OPERATING CONTROLS AND INSTRUMENTS . . . . . . . . . . . . . . . . . . . 4-1
OPERATING CONTROLS AND INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
ARTICULATION LOCK PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
OPERATING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
IMPACTMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
VIBRATION FREQUENCYCONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
VOLTMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
ENGINE COOLANT TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
TACHOMETER/HOURMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
FUEL GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
HORN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
ENGINE OIL PRESSURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
HYDRAULIC OIL TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
SPEEDOMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
IGNITION SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
HIGH/LOW ENGINE SPEED SWITCH (THROTTLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
SPEED RANGE 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 INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
AIR FILTER RESTRICTED INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
GRID HEATER INDICATOR (REF. ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
TURN SIGNAL INDICATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
CHECK ENGINE LIGHT (AMBER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
STOP ENGINE LIGHT (RED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
HYDRAULIC OIL TEMPERATURE INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
BATTERY MASTER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
FUSE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
FUSE IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
FUSE RATINGS/CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
RELAYS AND DIODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX iii
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TITLE PAGE
SECTION 4 - OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
PRE-START CHECKS / VERIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
PROPELLING MACHINE AND OTHER CHECKS/VERIFICATIONS
WHILE ENGINE IS RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
DAILY PRECAUTIONS AFTER WORK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
MOVEMENT OF MACHINE BETWEEN WORK SITES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
LOWERING THE OPERATOR PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
TOWING THE MACHINE - WITHOUT TOW VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
BYPASSING THE PROPULSION PUMP AND RELEASING THE BRAKES . . . . . . . . . . . . . . . . . 5-22
RESTORING OPERATION OF THE PROPULSION PUMP AND APPLYING THE BRAKE. . . . . . 5-25
TOWING THE MACHINE - WITH TOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
RESTORING OPERATION OF THE PROPULSION PUMP AND APPLYING THE BRAKE. . . . . . 5-31
SECTION 5- MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
GENERAL MAINTENANCE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Handling Fluids and Oil, Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
INITIAL BREAK-IN MAINTENANCE - 50 HOURS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
INITIAL BREAK-IN MAINTENANCE - 150 HOURS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
ACCESS 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Check Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Check Engine Coolant Level, Clean Radiator and Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Check Fuel Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Drain Water from Fuel Filter/Water Separator - SD-116, -122 (155 HP Electronic Engine) &
SD-122, -160 (173 HP Mechanical Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Drain Water from Fuel Filter/Water Separator - SD-116, -122 (155 HP Electronic Engine) . . . 5-24
Drain Water from Fuel Filter/Water Separator - SD-190 & SD-200
(205 HP Electronic Tier II Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Drain Water from Fuel Filter/Water Separator - SD-190 & SD-200
(203 HP Electronic Tier III Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Inspect Cooling Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Inspect Cooling Fan Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Lamp (Indicator Light) Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Check Parking Brake Using The Parking Brake Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Check Condition of Drum and Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Check Drum Scraper Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Check Seat Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

iv SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX
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TITLE PAGE
50 HOUR OR WEEKLY ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Check Batteries, Cables and Grease Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Check Tire Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Torque Wheel Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Check Air Cleaner Integrity and Filter Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Check Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Check Eccentric Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Check Wheel Ends Oil Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Check Carrier Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Check Axle Transfer Case Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Check Axle Differential / Brake Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Check Drum Drive (Torque Hub) Oil Level - SD-116, -122, -160, and -190 TF . . . . . . . . . . . . . 5-39
Check Drum Drive (Torque Hub) Oil Level - SD-200 TF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Grease Horizontal / Vertical Swivel Pins - SD-116, -122 & -160 TF. . . . . . . . . . . . . . . . . . . . . . 5-41
Grease Horizontal / Vertical Swivel Pins - SD-190 & -200 TF . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Clean the Carrier Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Grease the Carrier Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
500 HOURS OR SEMI-ANNUAL MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Grease Steering Cylinder Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-44
Change Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-44
Change Three Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Replace In-Line Fuel Filter - Tier 2 Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Replace In-Line Fuel Filter - Tier 3 Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Change Fuel 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 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-54
Clean Axle Breathers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
Grease the Ratchet Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Check Cooling System Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
1000 HOUR OR ANNUAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Torque the Horizontal Swivel Pin - SD-116, -122 and -160 TF . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Torque The Vertical Swivel Pin - SD-116, -122 and -160 TF . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
Torque the Horizontal Swivel Pin - SD-190 and -200 TF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
Torque the Vertical Swivel Pin - SD-190 and -200 TF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
Change Axle Wheel Ends Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
Change Axle Differential Brake Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Change Axle Transfer Case Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
Change Eccentric Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
Change Carrier Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Drain and Flush Radiator, Replace Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
Drain and Clean Hydraulic Tank and Three Hydraulic Suction Strainers. . . . . . . . . . . . . . . . . . 5-69
Check Engine Belt and Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
Adjust and Set Valve Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
Change Drum Drive (Torque Hub) Oil Level - SD 116, 122, 160 and 190. . . . . . . . . . . . . . . . . 5-71
Change Drum Drive (Torque Hub) Oil Level - SD 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72

