OPERATION AND MAINTENANCE MANUAL SD-100 / SD-100D / SD-100F C SERIES Vibratory Compactors Effective with S/N 188570 CPN 13859038 March 20, 2006 Read and understand this manual before operating or servicing this equipment.CALIFORNIA 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.TABLE OF CONTENTS TITLE PAGE INTRODUCTION Overview Identification Data Machine Identification Engine Identification. Instruction Manual Storage General Information Machine Description .. . Vibration System Versatility . cee Variable Frequency Gradeability wee Safety Information .. BAAARRROONN= SECTION 1 - SAFETY Be Aware Of Safety Information Understand Signal Words . . Overview General . ee Selection And Qualification Of Personnel... . Organizational Measures. Pre Start Inspection... . Safety Instructions Starting. . Operating. Stopping. . Maintenance .............. Transporting, Towing And Roading Warning Of Special Dangers Hazardous Substance Precaution . Safety Related Decals. . Us Decals. International Decals With Interpretation ‘SECTION 2 - SYMBOL IDENTIFICATION Ingersoll-Rand Machine Symbols 24 International Road Machine Symbols 22TABLE OF CONTENTS TITLE SECTION 3 - OPERATING CONTROLS AND INSTRUMENTS. Overall View Of Controls And Indicators Indicator Light Cluster Battery... Oil Pressure Indicator Engine Coolant Temperature. Hydraulic Oil Temperature. Air Cleaner Warning Light. Tachometer Hourmeter ...... Front Light Switch (Optional) Rear Lights Switch (Optional) Park Brake Switch : Emergency Stop Switch... Two-speed Axle Control Switch. Fuel Gauge Articulation Lock Pin Propulsion Control . Ignition Switch Vibration (Vpm) Control. Throttle Control Throttle Control (Tier li Engine Only) Warning Lights (Tier li Engine Only). .... Battery Master Switch (Tier li Engine Only). Diagnostic Plug (Tier Il Engine Only) SECTION 4 - OPERATING INSTRUCTIONS General Information Safety Checks - Pre-starting Start-up Procedure. . .. . Operating The Machine . Propelling The Machine Shutdown Procedure Towing PAGETABLE OF CONTENTS TITLE PAGE SECTION 5 - MAINTENANCE INSTRUCTIONS. General Information. 54 Prior To Conducting Any Maintenance Work, Ensure The Following Are Instructions Observed: . 51 Handling Fluids And Filters. - Initial Break-in Maintenance.......-++.... Maintenance Schedule .... Routine Maintenance - As Required . ‘Check Air Cleaner Restriction Indicator Checking And Removing Air Cleaner Element Cleaning The Air Cleaner Element Cleaning The Machine 10 Hour Or Daily Maintenance .. Check Engine Oil Check Engine Coolant Level Drain Water From Fuel Filter - 95 And 125 Hp Engines Drain Water From Fuel Filter -110 Hp Engine Check Fuel Level Check Air Cleaner Restriction Indicator Check Parking Brake Seat Belt ; 50 Hour Or Weekly Routine Maintenance . Grease Articulation Swivel Pins Grease Steering Cylinder Pins Grease Oscillation Swivel Pin Check Tire Pressure Check Hydraulic Oil Torque Wheel Nuts ‘Seal Boot Grease (Sd-100 Only) Check Air Cleaner System Integrity Check Axle Input Case Oil Check Axle Differential And Brake Oil Level Check Wheel End Oil Level Check Eccentric Oil Level Check Drum Drive Oil Check Battery, Clean And Grease Terminals 250 Hour Or Quarterly Routine Maintenace .. Change Engine Oil And Filter Change Hydraulic Filters. Change Fuel Fiters (95 And 125 Hp Engines) Change In-line Fuel Filter (95 And 125 Hp Engines) ..... ‘Change Engine Fuel Filter (110 Hp Electronic Engine) Grange imine Fue Fier (110 Hp Electronic Engine) - Clean Axle Housing Breathers Grease Carrier Seal Clean Carrier Breather 1000 Hour Or Annual Routine Maintenance Change Axle Input Case Oil (SD-100 Only) . Change Wheel End Oil. Change Axle Differential / Brake Housing Oil. Change Drum Eccentric Oil A Change Carrier Oil... ‘Change Drum Drive Oil ‘Change Hydraulic Oil And Clean Suction Strainer . Drain, Flush and Replenish Engine Cooling SystemTABLE OF CONTENTS TITLE PAGE Torque Oscillation Swivel Pin Nut ceceeeeeeeee : 5-46 Torque Articulation Swivel Pin Nuts... : cecceeeeee eters BAB Check Engine Valve Clearance eegagcoo5n0 cecceeeeeeteeeee ss SMT Check Engine Belts and Tensioner. 5.47 ‘SECTION 6- TROUBLESHOOTING Engine Diagnostic Port (110 Hp Electronic Engine) 64 Pre-start Check 62 Engine Will Not Start 62 Difficult Starting & Poor / Irregular Performance ...... 06... ..seeeeeeeeeeeeeeee neces 68 Engine Making Excessive Fumes 63 Engine Over Heats - Stop Engine Immediatiey 64 Low Engine Oil Pressure - Red Warning Light Illuminates. 64 Battery Indicator Light lluminates ...........secc0ceeeeeeeeeeeeeeeeeeeee + 64 No Power To Ignition Switch... 0.0... css ecceeeeeeeeeeeeee nett et eeee eee eees od SECTION 7- TECHNICAL SPECIFICATIONS General Identification........ Be se mA Machine Weights And Figures A Machine Dimensions - SD-100 74 Machine Dimensions - SD-100D 75 Machine Dimensions - SD-100F 76 SECTION 8 - FUEL AND LUBRICANT SPECIFICATIONS General Information. .... 0.6... ccee eee cece eee eee cece ee eeeeeeeeee en eeees BT Lube Chart a2 Fluid Capacities 84 Hazardous Substance Precaution 85 SECTION 9 - TORQUE SPECIFICATIONS General Information 9 Sae Torque Chart... 0... eee eee cee eee ee cece eect een eee een eee ett eee renee Iso Metric Torque Chart. 9 Special Torque Values. 9TABLE OF CONTENTS TITLE PAGE SECTION 10 -SCHEMATICS. GENERAL INFORMATION . conte eee eeeeeee cee cee N04 APPLICABILITY OF SCHEMATICS TO SPECIFIC MACHINES 10-2 Electrical Schematic for SD-100 C-Series Compactors with standard Mechanical Engines (13301593) 10-3 Electrical Schematic for older SD-100 C-Series Compactors (13154992) 10-4 Electrical Schematic for SD-100D/F C-Series Compactors with Electronic Engines 105 Hydraulic Schematic for Axle Drive 13301577 10-6 Hydraulic Schematic for SD-100D & SD-100F C-Seriss Compactors equipped with Rexroth Drum Drives (13865605_001) 10-7 Hydraulic Schematic for SD-100D & SD-100F C-Serias Compactors equipped with Optional Poclain Drum Drives (13865605_002) 10-8 SECTION 11 - SPARE PARTS GENERAL INFORMATION . covet teeta eeseeseeeteeeeee ceeeeee WA Recommended Spare Parts for the SD-100 C-Saties Compactors...... 0... 0e.00e0ee05 Wed Recommended Spare Parts for the SD-100D C-Series Compactors 117 Recommended Spare Parts for the SD-100F C-Series Compactors. .. . 11-14 SUBJECT INDEXTABLE OF CONTENTS Genuine Parts For Genuine Ingersoll-Rand Parts, Service And Nearest Distributor http:/www.road-development.irco.com 800-227-0573 (US and Canada) 717-532-9181 (Latin America - Ingersoll-Rand) 49-5151-209-0 (Europe) {852-2527-0183 (Asia) Genuine Ingersoll-Rand Protective Lubricants See Your Authorized Ingersoll-Rand Distributor For DetailsINTRODUCTION 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 manual is to provide the operator and site maintenance personnel with knowledge of the fundamental rules and criteria to be followed for the on-site use and maintenance of the SD-100C Series vibratory compactor. This instruction manual must have been read and fully understood by the operator before operating the machine. This instruction manual consists of: Introduction describing the machine General safety rules Identification of control and safety symbols Operator controls and instrumentation Operation and use Maintenance instructions Troubleshooting, control / instrument problems ‘Technical Specifications Fuel and Lubrication Instructions Torque specifications Electrical/Hydraulic Schematics ‘Always keep the "Operation and Maintenance Instruction Manual on the machine and within reach of the operating position. If any part of this manual cannot be understcod, 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. ‘Some illustrations in this manual may be of prototype models. Production machines may vary in some detail 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 ‘SD-100/SD-100D/SD-100F C SERIESINTRODUCTION notice, and without incurring any liability to retrofit machines previously shipped from the factory. Contact your Ingersoll-Rand Road Mactinery 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. MACHINE IDENTIFICATION ‘The machine identification plate (1, Figure 1) is located on the forward left side of the rear frame. Figure 1: ‘SD-100/SD-100D/SD-100F C SERIESINTRODUCTION ENGINE IDENTIFICATION The Cummins engine number can be found on the engine data plate (1, Figure 2). Figure 2: INSTRUCTION MANUAL STORAGE A storage pouch (1, Figure 3) provides space for the machine manuals. The manuals are located within easy reach of the operator's siation. Figure 3 : ‘SD-100/SD-100D/SD-100F C SERIESINTRODUCTION 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 Company Road Development Shippensburg, PA 17257 USA Tol:717-532-9181 Fax:717-530-3402 (Service and Warranty) 717-530-3403 (Customer Service Parts) Ingersoll-Rand reserves the right to make any changes or modifications without prior notice and without incurring any liability to retrofit machines previously shipped from the factory. MACHINE DESCRIPTION The SD-100 (C Series) Vibratory Compactors ate designed for high productivity and ease of operation. Performance characteristics allow contractors to match these machines to a variety of job conditions. Density requirements are quickly met on thin or thick lifts of granular or cohesive materials. MODELS: There are various models available within the SD-100 (C Series) compactors. The SD-100 model is axle-drive only. The engine is water cooled and rated at 95 horsepower The SD-100D model has a smooth drum and is adrum and axle-drive vibratory compactor that provides the extra traction necessary on steep grades or deep lifts of loose granular soils. The ‘SD100D is designed to allow high field gradeabilty while vibrating for unexcelled performance on the really difficult projects. The standard engine is water cooled and rated at 125 horsepower. An optional 110 horsepower Tier Il engine is available. The SD-100F model is a padfoot drum vibratory compactor that delivers the necessary compaction force to economically compact cohesive soils. The 120 rectangular manganese steel tamping feet compact and exit soil with minimal loosening of the surface. The combination of standard drum drive and axle drive provides maximum gradability and traction, even under extreme site conditions, for maximum compaction performance and productivity. The standard engine is water cooled and rated at 125 horsepower. An optional 110 horsepower Tier Il engine is available. VIBRATION SYSTEM ‘A dual amplitude, eccentric mechanism is reliable and maintenance-free. This proven design provides positive lubrication to the eccentric shaft bearings for long life. ‘SD-100/SD-100D/SD-100F C SERIESINTRODUCTION VERSATILITY ‘An optional bolt-on padfoot conversion kit is easily installed. This permits a smooth drum unit to be used on granular or cohesive soils, thus, increasing machine utilization. VARIABLE FREQUENCY A variable frequency of 0 - 1800 VPM (0 - 30 Hz) can be adjusted at the operator's station to accommodate varying job conditions by matching natural frequencies of different soils. GRADEABILITY ‘Superior gradeability is achieved through a proper balance of drum-to-tractor weight, torque- balanced hydraulic system and high engine horsepower. SAFETY INFORMATION Ingersoll-Rand strongly recommends a ROPS (rollover protective structure) equipped ‘compactor for operator and equipment protection if the machine is to be used on other than level ground. Basically, a ROPS used with a seat belt will protect the vehicle operator from injury if the vehicle undergoes a single rollover. Safe operation depends on reliable equipment and the use of proper procedures. Performing the checks and service described in this manual will