Single Drum Roller: SSR200C-8H SSR220C-8H

Quality Changes the World
Single Drum Roller
SSR200C-8H
SSR220C-8H
Safety, Operation & Maintenance Manual

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SSR200/220 Series Single Drum Roller
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SSR200/220 Series
Single Drum Roller
Safety, Operation & Maintenance Manual
WARNING
Read and follow the safety precautions and instructions in this manual and on the machine
decals. Failure to do so can cause serious injury, death or property damage. Keep this
manual with the machine for reading and future reference.
Safety, Operation and Maintenance Manual- January 2019

SSR200/220 Series Single Drum Roller
Sany Group
SANY Automobile Manufacturing CO.,LTD
Sany Industry Zone,
Economic & Technical Development Zone
Changsha, Hunan, China 410100
http://www.sanygroup.com
Tel: 0086-4006098318
Scan here to download the Service Cloud APP
Android iOS
© 2019 by Sany Group. All rights reserved. No part of this publication may be reproduced,
used, distributed or disclosed except for normal operation of the machine as
described herein. All information included within this publication was accurate
at the time of publication. Product improvements, revisions, etc., may result in
differences between your machine and what is presented here. Sany Group assumes no
liability. For more information, contact Sany Group.
Safety, Operation and Maintenance Manual- January 2019

SSR200/220 Series Single Drum Roller Responsibility
RESPONSIBILITY
SPECIFIC DECLARATION
The single drum roller is used to compact sand soil and sand gravel in the construction of
roads and foundations, which are suitable for most types of road construction, airfields, dam
construction and harbor projects. Any other use or any operation beyond the specified working
range is not authorized use. Sany expressly bears no liability for any consequence due to any
unauthorized use.
Information on this manual is used to guide qualified operators to operate and maintain rollers
correctly. Sany expressly bears no liability for any consequence due to any use not observing the
information on this manual.
It is forbidden to convert the roller without authorization.Sany expressly bears no liability for
any consequence. When crack or electrical malfunction on the roller occurs, please contact
the supplier, and don’t conduct welding or make changes without permission, or else, for any
consequence due to such contravention, Sany shall not bear any liability.
Use genuine spare parts from Sany. Sany expressly bears no liability for any machine damage or
accident due to the use of untested or unauthorized spare parts or tools.
Operate and maintain parts (such as engine, a/c) on the roller, and observe related regulations
on Users' guide supplied from their manufacturer.
Sany expressly bears no liability for any machine failure or damage due to force majeure of
natural disasters (earthquake, typhoon) and wars.
Sany cannot predict every circumstance that might involve a potential hazard in operation or
maintenance. Operators and owners should highly attach importance to safety. Local specific
safety rules of the countries may be stricter. If they differ from the regulations on this manual,
observe the stricter one.
Duty of Sany
• Be responsible for providing qualified products and correct documents
• Fulfill their promises on after-sales service, and document all maintenance and repair working
done by after-sales service personnel.
• Train the operation and maintenance personnel based on their needs.
Duty of owners or other authorized personnel

• Only after each person involved in the product’s operation, maintenance and repair is trained
and fully understands the Parts Book and Operation and Maintenance Manual, can they
operate and maintain the roller.
• Ensure the operation and maintenance personnel are qualified and know their related
responsibilities.
Safety, Operation & Maintenance Manual - January 2019

Responsibility SSR200/220 Series Single Drum Roller
• Periodically check related personnel's safety consciousness during working.

• If any fault which will lead to unsafe situation occurs, stop the roller immediately.
• If necessary Sany service personnel have the right to check the roller for safety.
• Besides check items regulated by Sany, observe local laws and regulations to check the
roller.
• Ensure timely maintenance and repair on the roller.
• Carefully plan the use of the roller.
Duty of all working personnel

• If there is any abnormal symptom which may cause abnormal working of the roller or potential
hazard, report to your leader. If possible, correct fault in time.
• All personnel working around the roller must observe all warning signals and take care of their
own and others' safety.
• All personnel should know their working tasks and procedures.
• Watch something like high voltage wire, unrelated personnel and poor ground for potential
danger, and report to the operators and signalmen.
Duty of managers
• Ensure the operators are trained and fully understand the Safety, Operation and Maintenance
Manual supplied by Sany. Ensure they are in physical fitness and have the certification of
operation. Otherwise, it is forbidden to operate the roller.
• Ensure the operators have good judgement, teamwork consciousness and psychological
quality. Otherwise, it is forbidden to operate or repair the roller.
• Ensure the signalmen have good vision and acoustic judgement, master standard command
signals. At the same time, they should have enough experience in recognizing danger factors
correctly, and inform the operators of danger factors to avoid them in time.
• Ensure assistant workers can identify the model and working condition to choose a proper
roller.
• Publicize safety consciousness to working personnel, and make them aware of safety
precautions and their related responsibilities.

SSR200/220 Series Single Drum Roller Table of content
Table of Contents
1 Introduction
1.1 Overview 1-1
1.2 Your Documentation Package 1-2
1.2.1 Recommendations on Using the Documentation 1-2
1.2.2 Documentation Storage 1-2
1.2.3 Organization of this Manual 1-2
1.2.3.1 Introduction 1-3
1.2.3.2 Safty 1-3
1.2.3.3 System Functions 1-3
1.2.3.4 Operation 1-3
1.2.3.5 Maintenance 1-3
1.2.3.6 Troubleshooting 1-3
1.2.3.7 Technical Specifications 1-4
1.3 Your SANY Equipment 1-4
1.3.1 Equipment Directions 1-4
1.3.2 Breaking in a New Equipment 1-4
1.3.3 Equipment Information 1-5
1.3.4 Serial Number and Distributor Information 1-6
1.4 Contact Information 1-7
2 Safety
2.1 General 2-1
2.1.1 Intended Use 2-3
2.1.2 Unintended Use 2-3
2.1.3 Qualifications of Operators and Maintainers 2-3
2.1.4 Unauthorized Modification 2-4
2.2 Safety Message 2-4
2.2.1 Safety Message Introduction 2-4
2.2.2 Safety Message Locations 2-5
2.2.3 Signal Words 2-6
2.2.4 An Example of Signal Words 2-6
2.2.5 Safety Decals 2-7
2.2.5.1 Safety Words 2-7
Safety, Operation & Maintenance Manual - January 2019 I
Table of content SSR200/220 Series Single Drum Roller
2.2.5.2 Safety Symbols 2-7

2.3 General Precautions 2-11
2.3.1 Safety Rules 2-11
2.3.2 Abnormal Case 2-11
2.3.3 Safety Devices 2-11
2.3.4 Protective Measures for Personal Safety 2-12
2.3.5 Precautions against Emergency 2-13
2.3.5.1 Use the Emergency Stop Switch Correctly 2-13
2.3.5.2 Evacuation in Fire Accident 2-14
2.3.5.3 Touching High-voltage Lines 2-14
2.3.5.4 Falling Object Protection 2-15
2.4 Precautions During Operation 2-15
2.4.1 Safe Starting 2-15
2.4.1.1 Safe Mounting 2-15
2.4.1.2 Seat Adjusting 2-15
2.4.1.3 Seat Belt 2-16
2.4.1.4 Before Starting the Engine 2-16
2.4.1.5 Engine Starting 2-17
2.4.1.6 After Starting the Engine 2-18
2.4.2 Safety Operation 2-19
2.4.2.1 Surveying the Worksite in Advance 2-19
2.4.2.2 Before Operation 2-20
2.4.2.3 Safe Traveling 2-21
2.4.2.4 Safe Turning 2-24
2.4.2.5 Safe Vibrating 2-24
2.4.3 Safe Parking 2-25
2.4.3.1 Requirements for Parking Area 2-25
2.4.3.2 Parking Rules 2-25
2.5 Maintenance Precautions 2-26
2.5.1 Basic Rules 2-26
2.5.2 Lockout/Tagout Procedures 2-26
2.5.3 Working Area Preparation 2-27
2.5.4 Washing the Equipment 2-28
2.5.5 Self-preparation 2-28
2.5.6 Proper Tool 2-29
2.5.7 Maintenance with Engine Running 2-29
2.5.8 Working under the Roller 2-30
II Safety, Operation & Maintenance Manual - January 2019

2.5.9 Working in Noisy Environment 2-31

2.5.10 Removing Paint before Welding or Heating 2-31
2.5.11 Correct Welding 2-31
2.5.12 No Heating beside Hydraulic Pipeline 2-32
2.5.13 No Heating the Pipes with Combustible Liquid 2-33
2.5.14 Correctly Operating the Hydraulic System 2-33
2.5.15 Being Aware of High-pressure Liquid 2-34
2.5.16 Regularly Replacing the Rubber Hoses 2-35
2.5.17 Avoid Scald by High-temperature Liquid 2-35
2.5.18 Preventing Battery from Explosion 2-36
2.5.19 Preventing Components from Flying out 2-37
2.5.20 Safe Storage of Parts 2-37
2.5.21 Safe Treatment of Liquid 2-37
2.5.22 Safe Treatment of Chemicals 2-38
2.5.23 Proper Disposal of Wastes 2-38
2.6 Safe Transportation 2-39
2.6.1 Load/Unload the Roller 2-39
2.6.2 Transport the Roller 2-40
2.6.3 Lift the Roller 2-40
3 System functions
3.1 Exterior Components 3-1
3.2 Control Console and Display 3-2
4 Operation
4.1 Check before Starting the Engine 4-1
4.1.1 Inspection (walk-around) 4-1
4.1.2 Inspection before Starting 4-1
4.1.2.1 Check the Engine Oil Level 4-1
4.1.2.2 Check the Coolant Level of the Engine 4-2
4.1.2.3 Check the Oil Water Separator 4-2
4.1.2.4 Check the Hydraulic Oil Level 4-3
4.1.2.5 Check the Washer 4-4
4.1.2.6 Check the Air Filter 4-4
4.1.2.7 Check the Tire Pressure 4-4
4.1.2.8 Check the Position of Limit Plate 4-5
4.1.2.9 Check the Vibratory Drum and Dampers 4-5
Safety, Operation & Maintenance Manual - January 2019 III
4.1.2.10 Check the Cables 4-5

4.2 Adjustments Prior to Startup 4-6
4.2.1 Seat Adjustment 4-6
4.2.2 Rearview mirror adjustment 4-6
4.3 Equipment Check Prior to Startup 4-7
4.3.1 Power on the Control System 4-7
4.3.2 Check the Fuel Level 4-8
4.3.3 Check the Propel Control Lever 4-9
4.3.4 Check the Emergency Stop Switch 4-9
4.3.5 Check the Park Brake Switch 4-10
4.3.6 Check other Switches (If Any) 4-10
4.4 Engine Starting 4-11
4.4.1 Normal Start 4-11
4.4.2 Jump-start 4-11
4.4.3 Engine Start in Cold Weather (optional) 4-11
4.5 After Engine Starting 4-12
4.6 Test Running 4-13
4.7 Travel Operation 4-13
4.7.1 Travel forward 4-13
4.7.2 Travel backward 4-13
4.8 Vibration Operation 4-14
4.9 Parking Operation 4-15
4.9.1 Service Brake 4-15
4.9.2 Park Brake 4-15
4.9.3 Emergency Brake 4-16
4.10 Correct Driving According to the Road Condition 4-17
4.10.1 Working near Ditch Edge and Road Shoulder 4-17
4.10.2 Working near Buildings Vulnerable to Vibration 4-17
4.10.3 Working on the Slope 4-18
4.11 Check after Each Work Day 4-19
4.12 Transportation 4-19
4.12.1 Transport Vehicle 4-19
4.12.2 Using a Slope 4-19
4.12.3 Shipping 4-21
4.12.3.1 Container Shipping 4-21
4.13.3.2 Non-container Shipping 4-25
IV Safety, Operation & Maintenance Manual - January 2019

5. Maintenance
5.1 Maintenance Information ................................................. 5-1
5.1.1 Checks before maintenance............................................ 5-1
5.1.2 Checks after maintenance or repairs. ................................... 5-2
5.1.3 Hour meter reading. .................................................. 5-3
5.1.4 Genuine SANY replacement parts....................................... 5-3
5.1.5 SANY approved lubricants............................................. 5-3
5.1.6 Windshield washer flui ................................................ 5-4
5.1.7 Grease.............................................................. 5-4
5.1.8 Oil and filter inspectio . ............................................... 5-4
5.1.9 Welding on the machine............................................... 5-4
5.1.10 Inventory your tools and parts......................................... 5-5
5.1.11 Cleaning parts of the machine......................................... 5-5
5.1.12 Adverse work site conditions.......................................... 5-5
5.1.13 Covers and locks .................................................... 5-6
5.1.14 Hydraulic hoses, lines or components.................................. 5-6
5.1.15 Torque values....................................................... 5-6
5.1.16 Notes on maintenance............................................... 5-8
5.1.17 Notes on fuel system................................................ 5-8
5.1.18 Notes on engine performance......................................... 5-9
5.1.19 Notes on hydraulic system............................................ 5-9
5.2 Requirements on use of oil & fluid ........................................ 5-10
5.2.1 Introduction of functional oil & fluid .................................... 5-10
5.2.1.1 Engine oil........................................................ 5-10
5.2.1.2 Fuel ........................................................... 5-11
5.2.1.3 Lubricant........................................................ 5-12
5.2.1.4 Grease.......................................................... 5-12
5.2.1.5 Coolant. ........................................................ 5-12
5.2.2 Oil & Fluids Selection................................................. 5-13
5.2.2.1 General requirements............................................. 5-13
5.2.2.2 Requirements of oil and fluid ...................................... 5-15
5.2.3 Filling capacities .................................................... 5-18
5.3 Test Run Instructions.................................................... 5-19
5.4 Maintenance........................................................... 5-20
5.5 Roller Maintenance Locations............................................. 5-21
5.6 Daily Maintenance....................................................... 5-22
5.6.1 Secure the machine for maintenance................................... 5-22
5.6.2 Clean. ............................................................. 5-24
Safety, Operation & Maintenance Manual - January 2019 V
5.6.3 Check ............................................................. 5-26