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TITLE PAGE
SECTION 6 - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
FUSE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
FUSE RATINGS/CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
RELAYS AND DIODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
ENGINE WILL NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
ENGINE WILL NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
DIFFICULT STARTING & POOR / IRREGULAR PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . 6-6
ENGINE MAKING EXCESSIVE FUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
ENGINE OVERHEATS - STOP ENGINE IMMEDIATELY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
LOW ENGINE OIL PRESSURE - RED WARNING LIGHT ILLUMINATES . . . . . . . . . . . . . . . . . . . 6-7
VOLTMETER INDICATES LOW OR NEGATIVE VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
FUSE FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
CONTROL MODULE DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
POWER MUST BE ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
TRACTION CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
CAUSE OF FAULTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
VARIABLE VIBRATION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
CAUSE OF FAULTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
AUTO VIBE / IMPACT METER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
SECTION 7- TECHNICAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
TECHNICAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
MACHINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
ENVIRONMENTAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
SD-116 DX/F TERRA FIRMA SERIES VIBRATORY SOIL COMPACTORS. . . . . . . . . . . . . . . 7-4
SD-122 D/F/DX TERRA FIRMA SERIES VIBRATORY SOIL COMPACTORS . . . . . . . . . . . . . 7-5
SD-160 F/DX TERRA FIRMA SERIES VIBRATORY SOIL COMPACTORS. . . . . . . . . . . . . . . 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 DATA, EQUIPMENT DESCRIPTIONS, AND SELECTED
PERFORMANCE DATA FOR THE SD-122F COMPACTOR (TERRA FIRMA SERIES). . . . . . 7-12
MACHINE WEIGHTS, ENGINE DATA, EQUIPMENT DESCRIPTIONS, AND SELECTED
PERFORMANCE DATA FOR THE SD-160DX COMPACTOR (TERRA FIRMA SERIES).. . . . 7-14
MACHINE WEIGHTS, ENGINE DATA, EQUIPMENT DESCRIPTIONS, AND SELECTED
PERFORMANCE DATA FOR THE SD-160F COMPACTOR (TERRA FIRMA SERIES). . . . . . 7-16
MACHINE WEIGHTS, ENGINE DATA, EQUIPMENT DESCRIPTIONS, AND SELECTED
PERFORMANCE DATA FOR THE SD-190DX COMPACTOR (TERRA FIRMA SERIES).. . . . 7-18
MACHINE WEIGHTS, ENGINE DATA, EQUIPMENT DESCRIPTIONS, AND SELECTED
PERFORMANCE DATA FOR THE SD-200DX COMPACTOR (TERRA FIRMA SERIES).. . . . 7-20
MACHINE WEIGHTS, ENGINE DATA, EQUIPMENT DESCRIPTIONS, AND SELECTED
PERFORMANCE DATA FOR THE SD-200F COMPACTOR (TERRA FIRMA SERIES).. . . . . 7-22
MACHINE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