help keep your compactor in good condition. These recommended operating procedures will help you to avoid unsafe practices. Safety notes have been included throughout this manual to help the operator avoid injury and prevent damage to the equipment. These notes are not intended to cover all situations; itis impossible to anticipate and evaluate all possible methods of operation. Therefore, the operator is the only person who can guarantze safe operation and maintenance. Itis important that any procedure not specifically recommended in this manual be thoroughly evaluated from the standpoint of safety before it is implemented. Your life may be endangered if the following are not complied with: DO NOT operate this machine if the Rollover Protective Structure (ROPS) or Falling Object Protective Structure (FOPS) is structurally damaged, shows cracks, is not properly secured as ally installed, or has been rolled. DO NOT repair, modify or add attachments to the ROPS/FOPS unless authorized in writing by the manufacturer. DO NOT add attachments to the machine that intrude into the operator's protective area, reduce ty, restrict emergency exits or add weight ing certification weight of ROPS/FOPS. ‘SD-100/SD-100D/SD-100F C SERIESINTRODUCTION Genuine Parts For Genuine Ingersoll-Rand Parts, Service ‘And Nearest Distributor http:viwww.road-development.irco.com 800-227-0573 (US and Canada) 717-532-9181 (Latin America - Ingersoll-Rand) 49-5151-209-0 (Europe) £852-2527-0183 (Asia) Genuine Ingersoll-Rand Protective Lubricants See Your Authorized Ingersoll-Rand Distributor For Details ‘SD-100/SD-100D/SD-100F C SERIESSAFETY SECTION 4 SECTION 1 - SAFETY BE AWARE OF SAFETY INFORMATION This is the Safety Alert Symbol. Itis used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Follow recommended precautions and safe operating practices. UNDERSTAND SIGNAL WORDS A signal word - DANGER, WARNING, or CAUTION - is used with the safety-alert symbol. DANGER identifies the most serious hazard. DANGER, WARNING, or CAUTION safety labels are located near specific hazards. NOTICE labels are for general information. SAFETY ALERT SYMBOL RED BACKGROUND, DANGER indicates an imminently hazardous situation which if not avoided, will result in death or serious injury. ORANGE BACKGROUND. WARNING indicates a POTENTIALLY hazardous situation which if not avoided, COULD result in death or serious injury. ‘SD-100/SD-100D/SD-100F SERIES C 14112 SECTION 1 SAFETY A CAUTION YELLOW BACKGROUND CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate Injury CAUTION YELLOW BACKGROUND CAUTION used without the Safety Alert Symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. BLUE BACKGROUND important but not hazard related. OVERVIEW BEFORE YOU OPERATE, MAINTAIN, OR IN ANY OTHER WAY USE THIS COMPACTOR: READ and STUDY this manual. KNOW how to safely use the compactor’s controls and what you must do for safe maintenance. ALWAYS wear or use the proper safety items required for your personal protection. Ifyou have ANY QUESTIONS about the safe use or maintenance of this compactor, ASK YOUR SUPERVISOR OR CONTACT ANY INGERSOLL-RAND DISTRIBUTOR. NEVER GUESS-ALWAYS CHECK! NOTE: Refers to special information on the efficient use of the machine. ‘SD-100/SD-100D/SD-100F SERIES CSAFETY SECTION 1 GENERAL Ingersoll-Rand can not for ensure possible ci-cumstances that might lead up to a potential hazard. Therefore, the combination of warnings listed in this manual and those placed on the machine itself are not intended to be all inclusive. Operators and maintenance personnel must te alert to recognize and avoid potential hazards. They should also have comprehensive training, required skills and necessary tools to properly perform their functions. The machine was built in accordance with state-of-the-art standards and recognized safety rules. Nevertheless, its misuse may constitute a risk to life and limb of the user or of third parties, and may cause damage to the machine or other material property The machine must be used in accordance with its designated use as described in the ‘operating manual. The machine must only be operated by safety-conscious persons who are fully aware of the risks involved in operating the machine. Any functional disorders, especially those affecting the safety of the machine, must be corrected immediately. The machine is designed exclusively for the compaction of soil. Use of the machine for purposes other than that mentioned (such as for towing other vehicles/equipment) is. considered contrary to its designated use. The manufacturer/supplier cannot be held liable for ‘any damage resulting from such use. The risk of such misuse lies entirely with the user. Operating the machine within the limits of its designated use also involves compliance with the inspection and maintenance directives contained in the operating manual. SELECTION AND QUALIFICATION OF PERSONNEL Work on and with the machine must be performed by qualified personnel only. Statutory minimum age limits must be observed. Individual responsibilities of the personnel responsible for operation, setup, maintenance and repair of the machine should be stated clearly. Define the machine operator's responsibilities - also with regard to observing traffic regulations - the operator should have the authority to refuse instructions by third parties that are contrary to safety. Do not allow persons being trained or instructed in the operation or maintenance of the machine to work without permanent supervision by an experienced person. Work on the electrical system and equipment of the machine must be done only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and must be in accordance with electrical engineering rules and regulations. Work on the chassis, brake, hydraulic and steering systems must be performed by skilled personnel with special knowledge and training for such work. ‘SD-100/SD-100D/SD-100F SERIES C 13SECTION 1 SAFETY ORGANIZATIONAL MEASURES ‘STOW manuals in the manual pouch provided on the machine. Manuals must always be available at the site where the machine is used OBSERVE AND INSTRUCT the user in all other generally applicable legal and mandatory regulations relevant to accident prevention and environmental protection. These compulsory regulations may also deal with the handling of hezardous substances, issuing and/or wearing of personal protective equipment, and traffic regulations. SUPPLEMENT operating instructions with detailed working instructions pertaining to the specific work location. ALWAYS be sure that persons entrusted with work on the machine have read the operating instructions and in particular the chapter on safety before beginning work. Reading the instructions after work has begun is too late. This is especially important for persons who work only occasionally on the machine, e.g. during set up or maintenance. MAKE CERTAIN personnel are working in comp iance with the operating instructions and are alert to risks and safety factors. ALWAYS tie back or otherwise secure long hair, wear close-fitting garments and avoid wearing jewelry such as rings. Injury may result fom clothing, hair, or jewelry being caught up in the machinery. USE protective equipment wherever required by the circumstances or by law. OBSERVE all safety instructions and warnings attached to the machine. BE SURE all safely instructions and war perfectly legible. ngs allached lo the machine are complete and STOP the machine immediately in the event of eny malfunction. REPORT the malfunction to the proper authority/person. NEVER provide service or maintenance to the machine unless the drum and wheels are adequately chocked, articulation lock bar/pin is in locked position, and parking brake is applied, NEVER make any modifications to the machine which might affect safety without the manufacturer's approval. This applies to the installation and adjustment of safety devices and valves as well as to welding work on load bearing elements. ALWAYS ADHERE to prescribed intervals or those specified in the operating instructions for routine checks and inspections. PRE START INSPECTION INSPECT your compactor daily. Ensure that the routine maintenance and lubrication are being dutifully performed. Have any malfunctioning, broken, or missing parts repaired or replaced before use. Refer to the Maintenance Schedule located in Section 5 of this manual. VERIFY that all instruction and safety labels are in place and readable. These are as important as any other equipment on the compactor. Refer to the decal location drawing in Section 1 in this manual. NEVER fill the fue! tank with the engine running, while near an open flame, or while smoking, ‘SD-100/SD-100D/SD-100F SERIES CSAFETY SECTION 1 ALWAYS wipe up any spilled fuel. CHECK for WARNING tags placed on the compactor. DO NOT operate the compactor until repairs have been made and the WARNING tags have been removed by authorized personnel. Check the seat belt regularly for wear or damage. Inspect belt hardware and fabric. replace if hardware is damaged or if strap is nicked, frayed or loose stitching is found. Check that mounting hardware is tight. CLEAN any foreign material from the operator's platform to reduce the danger of slipping. KNOW the location of the Emergency Shut-Down Control if compactor is so equipped. ALWAYS know the capabilities and limitations of your equipment-speed, gradeabili steering, and braking BE AWARE of the dimensions of your compactor-height and weight-as well as your transporter dimensions and weight. CHECK for any conditions that could be dangerous-holes, banks, underground culverts, manhole covers, water meter pits, curb and/or street boxes. SAFETY INSTRUCTIONS AVOID any operational mode that might sacrifice safety. TAKE all necessary precautions to ensure that the machine is used only when in a safe and rellable condition, OPERATE the machine only if all protective and safety oriented devices, such as removable safety devices, emergency shut off equipment, soundproofing elements and exhausts, are in place and fully functional ‘START the machine from the driver's seat only and always wear the seat belt. WATCH the indicators during start up and shutdown procedures in accordance with the ‘operating instructions, MAKE SURE no one is at danger or risk before starting up or setting the machine in motion. CHECK that braking, steering, signalling and lighting systems are fully functional before starting work or travelling with the machine. CHECK that accessories have been safely stowed away before setting the machine in motion. OBSERVE the valid traffic regulations when traveling on public roads and ways and MAKE ‘SURE the machine is in a condition compatible with these regulations. ALWAYS SWITCH ON the lighting system in conditions of poor visibility and after dark. MAKE SURE there is sufficient clearance whan crossing underpasses, bridges and tunnels or when passing under overhead lines. ALWAYS KEEP at a distance from the edges of building pits and slopes. AVOID any operation that might be a risk to machine stability. ‘SD-100/SD-100D/SD-100F SERIES C 15SECTION 1 SAFETY NEVER CHANGE to a lower gear on a slope; always change before reaching it. On sloping terrain, always adapt your travelling speed to the prevailing ground conditions. ALWAYS SECURE the machine against inadvertent movement and unauthorized use before leaving the driver's seat. Starting ALWAYS USE hand rails and steps (if eq yed) to get on and off the compactor. ALWAYS MAINTAIN a three-point contact when climbing onto or off of compactor. Refer to Figure 4 READ and FOLLOW ALL instruction decals. ALWAYS be seated with the