5.6.3.1 Safety, Operation & Maintenance Manual ........................... 5-26
5.6.3.2 Operating functions............................................... 5-26
5.6.3.3 Signal, running lights and horn..................................... 5-27
5.6.3.4 Back-up alarm. .................................................. 5-27
5.6.3.5 Brakes(Service and parking)....................................... 5-27
5.6.3.6 Level indicator. .................................................. 5-28
5.6.3.7 Hourmeter....................................................... 5-28
5.6.3.8 Air filter......................................................... 5-28
5.6.3.9 Engine oil level................................................... 5-33
5.6.3.10 Engine coolant level............................................. 5-33
5.6.3.11 Hydraulic oil level................................................ 5-34
5.6.3.12 Fuel level....................................................... 5-34
5.6.3.13 Tires and rims................................................... 5-34
5.6.3.14 Oil leaks........................................................ 5-35
5.6.3.15 Electrical circuit................................................. 5-35
5.6.3.16 Bolts........................................................... 5-35
5.6.3.17 Electrical system................................................ 5-36
5.6.3.18 Engine belt..................................................... 5-39
5.6.3.19 Compressor V-belt............................................... 5-40
5.6.3.20 Engine air intake pipeline......................................... 5-42
5.6.3.21 Crankcase vent line.............................................. 5-42
5.6.3.22 Exhaust manifold................................................ 5-42
5.6.3.23 Muffler lines .................................................... 5-43
5.6.3.24 Oil tank and pipes............................................... 5-43
5.6.4 Drain-oil water separator.............................................. 5-43
5.6.5 Fill-Windshield washer fluid .......................................... 5-43
5.7 Initial 50 Hour Maintenance............................................... 5-44
5.7.2 Change............................................................. 5-45
5.7.2.1 Engine oil........................................................ 5-45
5.7.2.2 Engine oil filter element .......................................... 5-46
5.7.2.3 Fuel filte ........................................................ 5-47
5.7.2.4 Oil water separator .............................................. 5-48
5.7.2.5 Lubricant for drum vibration bearing................................ 5-49
5.7.2.6 Reducer........................................................ 5-50
VI Safety, Operation & Maintenance Manual - January 2019

5.7.2.7 Rear axle ...................................................... 5-50
5.7.3 Check ............................................................ 5-51
5.7.3.1 Engine belt ..................................................... 5-51
5.7.3.2 Compressor belt ................................................ 5-51
5.8 Initial 250 Hour Maintenance ............................................. 5-52

5.8.1 Replace-lubricant for drum ........................................... 5-52
5.9 Every 250 Hour Maintenance............................................. 5-53
5.9.2 Replace-engine oil................................................... 5-53
5.9.3 Replace-engine oil filter element ...................................... 5-54
5.9.4 Replace-fuel filter ................................................... 5-54
5.9.5 Replace-oil water separator........................................... 5-55
5.10 Every 500 Hour Maintenance............................................ 5-56
5.10.1 Secure the machine................................................. 5-56
5.10.2 Fill................................................................ 5-57
5.10.2.1 Propel bearing.................................................. 5-57
5.10.2.2 Central articulation frame........................................ 5-57
5.10.3 Replace........................................................... 5-58
5.10.3.1 Air filter main/safety elemen ...................................... 5-58
5.10.3.2 Lubricant for drum. ............................................. 5-58
5.10.3.3 Lubricant for reducer ............................................ 5-58
5.10.4 Check............................................................. 5-59
5.10.4.1 Key welding parts/power train parts................................ 5-59
5.10.4.2 Damper........................................................ 5-59
5.11 Every 1000 Hour Maintenance........................................... 5-60
5.11.1 Secure the machine for maintenance . ................................ 5-60
5.11.2 Check/maintain-A/C (if equipped)..................................... 5-61
5.11.2.1 Instructions for using the A/C...................................... 5-61
5.11.2.2 Maintaining intervals for the A/C................................... 5-62
5.11.3 Replace........................................................... 5-66
5.11.3.1 Oil water separator.............................................. 5-66
5.11.3.2 Hydraulic oil. ................................................... 5-67
5.11.3.3 Hydraulic oil filte ............................................... 5-69
5.11.3.4 Coolant........................................................ 5-70
5.12 Others................................................................ 5-71
5.12.1 Clean-fuel tank..................................................... 5-71
5.12.2 Clean-fuel radiator.................................................. 5-72
Safety, Operation & Maintenance Manual - January 2019 VII
5.13 Maintenance for long-time storage ....................................... 5-73

5.13.1 Engine............................................................ 5-73
5.13.2 Complete machine ................................................. 5-74
5.14 Antifreezing Maintenance .............................................. 5-75
5.15 Check after Maintenance .............................................. 5-76
6 Troubleshooting
6.1 Mechanical Parts 6-1
6.1.1 Engine 6-1
6.1.2 Vibratory Drum 6-3
6.1.3 Propel system 6-4
6.1.4 Brake 6-5
6.2 Typical Hydraulic Elements 6-6
6.2.1 Axial Plunger Pump 6-6
6.2.2 Axial Plunger Motor 6-10
6.2.3 Change Valve 6-12
6.2.4 Overflow alve 6-16
6.2.5 Steering Cylinder 6-20
6.2.6 Oil Filter 6-25
6.2.7 Sealing Elements 6-26
6.2.8 Hydraulic Steering Gear 6-28
6.3 Electrical Parts 6-30
6.3.1 Basic Electrical System 6-30
6.3.2 Electrical System of Working Devices 6-32
6.3.3 Fuses 6-33
6.3.4 Radio 6-34
6.4 Air Conditioning System 6-35
6.4.1 System with Poor Cooling 6-35
6.4.2 Insufficient System Cooling 6-36
6.4.3 Abnormal Noise Caused by Cooling System 6-38
6.4.4 Air Heating Device Fault 6-39
6.4.5 Other Faults 6-39
6.5 Troubleshooting Examples 6-41
7. Specifications
7.1 Dimension of the Equipment 7-1
7.2 Specifications of the Equipment 7-2
VIII Safety, Operation & Maintenance Manual - January 2019

SSR200/220 Series Single Drum Roller Introduction
Introduction
1 Introduction
1.1 Overview 1-1
1.2 Your Documentation Package 1-2
1.2.1 Recommendations on Using the Documentation 1-2
1.2.2 Documentation Storage 1-2
1.2.3 Organization of this Manual 1-2
1.2.3.1 Introduction 1-3
1.2.3.2 Safty 1-3
1.2.3.3 System Functions 1-3
1.2.3.4 Operation 1-3
1.2.3.5 Maintenance 1-3
1.2.3.6 Troubleshooting 1-3
1.2.3.7 Technical Specifications 1-4
1.3 Your SANY Equipment 1-4
1.3.1 Equipment Directions 1-4
1.3.2 Breaking in a New Equipment 1-4
1.3.3 Equipment Information 1-5
1.3.4 Serial Number and Distributor Information 1-6
1.4 Contact Information 1-7

Introduction SSR200/220 Series Single Drum Roller
WARNING
Read and understand all safety
precautions and instructions in this
manual before reading any other manuals
provided with this roller and before
operating or servicing the roller.Failure
to do this can cause property damage,
personal injury or death.

1 INTRODUCTION
1.1 Overview
• SANY-built equipment offers high-quality
performance and excellent after-sales
service support.
• SANY-built equipment is widely used
throughout the industry for various types of
applications.
• SANY is a leading manufacturer of heavy
construction equipment worldwide.
This operator ’s manual provides safety,
operation, maintenance, troubleshooting
and specifications. In order to properly use
your equipment, it is important to read and
understand this manual before using the
equipment.
Items addressed in this manual are designed
to help you:
• Understand the structure and performance
of your equipment.
• Reduce improper operation and point out
possible hazardous situations when using Fig.1-1
equipment.
• Increase equipment efficiency during
operation.
• Prolong the service life of your equipment.
• Reduce maintenance costs.
Always keep this manual nearby and have all

personnel involved with any work operations
read it periodically. If this manual becomes
damaged or lost and cannot be read, it is
advised to request a replacement copy from
your SANY distributor as soon as possible.
If you sell the equipment, be sure to give
this manual to the new owner. Continuing
improvements in the design can lead to
changes in details which may not be reflecte
in this manual. Always consult your SANY
distributor for the latest available information
on your equipment or if you have questions
regarding information in this manual.
Safety, Operation & Maintenance Manual - January 2019 1-1

1.2 Your Documentation Package

The documentation includes:
• Safety,Operation and Maintenance Manual.
• Parts Book– including the Parts List and
the Drawings needed when ordering parts.
If the Parts Book is not attached with the
equipment, contact SANY.
1.2.1 Recommendations on using the

documentation
• The documents only apply to this
equipment, and should not be used with
any other equipments.
• Ensure that the documents are complete
and up to date.
• Put all data in a folder (if including leaflets)
• Print and replace the lost, damaged and
blotted pages.
• Add the latest SANY data in time and
destroy the inapplicable old documents.
1.2.2 Documentation storage

Always keep the operator manual with the
equipment in the operator cabin. The Parts
Book is best left either shelved in the workshop
area or office. It should always be available
to the maintenance and service personnel as
required.
1.2.3 Organization of this manual

This operator's manual covers operation and
maintenance of your equipment. Get familiar
with it before performing any operations.
Put this manual within easy reach for
your reference and replace it if it is lost or
damaged. Due to improvement and updating
of products, some information may differ from
your equipment. If you have any question on
the use and maintenance of your equipment,
contact your SANY distributor.
1-2 Safety, Operation & Maintenance Manual - January 2019

1.2.3.1 Introduction
This section provides an overview of what is
covered in the rest of this manual, including
equipment label information and SANY contact
information.
1.2.3.2 Safety
This section covers basic safety information
relating to this equipment. Make sure you fully
understand all the precautions described in this
manual and the safety decals on the equipment
before operating or maintaining this equipment.
Failure to do so may result in serious injury or
death.
1.2.3.3 System functions

This section provides an overview of all the
controls and prompt & operating systems on
your equipment. Only when you are familiar
with all systems, can you operate and maintain
the equipment safely.
1.2.3.4 Operation
This section provides the basic operating
procedures for the equipment. It is important to
study and become familiar with all procedures
before performing any operations with the
equipment.
1.2.3.5 Maintenance
This section provides all general maintenance
and repair procedures. It is important to study
and become familiar with all the maintenance
and repair procedures before performing
any maintenance or repair operations on the
equipment.
1.2.3.6 Troubleshooting
This section includes common malfunctions
and fault diagnostic procedures for the
operating system of this single drum roller. The
basic troubleshooting methods for mechanical,
hydraulic and electrical systems are included.

1.2.3.7 Specifications
This section provides the general information
about this equipment. Some information may
change as design modification
1.3 Your SANY Equipment A
1.3.1 Equipment directions

(A) Front
(B) Back
(C) Left
(D) Right
C D
Fig.1-2
1.3.2 Breaking in a new equipment
Your equipment has been well adjusted
and tested before delivery. However, initial
operation on the equipment in severe
conditions will seriously affect the performance
or reduce the service life of the equipment.
Thus SANY recommends you to perform 100-
hour test run before putting the equipment into
production use.
During the break-in period:

• Let the equipment warm up prior to any
operation.
• Avoid operating or running the equipment
at a high speed in overload working
conditions.
• Avoid sudden starting, rapid movement or
abrupt stop of the equipment.
• Cool down the equipment system at the
end of every working day.