vi SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX
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TITLE PAGE
SECTION 8- FUEL AND LUBE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
FUEL AND LUBE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
LUBRICATION CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
PERIODIC LUBRICATION SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
HAZARDOUS SUBSTANCE PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
SECTION 9 - TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
SAE TORQUE CHARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
ISO METRIC TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
SAE TORQUE CHART - SD 116/122/160/190/200 TF SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
SAE TORQUE CHART - SD 116/122/160/190/200 TF SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
SAE TORQUE CHART - SD 116/122/160/190/200 TF SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
SECTION 10 - SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Hydraulic Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
APPLICABILITY OF ABOVE-LISTED SCHEMATICS TO SPECIFIC MACHINES. . . . . . . . . . . . . . 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 SCHEMATICS FOR THE SD-122F/D/DX COMPACTORS
W/MECHANICAL ENGINES (13304852) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
ELECTRICAL SCHEMATICS FOR THE SD-122F/D/DX & SD160F/DX COMPACTORS
W/MECHANICAL ENGINES (13375704) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
HYDRAULIC SCHEMATICS FOR THE SD-116F/DX COMPACTORS (13238902) . . . . . . . . . . . . 10-17
HYDRAULIC SCHEMATICS FOR THE SD-116F/DX &
SD-122F/D/DX COMPACTORS (13463336) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
HYDRAULIC SCHEMATICS FOR THE SD-116F/DX &
SD-122F/D/DX COMPACTORS (13375670) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
HYDRAULIC SCHEMATIC FOR THE SD-160F/DX COMPACTORS (13365374). . . . . . . . . . . . . . 10-24
HYDRAULIC SCHEMATIC FOR THE SD-190DX AND SD-200F/DX COMPACTORS (13414289) 10-25

SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX vii
TABLE OF CONTENTS
TITLE PAGE
SECTION 11 - RECOMMENDED SPARE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
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

SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX 1
INTRODUCTION

INTRODUCTION
2 SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX
INTRODUCTION
OVERVIEW
CONGRATULATIONS! You have just acquired an Ingersoll Rand compactor, an application-
designed product built with your needs in mind.
The primary purpose of this manualis to provide the operator and site maintenance personnel
with knowledge of the fundamental rules and criteria to be followed for the on-site use and
maintenance of the following Terra Firma series compactors.
• SD-116 DX
• SD-116 F
• SD-122 D
• SD-122 DX
• SD-122 F
• SD-160 DX
• SD-160 F
• SD-190 DX
• SD-200 DX
• SD-200 F
This instruction manual must have been read and fully understood by the operator before
operating the machine. The instruction manual consists of
• INTRODUCTION
• SECTION 1 - SAFETY
• SECTION 2 - SYMBOL IDENTIFICATION
• SECTION 3 - CONTROLS AND INSTRUMENTS
• SECTION 4 - OPERATING INSTRUCTIONS
• SECTION 5 - MAINTENANCE INSTRUCTIONS
• SECTION 6 - TROUBLESHOOTING
• SECTION 7 - TECHNICAL SPECIFICATIONS
• SECTION 8 - FUEL AND LUBRICATION SPECIFICATIONS
• SECTION 9 - TORQUE SPECIFICATIONS
• SECTION 10 - SCHEMATICS
• SECTION 11 - RECOMMENDED SPARE PARTS LISTS

INTRODUCTION
SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX 3
Always keep the Operation and Maintenance Manual on the machine and within reach of the
operating position.
If any part of this manual cannot be understood, contact your supervisor or local Ingersoll
Rand Distributor. This is an essential condition for working safely with this machine.
The correct machine operation, use and regular maintenance are also essential elements to
provide the highest performance and safety.
The present manual is accompanied with an engine instruction manual. You are therefore
advised to follow the operation and maintenance instructions as specified in both the engine
and the machine instruction manuals.
Some illustrations in this manual may show machines with optional equipment installed. This
optional equipment maybe purchased from your local Ingersoll Rand Road Machinery
Equipment Distributor.
Each manual is reviewed and revised regularly to include all necessary changes. Ingersoll
Rand reserves the right to modify or make changes within a specific model group without
notice, and without incurring any liability to retrofit machines previously shipped from the
factory. Contact your Ingersoll Rand Road Machinery Equipment Distributor for non-routine
maintenance that is not covered in this manual.
IDENTIFICATION DATA
An exact description of the model type and serial number of your machine will facilitate fast
and efficient response from our parts and service support operations.
Always provide the model of your machine and it's serial number when you contact the local
Ingersoll Rand service or parts office.
We advise you to enter your machine data in the following lines to maintain machine and
engine information:
Model............................
Serial No..................................
Year of manufacture..............
Engine Serial No. and type of engine..............................