seat belt on when operating the machine. BEFORE starting the engine, ENSURE that the propulsion (travel) control is in the “STOP” position, BEFORE starting the engine, ENSURE that the parking brake control is in the “Applied” position. START the engine from the operator's posi n only. ‘SD-100/SD-100D/SD-100F SERIES CSAFETY SECTION 1 Never jump start the compactor directly to the starter or starter solenoid. Severe injury or death could result from the compactor lurching forward or backward and running over the person/s attempting to jump start the compactor. Normal safety devices are bypassed when jump starting directly to the starter or starter solenoid. AVOID personnel injury by making sure the compactor does not touch the other machine while itis being jump started. NEVER jump start a frozen battery, as i generate explosive gases. will explode. While charging, lead acid batteries KEEP SPARKS, flames and lighted smoking materials away from batteries. While charging, lead acid batteries generate explosive gases. ALWAYS wear safety glasses when working on or near batteries, PROCEED as follows when jump starting the compactor. + Connect the Positive (+) terminal of the booster battery to the Positive (+) terminal of the discharged battery + Connect the Negative (-) terminal of the booster battery to the best ground point of the compactor away from the battery. + Follow all recommended engine starting procedures. + Remove the jumper cables in the reverse order of their connection as soon as the engine has started. Operating ALWAYS make sure that no person or obstruction is in your line of travel before starting the ‘compactor in motion. NEVER CLIMB onto or off of the compactor while it is in motion. ALWAYS remain seated with the seat belt on when operating the compactor whether compacting, traveling, or loadinglunloading. USE EXTREME CAUTION and be very observant when operating in close quarters or congested areas. NEVER carry passengers. CLOSE all sound baffles during operation. KNOW the area in which you are working. Familiarize yourself with work site obstructions and any other potential hazards in the area. KNOW and USE the hand signals required for particular jobs and know who has the responsibility for signaling. ‘SD-100/SD-100D/SD-100F SERIES C 1718 SECTION 1 SAFETY DO NOT work in the vicinity of overhanging banks or on grades that could cause the compactor to slide or roll over. AVOID side hill travel. ALWAYS operate up and down slopes. ALWAYS keep the propulsion (travel) contro! lever in low speed range close to the “STOP” position when climbing or descending hills. NEVER allow anyone to stand within the compaztor's articulation area when the engine is running. USE the rear window or the right hand window as an emergency exit in case of a rollover of a machine with a factory installed cab if the cab access door is cannot be opened. ALWAYS LOOK in all directions BEFORE changing your direction of travel. DO NOT attempt to control compactor travel speed with the throttle control. When operating the compactor maintain the engine speed at full “Operating rpm." DO NOT tow or push the compactor except as explained in SECTION 4 of this manual. DO NOT run the engine in a closed building for an extended length of time. EXHAUST FUMES CAN KILL. ‘Stoppi ALWAYS park the compactor on solid level ground. If this is not possible, always park the compactor at a right angle to the slope and chock the drum and wheels. AVOID leaving the operator's platform with the engine running. ALWAYS move the propulsion (travel) control to “STOP”, apply the parking brake, install the articulation lock barflock pin, position the throttle control to “idle rpm”, pull the fuel shut-off control (if so equipped), turn ignition switch to OFF, and lock all lockable compartments. USE proper flags, barriers, and warning devices, especially when parking in areas of heavy traffic. Maintenance In any work concerning the operation, conversion or adjustment of the machine and its safety oriented devices or any work related to maintenance, inspection and repair, always observe the start up and shutdown procedures set out in the operating instructions and the information on maintenance work. ENSURE that the maintenance area is adequately secured, Ifthe machine is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by: + locking the principal control elements and removing the ignition key and/or + attaching a warning sign to the ignition or main switch CARRY OUT maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movement and buckling. ‘SD-100/SD-100D/SD-100F SERIES CSAFETY SECTION 1 USE CARE when attaching and securing lifting tackle to individual parts and large assemblies being moved for replacement purposes to avoid the risk of accidents. USE lifting gear that is in perfect condition and with adequate lifting capacity. NEVER work or stand under suspended loads. ALWAYS USE the correct tools and workshop equipment when performing maintenance to the machine. ALWAYS USE specially designed or otherwise safety oriented ladders and working platforms when doing overhead assembly work. Never use machine parts as a climbing aid. KEEP all handles, steps, handrails, platforms, landings and ladders free from mud, dirt, snow and ice. CLEAN the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair. NEVER use aggressive detergents. Use lint free cleaning rags. COVER OR TAPE all openings which - for safety and functional reasons - must be protected against water, steam or detergent penetration before cleaning the machine with water, steam jet (high pressure cleaning) or detergents. Special care must be taken with electric motors and switch gear cabinets. ENSURE during cleaning of the machine thet temperature sensors do not come into contact with hot cleaning agents. REMOVE all covers and tapes applied for that purpose after cleaning machine. EXAMINE all fuel, lubricant, and hydraulic fluid lines for leaks, loose connections, chafe marks and damage after cleaning. REPAIR or REPLACE defective parts immediately. TIGHTEN any screwed connections that have been loosened during maintenance and repair. REPLACE any safety devices removed for setup, maintenance or repair purposes and checked immediately upon completion of the maintenance and repair work. ENSURE that all consumables and replaced parts are disposed of safely and with mi environmental impact. AVOID, whenever possible, servicing, cleaning, or examining the compactor with the engine running, AVOID, whenever possible, servicing or providing maintenance to the compactor unless the drum and wheels are adequately chocked, the articulation lock barflock pin is in the locked position, and parking brake is applied. NEVER fill the fuel tank with the engine runn ng, while near an open flame, or while smoking, ALWAYS wipe up any spilled fuel. DO NOT alter the engine governor settings from those indicated in the engine manual and the engine option plate. ALWAYS replace damaged or lost decals. Refer to the parts manual for the proper location and part number for all decals. ‘SD-100/SD-100D/SD-100F SERIES C 19SECTION 1 SAFETY ENSURE the safe operation, optimum performance and safety of your warranty by using only genuine Ingersoll-Rand replacement parts. DISCONNECT the battery cables when working on the electrical system or when welding on the compactor. BE SURE the battery area is well ventilated (clear of fumes) should it be necessary to connect a jump battery or battery charger. Fumes from the battery can ignite by a spark and explode. BE SURE the battery charger required. “Off” when making the connections if battery charging is USE only original fuses with the specified currert rating. Switch off the machine immediately if trouble occurs in the electrical system. WORK on the electrical system or equipment may only be carried out by a skilled electrician or by specially instructed personnel under the control and supervision of an electrician and in accordance with the applicable electrical enginearing, CUT off the power supply to parts of the machine on which inspection, maintenance and repair work is to be carried out. CHECK the de-energized parts for the presence of power and ground or short circuit them in addition to insulating adjacent live parts and elements before starting work. INSPECT the electrical equipment of machines at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately. DO NOT weld, flame cut or peform any grinding operations on the machine unless expressly authorized as there may be a rick of explosion and fire, CLEAN the machine and its surroundings from dust and other flammable substances and make sure that the premises are adequately vertilated (risk of explosion) before beginning welding, flame cutting and grinding operations. INSPECT hydraulic hoses at regular intervals and immediately replace if they show signs of chafing, cracking, brittleness, deformation, blistering, leakage, fitting separation, corrosion or other damage which may affect their function or strength. DO NOT work on hydraulic ines while the engines running and the system is under pressure. The hydraulic fluid remains pressurized long after the engine has stopped. DO NOT work on any hydraulic hose or fitting until the pressure has been properly relieved. WAIT for fluid to cool down before disconnecting. Hot hydraulic fluid will cause severe burns. NEVER use your hands to check for leaks when inspecting an hydraulic system. Use a piece of cardboard and always wear gloves and safety glasses. GET immediate attention if fluid has been injected under your skin. Fluid penetration from a pin hole leak can cause severe injury or death. ENSURE hydraulic lines are laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements. OBSERVE the product related safety regulations when handling oil, grease and other chemical substances. Be careful when handling hot consumables (risk of burning or scalding). ‘SD-100/SD-100D/SD-100F SERIES CSAFETY SECTION 1 TRANSPORTING, TOWING AND ROADING USE only appropriate means of transport and lifting gear of adequate capacity. ENTRUST to experienced persons only the fastening of loads and the instructing of crane operators. The personnel giving the instructions must be within sight or sound of the operator. DONOT attemptto load the compactor on the transporters without knowledge and experience with the operation of the compactor. ALWAYS use a ramp when loading the compactor on the transporter. Be sure ramps are of adequate strength, low angle, and proper height and width. USE proper chock blocks in front and rear of the wheels of the transporter when loading the compactor. ENSURE the trailer is on level ground and aoproach the transporter loading ramps squarely to make sure the compactor does not drop off the side of the ramp. KEEP the transporter deck clean of clay, oil, mud, ice, frost and other material that can become slippery. USE proper chock blocks on the front of the drum and rear of the wheels once loaded onto the transporter. ‘SHUT the engine OFF, apply the parking brake, and lock all lockable compartments. ENSURE the articulation lock barilock pin is secured in the locked position before transporting the compactor. KNOW the overall height of the compactor and hauling vehicle. Observe height and weight regulations and at overhead objects be sure you can safely pass beneath them, Refer to Section 4 - OPERATING INSTRUCTIONS for proper brake release and towing procedures. OBEY all traffic regulations and be sure that the proper clearance flags, lights, and warning signs, including the "Slow Moving Vehicle” emblem, are properly displayed when