1.3.3 Equipment information

The serial numbers and model numbers on
the components are the only numbers that
your SANY distributor will need when ordering
replacement parts or requiring assistance
for your equipment. You can find the related
information on the data plate. It is a good idea
to record this information in this manual for
future use.
Product identification plate is riveted on the left

side of the rear frame(See Fig.1-3).
●
三一单钢轮压路机
SANY Single Drum Roller
产品型号
Product Type
整机质量 kg
Gross Mass
额定功率 kW
Rated Power
生产日期
Date of Production
出厂编号
Number
中国制造 / Made in China
Fig.1-3

1.3.4 Serial number and distributor information
This location is for you to record information relating to your equipment. It is advised that you keep this
manual with your equipment at all times for reference.
Product Type
Serial No.
Date of Production
Vehicle Identification
Number (VIN)
Distributor Name:
Address:
Phone Numbers:

1.4 Contact Information

Thank you for purchasing a SANY product. In
the event that you need to contact us for any
reason, you can reach us as follows.
Our address:
Sany Industry Zone,
Economic & Technical Development Zone
Tel: 0086 4006098318

Email: [email protected]

E
G
PA
K
AN
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SSR200/220 Series Single Drum Roller Safety
Safety
2 Safety
2.1 General 2-1
2.1.1 Intended Use 2-3
2.1.2 Unintended Use 2-3
2.1.3 Qualifications of Operators and Maintainers 2-3
2.1.4 Unauthorized Modification 2-4
2.2 Safety Message 2-4
2.2.1 Safety Message Introduction 2-4
2.2.2 Safety Message Locations 2-5
2.2.3 Signal Words 2-6
2.2.4 An Example of Signal Words 2-6
2.2.5 Safety Decals 2-7
2.2.5.1 Safety Words 2-7
2.2.5.2 Safety Symbols 2-7
2.3 General Precautions 2-11
2.3.1 Safety Rules 2-11
2.3.2 Abnormal Case 2-11
2.3.3 Safety Devices 2-11
2.3.4 Protective Measures for Personal Safety 2-12
2.3.5 Precautions against Emergency 2-13
2.3.5.1 Use the Emergency Stop Switch Correctly 2-13
2.3.5.2 Evacuation in Fire Accident 2-14
2.3.5.3 Touching High-voltage Lines 2-14
2.3.5.4 Falling Object Protection 2-15
2.4 Precautions During Operation 2-15

Safety SSR200/220 Series Single Drum Roller
2.4.1 Safe Starting 2-15

2.4.1.1 Safe Mounting 2-15
2.4.1.2 Seat Adjusting 2-15
2.4.1.3 Seat Belt 2-16
2.4.1.4 Before Starting the Engine 2-16
2.4.1.5 Engine Starting 2-17
2.4.1.6 After Starting the Engine 2-18
2.4.2 Safety Operation 2-19
2.4.2.1 Surveying the Worksite in Advance 2-19
2.4.2.2 Before Operation 2-20
2.4.2.3 Safe Traveling 2-21
2.4.2.4 Safe Turning 2-24
2.4.2.5 Safe Vibrating 2-24
2.4.3 Safe Parking 2-25
2.4.3.1 Requirements for Parking Area 2-25
2.4.3.2 Parking Rules 2-25
2.5 Maintenance Precautions 2-26
2.5.1 Basic Rules 2-26
2.5.2 Lockout/Tagout Procedures 2-26
2.5.3 Working Area Preparation 2-27
2.5.4 Washing the Equipment 2-28
2.5.5 Self-preparation 2-28
2.5.6 Proper Tool 2-29
2.5.7 Maintenance with Engine Running 2-29
2.5.8 Working under the Roller 2-30
2.5.9 Working in Noisy Environment 2-31
2.5.10 Removing Paint before Welding or Heating 2-31
2.5.11 Correct Welding 2-31
2.5.12 No Heating beside Hydraulic Pipeline 2-32
2.5.13 No Heating the Pipes with Combustible Liquid 2-33
2.5.14 Correctly Operating the Hydraulic System 2-33
2.5.15 Being Aware of High-pressure Liquid 2-34
2.5.16 Regularly Replacing the Rubber Hoses 2-35
2.5.17 Avoid Scald by High-temperature Liquid 2-35
2.5.18 Preventing Battery from Explosion 2-36
2.5.19 Preventing Components from Flying out 2-37
2.5.20 Safe Storage of Parts 2-37

2.5.21 Safe Treatment of Liquid 2-37

2.5.22 Safe Treatment of Chemicals 2-38
2.5.23 Proper Disposal of Wastes 2-38
2.6 Safe Transportation 2-39
2.6.1 Load/Unload the Roller 2-39
2.6.2 Transport the Roller 2-40
2.6.3 Lift the Roller 2-40

WARNING

2 SAFETY
2.1 General
This Safety, Operation and Maintenance
Manual is a guide for you to operate your
equipment properly.
It contains technical and safety information

necessary for operation of your equipment.
Read and understand each section of the
manual.
Always operate your equipment according to

national, provincial, prefectural and municipal
laws and regulations. The safety information
for operation in this manual are just suggestive.
SANY cannot anticipate every possible

circumstance that might involve a potential
hazard during operation and maintenance.
The safety messages in this manual and on
the product are, therefore, not all inclusive. If a
procedure,work method or operating technique
that is not specifically recommended in this
manual is used, you must be sure that it is
safe for you and for others. You should also
ensure that the product will not be damaged or
be made unsafe by the operation, lubrication,
maintenance or repair procedures that you
choose.
Equipments covered by this manual are used

for various operations under normal conditions.
Never use the equipment in flammable or

explosive environment, or in areas containing
asbestos dust.
Select a SANY single drum roller with a

configuration suitable for high-plateau
operation when operating in areas 2000 meters
above the sea level.
The information, specifications, and illustration

in this publication are on the basis of
information that was available at the time that
the publication was written. SANY reserves the
right to change these information at any time

without prior notice. Consult SANY distributor
to obtain the latest information or if you have
any question on the information provided in
this manual.
Before starting operation and maintenance,

operator and maintainer shall observe the
following items.
• Read and understand the whole manual.
• Read and understand the safety notices
contained in this manual and the safety
messages on the equipment.
• Never apply or operate your equipment
under any circumstances in a manner that
is prohibited in this manual.
• If the amount of fuel added, content of
particulates ,or latitude is beyond the
specification of this type of equipment,
damage could occur and the warranty of
your equipment would become invalid. Fig.2-1
The manual should be kept in the cabin all

the time for operator to refer to at any time.
Contact SANY distributor to obtain a new
manual if the original one is missing or cannot
be read.
This manual should be regarded as a

permanent component of your equipment.
If the equipment is sold to a third party, give
this manual to the new owner. The equipment
provided by SANY Road Machinery Co., Ltd
to its buyer is in line with all specifications and
standards of buyer's country. If the equipment
is purchased from another country or someone
of a third country, it might be lacking of some
safety devices or technical requirements
necessary for using the equipment in your
country. In case you question whether the
equipment is in accordance with the standards
and specifications of your country, contact
SANY distributor before operating the
equipment.

2.1.1 Intended use

The equipment is mainly designed for the
following operations.
• Compacting different kinds of pavements,
such as various of non-viscous soil
(including sandy soil, gravel an so on),
detritus, stone and rock.
• Compacting work on earth and stone
foundations of road, airport, dam and so
on.
2.1.2 Unintended use

• Operation by untrained personnel in
an unprofessional manner or using the
equipment for purposes unmentioned in
this manual may pose hazard.
• Av o i d s t a r t i n g v i b r a t i o n o n a s p h a l t
pavement and pavement with thick ice.
• Avoid starting and operating the equipment
in an explosive environment.
2.1.3 Qualifications of operators and

maintainers
• The equipment can only be operated by
trained and authorized persons who are at
least 18 years old.
• The operator must fully understand
and observe the operation rules of the
equipment.
• Persons under the influence of alcohol,
medication or drugs are not allowed to
operate, service or repair the equipment.
• Only trained and qualified personnel can
carry out maintenance and repair tasks of
the equipment.
Fig.2-2

2.1.4 Unauthorized modification

Any modification to the machine without
authorization from SANY may have an adverse
effect on the machine's performance or pose
more serious hazard. Improper operation
or unauthorized application may lead to
equipment failure, personal injury or possible
death. SANY assumes no responsibility for
such losses.
2.2 Safety Message

The following warning decals and safety
messages are used on the machine.
• Make sure that you get familiar with the
locations and information of all safety
decals on the machine.
• All warning decals must be placed in the
proper locations on the machine. They
must be kept clean for readability. Never
use organic solvent or gasoline to clean
the warning decals, which may cause the
paints on the safety decal to fall.
• Other signs are also on the machine
besides safety decals and safety
messages, which must be kept clean and
intact.
• Use a new safety decal or safety message
in a timely manner to replace the old one
which is damaged or missing.
2.2.1 Safety message introduction

For using the machine safely and properly,
this manual has provided you with the detailed
illustrations to the decals on the machine to
make you be aware of potential hazards and
prevent the hazards.
All operators or maintenance personnel

involved with the use of this machine must read
this manual thoroughly and fully understand
the safety message on the machine prior to

operating or maintaining this machine. Strictly

observe the safety rules provided in this
manual to avoid personal injury and damage to
the machine.
2.2.2 Safety message locations
1 4 2
6 3
(1) Noise & read the manual (5) Never enter the rolling range
(2) Caution sign for filter element (6) Caution sign for vibration
(3) Power switch notice (7) Keep away
(4) Indication of hood lock (8) No operation as a handrail
Fig.2-3

2.2.3 Signal words

The following signal words are used to inform
you there may be potential dangers that lead
to personal injury or damage.
In this manual and on the machine decals,

different signal words or illustrations are used
to express the potential level of hazard.
Table 2-1 Safety Decal and Explanation

Safety Decal Explanation
Indicates an imminent hazard which, if not avoided, will result in

DANGER serious injury or death.
Indicates a potentially hazardous situation which, if not avoided,
WARNING could result in injury or possibly death.
Indicates a possible potential hazardous situation which, if not
CAUTION avoided, could result in minor or major injury.
Indicates a situation which can cause damage to the equipment,

NOTICE personal property and/or the environment, or cause the equipment to
operate improperly.
This hazard alert symbol appears with most hazard alerts. It means
attention, become alert, your safety is involved! Please read and
abide by the message that follows the hazard alert symbol.
Indicate the operation disobeys the safety regulations, which may

cause personal injury or death and is prohibited.
2.2.4 An example of signal words
NOTICE
If the hydraulic oil level is found to have
dropped during the daily check, check all
lines and hydraulic elements for leaks,
or it may cause failure in operation and
environment pollution.

2.2.5 Safety decals

Safety signs are fixed to the equipment, which
are used to alert local operator or maintenance
workers that potential danger might be involved
when operating or servicing the equipment.
The equipment uses "safety words" and "safety

symbols" to indicate safety measures.
2.2.5.1 Safety words
NOTICE
Protect generator from water when washing machine
Fig.2-4
2.2.5.2 Safety symbols
Safety symbol uses an image to indicate a haz-

ardous situation that is equivalent to a signal
word. To make an operator or serviceman
understand the type and level of a hazardous
situation at any time, these safety signs are
presented with images. The safety symbol
indicates the type of dangerous situation when
the operator or serviceman does some work
on the equipment that the safety symbol is
fixed to
Fig.2-5

(1) Noise & read the manual
Fig.2-6
(2) Caution sign for filter elemen
Fig.2-7
(3) Power switch notice
Fig.2-8

(4) Indication of hood lock
Fig.2-9
(5) Never enter the rolling range

The sign indicates the danger of being
run over.
Fig.2-10

(6) Caution sign for vibration
Fig.2-11
(7) Keep away

Keep away from the center articulation
frame when the roller is working, or you
may be squeezed.
Fig.2-12
(8) No operation as a handrail

Don't operate the air spring as a handrail.
Fig.2-13

2.3 General Precautions

2.3.1 Safety rules
• Only trained personnel are allowed to
operate and service the equipment.
• Never operate the roller that has fault.
• Never operate the roller in a hazardous
situation.
• All safety rules, precautions and instructions
must be followed when operating and
servicing the equipment.
• Taking alcohol or drug could seriously
impair one's ability in operating or repairing
the equipment, and it is hazardous for you
and other persons.
• When working with another operator or
traffic signalman on the worksite, be sure t
make all people understand all gestures to
be used.
2.3.2 Abnormal case

In case of any abnormalities found during
operation and maintenance, such as noise,
odor, incorrect gauge display, smoke, or oil
leakage, you are obligated to inform your boss
and take necessary measures. Never operate
the equipment before the faults are eliminated.
2.3.3 Safety devices

To protect yourself and others around you, your
roller may be equipped with the following
safety devices. See that each item is securely
in place and in operating condition.
• Headlights, rear lights, turn lights
• Alert lights
• Rearview mirror
• Windshield wipers & washers
• Horn
• Safety decals

2.3.4 Protective measures for personal

safety
Wear all work clothes and personal safety
devices issued to you or called for your job
conditions. You may need:
• Hard hat
• Hearing protection
• Reflective clothin
• Protective gloves
• Safety shoes
If necessary, wear respirator or filter mask.
Wear necessary equipment, and other safety
Fig.2-14
equipment required by your employer, public
and governmental administrations, laws and
regulations. Never take a risk.
WARNING
• Never wear loose fitting clothes and
decorative ornaments, or you may
easily get caught by the control lever
or other protruding parts.
• Never let the long hair outside of the
safety hat, or you may be entangled by
rotating parts.
• If required, wear a hard hat, safety
glasses, safety shoes, filter mask and
gloves when operating or maintaining
the equipment.
• Check all protective devices for proper
functions prior to operation.
• Never listen to the radio or wear music
earphones when operating, or it will
easily attract your attention and cause
accidents.
Working around noise for a long time will

cause damage or failure to hearing. When the
roller with no cabin is used or the noise on the
worksite is beyond 85 dB, please wear the
audition protection device as earplugs. This
would reduce the damages to human ears.