INTRODUCTION
4 SD-116F/DX/122D/F/DX/160F/DX/190DX/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

INTRODUCTION
SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX 5
INSTRUCTION MANUAL STORAGE
A storage pouch (1, Figure 3) provides space for the machine manuals. The manuals are
located to the right side of the operator’s seat and provides space for the operation and
Maintenance Manual.
Figure 3
GENERAL INFORMATION
All safety rules in Section 1 must be observed.
If further information is required concerning the recommended use on soil applications,
contact your local Ingersoll Rand Distributor.
Ingersoll Rand Construction Technologies
Road Development Division
312 Ingersoll Drive
Shippensburg, PA 17257 USA
Tel:[phone]
Fax:[phone] (Service and Warranty)
717-530-3403 (Customer Service Parts)
Ingersoll Rand reserves the right to make any changes or modifications without prior notice
and without incurring any liability to retrofit machines previously shipped from the factory.

INTRODUCTION
6 SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX
MACHINE DESCRIPTION
The SD 116, 122, 160, 190, and 200 TF Series of single-drum vibratory roller soil compactors
are powered by a Cummins diesel engine driving three hydraulic pumps. One pump powers
the vibration drive motor, a second pump powers the steering control valve and cylinders and
a third pump powers the drum and differential/wheel propulsion systems. Direction and speed
arecontrolled by a propulsion control lever,engine idle speed selector switchand a compactor
speed selector switch.
The compactor uses the positioning of the propulsion lever to the S, stop position, as an
operating brake. An independent spring applied hydraulically released drum drive brake and
an independent spring applied hydraulically released axle differential drive brake serve as a
unit as a parking brake.
Standard equipment includes an Emergency Stop Push/Pull Control to shut down the engine
and apply the mechanical brake/s in an emergency situation. In addition dual machine speed
range capability and dual engine speed (rpm) capability are included.
ROPS“RolloverProtectionStructure”, FOPS“Falling ObjectsProtection Structure”plus aseat
belt and several additional standard items and numerous optional features are availabe.l
For a complete listing of currently supplied / available standard and option features contact
your nearest Ingersol Rand distributor.
ENGINE
The SD-116 TF and SD 122 TF series compactors are powered via a 156 horsepower
electronicTierIIfuelinjectedCummins dieselengine. Anoptional 173horsepowermechanical
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 horsepower electronic turbocharged Tier III Cummins diesel engine.
The 156 horsepower water cooled engine includes a long screw on cannister style fuel water
separator with screw style drain, an in line fuel filter, and a second fuel filter with replaceable
element.
The 173 horsepower water cooled engine includes a short screw on cannister style fuel filter,
an in line fuel filter, and a second fuel filter with replaceable element.
Each engine includes a dry type two stage air cleaner which signals a operator console
mounted air filter restrictor indicator light whenever the air filtration system needs attention.
Unless this light is illuminated maintenance on the air cleaner system is not recommended.
The 205 horsepower water cooled Tier II engine includes a long screw-on cannister style fuel
waterseparator with a lift tab drain, an inlinefuelfilter, and a second fuel filter with replaceable
element.
The 203 horsepower water cooled Tier III engine includes a long screw-on cannister style fuel/
water separator with a lift tab drain and a primary fuel filter with a replaceable element. No in-
line fuel filter is required.
Electric start and belt driven alternator charging are standard. Engine shutdown is by a key
operated ignition switch or the emergency push/pull control.