moving the ‘compactor on public access roads. KNOW your approximate stopping distance at any given speed. NEVER tum comers at excessive speeds. Look in all directions before reversing your direction of travel. POSITION the compactor on the transporter or hauling vehicle centered from side to side and apply the brake. REFER to Section 4 of this manual for proper towing instructions. WARNING OF SPECIAL DANGERS. When working with the machine, maintain a safe distance from overhead electric lines. If work is to be carried out close to overhead lines, the working equipment must be kept well away from them. CAUTION! DANGER! Check out the prescribed safety distances. ‘SD-100/SD-100D/SD-100F SERIES CSECTION 1 SAFETY If your machine comes in contact with a live wire do the following: Do not leave the machine. Do not touch any part of the machine. Warn others against approaching and touching the machine. Have the live wire de-energized. Do not leave the machine until the damaged line has been safely de- energized. OPERATE internal combustion engines and fuel operated heating systems only in adequately ventilated premises. Before starting the machine in enclosed premises, make sure that there is sufficient ventilation. HAZARDOUS SUBSTANCE PRECAUTION The following information is provided to assist the owners and operators of Ingersoll-Rand Road Machinery Equipment. Further information may be obtained by contacting your Ingersoll-Rand Road Machinery Equipment Distributor. The following substance are contained in this machine and may be hazardous to health if exposed to or used incorrectly Table 1- ‘SUBSTANCE PRECAUTION (Antifreeze (Water-cooled Engine) [Avoid ingestion, skin contact and breathing fumes. Hydraulic Oi ‘Avoid ingestion, skin contact and breathing fumes. Engine Lubricating Oil ‘Avoid ingestion, skin contact and breathing fumes Preservative Grease ‘Avoid ingestion, skin contact and breathing fumes Rust Preventative ‘Avoid ingestion, skin contact and breathing fumes Engine Fuel ‘Avoid ingestion, skin contact and breathing fumes: Battery Electrolyte ‘Avoid ingestion, skin contact and breathing fumes: SAE Gear Oil ‘Avoid ingestion, skin contact and breathing fumes The following substances may be produced during the operation of this machine and may be hazardous to health. ‘SD-100/SD-100D/SD-100F SERIES CSAFETY SECTION 1 Table 4~ SUBSTANCE PRECAUTION Engine Exhaust Fumes (Avoid breathing, Engine Exhaust Fumes (Avoid buildup of fumes in confined spaces. Electric Motor Dust (Brushes? [Avoid breathing dust during Insulation) maintenance. ‘SD-100/SD-100D/SD-100F SERIES CSECTION 1 SAFETY SAFETY RELATED DECALS Table 2: REF DECAL NO TOCATION No. REQ’D 7 |WARNING: Do Not StOn Rall _|2 Both Sides of Railing 2 |WARNING: Crushing Hazard 2 Both Sides of Drum Frame 3 |WARNING: Improper Operation _|2 Console and Left Side Cowling 4 _ | WARNING: Rotating Biades 2 Both Sides of Cowiing 5 __|WARNING: Rollover Hazard 2 Left Side of Frame 6 _ |WARNING: Pressurized Fluid 7 ‘Top of Cowling Near Radiator Cap 7_ [Checklist 7 Cowling Support ‘SD-100/SD-100D/SD-100F SERIES CSAFETY SECTION 4 US Decals 1. Do Not Sit On Rail 2. Crush Area 3. Improper Operation Improper operation of this. ‘equipment. Can cause severe injury or death. Read Operation and Maintenance ‘Manual, and Safety Manual supplied with this equipment belore operating or servicing, Do not sit on rail. Crush area. Can cause severe injury or death. Stay clear or install articulation lock before entering area. ‘SD-100/SD-100D/SD-100F SERIES C1-16 SECTION 1 SAFETY 4, Rotating Blade Hazard Rotating fan blade. Gan cause severe injury. Do not operate with guard removed 5. Rollover ay Rollover of this machine can cause severe injury or death. Do not opera'e this machine near or on an inclined surface. Arollover can occur. With a Rollover Protection Structure (ROPS), seat belts must be worr to avoid severe injury or death from being thrown out. ‘SD-100/SD-100D/SD-100F SERIES CSAFETY SECTION 4 6. Pressurized Fluid burns. while hot. 7. Checklist, Geer Selector SHIFT TO : (W Appicate) ‘eparing STAY SEATED. Hot pressurized fluid. Can cause severe Do not open radiator SHUTDOWN Glamanion UGH - VERIFY OFF ‘tapers ta Se SAKE LIGHT - VERIFY ON START G0 Soe. Moxy iaapotati os Paring Brake - SWITCH ON ou Slo LOW GEA, Engine IDLE SHORTLY ‘SD-100/SD-100D/SD-100F SERIES CSECTION 1 SAFETY INTERNATIONAL DECALS WITH INTERPRETATION 1. Do Not sit On Rail Never sit on railing around operator's compartment. 2. Crush Area ahs: Crush Area. Can cause serious injury or death. Install lock pin before servicing. 3. Misoperation Improper operation of this equipment can cause serious injury or death. Read and understand the operator's and safety instructions before operating or servicing. 1-18 ‘SD-100/SD-100D/SD-100F SERIES CSAFETY SECTION 1 4. Rotating Fan and Belt 376 Rotating Blade. Can cause severe injury. Do not operate with guards or shields removed. Stop machine before performing maintenance. 5. Rollover Rollover of this machine can cause severe injury or death. Do not operate this machine near or on an inclined surface. A rollover can occur. If this machine has a Rollover Protective Structure (ROPS), seat belts must be worn to avoid severe injury or death from being thrown out. 6. Radiator Injury can result when removing the radiator cap. Steam or fluid escaping from the radiator can burn. Inhibitor contains alkali. Avoid contact with skin and eyes. Always shut down the engine and allow to cool before removing the radiator cap. Remove the cap slowly to relieve pressure. Avoid contact with steam or escaping fluid ‘SD-100/SD-100D/SD-100F SERIES C1-20 SECTION 1 SAFETY 7. Checklist PRE-STARTING Hoses, Saety Shouts, CeurSlecor- SHIFT TO: (Apa TRANSPORT STARTING Clad BRAKE LIGHT VERIFY On WApemcable) aa " GPkeptese) ‘SD-100/SD-100D/SD-100F SERIES CSYMBOL IDENTIFICATION SECTION 2 SECTION 2 - SYMBOL IDENTIFICATION INGERSOLL-RAND MACHINE SYMBOLS NOTE Some symbols shown in this section may not appear on your machine. 11 12 13} 1. Drum Vibration Drum Vibration Control High Amplitude Low Amplitude Ignition Switch Tiedown P. t 2 3 4. 5. Frequency (Vibration) 6. 7. 8. Anti-Wheel Spin Table 1: IR Machine Symobls 9. Anti-Drum Spin 10. Manual Vibration Control 11. Automatic Vibration Control 12. Vibration Control Mode 13, Caution ‘SD-100/SD-100D/SD-100F C SERIES at22 SECTION 2 ‘SYMBOL IDENTIFICATION INTERNATIONAL ROAD MACHINE SYMBOLS. NOTE: ‘Some symbols shown in this section may not appear on your machine. 5 6 1 16 & | a & | & leo 31) pest 32 33 34 35 36 G/O|G| Slee} ) G/@}IO| S| HO 6} 49. 50 51 vert 52 3 54 Ane a B| Ale] ti} + 55 56 57 58 59 60 > | BD | FE ‘SD-100/SD-100D/SD-100F C SERIESSYMBOL IDENTIFICATION SECTION 2 Table 2: International Machine Symbols 1. On Start 34. Fan Belt - Failure 2. Off/Stop 35. Emergency Engine Stop 3. On/Off 36. Engine Start 4, PlusiPositive 37. Engine On Run 5. MinusiNegative 38. Start Switch 6. Hom 39. Transmission 7. Battery Condition 40. Transmission Oil Level 8. Hourmeter 41. High Gear 9. Seat (Lap) Belt 42. Low Gear 10. Linear 43. Forward Direction 11. Rotational a4, Reverse Direction 72, Volume Empty 45, Parking Brake 73. Volume Half-Full 46. Brake On 14 volume Half-Full 47. Brake Off 15. Grease 48. Primer (Start Aid) 16. Oil Lubrication Point 49, Hydraulic Oi 17. Lift Point 50. Hydraulic Oil Pressure 18. Jack or Support Point 51. Hydraulic Oil Level 19. Filling/Emptying 52 Hydraulic Oil Filter 20. Read Operator's Manual 53. Hydraulic Oil Temperature 21. Engine Oil ‘54. Fuel (Diesel) 22, Engine Oil Pressure 55. Fuel Level 23. Engine Oil Pressure - Failure | 66. Fuel Filter 24, Engine Oil Level 87. Work Light 25. Engine Oil Filter 58. Flashing Beacon 26. Engine Oil Temperature 59. Control Lever - Dual Direction 27. Engine Coolant 60. Control Lever - Multi Direction 28. Engine Coolant Level 61. Clockwise Rotation 29. Coolant Temperature 62. Counterclockwise Rotation 30. Engine Rotations (RPM) 63. Engine Electrical Preheat 31. Gas Inject (Cold Start) 64. Fast Speed 32. Engine Air Filter 65. Slow Speed 33. Engine Air Filter - Failure ‘SD-100/SD-100D/SD-100F C SERIES 2324 SECTION 2 ‘SYMBOL IDENTIFICATION Genuine Parts For Genuine Ingersoll-Rand Parts, Service And Nearest Distributor http:/www.road-development irco.com 800-227-0573 (US and Canada) 717-532-9181 (Latin America - Ingersoll-Rand) 49-5151-209-0 (Europe) (852-2527-0183 (Asia) Genuine Ingersoll-Rand Protective Lubricants See Your Authorized Ingersoll-Rand Distributor For Details ‘SD-100/SD-100D/SD-100F C SERIESOPERATING CONTROLS AND INSTRUMENTS SECTION 3 SECTION 3- OPERATING CONTROLS AND INSTRUMENTS OVERALL VIEW OF CONTROLS AND INDICATORS Figure 3-1 8 210 11 42 1. Indicator Light Cluster A. Voltmeter B. Engine Oil Pressure C. Engine Coolant Temperature D. Hydraulic Oil Temperature Air Cleaner Warning Light Tachometer Hourmeter Front Light Switch (Optional) Rear Light Switch (Optional) Steering Wheel Table 3-1. a 9. 10. " 12, 13. 14. 15. 16. "7 18 Park Brake Switch Options Emergency Stop Switch ‘Two-Speed Axle Control Fuel Gauge Articulation Lock Pin Propulsion Control Ignition Switch Vibration Control Hom ‘Throttle Control (See Page 3-14) ‘SD-100/SD-100D/SD-100F C SERIES a432 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS For your safety and the safety of others, please ensure you thoroughly read and understand this section before operating the machine. INDICATOR LIGHT CLUSTER The Indicator Light Cluster (1, Figure 3-2) is located at the lower left side of the left-hand console panel. It contains four separate indicators. A. Battery B. Engine Oil Pressure C. Engine Coolant Temperature D. Hydraulic Oil Temperature Figure 3-2 ‘SD-100/SD-100D/SD-100F C SERIESOPERATING CONTROLS AND INSTRUMENTS SECTION 3 BATTERY ‘The BATTERY Indicator (Figure 3-3)is located at the bottom left of the Instrument Light Cluster. With the ignition switch at the ON position, the indicator wil illuminate if the battery is not charging. Figure 3-3 OIL PRESSURE INDICATOR The Oil Pressure (OIL PRESS) Indicator (Figure 3-4) is located at the top left of the Instrument Light Cluster. The indicator illuminates if the engine oil pressure drops below an acceptable level Figure 3-4 ‘SD-100/SD-100D/SD-100F C SERIES 33SECTION 3 OPERATING CONTROLS AND INSTRUMENTS ENGINE COOLANT TEMPERATURE The Engine Coolant (WATER TEMP) Temperature Indicator (Figure 3-5) is located at the top right of the Instrument Light Cluster. The indicator illuminates if the engine coolant temperature exceeds an acceptable level. Figure 3-5 HYDRAULIC OIL TEMPERATURE. The Hydraulic Oil Temperature Indicator (Figure 3-6) ie located at the bottom right of the Instrument Light Cluster. The indicator illuminates if the engine coolant temperature exceeds an acceptable level. Figure 3-6 ‘SD-100/SD-100D/SD-100F C SERIESOPERATING CONTROLS AND INSTRUMENTS SECTION 3 AIR CLEANER WARNING LIGHT The Air Cleaner Warning Light (2, Figure 3-7) is located on the bottom right of the LH console panel. If the indicator illuminates during machine opzration, shut down the machine immediately to prevent engine damage. Check and clean or replace the air cleaner element following the procedures in Section 8 - 10-hour or daily routing maintenance. Figure 3-7 TACHOMETER ‘The Tachometer (3,Figure 3-8) is located at the far left of the LH console panel. Itis calibrated in RPM x 100 with a range of zero (0) to 30. It utilizes a signal from a sending unit on the engine and uses the 12-volt electrical system. Figure 3-8 ‘SD-100/SD-100D/SD-100F C SERIES 3536 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS HOURMETER The Hourmeter (4, Figure 3-9) is located center