2.3.5 Precautions against emergency

Fully read the operation regulations and local
driving laws, mastering the meaning of signal,
gesture, symbol, and notification. Before
driving the roller, it is forbidden to take excitant
drink or drugs.
Find out the places placing fire extinguisher,

emergency apparatus, and alarm telephone as
well.
Avoid commonsense accidents. If accident

occurs, try to adopt effective measures rapidly.
First of all, it is most important to guarantee the
personal safety, and then, consider reducing
losses of goods and materials.
2.3.5.1 Use the emergency stop switch

correctly
NOTICE
The emergency stop switch should not be
used as a brake switch normally. Or it will
shorten the service life of the engine and
other important parts.
When an emergency incident happens, the

operator can press down the emergency stop
switch immediately to stop the roller. The
switch is installed on the side box.
When the incident is eliminated, the operator

can release the switch by rotating it clockwise
and start the roller again.
Fig.2-15

2.3.5.2 Evacuation in fire accident

Evacuate the equipment with the following
methods in case of fire accident
1. If time is sufficient, move the travel control
lever to STOP position, turn the park brake
switch (on the panel) to P position, and turn
the key swith to P/O position. Remove the
key.
2. Evacuate the equipment.
3. Use the fire extinguishe .
Fig.2-16
If time is insufficient, press down the emergency

stop switch and evacuate the roller. Then use
extinguishers or call fire fighters for hel
Fig.2-17
2.3.5.3 Touching high-voltage lines
When working near high-voltage lines, the
operator should take extreme care. If the roller
touches them during traveling, take measures
as follows.
• Never leave the operator’s seat.
• Warn other people to stay away from the
roller.
• If possible, drive the roller away from the
dangerous area.
• Cut off the power supply of the roller.
Fig.2-18

2.3.5.4 Falling object protection
If at a worksite the cabin has the danger of

being hit or invaded by falling objects and
scattered materials, protective cover must
be used to protect operator according to the
operating condition.
Fig.2-19
2.4 Precautions During Operation

2.4.1 Safe starting
2.4.1.1 Safe mounting
When you mount or dismount the equipment:
• Always face the roller and maintain a three-
point contact (one hand and two feet or two
hands and one foot).
• Never jump on/off the roller. Never mount a
moving roller.
• Never use any control lever as a handrail.
• Remove the mud, oil dirt and water from
pedal, handrails and shoes at any time.
2.4.1.2 Seat adjusting

Uncomfortable seat position can easily lead to
operator fatigue and operating mistake.
The seat position should be adjusted upon

change of operator.
Leaning against the back of seat, operator shall

be able to operate the control lever properly.
Otherwise, the seat should be readjusted by
moving it forward or reverse.
Fig.2-20

2.4.1.3 Seat belt

In case of tipping-over of the equipment, the
operator could be injured or thrown out of the
cabin, or be crushed by roller, causing serious
injury or death. Before operating the roller,
check the buckles for seat belt and fastening
fittings carefully. In case of any damage or
wear, the seat belt and other attachments
should be replaced prior to operation. When
the equipment is running, be seated in
operator seat and fasten your seat belt to avoid
accidents.
The seat belt should be replaced every three Fig.2-21

years regardless of its condition.
2.4.1.4 Before starting the engine
Before starting your daily work, the following

items are to be observed prior to start of the
engine.
• Check the levels of engine oil, hydraulic oil
and coolant.
• Check if the lubrication points are lubricated
properly.
• Check air filter for blocking

• Check wires for damage.
• Set all control switches and levers to "0"
positon or "NEUTRAL"position except the
emergency stop switch.
• Adjust the seat to a position easy for
operation; check seat belts and buckles for
damage and wear.
• Adjust the rearview mirrors so as to
see clearly from the driver's seat what is
happening behind the roller.
• Clean the windows to ensure a good vision.
• Clean the headlights and work lights, and
check them for regular functions.

Table 2-2 Diagram of Lubrication Points on Single Drum Roller
Note: Those lubricants are recommended for

normal temperature. Proper liquid types should be
selected according to different environment
temperature.
2.4.1.5 Engine starting
Before starting, be sure there is nobody

under or around the roller. Sound the horn for
warning.
• Start or operate the roller in a seated
position.
• No one is allowed to stay on the roller
except the operator.

• Never start the engine if you think there

could be a short circuit, which is dangerous
and can cause damage to the roller.
To understand proper starting steps of the

roller, see: Section 4.4 "Engine Starting" on
page 4-11.
In cold weather, sufficient warm-up operation is

necessary. Incomplete warm-up may result in
slow reaction and accidents.
Before starting, check the battery to see if its

electrolyte is frozen or leaks. In case of frozen
electrolyte, never charge the battery.
The use of jump-start must be carried out

according to the instructions in operation
section. See:Section 4.4.2 "Jump-start" on
page 4-11. Improper operation can lead to
battery explosion or roller out of control, hence
personal injury and death.
NOTICE
Never use the jump-start personally. Or
it may lead to serious accident. Contact
SANY distributor when necessary.
2.4.1.6 After starting the engine
WARNING
Prior to operation, be sure you can properly
control the speed, direction, braking,
turning and working mode of the roller.
Roller out of control can cause serious
injury or death.
Observe the pressure gauges, instrument and

warning lights to ensure they are properly
functioning, with all readings within specific
ranges.

2.4.2 Safe operation

2.4.2.1 Surveying the worksite in advance
WARNING
The roller may roll over when working at
the ditch edge or on road shoulder, which
may result in serious accidents.
Check the worksite and road conditions in

advance to prevent the roller from overturning,
or even the ground, material stockpile or bank
from collapse. Reinforce the ground, ditch edge
and road shoulder according to requirements
and keep a certain distance between the roller
and the ditch edge or road shoulder. Formulate
a working plan and use the roller applicable to
the work and construction site.
Fig.2-22
For the multi-roller operation, the united signals

are required to be applied. Appoint a signalman
to organize the operation, and make sure all
workers obey the guide of the signalman. A
signalman is also on demand when working on
a slope or on a road shoulder.
Fig.2-23
Keep especially alert when working on an icy
road, since the rise of the ambient temperature
will make the foundation soft and slippery.

NOTICE
Never run the roller on a slope or a muddy
road beyond its allowable gradeability. Or
it will affect the service of the engine.
See:Section 7.2 "Specifications of the

Equipment" on page 7-2 for the roller's
gradeability.
Fig.2-24
Don’t operate the roller on the ground not
solid enough or with holes. Never start up
and operate the roller in a combustible and
explosive environment. For example, avoid
operating it in a narrow or unventilated space.
Keep good ventilation in any conditions.
Make sure when the vibratory roller is working,

there isn’t any vulnerable building and
equipment around. The damage caused by
the vibratory roller can affect certain distance
range.
If the rolling materials will induce dust, install

ventilation devices, water the pavement or
wear a gauze mask.
2.4.2.2 Before operation
Test the roller before operation.

• When conducting inspection, move the
equipment to a spacious area without
barriers and operate slowly. Any other
person is not allowed to approach the
equipment.
• Check the roller for abnormality such as
abnormal noise, vibration, smoke, odor or
gauge reading and leakage.

• When the travel control lever is at the

"STOP" position, move the throttle switch
to test the engine's speed and then operate
the lever to check the machine works
normally.
Fig.2-25
• Fully understand the working mode of the

roller.
• In case of any abnormality, stop operation
and take corrective measures immediately.
NOTICE
When hearing abnormal noise, first check
the noise to see if it comes from inside. If
it really comes from inside, shut down the
roller immediately, or it may lead to further
fault.
2.4.2.3 Safe traveling
When driving the roller, the operator should

observe the following provisions:
• It’s forbidden to carry people on the roller
except the operator.
• It’s forbidden to mount or jump off a moving
roller.
• Operate the equipment only on the
operator’s seat. Keep the seat belt fastened
and the cabin door closed during working.
• Do not adjust operator’s seat when driving.

• Sound the horn to warn persons around,

and make sure there’s no person or
obstacle nearby.
Fig.2-26
• The driving speed should match the

working condition. When the road is
flat and straight, high speed is allowed;
when the road is getting worse, the low
speed is demanded.
• Do not operate the machine continuously
for more than one hour at high speed (rabbit
gear), otherwise the machine can only work
at low speed (tortoise gear) or stop at least
20 minutes.
Fig.2-27
• Only when the roller is stopped can the
operator change the gear.
• When traveling on a slope, make sure
the degree of the slope is not beyond the
roller's allowable gradeability. See: Section
7.2 "Specifications of the Equipment"
on page 7-2 for more details.
Fig.2-28

• When driving on a slope, it's only allowed

to drive upward or downward in a straight
line at a low speed. Traveling across a
slope is prohibited.
• Do not run the machine on a slope at high
speed (rabbit gear). On a slope, the control
lever should be operated slowly to drive the
machine.
Fig.2-29
• When danger occurs, press down the
emergency stop switch immediately. Do
not use the emergency stop switch as the
normal brake. The emergency stop switch
should only be used in an emergency.
• Restart the equipment only after the danger
is eliminated.
Fig.2-30
• Do not apply P（Parking）knob before the
machine stops completely.
• In poor visibility conditions, turn on the work
lights for clearer vision.

2.4.2.4 Safe turning
When making turning, the operator should

• When changing direction, make sure there
is no person near the center articulation
frame.
Fig.2-31
• Only when the roller is at the low speed
can the operator change the direction.
• Don't make any abrupt turning.
2.4.2.5 Safe vibrating
When the roller starts vibrating, the operator

should observe the following provisions:
• Never start vibration without traveling.
• Never start vibration on hard ground.
• Take the nearby buildings and underground
facilities into consideration before vibration.
• Don't start vibration on sloppy road, for it
will increase the danger of side sliding.
• When compacting the road edges adjacent
to pavement, ensure that more than 2/3
part of the drum is on the road compacted
previously.
Fig.2-32

• Only when the roller stops vibrating can

the operator change vibration frequency or
working mode.
Fig.2-33
2.4.3 Safe parking
2.4.3.1 Requirements for parking area
When parking the roller, the operator should

• Try to park the roller on flat and solid
ground.
• Try to park the roller indoors, avoiding
direct sunlight and precipitation.
• If it is required to park on a slope, make
sure that the gradient of the slope is not
beyond the roller's gradeability. See:
Section 7.2 "Specifications of the
Equipment" on page 7-2 for more details.
• If parking the road roller in the open air
in rain or snow, please protect the control
console and the instrument panel in the
cab with waterproof covers.
2.4.3.2 Parking rules
• Follow the parking steps to park the roller.

See : Section 4.9.2 "Park brake" on page
4-15.
• Do not park the machine on a slope. If
unavoidable, operate the control lever until
the machine stops completely, and then
apply P knob for parking brake, and take
measures to prevent sliding. The gradient of
slope should be within the allowed scope.
Fig.2-34
2.5 Maintenance Precautions

2.5.1 Basic rules
• It is forbidden to use a damaged roller or
the one with potential troubles.
• Only the qualified and authorized aintenance
staff can maintain the equipment.
• Observe the maintenance regulations,
including spare parts replacement.
2.5.2 Lockout/Tagout procedures

Only authorized employees performing repairs
on the roller shall perform Lockout/Tagout in
accordance with the procedure listed below.
DANGER
If the employee performing repairs to the roller
is issued a lock and key, the employee shall
not share the lock or key with other employees
until all repair procedures are complete and the
machine is ready to put back into service. NO OPERATION
The following steps shall be performed in the
sequence listed when the roller is to be locked
out and tagged-out for service or repair.
Locking out of service Fig.2-35
• Notify all employees who may be potentially

affected by the repair or maintenance on
the roller.
• Secure the machine in a safe position. Set
the park brake switch to "P" position (See
Fig.2-16 on page 2-14).
• Identify, remove or disconnect all power
or energy sources and be sure to install a
Lockout/ Tagout device on them.
• Be sure all employees involved in the
repairs have installed the lock on the power
source before performing any repairs. Once
an employee has completed the repair
procedure, they must remove the lock and
not access the roller in any manor.

Returning to service
• The authorized person who performed the

lockout/tagout procedure shall check the
area around the roller to ensure that no one
is exposed to any hazard before start-up.
lockout/ tagout shall ensure that all guards
have been reinstalled to their proper
place, all tools and equipment have been
removed and all locks are removed.
lockout/tagout shall verify that all controls
are at the "NEUTRAL" or “0” position and
all personnel are aware of the time the
roller will be back in service.
• Remove the Lockout/Tagout mechanisms
and all tags and re-energize the roller for
return to service.
2.5.3 Working area preparation
CAUTION
If a clean, tidy working area cannot be
guaranteed, there would be danger of
tipping, thus resulting in personal injury.
• For maintenance work, select a clean flat

area with plenty of space, ample sunlight
and good ventilation.
• Clean the working area by removing fuel,
lubricant and water, and covering slippery
ground with sand or other absorptive
materials.