INTRODUCTION
SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX 7
Refer to the Cummins Engine Operation and Maintenance Manual and the Engine Parts
Manual supplied with the compactor for additional engine operating and maintenance
procedures. Note: Electronic and Mechanical Engines have separate Operation and
Maintenance Manuals and separate Engine Parts Manuals.
MAIN FRAME
The SD TF series compactors include a rear frame assembly and a front frame assembly
connected by an articulation pin and an oscillation pin. The rear frame assembly includes a
frame weldment, hydraulic tank assembly, fuel tank, battery box plus the control components
the engine and hydraulic drive components except for the drum drive and eccentric drive. The
front frame assembly includes the drum, drum support and drive components plus the
eccentric components and eccentric hydraulic drive motor.
DRUM
Drums available with these machines include smooth or footed plus optional scrapers for
each. Vibration is supplied to the drum by an eccentric assembly mounted internally and
powered by an hydraulic motor with amplitude and frequency of vibration controlled by the
operator.
CONTROLS
All operator controls, gauges and indicator lights are located for operator convenience and
comfort.
The machine propulsion direction, speed and braking controls plus vibration On/Off control
and emergency stop push/pull control are located to the right of the operator.
Thecontrolconsoleincludes thefollowing controls suppliedas standard oroptional equipment
(dependent on model). The controls and indicator lights include: vibration frequency control,
engine coolant temperature gauge, tachometer, hourmeter, engine speed selector switch,
engine speed range selector switch, parking brake on/off switch, parking brake test switch, tilt
steering, work light on/off switch, and a vibration amplitude selector switch.
Other lights include air filter restrictor indicator light, alternator (not) charging indicator light,
low oil pressure indicator light stop engine indicator light (electronic engines only) and a check
engine light (electronic engine only) plus the battery master switch located on the battery box.
Pre-programmed controls for the traction, frequency and auto vibration systems are available.
Refer to Section 3 of this manual for a complete description of the controls and indicator lights.
VIBRATION SYSTEM
he vibration system consists of aneccentric mounted in thedrum and powered by an hydraulic
motor. This system is has dual amplitude capability, is time proven and reliable. Selection of
high or low is by the operator pressing a selector switch on the console. High amplitude is
recommended for thick lift compaction, low amplitude for thinnerlifts and sensitive compaction
areas.

INTRODUCTION
8 SD-116F/DX/122D/F/DX/160F/DX/190DX/200F/DX
VIBRATION FREQUENCY
Drum vibration frequencies available to the operator includes a rangeof five frequencies when
in the hi amplitude condition and a range of five frequencies when in the low amplitude
condition. They are selected by a five position rotary selector switch on the console.
Frequency ranges available for the SD TF Series Compactors is identified in the machine
specifications in Section 7, Techical Specifications. A dual range feature is also available
controlled by a two position switch.
OPERATOR’S STATION
The operator’s station is designed for convenience, ease of control, comfort and safety while
providing maximum visibility to the work area. The operator’s station is isolated from vibration
by four independent vibration isolators and can be equipped with several available options.
The operator’s station/cab can be tilted forward for maintenance by a jack assembly supplied
with the machine.
GRADEABILITY
Superior gradeability of this machine is the result of A powerful torque-balanced hydrostatic
propulsion system which includes dual machine speed range capability and use of the High
engine 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
theaxle assembly are designed for useas a parking brake/ emergencybrake.The mechanical
brake/s are spring applied and hydraulically released. Loss of engine power for any reason or
loss of hydraulic pressure to the brake circuit will allowthe mechanical brakes The positioning
of the propulsion control lever the S (stop) position acts as a dynamic (operating brake). to
apply.
Refer to Section 5 of this manual for additional information.
SERVICEABILITY
Machine maintenance and service, as described in Section 5 of this manual, will require
raising of the spring loaded hood for access to the engine, air cleaner, oil filter, fuel filters and
related service items. Tilting of the operator’s platform / cab will be necessary for other
particular items.
The battery, tilting jack, and control/s are located in the battery box behind the steps on the left
side of the machine. Removal of two bolts and lifting on the front panel of the battery box will
allow the front panel and attached steps to be pivoted down to the ground allowing easy
access.
It is recommended the Maintenance Schedule located in Section 5 of this manual be followed.