right of the of the LH console panel. It operates any time the ignition switch Is ON to indicate the operating time of the machine. Figure 3-9 FRONT LIGHT SWITCH (OPTIONAL) The Front Light Switch (5, Figure 3-10) is located at the top right of the LH console panel. It is a two-position ON/OFF switch that when positioned to ON activates the front lights. When the switch is positioned to OFF, the front lights are rot lit Figure 3-10 ‘SD-100/SD-100D/SD-100F C SERIESOPERATING CONTROLS AND INSTRUMENTS SECTION 3 REAR LIGHTS SWITCH (Optional) The Rear Light Switch (6, Figure 3-11) is located at the top right of the LH console panel. It is a two-position ON/OFF switch that when positioned to ON activates the rear lights. When the switch is positioned to OFF, the rear lights are not lit Figure 3-11 PARK BRAKE SWITCH The Park Brake Switch (8, Figure 3-12) is a two-position switch located on the top left of the RH console panel. When tured ON, the parking brake is applied. Indicator light turns ON. Figure 3-12 ‘SD-100/SD-100D/SD-100F C SERIES a738 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS EMERGENCY STOP SWITCH The emergency stop switch (10, Figure 3-13) is top right of the RH console panel. Itis used to stop all machine functions in the event of an emergency. After the switch is depressed, it must be reset before the machine can be started. To reset the switch, Pull Out on switch. The switch will release and allow the machine to be started. Figure 3-13 TWO-SPEED AXLE CONTROL SWITCH Runaway machine may cause death or serious injury. Never descend ar which was use incline in a speed range or at a speed greater than that ascending the incline. High gear is only to be used in traveling to and from the job site. All compacting must be done in low gear only. The Two-Speed Axle Control Switch (11, Figure 3-13) is a toggle switch located on the lower left of the RH console panel. Place the switch in the appropriate position to select either High or Low axle speed. All compacting must be done with the switch in the LOW (@™ ) position, while the HIGH (4% ) position is used for “roading” the machine. ‘SD-100/SD-100D/SD-100F C SERIESOPERATING CONTROLS AND INSTRUMENTS SECTION 3 FUEL GAUGE The fuel gauge (12, Figure 3-14) is located cn the bottom right of the RH console panel. The fuel gauge indicates the amount of fuel in the fuel tank. The fuel tank should be refilled when the indicator needle moves to below 1/4 tank, Figure 3-14 ‘SD-100/SD-100D/SD-100F C SERIES 39310 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS ARTICULATION LOCK PIN During shipment and before performing any checks or service operations, place the articulation lock pin into its locked position. For compactor operation, the lock to be removed from its locked position and placed into its stowed position. The Articulation Lock Pin (13, Figure 3-15 and Figure 3-16) must be installed in the lock pin holes while the machine is parked, during shipment, and before performing any checks or service operations. For compactor operation, the lock pin must be removed from its locked position and placed into the special bracket at the front of the console weldment. The pin should be stored here when the machine is operating. Figure 3-15 Figure 3-16 ‘SD-100/SD-100D/SD-100F C SERIESOPERATING CONTROLS AND INSTRUMENTS SECTION 3 Loss of machine control. PROPULSION CONTROL Moving the Propulsion (Travel) Control quickly may cause loss of machine control, lurching, or serious injury. Move the Propulsion (Travel) Control slowly. The Propulsion Control (14, Figure 3-17) is located at the right side of the operator seat. This control varies machine direction and speed of travel. It also functions as the control for hydrostatic braking. The control has three positions: Forward, Stop, and Reverse with variable speed ranges in either direction. To propel the machine forward, gradually move the control to the Forward position. To stop the travel of the machine, move the control slowly back to the Stop position. This will provide hydrostatic braking. To propel the machine in reverse, gradually move the control backward to the Reverse position. Te stop the travel of the machine, move the control slowly back to the Stop position. Figure 3-17 ‘$D-100/SD-100D/SD-100F C SERIES attSECTION 3 OPERATING CONTROLS AND INSTRUMENTS Starter may overheat if operated longer than 30 seconds. IGNITION SWITCH Ifthe engine does not start, allow the starter to cool for two (2) to three (3) minutes before trying again. The Ignition Switch (15, Figure 3-18) is a three position OFF/ON/START switch. The switch is on the right-hand side of the console pedestal. When the switch is straight up and down (OFF), the electrical system is not energized. When the switch is turned clockwise to the first position (ON), the electrical system is energized. When turned past the ON position to the second position (START), the starter will engage. Once the engine starts, release the switch immediately, and the switch automatically returns to the ON position. Figure 3-18 3412 ‘SD-100/SD-100D/SD-100F C SERIESOPERATING CONTROLS AND INSTRUMENTS SECTION 3 VIBRATION (VPM) CONTROL The Vibration (VPM) Control (16,Figure 3-19) is located at the right side of the operator's seat beside the Propulsion Control. The Vibration (VPM) Control varies the vibrations per minute of the drum. The closer the control is to the Neutral (N) position, the lower the frequency. To select high amplitude, move the control in the HIGH direction, toward the drum. To select low amplitude, move the control in the LOW direction, away from the drum. Figure 3-19 Horn Pressing the Horn button (17, Figure 3-20) causes the horn to sound. Figure 3-20 ‘$D-100/SD-100D/SD-100F C SERIES 313SECTION 3 OPERATING CONTROLS AND INSTRUMENTS THROTTLE CONTROL The THROTTLE Control (18, Figure 3-21) is located on the right side of the operator seat. The controls connected to the engine governor by a cable. Move the control tothe up position, SLOW oF Idle to obtain engine idle rpm and to the down position, FAST or OPERATING to obtain operating rpm. Figure 3-21 THROTTLE CONTROL (TIER Il ENGINE ONLY) The THROTTLE Control (18, Figure 3-22) is located adjacent to the propulsion lever. Press down and turn clockwise to increase engine idle speed. Press down and rotate counterclockwise to decrease idle speed. Figure 3-22 a4 ‘SD-100/SD-100D/SD-100F C SERIESOPERATING CONTROLS AND INSTRUMENTS SECTION 3 WARNING LIGHTS (TIER Il ENGINE ONLY) The Tier Il Engine Controls include an amber check engine light (1, Figure 3-23) and a red stop engine light (2). They are located adjacent tc the Air Filter Restrictor Indicator light on the left hand panel. When illuminated the amber light indicates the engine sensors have detected an area of concem and should be investigated by maintenance personnel. lumination of the red light advises to operator to stop the engine as soon as possible following all safety precautions. An illuminated light red light indicates serious areas of concer. Figure 3-23 BATTERY MASTER SWITCH (Tier Il Engine Only) The battery master switch (1, Figure 3-24) is connected to the negative (-) cable of the battery. ‘When the switch is turned to the Off position, electrical power is disconnected from the machine. The switch, located on the engine side of the control console, should be turned off whenever the machine is not in use. Figure 3-24 ‘$D-100/SD-100D/SD-100F C SERIES 345316 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS DIAGNOSTIC PLUG (Tier II Engine Only) The Tier Il engine is of electronic design and control. A diagnostic plug (1, Figure 3-25) is located in the engine compartment to allow connection of appropriate connectors and software. Figure 3-25 ‘SD-100/SD-100D/SD-100F C SERIESOPERATING INSTRUCTIONS SECTION 4 SECTION 4- OPERATING INSTRUCTIONS Ifyou are not experienced with the machine's operation and control, before operating the machine, read Section 3 - Operating Controls and Instruments. Unexpected machine motion or moving parts can cut or crush. Install the articulation lock pin, apply the parking brake and shut down the engine before working on the machine. Improper maintenance can cause injury or death. Read and understand SECTION 1 - SAFETY before you perform any maintenance, service or repairs. GENERAL INFOPRMATION The following operational hints should be observed: Do not speed engine when it is cold ‘Always chock the drum/wheels. There is a possibility of uncontrolled movement. Do not grease the machine while the engine is running. ‘Always perform safety checks prior to starting/using the machine. Do not control travel speed using the engine speed control lever. Do not shift speed range selector at speeds above 3 MPH. ‘Always operate the machine at full engine power when compacting or traveling the unit. Never stop the machine on a slope that is liable to collapse or cause a roll-over risk. On machines equipped with a Rollover Protective Structure (ROPS), wear seat belt atall times. Before starting engine, always check that propulsion control is at STOP position and that the parking brake is applied. Always sound the horn before roving the machine in either direction to alert personnel, and to allow sufficient time before putting machine into motion. Always use protective clothing such as gloves, goggles and safety helmet when performing service maintenance. Do not wear oil stained or damaged garments. ‘SD-100/SD-100D/SD-100F C SERIES atSECTION 4 OPERATING INSTRUCTIONS SAFETY CHECKS - PRE-STARTING Before starting each day, check or inspect the fellowing items to ensure trouble-free performance. In addition to these items, check and inspect those items in the 10-HOUR OR DAILY ROUTINE MAINTENANCE section of this manual. Also, it is extremely important to heed and follow safety recommendations listed here to ensure machine and operator safety, 1. Check fluid lines, hoses, fitings, filler openings, drain plugs, pressure cap, tires, muffier, engine, safety rail, safety shrouds and the area underneath the machine for signs of leakage. Correct the problem before operating the machine. 2. Use the “Routine Maintenance" sections of this manual along with the Lubrication Chart to perform any required fluid checks and/or maintenance. Injury can occur when removing the radiator cap. Steam or fluid escaping from the radiator can burn. Rust contains alkali. Avoid contact with skin and eyes. Always shut down the engine and allow to cool down before removing the radiator cap. Remove cap slowly to relieve pressure. Avoid contact with steam or escaping fluid. 3. Check the coolant level in the radiator. The radiator is located in the engine compartment at the rear of the machine. Coolant level, with a cold engine, should be 1 1/2 inches below the bottom of the filler neck at all times. This is recommended to allow the coolant to expand at engine operating temperature without overflowing the system. If you need to add coolant, use a 50-50 mixture of a reliable brand of permanent antifreeze and water. 4. Inspect the entire machine for damaged or missing parts and repair or replace them as needed. 