2.5.4 Washing the equipment

When washing the equipment, always do as
follows.
• Wear non-slip shoes to prevent yourself
from slipping on the wet surface.
• When using high-pressure steam to
wash the equipment, always wear protective
clothing.This will protect you from being
hit by high-pressure water, and cutting
your skin or getting mud or dust into your
eyes.
• Never spray water directly onto the electrical
system (sensors, connectors). If water gets
into the electrical system, there is danger
that it will cause defective operation and
malfunction.
2.5.5 Self-preparation
Only approved personnel can maintain or repair
the equipment. An observer could be assigned
if necessary.
Wear protective clothing and shoes necessary

for the job.
• Wear rubber apron and rubber gloves when
handling corrosive materials. Wear heavy
gloves when handling wooden materials,
wire ropes or sharp-edged metals.
• Wear a face shield when removing spring
or elastic parts, or adding acid to battery.
• Wear safety hat and goggles when you weld
or cut with a torch.
• Never carry out grinding, flame cutting or
welding without aspirator and ventilation
equipment.

2.5.6 Proper tool

Use proper tools and use them correctly. Using
damaged, inferior, defective, temporary tools or
using the tools incorrectly could lead to serious
accidents.
Be careful when using the following kinds of

tool.
• When using a spanner to disassemble
bolts and nuts, please refer to the torque
table (See Table 5-1 on page 5-6 and
Table 5-2 on page 5-7).
• When using instruments, please follow
their instructions. Fig.2-36
• When using gas cutting or gas welding

equipment, make sure that the work
won't lead to explosion or cause the
precise parts to lose precision.
• When using grinding wheel to burnish
parts, it is prohibited to stay at the
tangent direction of the grinding wheel.
2.5.7 Maintenance with engine running

In most cases, the engine should be shut down
prior to the maintenance work. If maintenance
has to be done on a running engine, there
should be at least two people handling the
maintenance according the following rules.
• One person should always be seated in
operator's seat and ready to shut down
the engine at any time. All personnel must
keep in touch.
• Place the travel control lever to "STOP"
position in order to prevent movement of
work equipment. If it must be used, send
signal to others and warn them to move
quickly to a safe area.

• Pay special attention to rotating parts like

fan and conveyor belt, people may get
caught by them when staying close.
Fig.2-37
• Never leave or insert any tool or other
objects in fan or conveyor belt, which may
cause the parts to break or fl .
2.5.8 Working under the roller

• No maintenance shall be carried out before
the roller is well supported. Ensure that the
the roller and its accessories are safely,
stably and reliably supported.
• Never use bricks or wood blocks to support
the roller.
• Never use the device which may slide to
support the roller.
• Never use slag bricks, hollow tires or
shelves to support the roller, as they may
Fig.2-38
collapse under continuous load.
• If the roller or the accessories must be
raised up for maintenance, the roller or
its working device shall be supported with
multiple jacks or iron columns.

2.5.9 Working in noisy environment

If noise of the roller is too big, it will cause
permanent or temporary hearing disability.
When maintaining the engine, wear ear covers

or ear plugs if you have to work in noise for a
long time.
2.5.10 Removing paint before welding

Fig.2-39
or heating
• Poisonous gas will be produced by paint
heating during the fusion welding, soldering
or gas torch application.
• Remove the paint outdoors or in the places
with good ventilation.
• If using sand paper or grinding wheels to
remove the paint, wear a qualified respirator
to protect yourself from inhaling dust.
• If the solvent or the rust remover is used,
the paint and solvent shall be handled in a
proper way. Wait for at least 15 minutes for
volatilization of volatile gas before welding
or heating.
2.5.11 Correct welding

The correct welding procedures must be
used to protect the electronic control and the
bearings from being damaged. When carrying
out welding on the roller equipped with the
electronic control, comply with the following
procedures:
• Stop the engine, and remove the key after
turning the key switch to the “O” position.
• Remove the negative cable of the battery.
Never use the grounding point of electric
spare part (including electric control
modules or sensors) as the grounding point
of the electric welder.
• Clip the components to be welded with the

grounding wire clamp of the welder. Set
the clamp near the welding point to make
sure the current flow is away from the key
components, such as transmission system
bearing, hydraulic parts, electrical parts,
and so on.
• Protect the wire harness from contacting
scraps and splashes produced during the
welding.
• Weld the materials together by following
standard welding process.
WARNING
If welding or other operations inducing
abundant heat or open fire are required,
oil in the oil tank should be drained out
completely, and dry it as well. Or it may
catch fire during welding, and endanger
the worker's safety.
CAUTION
Welding near the plastic and rubber
materials is forbidden, such as, near the
scraper made by polyurethane, for toxic
fume will be produced and it will do harm
to the worker's health.
2.5.12 No heating beside hydraulic

pipeline
• Heating beside the pressure pipe will produce
combustible spray, which may cause the
operator and the bystanders to be seriously
burned.
• Fusion welding, soldering or usage of gas
torch beside hydraulic pipeline or other
combustible materials are not allowed.
• When the heat goes beyond the direct
combustion area, the hydraulic pipeline
Fig.2-40
may be cut off at any time. Establish

a temporary fire protective sleeve when
performing fusion welding or soldering to
protect hoses or other materials.
2.5.13 No heating the pipes with

combustible liquid
• Welding or gas cutting of the pipeline or
hose with combustible liquid is not allowed.
• Remove the combustible liquid completely
with noncombustible solvent before welding
or gas cutting the pipeline.
2.5.14 Correctly operating the hydraulic

system
• Periodical maintenance to the hydraulic
system is very important. The hydraulic
system of the roller works under high oil
pressure, small damages and cracks at
the rubber hose and the adaptor will cause
disastrous results. As the hydraulic tube is
made up of rubber, cracks will appear after
a certain period; in any circumstances, if the
service life of the rubber tube is uncertain,
replace it with a new rubber hose provided
by SANY.
• Never fill oil directly to the hydraulic oil tank,
otherwise the cleanness of the hydraulic
system may be influenced, and the valid
life of the equipment may be reduced!
When filling the hydraulic oil tank, use a
filtering equipment with a filtration precision
of 10µm.
• Make sure the pressure control valve is
set correctly. High pressure will result in
hydraulic line leakage. Low pressure will
result in difficult operation of the rolle .
• Adjustment of the system pressure, main oil
pump as well as assembly, disassembly
or replacement of the valve block only can
be done under the instruction of a hydraulic
engineer or an after-sales engineer.

Unauthorized persons are forbidden to
adjust by themselves.
• As the rubber hose is an easily-corrosive
product, do not store it for a long time.
• When dismantling the oil pipes, close the
port and keep the hydraulic pipeline clean.
• Check the filter element frequentl .
• The hydraulic parts are essential to the
system. Use the original hydraulic parts
produced by our company.
2.5.15 Being aware of high-pressure

liquid
• The hydraulic system may still have pressure
even when operation has been stopped;
such liquid as diesel oil and hydraulic oil
spurting out under pressure may penetrate
the skin or eyes resulting in serious injury,
blindness or even death.
Fig.2-41
• Release pressure before disassembling the

hydraulic parts or other pipelines to avoid
such dangers caused by high-pressure
liquid.
• Fasten all joints before pressurizing.
• Wear protective goggles, masks and gloves
when checking the hydraulic system. Use
cardboard when checking for leaks.
Fig.2-42

• Protect your hands and body from contacting

with high-pressure liquid. If the hydraulic liquid
spatters onto the skin or into the eyes, seek
medical care immediately.
• If any liquid jets into skin, remove it within
several hours by surgical treatment from a
professional surgeon.
2.5.16 Regularly replacing the rubber

hoses
• Rubber hoses with combustible liquid may
break under pressure due to aging and
excessive abrasion. The ageing and
abrasion of the rubber hoses are difficult to
be judged only through check. Regularly
replace the rubber hose.
2.5.17 Avoiding scald by high-temperature

liquid
• After operation, the coolant in the engine
becomes hot with pressure, and the
water pipes of the engine and the radiator
are full of hot water and vapor. Avoid scald
by possibly jetting hot water. Hot water or
vapor overflowed will result in serious cald.
• Before removing the radiator cover, stop
the engine and let the system cool down.
The radiator cover could only be removed
after the cooling fluid has cooled down Fig.2-43
• The hydraulic oil tank is pressurized after
operation. Release the pressure before
removing the cover.
• The engine, gear and hydraulic oil will turns
hot during operation; meanwhile, the
engine, hose, pipeline and other parts will
turn hot. Check or maintain the equipment
after the oil and parts cool down.

2.5.18 Preventing battery from explosion

• The battery contains toxic and corrosive
sulfuric acid. If the battery explodes, the
electrolyte may spatter into eyes, which
may cause blindness. Always wear goggles
before checking the the electrolyte.
Fig.2-44
• Wear gloves when operating on the battery.
Battery electrolyte is strongly corrosive. If
your clothing and skin are contaminated
by electrolyte, flush immediately with large
amount of water and then seek medical
treatment immediately.
• Don’t charge a frozen battery, which may
lead to explosion. Warm the battery to 16℃
at first
• The gas produced by the battery is easily
explosive; if the battery is very close to
open fire or sparkle, explosion will possibly
occur.
• Take extreme care when installing and
replacing battery so as to avoid short
circuit. When removing the connection
of the battery, first cut off the negative
terminal.
• When charging the battery, first disconnect
the power supply of the charger before
connecting the charger with the cable of
the battery.

2.5.19 Preventing components from

flying out
Since the components may fly out, keep your
body and face away from the valve body to
avoid injury.
Fig.2-45
2.5.20 Safe storage of parts
• The stored parts may fall off, resulting in
severe injury or death.
• Store the parts and instruments properly

to prevent them from falling. Keep children
and other persons away from the storage
area.
Fig.2-46
2.5.21 Safe treatment of liquid

• No smoking when refilling the fuel tank
Fig.2-47

• Stop the engine before refilling

• Refill outdoors
• Store the combustible liquid away from the
places where fire easily bursts out
• Don’t burn or pierce the pressure container.
• Don’t store the oily cloth for it is easily
ignited or easily burns spontaneously.
2.5.22 Safe treatment of chemicals

• Contacting hazardous chemicals directly
will cause serious personal injury. The
chemicals used for this equipment include
lubricant, coolant, paint and adhesive.
• Check and understand the hazardous
character of the chemical before using it. Use
recommended instrument in accordance
with the regulations.
2.5.23 Proper disposal of wastes

• The improper disposal of wastes will en-
danger the environment and ecology. The
toxic substances hidden in the equipment
of SANY involve oil, fuel, coolant, brake
fluid, filter and battery and so o
• Use a leak-proof container to drain fluid.
Never use the container used for food or
drink.
• Never pour waste fluid on the ground, into
the sewer or any water sources.
Fig.2-48
• Consult the local environmental protection
or recycle center or your appointed distributor
for correct recycle and disposal methods of
wastes.

2.6 Safe Transportation

2.6.1 Load/Unload the roller
When loading or unloading the roller from the
truck or platform trailer, the roller may overturn.
Provide a truck or platform trailer with suitable

size and load to transport the roller.
Precautions during the loading/unloading of the

roller.
• Choose the solid and level ground.
• Adopt a platform or incline.
• Assign a signalman to guide the loading/
unloading of the roller.
• Since it is quite dangerous to steer on the
incline, avoid steering when driving upward
or downward on the incline. If necessary, drive
the roller back to the ground and correct
the direction before driving on the incline.
• Carefully drive over the convex adaptor
between the incline top and the flat plate
• For more details on how to load and unload
the roller, see: Section 4.12.2 "Using a
slope" on page 4-19.
Fig.2-49

2.6.2 Transport the roller

Observe the local laws and regulations when
transporting the equipment by highway.
Wedge the wheels with triangle wood blocks and

fasten the roller with other measures during the
transportation by sea and by road. Besides,
drain the water tank of the diesel engine,
reserve some fuel for loading, unloading and
transportation, and then disconnect the circuit
between the storage battery and the frame.
Fig.2-50
2.6.3 Lift the roller

Small-sized roller can be loaded to the truck by
a crane.
• In any small-sized roller there are lifting
eyes. Use qualified lifting hooks and
ropes appropriately.
WARNING
Improper lifting may cause damage to the
machine, even severe personal injury or
death.
Fig.2-51

• Before lifting the roller, lock the center

articulation frame by a limit plate (A) to
avoid turning.
Fig.2-52
• The total weight of the roller is marked on

the nameplate. When lifting the roller, check
the weight on the nameplate and operate in
consistence with the safety regulations of
the crane.

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SSR200/220 Series Single Drum Roller System functions
System function
3 System functions
3.1 Exterior Components 3-1
3.2 Control Console and Display 3-2

System functions SSR200/220 Series Single Drum Roller
WARninG
operating or servicing the roller. Failure

3 System functions
3.1 Exterior Components
1 2 3 4 5 6
●
产品型号
Product Type
整机质量 kg
Gross Mass
额定功率 kW
Rated Power
生产日期
Date of Production
出厂编号
Number
11 12 10 9 8 7
Fig.3-1
1- Cab (Control console assembly is optional) 7- Rear frame
2- Control system 8- Rear axle assembly
3- Air conditioning system (Optional) 9- Central articulation frame
4- Electrical system 10- Hydraulic system
5- Hood 11- Front frame
6- Power system 12- Vibratory drum (drum with pad foot is
optional
• The above figure shows a machine with the

cab, A/C and smooth drum.
• Client may select operation platform, drum
with pad foot or other optional components
as demanded by construction conditions.
• If the machine is used at an altitude of
2,500m to 4,500m, plateau adaptive
components for the machine should be
selected for such work condition to ensure
normal running of the machine and its
engine.