42 ‘SD-100/SD-100D/SD-100F SERIES COPERATING INSTRUCTIONS SECTION 4 Fuel is flammable. May cause severe injury or death. Shut down the engine, extinguish all open flames and do not smoke while filling the tank. Always wipe up any spilled fuel. Check the fuel level. The diesel fuel tank is located on the right side of the machine. If necessary, fill the fuel tank with clean No. 2 diesel fuel per the specifications outlined in SECTION 6 - FUEL AND LUBRICATION SPECIFICATIONS of this manual. Check the hydraulic oil level. The hydraulic reservoir is located on the left side of the machine. If necessary, fill the reservoir with a fresh, clean, antiwear hydraulic oil as specified in SECTION 6 - FUEL AND LUBRICATION SPECIFICATIONS of this manual Batteries contain an acid and can cause injury. Battery fumes can ignite and explode. Skin and eye contact with the battery fluid can cause injury. Do not smoke when observing battery fluid level. Avoid skin and eye contact with the battery fluid. If contact occurs, flush area immediately with water. The machine is shipped from the factory with a maintenance-free battery. Ifa non-maintenance-free battery is installed later, check the electrolyte level daily. The battery is located under the operator's seat and is accessible by tilting the seat forward. If necessary, add only clean, distilled water as instructed in SECTION 7 - 10-HOUR OR DAILY ROUTINE MAINTENANCE of this manual. DO NOT operate faulty equipment. 9. Be observant of people and obstructions within the work area, |. Know the job site requirements, such as the number of required passes to achieve the desired density. ‘SD-100/SD-100D/SD-100F C SERIES 43SECTION 4 OPERATING INSTRUCTIONS START-UP PROCEDURE A CAUTION Any machine defects should be reported to the proper personnel. Defects must be corrected before operating the machine. Checks and verifications of machine controls must be performed prior to operating the machine 1, Mount the compactor using a three-point contact. See Figure 4-1. Figure 4-1 2. Place the Propulsion Control in the STOP position. The Propulsion Control must be in the STOP position for the engine to start Position the Throttle Control to the "SLOW" or “Idle RPM" Place the Park Barke switch in the "ON" position. Place Vibration Control in “OFF” position. Pull up on the Emergency Stop Switch. NORae Turn Ignition switch to “ON” position and verify Brake Indicator light is ON. ‘SD-100/SD-100D/SD-100F SERIES COPERATING INSTRUCTIONS SECTION 4 Starting aids are extremely flammable and can explode. May cause serious injury or death. Overloading the engine in an explosion. intake system with starting aids could result Avoid overloading the engine air intake system with starting aids. Starter may overheat if operated longer than 30 seconds. If engine does not start, allow the starter to cool for two (2) to three (3) minutes before trying agai NOTE: For cold weather starting, use starting aids as necessary. However, refer to the engine operators manual before doing so. 8. Turn the Ignition Switch key to the extreme right or START position, and immediately release it when the engine starts. The switch will automatically return to the ON position. CAUTION Hydraulic component damage. To prevent damage to the hydraulic components, warm up the hydraulic system oil before operating. CAUTION Engine Damage. Incorrect oil pressure or temperature can cause engine damage. If gauges do not display the proper readings, shut down the engine and correct the malfunction before operating the machine. ‘SD-100/SD-100D/SD-100F C SERIES46 SECTION 4 OPERATING INSTRUCTIONS Idling the engine unnecessarily for long periods of time wastes fuel and fouls injector nozzles. Unburned fuel causes carbon formation; oll dilution; formation of lacquer or gummy deposits on the valves, pistons and rings; and rapid accumulation of sludge in the engine. Do not idle unnecessarily for long periods of time. 9. Continually monitor all gauges and instruments for proper operation. Refer to SECTION 3- OPERATING CONTROLS AND INSTRUMENTS of this manual for normal gauge and instrument readings. 10. Allow the engine to run at slow throttle for a few minutes before normal operation. Never race the engine during the warm-up period, Observe and heed all safety rules. Remain seated at all times. Do not carry passengers and avoid any bystanders. OPERATING THE MACHINE. Exercise extreme caution when on a hill or bank. Use slow travel speed ‘on down hill tra 1. Always sound horn before moving the machine in either direction to alert persons. Allow sufficient time for persons to move from vehicle's path before putting the machine into motion. 2. Monitor all warning lights. If instruments or lights indicate a fault or problem, do not operate machine until condition is corrected. 3. Monitor and ensure horn and back-up alarm function and that optional lights properly illuminate the working area. 4, Monitor working area for obstacles and persons. Move the steering wheel slowly and monitor steering action. 6. Apply parking brake, tum off the engine and remove the ignition key before leaving the operator station. ‘SD-100/SD-100D/SD-100F SERIES COPERATING INSTRUCTIONS SECTION 4 NOTE: The speed of travel of a vibratory roller has a tremendous effect on the compaction results. As opposed to a static roller where speed of travel matters very little to the compaction process. a vibratory roller needs “dwell” time for each vibration to develop its potential. This means that travel speed is of the utmost importance if maximum consolidation is to be accomplished. Travel speeds of more than 3 mp.h. (4.83 km/hr) usually do not develop the compaction needed, in proportion to the increased travel speed. On the other hand, itis very easy to achieve over compaction with multiple passes over the same plot due to the efficiency of Ingersoll-Rand compactors. Statistics show that over compaction may actually reduce final density due to machine bounce, which tends to break down the already achieved density. Over compaction can also lead to excessive wear on your unit. fin doubt about the proper compaction technique, consult your Ingersoll-Rand Road Machinery Equipment distributor. PROPELLING THE MACHINE After the engine has started and warmed up, the compactor is ready for operation in accordance with the following procedure: ‘Check the travel and work area for people and obstructions. 2. Move the Throttle Control to the FAST or “Operating RPM" Place the Two-Speed Control Switch in the LOW position. The HIGH speed position is to be used only for “roading” the compactor 4. Push the Parking BRAKE Control inward to the “Release” position. Loss of machine control. Moving the propulsion control (F-STOP-R) quickly may cause loss of machine control, lurching or serious injury. DO NOT shift propulsion control at speeds greater than 3 mp.h. Move the propulsion control (F-STOP-R) slowly. 5. Move the Propulsion Control to achieve the desired direction and safe speed of travel as determined by the conditions. The further the control is moved from the STOP position, the greater the speed in that direction. Return the control to STOP for normal braking. 6. Once the compactor is in motion, move the Vibration Control toward the drum for high amplitude or away from the drum for low amplitude. The closer the control is to the Neutral position, the lower the frequency. ‘SD-100/SD-100D/SD-100F C SERIES a748 SECTION 4 OPERATING INSTRUCTIONS NOTE: When the eccentrics are engagedi/disergaged, or the direction of rotation is changed, a “clunk” sound will be heard. This is a normal condition and is caused by the eccentric weights changing position. SHUTDOWN PROCEDURE NOTE: Every attempt should be made to stop movement of the compactor on a solid, level surface. 1. Return the Vibration Control to the N or “Neutral” position. 2. Stop movement of the compactor by returning the Propulsion Control to the STOP position. Severe cutting or crushing injury. On some machines, during engine shutdown the blade lowers automatically. Operator must ensure that the area around the blade is clear of personnel and obstructions prior to engine shutdown. Lower the Strike-off Blade if the machine is so equipped. 4. Apply the Parking BRAKE Control by pressing rocker switch to the “Applied” position. Indicator light illuminates. 5. Ensure that the Two-Speed Control Switch is in the LOW speed position. Idling the engine unnecessarily for long periods of time wastes fuel and fouls injector nozzles. Unburned fuel causes carbon formaticn; oil dilution; formation of lacquer or gummy deposits on the valves, pistons and rings; and rapid accumulation of sludge in the engine. Do not idle unnecessarily for long periods of time. 6. Position the Throttle Control to the, SLOW or “Idle RPM”. Allow the engine to idle for a few minutes to avoid high internal heat rise and allow for heat dissipation. ‘SD-100/SD-100D/SD-100F SERIES COPERATING INSTRUCTIONS SECTION 4 7. Turn the Ignition Switch to the OFF position. 8. Chock the machine to prevent it from moving. 9. Fill the diesel fuel tank with clean No. 2 Diesel Fuel to prevent condensation in the tank, 10. Lock all lockable compartments and remove the ignition key. jon could occur. TOWING Machine runaway con Always chock the drum and wheels of a disabled machine or hitch it to its towing vehicle to prevent accidental movement while preparing the machine for towing. This is especially important if machine failure occurs on an incline. A CAUTION Towing the compactor is limited to off the job site, onto the transporter, off the transporter, and into the shop. The machine used to tow the compactor should be heavier than or equal to the weight of the compactor being towed. When towing, use a chain rated for a minimum of 13.6 metric tons (15 tons). Tow only on level ground or up a slight grade. Since the compactor braking system has been disabled, the towing machine is the only means of restraining the compactor while being towed. Chock the disabled compactor whene\ F towing has stopped. Refer to Transporting, Towing and Roading in Section 1 before transporting the compactor. In the event of an engine problem or other malfunction, it may become necessary to tow your compactor. ‘SD-100/SD-100D/SD-100F C SERIES 49440 SECTION 4 OPERATING INSTRUCTIONS Towing the compactor requires disengaging the propulsion system and releasing the spring- applied brakes. The propulsion pump is designed with a bypass function that consists of two multifunction valve cartridges used for disengagement of the propulsion system. Use the next three steps to disengage the propulsion system: 1. Ensure that the Parking BRAKE Contra! is in the “Applied” position and the wheels/drums are chocked. 2. Gain access to the hex adjustments on the cartridges (2, Figure 4-2) of the propulsion pump (1, Figure 4-2). Using a 1-1/16" wrench on the middle size hex and a 1 1/4" wrench on the large hex to prevent cartridge rotation, rotate the middle size hex three (3) revolutions counterclockwise to open the bypass valve. Do not rotate more than three (3) revolutions, as additional rotation will generate external leakage. Figure 4-2 3. Move the Propulsion (Travel) Control in the operator's compartment to the full “Forward!” or "Reverse" position. NOTE: If the machine will not run, a portable hydraulic pressure source is required to release the brakes prior to towing the compactor. Release the brakes as follows: ‘SD-100/SD-100D/SD-100F SERIES COPERATING INSTRUCTIONS SECTION 4 4, Locate the brake valve (3, Figure 4-3) inside the main frame (4). Figure 4-3 in the hydraulic system will lead to premature component failure. clean, contaminant-free system Is extremely important to the machine's proper function. Take extra care when working around or on the hydraulic system to ensure its complete cleanliness. 5. Clean the area around the hydraulic line that leads from the valve to the propulsion pump at the brake valve (Port 3, Figure 4-4), disconnect the line from the valve and plug the line. ‘SD-100/SD-100D/SD-100F C SERIES antSECTION 4 6. 