3.2 Control console and display
4
16
17
2
6 10
3 11
7
12
8
13
9
14
指示灯
15 H
M
L
O OFF
风量开关温控开关
Fig. 3-2
1- Display 10- Turning lamp switch
2- Steering wheel 11- Emergency stop switch
3- Seat 12- Gear selection switch
4- Master power switch 13- Ignition key switch
5- Side control box 14- Parking brake switch
6- Propel control lever 15- A/C panel
7- Vibration frequency selection switch 16- Windshield wiper switch
8- Throttle control switch 17- Dome lamp switch
9- Working lamp switch
If the actual installations are not in accordance
with the figure, take the machine as the
reference.

no.1 Display
1 3 7 6 5 2 16
11
12
13
14
15
8 9 10
Fig.3-3
1- Left turn indicator icon 9- Water temperature gauge

2- Right turn indicator icon 10- Water temperature alarm
3- Operating hours 11- Model and vibration status
4- Engine speedometer 12- Parking brake indicator icon
5- Fuel gauge 13- Brake pressure indicator icon (if any)
6- Fuel level alarm 14- Neutral position indicator icon
7- Engine oil pressure gauge 15- Alarm information prompt
8- Engine oil pressure alarm 16- Functional buttons and icons （F1-F6）

NO.2 Steering wheel

Rotate the steering wheel to the target direction
for the roller steering.
Fig. 3-4
NO.3 Driver's seat

The driver's seat can be adjusted forward and
backward to set proper position. Its backrest
can be adjusted with the lift lever.
Fig. 3-5
NO.4 Master power switch

The master power switch controls the power
supply for the whole roller. Ensure to connect
ON
the master power switch before the engine is
started. Disconnect the master power switch
after daily work has been finished
OFF
Fig. 3-6

NO.5 Side control box
NO.6 Propel control lever

When engine starts, the propel control lever
controls the movement of the roller.
• Position STOP: Roller stays stationary.
• Push forward from position STOP: Roller
drives forward.
• Pull backward from position STOP: Roller
drives reverse.
Distance of the lever from the "STOP"

position determines the speed of the roller.
Fig. 3-7
NO.7 Vibration frequency selection

switch
There are two vibratory compaction
frequencies: high frequency and low frequency.
• Position (Left): High frequency, small
amplitude and small centrifugal force.
• Position (Right): Low frequency, large
amplitude and large centrifugal force.
notice
Before switching the frequency mode,
assure the vibration has come to complete
stop,or it may cause significant impact to
the hydraulic system.
Fig. 3-8

NO.8 Throttle control switch

Turn the throttle control switch to adjust the
throttle. When starting and stopping the
engine, the throttle control switch should be at
the "MIN" position to make the engine idle for
3-5 minutes.
NOTE : If the roller has not been in use for

a long time, the warmup time of the
engine should be properly increased.
During winter, the idle warmup time
should be prolonged to 8-10min. Fig. 3-9
• Position (right): Lights are turned on.

• Position (left): Lights are turned off.
Front working lamp switch
Rear working lamp switch
Fig. 3-10

no.10 Turning lamp switch

When making a turning, the turning lamp at the
turning side should be switched on to inform
other people.
• Position (Left): The left turning lamp is

flicking
• Position (Middle): The turning lamps are
off.
• Position (Right): The right turning lamp is
flicking
Fig. 3-11
NO.11 Emergency stop switch
notice
The emergency stop switch shall not be
used as a service brake, or it will shorten
the service life of the engine and other
components.
• In case of an emergency, press the

switch down to shut down the engine.
Fig. 3-12

• Rotate the switch clockwise to release the

emergency stop.
Fig. 3-13
is in the neutral position, can the

engine be started. Only after the
troubleshooting has been eliminated,
can the roller be started.
NO.12 Gear selection switch

• Low speed: gear Ⅰ (0~3.5 km/h);
gear Ⅱ (0~4.5 km/h)
• High speed: gear Ⅲ (0~5.5 km/h);
gear Ⅳ (0~7.5 km/h).
notice
Before gearshift, assure the vibration has
come to complete stop, or it may cause
significant impact to the hydraulic system. Fig. 3-14

NO.13 Ignition key switch

The ignition key switch is powering on or off
the engine.
• Position (P/O):Stop position. It allows you
to insert or remove the key. The electrical O I
II
system is off and the engine is shut down. P
III
• Position (I): Working position. The control
system and circuits are energized. Keep
the ignition key switch in the "I" position
when operating the engine.
• Position (II): Preaheating position. No
preheating function.
• Position (III): Ignition position. Activates
the starter, and keep the key in the "III"
position. Until engine starts, release the
key immediately after it is started. The key Fig. 3-15
will return to the "I " position automatically.
notice
If the engine does not stop at low idle
speed, the service life of engine will be
reduced. Except for emergency, do not
shut off the engine while it is running at
high speed, otherwise engine components
may be damaged. Each starting time shall
not exceed 10 seconds and the interval
shall be no less than 5min. If it cannot be
started after 3 attempts continuously, stop
starting and find out the cause, or it will
shorten the service life of the engine.
NO.14 Parking brake switch

• Position (Left): Parking brake is released;
• Position (Right): Parking brake is applied.
When parking the roller, operate the propel
control lever to the "STOP" position to stop
the roller slowly. Then rotate the parking brake
switch to the "P" position to apply the parking
brake.
Before starting the roller, assure that the propel
control lever is in the “STOP” position, then
rotate the parking brake switch to the left to
release the brake. Fig. 3-16

NO.15 A/C panel (optional)

The air conditioner is mainly composed of
evaporator, condenser, compressor, heat
exchange valve and control panel. It can be
used for cooling and warming. The control
panel is at the left front side of the cab top, as
shown in the figure
Fig. 3-17
Fan speed control switch: Adjust the fan speed.

• Position (O) : Off.
• Position (L) : Low fan speed.
• Position (M) : Medium fan speed.
• Position (H) : High fan speed.
Indicator
Temperature control switch: Turnit it to adjust
H
COOL
the cooling temperature. M
• Rotate clockwise: Temperature drops. L
O
• Rotate anticlockwise: Temperature rises. Fan speed control switch Temperature control
Indicator: When it is on, it indicates the

Fig. 3-18
compressor has been started and the cooling
system is working.
Four air vents are installed at the rear of the
cab. Operate the switches on air vents to
control the direction of air outlets.

Cooling
1. Start the engine.
2. Turn the fan speed control switch to the "H"
position for about 5 min.
3. Turn the temperature control switch to the
"COOL" position.
4. When the temperature drops to the desired
value, turn the temperature control switch
anticlockwise slowly until the indicator goes
off and the compressor stops. Now, the
cabin temperature is the set temperature.
5. When the cab temperature exceeds this
temperature, the Indicator is lit up, the
compressor starts automatically and the
system starts cooling again until the set
temperature is reached.
notice
When the A/C is in use, never turn the
temperature control switch to the "COOL"
position while turning the fan speed
control switch to the "L" position. This will
lead the evaporator to frost.
NO.16 Windshield wiper switch

In order to get a clearer visibility, the windshield
can be washed by the washer and the front
wiper system.
• Position (Up): The washer sprays water
onto the front windshield and wipers work.
• Position (Middle): The front wiper wipes the
front windshield.
• Position (Down): The front wiper stops
movement.
Fig. 3-19

Every day before you operate the roller, you

must check the water level of this water tank.
Once the water level is less than the 2/3 of
the water tank, it should be fille it up. Assure
sufficien antifreeze agent content.
Fig. 3-20
NO.17 Dome lamp switch

The dome lamp is installed on the top in the
front cab. Its switch is integrated on the lamp.
• Position (ON): The dome lamp is on.

• Position (OFF): The dome lamp is off.
Fig. 3-21

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SSR200/220 Series Single Drum Roller Operation
Operation
4 Operation
4.1 Check before Starting the Engine 4-1
4.1.1 Inspection (walk-around) 4-1
4.1.2 Inspection before Starting 4-1
4.1.2.1 Check the Engine Oil Level 4-1
4.1.2.2 Check the Coolant Level of the Engine 4-2
4.1.2.3 Check the Oil Water Separator 4-2
4.1.2.4 Check the Hydraulic Oil Level 4-3
4.1.2.5 Check the Washer 4-4
4.1.2.6 Check the Air Filter 4-4
4.1.2.7 Check the Tire Pressure 4-4
4.1.2.8 Check the Position of Limit Plate 4-5
4.1.2.9 Check the Vibratory Drum and Dampers 4-5
4.1.2.10 Check the Cables 4-5
4.2 Adjustments Prior to Startup 4-6
4.2.1 Seat Adjustment 4-6
4.2.2 Rearview mirror adjustment 4-6
4.3 Equipment Check Prior to Startup 4-7
4.3.1 Power on the Control System 4-7
4.3.2 Check the Fuel Level 4-8
4.3.3 Check the Propel Control Lever 4-9
4.3.4 Check the Emergency Stop Switch 4-9
4.3.5 Check the Park Brake Switch 4-10
4.3.6 Check other Switches (If Any) 4-10
4.4 Engine Starting 4-11

Operation SSR200/220 Series Single Drum Roller
4.4.1 Normal Start 4-11

4.4.2 Jump-start 4-11
4.4.3 Engine Start in Cold Weather (optional) 4-11
4.5 After Engine Starting 4-12
4.6 Test Running 4-13
4.7 Travel Operation 4-13
4.7.1 Travel forward 4-13
4.7.2 Travel backward 4-13
4.8 Vibration Operation 4-14
4.9 Parking Operation 4-15
4.9.1 Service Brake 4-15
4.9.2 Park Brake 4-15
4.9.3 Emergency Brake 4-16
4.10 Correct Driving According to the Road Condition 4-17
4.10.1 Working near Ditch Edge and Road Shoulder 4-17
4.10.2 Working near Buildings Vulnerable to Vibration 4-17
4.10.3 Working on the Slope 4-18
4.11 Check after Each Work Day 4-19
4.12 Transportation 4-19
4.12.1 Transport Vehicle 4-19
4.12.2 Using a Slope 4-19
4.12.3 Shipping 4-21
4.12.3.1 Container Shipping 4-21
4.13.3.2 Non-container Shipping 4-25
WARNING
operating or servicing the roller. Failure

4 OPERATION
4.1 Check before Starting the Engine
4.1.1 Inspection (walk-around)
• Check the motors, cylinders, hoses for
cracks, excessive wear or looseness.
Repair or replace it according to the fact.
• Remove the dirt and debris around the
engine, battery and radiator. Check the
surrounding of engine and radiator for
buildup of dirt. Check the surrounding
of muffler, turbocharger or other hot
components for flammable materials like dr
leaves and thin branches. Remove them if
any dirt or flammable materials are found
• Check for any leaks of coolant or oil around
the engine. Repair it in case of any problem.
• Check the hydraulic unit, hydraulic tank,
hoses and joints for any leaks of oil. Repair
the leaks if any.
• Check the handrails and step for any
problem like loose bolts. Repair it in case of
any problem.
4.1.2 Inspection before starting

4.1.2.1 Check the engine oil level
1. Take out oil dipstick (A) and wipe the oil
off the dipstick with clean cloth. Insert the
dipstick (A) to bottom and then pull it out.
2. Oil level should be between the MAX and A
MIN marks on dipstick. Add appointed
engine oil through filler (B) if oil level is
below the MIN mark.If oil level is above
MAX mark, open the screw plug (C) to Fig. 4-1
drain extra engine oil. Check oil level again.
Fig. 4-2
4-1
CAUTION
If the engine has been just shut down, the
engine oil is still very hot. And you may be
burned by the hot engine oil when draining
the engine oil.
C
Fig. 4-3
4.1.2.2 Check the coolant level of the engine
Open the cover of the radiator when engine
is in cool condition. Generally, the level of A
the coolant is 15 millimeters below the inner
top surface of the radiator. When coolant in
radiator is not enough, fill it with the appointed
coolant (See Table 5-10 on page 5-18) to
the required level.
Check the sealing of the water intake port (A)

and water outlet (B).
B
Fig. 4-4
4.1.2.3 Check the oil water separator
1. Open the hood. The oil water separator (A)

is on the left side of the roller.
2. T h r o u g h t r a n s p a r e n t c o v e r ( B ) y o u
can observe water level and volume of
sediment. In case of water or sediment built
up at bottom, place a vessel under drain A
hoses (C) to receive drainage.
3. Open drain valves (D) to discharge water.
4. When fuel is seen coming out of the drain
hoses, close the drain valves immediately. B
Besides, check the hoses and pipe connector for C D

looseness to avoid the air going into the pipeline.
Fig. 4-5
DANGER
Never maintain the fuel system near an
open flame or while smoking. Failure
to follow this rule will result in death or
serious injury.