7. Figure 4-4 | [> G Connect a portable hydraulic pressure source (300 to 500 psi) to brake valve Port 3 to supply the required pressure to release the brakes. Remove the chocks and tow the machine for a short distance only at a maximum of 200 feet per minute. Machine runaway condition could occur. Never leave the machine with the brakes released after towing. 8. Chock the wheels and drum. 10, " Relieve the pressure from the portable hydraulic system and disconnet the brake valve. |. Reconnect the hydraulic line to the brake valve at (Port 3) ‘To reengage the propulsion system, gain access to the hex adjustments on the cartridges and use the wrenches as mentioned in step 2 above. However, the middle size hex is now rotated approximately three (3) revolutions clockwise Until it seats. The hex adjustments should then be torqued to 30 pound-feet. ‘SD-100/SD-100D/SD-100F SERIES C OPERATING INSTRUCTIONSMAINTENANCE INSTRUCTIONS SECTION 5 SECTION 5 - MAINTENANCE INSTRUCTIONS In order to ensure safe operation, optimum performance, and to protect your warranty, use only genuine Ingersoll-Rand replacement parts. Unexpected machine motion or moving parts can cut or crush. Install the articulation lock pin, apply the parking brake and shut down the engine before working on the machine. Improper maintenance can cause injury or death. Read and understand SECTION 1 - SAFETY before you perform any maintenance, service or repairs. GENERAL INFORMATION To prevent minor irregularities from developing into serious conditions, several other services or checks are recommended for the same intervals as the periodic lubrication. ‘The purpose of these services or checks s to ensure the uninterrupted and safe operation of the unit by revealing the need for adjustment caused by normal wear. Prior to conducting any maintenance work, ensure the following instruc observed: 1. Park the machine on firm, level ground. 2. Shut down the engine and allow to cool. NOTE: Replacement of engine oil, planetary wheel end gear oil, carrier gear oil, differential and brake assembly gear oil and the transfer case gear oil require the machine oil to be at operating temperatures. 3. Following shut down, allow hydraulic oil pressures to fall before working on the hydraulic hose installations. 4. Disconnect battery power (as required) using the optional master switch or remove the black ground terminal/s and cover exposed terminals before working on the machine's electical system. Certain troubleshooting procedures will require that battery terminals not be removed. ‘SD-100/SD-100D/SD-100F C SERIES B4152 SECTION 5 MAINTENANCE INSTRUCTIONS 5. Thoroughly wash all fittings, caps, plugs, etc. with nonflammable, nontoxic cleaning solution before servicing, to prevent dirt from entering while performing the service. Handling Fluids and Filters 1. When draining fluids, ensure that adequate sealable containers are available and that every care is taken to prevent spillage. Always ensure waste fluids are disposed of in an environmentally safe manner. Always ensure that used filters are stored in secure containers and disposed of in an environmentally safe manner. INITIAL BREAK-IN MAINTENANCE Any new equipment requires an initial modification of the maintenance schedule to properly break in the various systems and component units. Perform this one-time initial break-in maintenance after 50 to 100 hours of operation IN ADDITION TO the 10-hour and ‘50-hour maintenance tasks which are described on the following pages. After this initial phase, the regular intervals should be followed Change drum eccentric housing oil. Refer to procedure on page 5-38. Change axle input case oll (SD-100 only). Refer to page 5-35. Change axle differential / brake housing oil. Refer to procedure on page 5-37 Change wheel end oil. Refer to procedure on page 5-36. Torque one articulation swivel pin nut to 225 Ib-ft (440 N-m). Refer to procedure on page 5-46. Skene 6. Torque oscillation swivel pin nut to 1,100 Ib-ft (1500 N-m). Refer to procedure on page 5-46. 7. Change the drum drive oil after 150 hours. Refer to procedure on page 5-41. MAINTENANCE SCHEDULE The maintenance chart (Table 5-1, on page 5-3) shows those items that require regular service and the interval at which service should be performed. A regular service program should be geared to the items listed under each interval. These intervals are based on average operating conditions and manufacturers recommendations. In the event of extremely severe, dusty or wet operating conditions, more frequent maintenance than specified may be necessary. ‘SD-100/SD-100D/SD-100F C SERIESMAINTENANCE INSTRUCTIONS SECTION 5 Table 5-1 MAINTENANCE SCHEDULE ‘A-As Reqd. B-10 Hours Function Specification C-50 Hours D-250 Hours E-1000 Hours/1 Year A|B[C|D|E| Paret. Check air leaner restriction indicator x 55 Checking and removing the air leaner 55 element Clearing the air cleaner element BT Clean the machine x 59 Check engine oil level Dipstick fal mark x 510 Check engine coolant level Expansion botle x emt Drain water from fuel filter x 5.12 Check and fil fue tank Ful level gauge x 5.13 Check ai cleaner restriction indicator —_| Clean or replace elements x 514 as requited ‘Check parking brake i 5-15 Check the seat belt regularly for wear or x 516 damage. Inspect belt hardware and fabric. Replace if hardware is damaged or if strap Is nicked, frayed or if loose stitching is ound. Seal belt assemblies should be replaced every 3 years regardless of appearance. Seat belt strength degrades overtime and use due to exposure to ] weather, UV (ultraviolet radiation) and abrasives (dit). Check that mounting hardware is tight Grease Aniculation Swivel Pins x wT Grease steering cylinder pins Refer to Section 8 x 5-17 Grease oscillation swivel pins x 518 Check tire pressure 1.4 Barl20 psi- 18.4 tre x 5-18 4.1 Bar (16 psi-23.1 Tire Check hydraulic ol level Refer to Section 8 x 5-20 Torque wheel nuts 550 Nem (405 lb-R) x 5-21 Seal boot grease x 5-21 Check air cleaner system integrity x 5-22 CCheck axle input case oll level efor to Section 8 x 5-22 Check axle diferentialbrake cil level Refer to Section & x 5-23 Check wheel end oil level x 5-24 Check eccentric oll level Refer to Section 8 x 5-25 Check drum drive oil level - D models only x 5-26 ‘Check battery and cables x 5-27 ‘SD-100/SD-100D/SD-100F C SERIES54 SECTION 5 MAINTENANCE INSTRUCTIONS MAINTENANCE SCHEDULE ‘A-As Req'd. B-10 Hours Function Specification €-50 Hours D-250 Hours E-1000 Hours/1 Year A[B|C|D]|E | PaRef. [Change engine oll and fier Refer to Section 8 x 5-27 [Change hydraulic fiters x 5:29 ‘Change fuel ters x 531 (Clean axle housing breathers x 5-34 Grease carer seal x 5-34 (Clean carer breather x 5-35 ‘Change axle input case oll (SD-100 Only) | Refer to Secion 8 x | 535 [Change axle wheel end oll Refer to Section 8 x | 536 orange a eens OEY Refer to Section 8 x | 537 [Change eccentric ol Refer to Section 8 x | 538 [Change carer oll Refer to Section 8 x | 540 [Change drum drive ol (0) modal Refer to Secion 8 x) 64 [Change hydraulic ol lean suction Refer to Secion 8 x | 542 strainers Drain, Tush and replenish engine cooling | Refer to Section 8 x | saa system Torque oscillation swivel nut x | 546 Torque articulation swivel nut x | 546 (Check engine valve clearance Refer to engine manual x | S47 (Check engine belis and tensioner x | S47 ‘SD-100/SD-100D/SD-100F C SERIESMAINTENANCE INSTRUCTIONS SECTION 5 ROUTINE MAINTENANCE - AS REQUIRED Check Air Cleaner Restriction Indicator 4. Check air cleaner restriction indicator (1, Figure NOTE: Maintenance to the air cleaner is required when the restriction indicator light turns ON permanently, indicatinfg a ciogged air cleaner. 1). Figure 5-1 @) 2. Ifindicator light turns ON during operation, shut down the machine immediately to prevent damage. 3. Check air cleaner elements and clean or replace as necessary. Checking and Removing Air Cleaner Element Maintenance of the air cleaner is due if the air cleaner restriction indicator on the operator's, control console turns ON and stays ON to indicate the air cleaner is plugged and requires attention. ‘The air cleaner is the dry-type with two elements. A primary element that is replaceable or can be cleaned, and a safety element that is only replaceable and should never be cleaned. The safety element should be changed after every third primary element cleaning ‘or change. ‘SD-100/SD-100D/SD-100F C SERIES 5556 SECTION 5 MAINTENANCE INSTRUCTIONS CAUTION Engine Damage. Raw, unfiltered air can cause engine damage. Never service the air cleaner while the engine is running. 1. Loosen thumb screw (2, Figure 5-2) enough to allow clamp (3) to free end cap (1). Figure 5-2 2, Remove end cap (1, Figure 5-3). Figure 5-3 3. Remove wing nut and washer (2, Figure 5-3)and carefully withdraw the primary ‘element from the housing (6). ‘SD-100/SD-100D/SD-100F C SERIESMAINTENANCE INSTRUCTIONS SECTION 5 4, Clean the inside of the end cap (1) end housing (6) with a clean, damp cloth. Do not use compressed air. NOTE: Dust that gets by the air cleaner cen often be detected by looking for dust streaks on the air transfer tubing or inside the intake manifold inlet. 5. Ensure safety element (5) wing nut (4) is secure. NOTE: The safety element is not cleanable. For maximum protection, replace the safety element every third primary element change or annually. Cleaning the Air Cleaner Element Never attempt to clean the element by striking or rapping it against a hard surface. This always leads to damage of the element. 1. To dry clean the element (Figure 5-4), carefully direct compressed air, not exceeding 5 bar (73 psi) pressure. onto the inside surface of the element. Figure 5-4 2. Towet clean the element (), requires lukewarm water mixed with commercially available detergent. Thoroughly dry the element before placing back in service. ‘SD-100/SD-100D/SD-100F C SERIES STSECTION 5 MAINTENANCE INSTRUCTIONS Sexe "1 12, Figure 5-5 Inspect the element for holes, tears, and be sure gasket NOTE: in good condition. Replace the element after six cleanings or annually. Inspect wing nut and washer (2, Figure 5-3) for cracks or damage and replace as necessary. Replace the safety element if any of the following conditions exist: “Examination of the primary element reveals a torn or perforated element. “The primary element has been replaced three times or one year duration “The restriction indicator light turns on after the primary element has been serviced. Ensure the air cleaner housing is clean before removing the safety element. Remove wing nut (4, Figure 5-3), then carefully remove safety element (6). Install the new safety element and secure with wing nut (4). Carefully install the new or cleaned primary element (3) and secure with washer and wing nut (2). Install dust cover (1) with word “TOP” in the twelve o'clock position. Position clamp (2) over the dust cover and filter housing and tighten thumb screw (2, Figure 5-2). Ensure all clamps are tight. ‘SD-100/SD-100D/SD-100F C SERIESMAINTENANCE INSTRUCTIONS SECTION 5 Cleaning the Machine The complete machine must be given a weekly cleaning, Daily cleaning will be necessary if material is adhering to the drum. Protect all electrical components and control panels against entry of water or steam when using high pressure cleaning methods. Cover the fuel and hydraulic breathers located at each tank. Do not use abrasive cleaning materials or harsh chemicals on painted ‘surfaces on the machine. 1. Check that no material is jammed between the drum and its scraper bar. 2. After cleaning check the following: *Check the air cleaner ducts for defects. *Check the security of air cleaner mounting hardware. “Check all hoses for cracks, chafing or deterioration. Replace at the first sign of probable failure. 