4-2
4.1.2.4 Check the hydraulic oil level
The hydraulic oil tank is welded on the right

side of the rear frame. A level meter (A) is
mounted on the hydraulic oil tank to show the A
level in the tank. Normally, the level is about H

2/3 of the level meter.
L
B
Fig. 4-6
When the level is higher than the mark "H",

take the following steps to drain the extra
hydraulic oil.
1. Clean around the hydraulic oil tank.
2. Remove the filter (C)
3. Fill the tank with the appointed hydraulic C
oil.
4. When the level is about 2/3 of the level
meter, stop draining.
N OTE: The oil level will change after startup
of engine, check the level again before
working.
N OTE: The oil level may change as the oil

temperature varies. While in operation,
keep the oil level about 2/3 of the level
meter. Fig. 4-7
CAUTION
• Components and hydraulic oil are still
hot after the engine has been just shut
down. People working on them can
easily get burned. Wait for them to cool
down before working on them.
• When removing the lube filter for oil
filling, turn it slowly to release internal
pressure before removing it.

4-3
4.1.2.5 Check the washer
The container of washer is mounted at the rear

right side in the cab. If the water level is below
2/3, add water fully.
Fig. 4-8
4.1.2.6 Check the air filter
Take the following steps to remove the

accumulated dust.
1. Open the access door at the side of the
covering part, and then the air filter can be
seen.
2. Empty dust by pressing the dust evacuator
(1).
3. Close the access door.
Fig. 4-9
4.1.2.7 Check the tire pressure
Check the tire pressure with a pressure gauge.

The range of tire pressure should be 1.4±0.3
kgf/c ㎡ . When the tire pressure is lower , you
have to charge the tires. The recommended
maximum pressure shall be 1.7 kgf/c ㎡ .
NOTICE
The tire pressure will increase if the tire is
exposed to the sun. Too much charging
will cause the tire to blow.
Fig. 4-10

4-4
4.1.2.8 Check the position of limit plate
Make sure the limit plate for front and rear

frames is unlocked. Then the roller can steer.
Fig. 4-11
4.1.2.9 Check the vibratory drum and dampers
Check the connection of the hydraulic

hoses on the motor and the reducer for the
vibratory drum, and ensure that they are in
good condition. Make sure that there is no
big crack (should be less than 15 millimeters)
on the dampers (shown in Fig.4-12), and the
connecting bolts and nuts are connected firml .
If not, the traveling function will be influenced
Replace the worn dampers.
Fig. 4-12
4.1.2.10 Check the cables
NOTICE
If any fuse burns frequently or any cable
shows the sign of short circuit, contact
SANY distributor to find the cause and
eliminate the trouble. If not, this will affect
the control system chronically.
Check whether the fuse is damaged; whether

the fuse with proper capacity is used; whether
any wire connection is off. Check for loose
terminals. Fix it if any.
Moreover, pay special attention to the cables
when checking battery, engine, start motor and
alternator. Make sure to check for flammable
materials around battery. Immediately remove
them if any.

4-5
4.2 Adjustments Prior to Startup

4.2.1 Seat adjustment
Before operation, the operator should adjust
the seat to get the best comfortable position.
And this will help to alleviate the fatigue. All
the adjustments can be done only when the
operator is seated.
• Forward and backward adjustment
Pull the lever (A) upward, slide the seat to
desired position, and release the lever.
• Backrest adjustment
Lift lever (B), move the backrest to an optimum
position at where operation can be easily
conducted, and release the lever.
Fig. 4-13
4.2.2 Rearview mirror adjustment

Adjust the angle of rearview mirror so that the
operatior can see the rear situations clearly.
Fig. 4-14

4-6
4.3 Equipment Check Prior to

Startup
Before starting up the engine, you need to
check some equipment to see whether they
are in good condition or not.
4.3.1 Power on the control system

In order to check the equipment, first you have
to power on the control system.
1. Connect the master disconnect switch of

power supply. ON
OFF
Fig. 4-15
2. Insert the key, and turn to position "I". So

the control system will be powered on.
O I II
P III
Fig. 4-16

4-7
Fig. 4-17
At this moment, if the parking brake indicator,

the neutral position indicator, the battery
charging indicator and engine oil pressure
indicator light on, while other indicators are off.
This indicates the circuit is ready.
4.3.2 Check the fuel level

If fuel level indicator lamp flashes, it means
the fuel is going to use up. You have to fill the
fuel tank with the appropriate fuel.
Fig. 4-18

4-8
The fuel tank is welded on the left side of the

rear frame. Take the following steps to fill the
fuel tank.
1. Select a good ventilated place.
2. Clean the dust around the fille .
3. Open the cover of fuel tank, and fill the fue
tank with appointed fuel through the filter
net.
4. While the fuel level pointer leaves the "E"
area, the fuel level alarm indicator icon
goes out. When the fuel level pointer gets
the point that you want, stop filling
5. Close the cover of fuel tank. Fig. 4-19
WARNING
When operating on the fuel tank, pay
great attention to the fuel. There is a great
potential to catch fire!
4.3.3 Check the propel control lever

Before starting the engine, the propel control
lever should be placed at STOP position, or
else the roller will suddenly run when engine
is started. And the impact will cause not only
danger to the operator, but also harm to engine
and pump.
Fig. 4-20
4.3.4 Check the emergency stop switch
Before starting the engine, the emergency
stop switch should be released, or else the
engine can not be started.
Fig. 4-21
4-9
4.3.5 Check the park brake switch

Before starting the engine, check the park
brake switch. Make sure that it is rotated to
position "P" and its indicator on instrument/
SYLD lights on. Ensure the park brake is
released before the roller drives.
Fig. 4-22
4.3.6 Check other switches (if any)

Before starting the engine, check the switches,
indicators and working device to see whether
they are in control or not. Fix if any problem
appears.
• The front/back working lamp switch
• The warning light switch (optional)
Fig. 4-23
• The wiper and the washer switches

4-10
4.4 Engine Starting

After checking the items above and eliminating
malfunction, you can start up the engine.
4.4.1 Normal start

1. Turn the key to position "III".
2. Hold the key at position "III".
3. Release the key immediately after the
engine is started. The key will return to
position "I" automatically.
4.4.2 Jump-start
If the batteries are short of energy, you can

start up the engine according to the steps as
follows.
1. Using jumper cable to start engine requires
two persons working together (One is
seated in the operator's seat and the other
handles the battery).
2. Always wear goggles and rubber gloves
when starting a machine with jump start
cables.
3. Jump start only with an energy source of
the same voltage as the stalled machine. Fig. 4-24
4. When using jumper cables, always connect
the positive (+) jumper cable to the positive
(+) battery terminal first. Next, connect the
negative (-) jumper cable to the frame away
from the batteries.
5. Do not allow the jump start cable ends to
contact each other or the machine.
4.4.3 Engine start in cold weather

(optional)
In cold weather, the engine may not be started
as normal because of the low temperature.
At this moment, you can warm up the engine
before starting. Keep the key at the “Ⅱ”gear
for about 10s to preheat. After that, turn the
key to the gear “Ⅲ”.

4-11
4.5 After Engine Starting

After starting the engine, the roller shouldn't
be used to work at once. There should be 3-5
minutes for the engine to run in idling speed.
Turn the throttle switch to the MIN position,

then the engine will run in idle speed.
MIN
Fig. 4-25
Observe the pressure gauges, instruments and
warning lights to ensure they are properly
functioning, with all readings within specific
ranges.
N O TE: A f t e r t h e e n g i n e i s s t a r t e d u p ,
generally the hydraulic oil level will be
lower. If the hydraulic oil level is lower
than 1/2 of the range, stop the roller.
Wait for the engine cooling down, and
then fill the hydraulic oil tank to the
recommended mark.
If any problem appears, rotate the key to

position P/O to stop the engine. Check out and
eliminate the fault.
If everything is ok, turn the throttle switch to the
MAX position to run the engine at rated speed.
MAX
Fig. 4-26
4-12
4.6 Test Running

If all the checking items above are qualified for
working, you can drive the roller to make some
simple movements such as moving forward
slowly, making a turning for testing. Before
testing running, turn the switch to the gear "I"
or "II".
If there is any problem such as abnormal

noise, vibration, smell, smoke, stop the engine
and check faults out. If everything is ok, the
roller can be used to work.
Fig. 4-27
4.7 Travel Operation

4.7.1 Travel forward
Take the following steps to travel forward.

1. Select speed gear according to the road
condition.
2. Push the propel control lever forward from

the neutral position.
CAUTION
It's forbidden to push/pull the propel
control lever without holding the steering
wheel, or this will lose direction control of
the roller and may cause accidents.
Fig. 4-28
4.7.2 Travel backward

Make the same settings as travel forward.
Then pull the propel control lever
backward from the neutral position.

4-13
4.8 Vibration Operation
N OTE: Only when the gear is at the I or II

position, can the roller vibrate.
Take the following steps to vibrate.

1. Choose gear I or II.
2. Choose vibration frequency according to

the working requirements.
• High frequency with small amplitude and

small compaction force
• Low frequency with big amplitude and big
compaction force
Before switching the vibration mode, stop

vibration first
The single drum roller is often used to compact

the foundations of the road. Different vibration
frequency is chosen according to the working
procedure. Generally, the working procedure
could be static rolling, high-frequency rolling,
low-frequency rolling and a final static rolling.
3. Push the propel control lever forward slowly

to speed up the roller.
4. Press down the vibration button to vibrate.
5. After work, press down the vibration button

again to stop vibration.
Fig. 4-29
4-14
4.9 Parking Operation

4.9.1 Service brake
Service brake is used to stop the roller but not
the engine. Service brake should be carried
out before switching speed gears. Take the
following steps to do service brake.
1. If the roller is vibrating, stop vibration first
2. Move the propel control lever slowly to
STOP position.
4.9.2 Park brake

Park brake is used to stop the roller completely.
Apply the park brake on a slope if the roller
needs to be parked. After everyday's work,
park brake will be carried out. Take the
following steps to do park brake.
1. Select an applicable place for parking.
Usually a flat ground is recommended.
2. Do service brake.
3. Rotate the park brake switch to position
"P".
Fig. 4-30
4. Turn the throttle knob to the MIN position

for engine's idle warm-up for 3-5 minutes.
MIN
MIN
Fig. 4-31
5. After 3-5 minutes' idle warm-up, rotate the

key to position P/O,and take off the key.
6. Turn off the master disconnect switch of
power supply. Lock the cabin's door.

4-15
4.9.3 Emergency brake

The emergency brake is used to stop the roller
immediately, and the engine will be shutdown
too. Whenever come across a dangerous
situation, press down the emergency stop
switch at once.
NOTICE
The emergency stop switch must not be
used as a service brake. Or else it will
reduce the engine's performance and
service life.
Fig. 4-32
After the emergency stop button has been

pressed, it is forbidden to start the engine.
Rotate the button clockwise along the arrow in
Fig.4-33 to relieve emergency brake.
NOTICE
Only after emergency has been eliminated,
can you restart the roller. Otherwise it will
cause damage to the roller and human
injuries.
Fig. 4-33

4-16
4.10 Correct Driving According to

the Road Condition
4.10.1 Working near ditch edge and
road shoulder
When working near ditch edge, keep a safe
distance to the edge. If necessary, reinforce
it prior to work. When working near road
shoulder, low speed gear is recommended.
The operator should pay attention to the
traveling direction to avoid destroying the road
shoulder.
Fig. 4-34
Edge
compaction
Fig. 4-35
4.10.2 Working near buildings vulnerable

to vibration
When working near buildings such as
overbridge and subway, generally the operator
shouldn't start vibration to keep them from the
vibration wave.

4-17
4.10.3 Working on the slope

Before working on the slope, survey the
gradient of the slope. When the value of
gradient is beyond the roller's gradeability, the
roller shouldn't be used to work without other
facilities.
While the gradient of the slope is in the range

of the roller's gradeability, the operator can
drive upward or downward in a straight line at
low gear.
Fig. 4-36
Vibration operation would increase the potential

danger of slipping on the iced slope in winter.
Fig. 4-37

4-18
4.11 Check after Each Work Day

• Inspect your roller and check the work
equipment of roller. Check for leaks of oil or
coolant. Repair it in case of any problem.
• Refuel the tank to maximum level.
• Check the engine compartment for any
paper or other debris. Remove them, if any,
in order to prevent fire
• If the ambient temperature is below -35°C,
make sure to drain the cooling water of
radiator and engine (SANY uses the type of
antifreeze liquid that freezes at -35°C).
4.12 Transportation
4.12.1 Transport vehicle
• No matter road or railway transport is
applied, select vehicles with appropriate
volume and loading capacity to transport
the roller. The vehicle must be qualified in
maximum loading capacity, engine power,
brake capability and others. It would be the
best to exclusively transport the product
without other machines each time.
• In transportation, take necessary measures
to avoid sliding and rolling of the roller.
• Keep a certain distance when passing
buildings, bridges, culverts, electric
facilities, etc.
• Use the transport vehicle for long-distance
machine transportation.
4.12.2 Using a slope

1. Use slopes for the loading and unloading
for heavy machines and ensure the slope is
in the best status. Try to use a metal slope
the one has been long laid aside and gone
bad must not be used. The slope shall have
sufficient width and strength to support the
machine and a gradient less than 15%.