2. Check the condition of the drum (1, Figure 5-6). Be sure material ia not adhering to the drum surface. Figure 5-6 ‘SD-100/SD-100D/SD-100F C SERIES 59SECTION 5 MAINTENANCE INSTRUCTIONS 4. Check condition of drum scraper (2, Figure 5-6) and be sure it is adjusted properly. Also check the optional inside scraped if used, 5. Adjust scraper clearance if required. Scraper bar clearance is maintained by shims located on the scraper bar assembly. Scraper to drum clearance should be no less than 20 mm (0.79 in.) and no greater than 25 mm ().98 in.). Check condition of shock mounts (3, Figure 5-6). for looseness or deterioration. Tighten capscrews and nuts as required. Replace shock mounts one at a time that are torn or have excessively cracked rubber. Torque loose bolted connections. Refer lo Section 9 -Torque Specifications. 9. Completely lubricate the machine with emphasis on: Articulation and swivel joint pins and bushings. Linkages. 40 HOUR OR DAILY MAINTENANCE Check Engine Oil 1. Park the machine on a a stable, level surface and shut down the engine. 2. Wait at least ten minutes for the engine to cool and for oil to drain into the oil pan. 3. Remove dipstick (1, Figure 5-7) and wipe clean with a clean, lint-free oloth. and push it back into the engine. 4, Pull out the dipstick and check the oil level. Oil level should be between the Full mark and Low mark on the dipstick. Add oil through fill point (2) if level is low. Refer to Section 8 - Fuel and Lubricant Specifications, Figure 5-7 ‘SD-100/SD-100D/SD-100F C SERIESMAINTENANCE INSTRUCTIONS SECTION 5 5. Restart the engine and run for one minute. 6. Shut down the engine and repeat the check. Hot pressurized fluid and steam can cause serious burns. Rust inhibitor contains alkali. avoid contact with skin and eyes. Check Engine Coolant Level Burn hazard. Do not open radiator cap while hot. Shut down engine and allow to cool. 4. Check engine coolant level by observing coolant overflow bottle (1, Figure 5-8). Figure 5-8 [avian] Be NOTE: Coolant level should be at the “COLD" mark if the engine is cold and at the “HOT” mark if the engine is at operating temperature. 2. Add a 50-50 mixture of anti-freeze and water as necessary to bring to the proper level. 3. Check radiator and oil cooler fins for clogging. Clean as required. ‘SD-100/SD-100D/SD-100F C SERIES 511512 SECTION 5 MAINTENANCE INSTRUCTIONS Drain Water From Fuel Filter - 95 and 125 HP Engines The 95 and 125 Horsepower engines have fuel filter and a water separator mounted on a dual filter adapter. Drain the water as follows: 1. Open drain cock (2, Figure 5-9) and drain off approximately 237 cc (8 02) of any collected water and sediment. 2. Close the drain cock and dispose of the collected water and sediment in an environmentally safe manner. Figure 5-9 \ (= ra 4 d Drain Water from Fuel Filter - 110 HP Engine The optional 110 horsepower electronic engine has an in-line filter and a fuel and water separator (1, Figure 5-10). Drain the Fuel and water separator as follows: 1. Raise drain cock (2, Figure 5-10) and drain off approximately 237 oc (8 02) of any collected water and sediment. 2. Close the drain cock and dispose of the collected water and sediment in an environmentally safe manner. Figure 5-10 ‘SD-100/SD-100D/SD-100F C SERIESMAINTENANCE INSTRUCTIONS SECTION 5 Fuel is Flammable. May cause serious injury or death. Check Fuel Level ‘Shut down engine, extinguish all open flames and do not smoke while filling the fuel tank. Always wipe up any spilled fuel. Never allow fuel tank to become completely empty. Otherwise, the entire fuel system will require bleeding. The fuel tank should be filled with the correct grade of fuel at the end of the shift to prevent condensation. 1. Check fuel gauge (12, Figure 5-11). Figure 5-14 2, Clean around the area of fuel filler cap (1, Figure 5-12); then, remove the cap and fill the tank with the correct grade of diesel fuel to the tank fill neck. Refer to Section 8 - Fuel and Lubricant Specifications. ‘SD-100/SD-100D/SD-100F C SERIES 513SECTION 5 MAINTENANCE INSTRUCTIONS Figure 5-12 Check Air Cleaner Restriction Indicator Maintenance to the air cleaner is due when the restriction indicator warning light (2, Figure 5-13) illuminates permanently, indicating a cogged air filter. Ifthe indicator turns On during operation, shut down the engine to prevent engine damage. Check and clean or replace the air cleaner element as described on page 5-5. Figure 5-13 514 ‘SD-100/SD-100D/SD-100F C SERIESMAINTENANCE INSTRUCTIONS SECTION 5 Check Parking Brake 1. Ensure no personnel or obstructions are in the travel area. 2. Ensure propulsion control lever (14, Figure 5-14) is in the STOP position. Figure 5-14 3. Start the engine by turning ignition kay (15, Figure 5-15) to the Start position. Release the key once the engine starts. Figure 5-15 4. Press park brake switch (8, Figure 5-16). Switch indicator light will turn On. ‘SD-100/SD-100D/SD-100F C SERIES 515516 SECTION 5 MAINTENANCE INSTRUCTIONS Figure 5-16 5. Move the propulsion control lever (14,) toward the Forward or Reverse positions. + Ifthe parking brake is working correctly, the machine will not move. Move the propulsion control lever back to the STOP position. + Ifthe machine moves, the parking brake is not working correctly. Shut down the machine and contact service personnel to correct the problem. Do not operate the machine with a faulty parking brake. Seat Belt CHECK the seat belt regularly for wear or damage. Inspect belt hardware and fabric. Replace if hardware is damaged or if strap is nicked, frayed or loose stitching is found, Seat belt assemblies should be replaced every 3 years regardless of appearance. Seat belt strength degrades over time and use due to exposure to weather, UV (untraviolet radiation) and adbrasives (dirt). Check that mounting hardware is tight. ‘SD-100/SD-100D/SD-100F C SERIESMAINTENANCE INSTRUCTIONS SECTION 5 50 HOUR OR WEEKLY ROUTINE MAINTENANCE Grease Articulation Swivel Pins Clean the two (2) grease fittings (1, Figure 5-17) and apply three (3) shots of MPG-EP2 grease with a grease gun. Refer to Secticn 8- Fuel and Lubricant Specifications for details on grease. Figure 5-17 Grease Steering Cylinder Pins NOTE: There is a grease fitting at each end of each steering cylinder. Clean the two (2) grease fittings (1, Figure 5-18) and apply three (3) shots of MPG-EP2 grease with a grease gun. Refer to Section 8 - Fuel and Lubricant Specifications for details on grease, Figure 5-18 ‘SD-100/SD-100D/SD-100F C SERIES SAT518 SECTION 5 MAINTENANCE INSTRUCTIONS Grease Oscillation Swivel Pin Clean the single grease fitting (Figure 5-19) and apply five (5) shots of MPG-EP2 grease with a grease gun. Refer to Section 8- Fuel and Lubricant Specifications for details on grease. Figure 5-19 Check Tire Pressure Excessive air pressure may cause tire and rim to burst. Flying tire and rim parts may cause severe injury or death. Ingersoll-Rand recommends that tire mounting be done ONLY by a qualified person who is equipped and trained to perform this service. When mounting a tire the qualified person should: + Ensure the rim is clean and rust free. + GENEROUSLY lubricate both tire and rim with rubber lubricant + NEVER inflate the tire to OVER 35 PSI (2.4 bar) to seat beads. Excessive inflation pressure when seating beads may cause tire and rim assembly to burst and cause severe injury. + CHECK to ensure normal operating pressure is not above 1.1 bar (16 psi) for 23.1 tire or 1.4 Bar (20 psi) for 18.4 tire. ‘SD-100/SD-100D/SD-100F C SERIESMAINTENANCE INSTRUCTIONS SECTION 5 The tires on this machine are ballasted and require special handling when removing and fitting the tire assembly. DO NOT ATTEMPT TO REMOVE THE WHEEL. @ assistance. Ifa tire or wheel needs to be changed, calll for special ser 4. Position the machine so the desired fire inflation valve shown in Figure 5-20 is located at the top. 2. Check the tires only when tires are cold using an appropriate pressure gauge. Normal tire pressure is 1.1 bar (16 ps) for 23.1 tire and 1.4 Bar (20 psi) for 18.4 tire. NOTE: After checking the pressure, be sure valve caps are in place to prevent dirt, moisture and foreign material from damaging the valve core. Figure 5-20 Placing water in tires is an economical means of adding weight to the wheels of a tractor. The addition of calcium chloride is recommended to prevent the water from freezing. Ifa tire with ballast is replaced, the replacement tire must also contain ballast. Contact your Ingersoll-Rand Road Machinery Distributor for more information on ballasted tires. ‘SD-100/SD-100D/SD-100F C SERIES 5-195:20 SECTION 5 MAINTENANCE INSTRUCTIONS Check Hydraulic Oil Dirt in the hydraulic system will lead to premature component failure. Aclean, contaminant-free system is extremely important to the machine's proper function. Take extra care when working around or on the hydraulic system to ‘ensure its complete cleanliness. 1. Check the hydraulic oil level by viewing the sight gauge (1, Figure 5-21). 2. Ifoilis not visible inthe sight gauge, remove plug (2, Figure 5-21) and add fresh hydraulic oil until itis visible in the sight gauge (1). NOTE: if gauge continually shows no oil, call for service assistance to investigate the cause of oil loss. Figure 5-21 3. If necessary, add fresh, clean (filtered through 10 micron filter) anti-wear hydraulic oil through the fill cap area (2, Figure 5-21) to bring level to Full. Refer to Section 8 - Fuel and Lubricant Specifications for details on oil. 4. Operate machine and check for leaks. ‘SD-100/SD-100D/SD-100F C SERIESMAINTENANCE INSTRUCTIONS SECTION 5 Torque Wheel Nuts Check that the nuts (Figure 5-22) are torqued to the correct value of 550 N-m (405 lb-ft). NOTE: If new wheel nuts have been recently installed, they may require more frequent checks until they seat property. , \ a \ Seal Boot Grease (SD-100 Only) Four (4) mounting bolts are used to hold the torque hub motor cover plate in position. One of the bolts contains a grease fitting (1, Figure 5-23) which serves as a lubrication point for the torque hub. Grease through the bolt with a few shots of MPG-EP2 grease until grease ‘appears around the seal area behind mounting plate. Wipe off excess grease. Figure 5-23 ‘SD-100/SD-100D/SD-100F C SERIES 5:21SECTION 5 MAINTENANCE INSTRUCTIONS Check Air Cleaner System Integrity 1. Inspect the complete air intake system to ensure it's integrity. Failure or looseness of air cleaner elements, hoses and hose clamps, as well as brackets and/or clamps can lead to the possibility of unfiltered air entering the engine. Serious engine damage could result if this happens. Refer to pages 5-5 through 5-8 for procedures to service the air cleaner filter elements. 2. Check the intake pipe cap and screen for accumulation of leaves, trash and other debris that could restrict air flow. Repair the screen or replace the cap if any large holes are found in the screen 3. Check all mounting hardware for security to eliminate possible vibration of intake piping. 4. Check all hoses for cracks, chafing or deterioration, and replace at the first sign of probable failure. Check Axle Input Case Oil 1. Park the machine on a level surface and shut off engine. 2. Allow axle transfer case to cool if necessary. 3. Remove oil level check plug (1, Figure 5-24). Figure 5-24 Verify oil is to the bottom of hole. If not, add oil until level with hole. Refer to Section 8 - Fuel and Lubricant Specifications for oil specifications. Clean, insert and tighten plug. Wipe up any excess oll 5:22 ‘SD-100/SD-100D/SD-100F C SERIES