4-19
2. Ensure the slope is placed between the

transport vehicle and the ground correctly.
Ensure the slope is not covered with oil,
snow, ice or mud. Ensure foundations are
laid for the transport vehicle.
3. Start the roller. Select the low gear. Adjust
its position to make its front align with the
slope. Drive it onto the transport vehicle
slowly. Place sleepers at the specified
parking position on the transport vehicle in
advance.
Slope spacing
Chock
Fig. 4-38
4. Fasten slings to fix the front and rear
frames.
Fig. 4-39

4-20
4.12.3 Shipping
4.12.3.1 Container shipping
1. Preparation
• Disconnect the washer water pipe from the

cabin. Fix the water pipe at the cab carrier.
• Disconnect the harnesses
• Remove the cover on the mounting bracket
of hood, and disconnect joints connecting
the cab harness and the frame harness.
• Remove the interior trims in the cab (each
at the left and right sides). Reinstall them
after the cab is secured on the carrier.
• Remove the two side plates on the cab
bottom (each at the left and right sides).
Reinstall them after the cab is secured on
the carrier.
• Remove the plates in the cab.
• Remove the connecting bolts between the
cab and cab floo .
• Lift the cab and fix it onto the cabin carrier
with bolts.
(2) Protection of removed extra high and wide

parts
Wrap up the removed interior trim clasp nails,
floor screws, hood screws and cover plate with
bubble film. Place them in the carton together
with the rearview mirror package box. Then put
the carton on the bottom plate of cabin.
(3) Check before protection

Before protection, ensure the roller coating
is qualified and has been dried completely.
Ensure the surfaces are clean, dry and without
any dust, water, oil or rust.
Ensure the fasteners connecting the roller

parts have been treated against rust and are
fixed at their original positions

4-21
2. Protection process
Cleaning - rust-proof treatment to exposed
non-coated parts - protection of engine -
protective coating of complete machine - drying
- partial protection - container loading.
(1) Cleaning
• Use solvent gasoline or paint diluent
to clean the exposed non-coated parts
such as lampshades, fasteners and tube
connectors. Make sure: a. the cloth and
paint brushes to be used are clean; b. the
cleaned parts are clean and without any
dust, rust or other foreign objects.
• After cleaning, dry them with compressed
air or clean soft paper/car cleaning paper.
Carry out protective treatment after 5-10
min.
(2) Rust-proof treatment to exposed non-

coated parts
• Apply anti-rust oil 377-HF evenly to the
exposed plated parts and aluminum parts
such as tube connectors, hydraulic valves,
screws, and the coupling disc seat, primary
filter support and secondary filter support of
the diesel engine.
• Cover the oil cylinder piston rod in advance
and remove the cover after applying
protective coat. Use a piece of clean cloth
dipped with diluent to clean these parts.
After the solvent volatilizes, coat these
parts with anti-rust oil 377-HF evenly.
(3) Protection of engine

Apply protective coat AP1520 to the engine
and the internal surfaces of hood for sealing
in accordance with Article 5.5 in Q/SY 042
025-2008 Specification for the Protection of
Exported Engineering Machinery.
(4) Drying
Dry the coated complete machine.
4-22
(5) Partial protection

Wrap up the control handle and control console
with bubble film and tape. Then place silica-gel
desiccant in the package.
3. Export container loading

(1) Container loading of basic machine
Start the roller. Adjust the engine speed to
1500rpm. Select gear 1. Adjust the roller
position to be aligned with the container
entrance. Drive the roller at a low speed into
the container. Set a sleeper at the sill of the
container for transition. Carefully observe the
distances between the machine sides and the
container to avoid the paint damage caused
by interference. Stop driving when the front
wheels contact with the limit sleeper. At last,
shut down the machine and disconnect it from
the power supply.
(2) Fixing of basic machine

Park the roller at the center in the container.
Set wedge blocks before/behind the drums and
at the points of contact with container. Fix the
wedge blocks with round steel nails. Connect
the fixing hole on the machine with the hook in
container by iron wires. This is to prevent roller
bounce. Set wearable cloth in the fixing hole
for protection.
(3) Container loading and Fixing of cabin

Use a forklift truck to load the cabin together
with the cabin bracket into the container. Then
fix them wit(4) Fixing of removed parts box
Seal the parts box containing the removed

parts. Then put it on the platform at the left
upper corner in the cabin.
(5) Fixing of attached accessories box

Lift the wooden box containing the attached
accessories to the middle under the cabin
bracket with a forklift truck. Then, fix the bottom
wood slats of the box to the container floor with
steel nails.
4-23
(6) Lifting of container with a reach stacker

Use a reach stacker to lift the container stably.
Later, keep the reach stacker stationary and
drive the flatcar to the place just under the
container. Stably lower the container to the
flatcar and fasten it
(7) Delivery: Carry out final check before

Delivery. After getting out of the container, lock
the container door.
4. Oil level standard

Table 4-1 Oil Level Standard
No. Item Standard
1 Hydraulic oil Between 1/2 ~ 2/3 of the level gauge scale
2 Lubricating oil Between the marks Min and Max of the oil dipstick
3 Reducer gear oil Just at the beginning of oil overflow from the overflow outl
4 Diesel oil 1/8 at the electronic fuel gauge
5. Key management
Table 4-2 Key List
No. Name Qty Unit Remarks
1 Ignition key 2 Piece
2 Cabin door key (left and right)
3 Fuel tank key
These 5 kinds of keys are
4 Electric control cabinet key 2 Piece
interchangeable.
5 Battery box key
6 Engine hood key
Total 4 Piece

4-24
4.12.3.2 Non-container shipping
1. Preparation
Before protection, make sure the roller coating
is qualified and has been dried completely.
Make sure the surfaces are clean, dry and
without any dust, water, oil or rust.
Make sure the fasteners connecting the roller

parts have been treated against rust and are
fixed at their original positions
2. Protection process
Cleaning - rust-proof treatment to exposed non-
coated parts - protection of engine - protective
coating of complete machine - drying - partial
protection - handover at the port - shipping.
(1) Cleaning
• Use solvent gasoline or paint diluent to
clean the exposed non-coated parts such
as lampshades, fasteners, tube connectors,
bolts and nuts. Make sure: a. the cloth and
paint brushes to be used are clean; b. the
cleaned parts are clean and without any
dust, rust or other foreign objects.
• After cleaning, dry them with compressed
air or clean soft paper/car cleaning paper.
Carry out protective treatment after 5-10
min.
(2) Rust-proof treatment to exposed non-

coated parts
Apply anti-rust oil 377-HF evenly to the

exposed plated parts and aluminum parts
such as tube connectors, hydraulic valves,
screws, and the coupling disc seat, primary
filter support and secondary filter support of
the diesel engine. Then wrap them up with
polyethylene film (or bags) against wate .

4-25
Cover the oil cylinder piston rod in advance

and remove the cover after applying protective
coat. Use a piece of clean cloth dipped with
diluent to clean these parts. After the solvent
volatilizes, coat these parts with anti-rust oil
377-HF evenly. Then wrap it up with cylinder
sleeve. At last, fasten it with bandage.
(3) Protection of engine

Apply protective coat AP1520 to the engine
and the internal surfaces of hood for sealing.
(4) Protective coating of complete machine

Apply protective wax AP585 to the following
parts: cabin, front frame, rear frame, center
articulation frame, hood, axles, hydraulic
elements, tube connectors, plated parts, and
spare parts without anti-rust oil and made of
anticorrosive materials such as stainless steel,
copper, nickel and chrome.
(5) Drying
Dry the coated complete machine.
(6) Partial protection

• Wrap up the operation box with bubble film
and tape. Place silica-gel desiccant in the
package.
• Seal the electrical connectors with tape
against water. Protect parts of cabin
connectors by the same means.
• Wrap up the 4 lamps at the front and rear
parts of cabin with polyethylene film
• Wrap up the products to be stepped on with
bubble film and tape
• Wrap up the cylinder axis pin with sleeve.
Fix the related parts with hose clamps.
3. Handover at the port

Carry out inspection after the goods arrive at
the port and before shipping. Accept the goods
only after the following conditions are met.
• The overall paint is undamaged.
4-26
• The seals for the rearview mirror carton,

attached accessories box and document
box are intact and undamaged.
• The cabin doors and windows and the hood
are closed and locked.
• The articulation fixing rod is locked
4. Shipping
(1) Equipment shipping
• General cargo ship
Carry out lifting according to the lifting
nameplate. Wrap the steel rope at the lifting
eye with wearable cloth to protect the paint
there. Lift and lower the roller slowly to protect
its structure against damage.
• Roll-on-roll-off ship
For roll-on-roll-off ships, a platform or slope
shall be used to connect the ship and wharf.
The gradient of the platform or slope shall
not exceed 35°.This is to avoid steering
when driving up/down the slope. If steering is
required, drive the machine back to the ground.
After correcting the direction, drive it onto the
slope.
(2) Equipment fixin

Fix the roller with solid pull rods. Wedge the
front and rear drums with triangle timber
blocks. Take other measures to fix the machine
firml . In addition, drain the engine water tank.
Reserve some fuel for dispatch. Disconnect
the circuit between the battery and the frame.
5. Oil level standard

See Table 4-1 on page 4-24 for the oil level
standards.
6. Key management
Complete the key handover procedures. See
Table 4-2 on page 4-24 for the key list.

4-27
E
G
PA
K
AN
BL

4-28
SSR200/220 Series Single Drum Roller Maintenance
Maintenance
5. Maintenance
5.1 Maintenance Information.................................................. 5-1
5.1.1 Checks before maintenance............................................ 5-1
5.1.2 Checks after maintenance or repairs..................................... 5-2
5.1.3 Hour meter reading.................................................... 5-3
5.1.4 Genuine SANY replacement parts....................................... 5-3
5.1.5 SANY approved lubricants............................................. 5-3
5.1.6 Windshield washer flui ................................................ 5-4
5.1.7 Grease.............................................................. 5-4
5.1.8 Oil and filter inspectio ................................................. 5-4
5.1.9 Welding on the machine............................................... 5-4
5.1.10 Inventory your tools and parts......................................... 5-5
5.1.11 Cleaning parts of the machine......................................... 5-5
5.1.12 Adverse work site conditions.......................................... 5-5
5.1.13 Covers and locks .................................................... 5-6
5.1.14 Hydraulic hoses, lines or components.................................. 5-6
5.1.15 Torque values....................................................... 5-6
5.1.16 Notes on maintenance............................................... 5-8
5.1.17 Notes on fuel system................................................ 5-8
5.1.18 Notes on engine performance......................................... 5-9
5.1.19 Notes on hydraulic system............................................ 5-9
5.2 Requirements on use of oil & fluid ........................................ 5-10
5.2.1 Introduction of functional oil & fluid .................................... 5-10
5.2.1.1 Engine oil........................................................ 5-10
5.2.1.2 Fuel ............................................................ 5-10
5.2.1.3 Lubricant........................................................ 5-12
Maintenance SSR200/220 Series Single Drum Roller
5.2.1.4 Grease.......................................................... 5-12

5.2.1.5 Coolant. ........................................................ 5-12
5.2.2 Oil & Fluids Selection................................................. 5-13
5.2.2.1 General requirements............................................. 5-13
5.2.2.2 Requirements of oil and fluid ...................................... 5-15
5.2.3 Filling capacities .................................................... 5-18
5.3 Test Run Instructions.................................................... 5-19
5.4 Maintenance........................................................... 5-20
5.5 Roller Maintenance Locations............................................. 5-21
5.6 Daily Maintenance....................................................... 5-22
5.6.2 Clean. ............................................................. 5-24
5.6.3 Check.............................................................. 5-26
5.6.3.1 Safety, Operation & Maintenance Manual............................ 5-26
5.6.3.2 Operating functions............................................... 5-26
5.6.3.3 Signal, running lights and horn..................................... 5-27
5.6.3.4 Back-up alarm. .................................................. 5-27
5.6.3.5 Brakes(Service and parking)....................................... 5-27
5.6.3.6 Level indicator. .................................................. 5-28
5.6.3.7 Hourmeter....................................................... 5-28
5.6.3.8 Air filter......................................................... 5-28
5.6.3.9 Engine oil level................................................... 5-33
5.6.3.10 Engine coolant level............................................. 5-33
5.6.3.11 Hydraulic oil level................................................ 5-34
5.6.3.12 Fuel level....................................................... 5-34
5.6.3.13 Tires and rims................................................... 5-34
5.6.3.14 Oil leaks........................................................ 5-35
5.6.3.15 Electrical circuit................................................. 5-35
5.6.3.16 Bolts........................................................... 5-35
5.6.3.17 Electrical system................................................ 5-36
5.6.3.18 Engine belt..................................................... 5-39
5.6.3.19 Compressor V-belt............................................... 5-40
5.6.3.20 Engine air intake pipeline......................................... 5-42
5.6.3.21 Crankcase vent line.............................................. 5-42
5.6.3.22 Exhaust manifold................................................ 5-42
5.6.3.23 Muffler lines .................................................... 5-43
5.6.3.24 Oil tank and pipes............................................... 5-43
5.7 Initial 50 Hour Maintenance .............................................. 5-44

5.7.1 Secure the machine for maintenance .................................. 5-44
5.7.2 Change............................................................. 5-45
5.7.2.1 Engine oil........................................................ 5-45
5.7.2.2 Engine oil filter element ........................................... 5-46
5.7.2.3 Fuel filte ........................................................ 5-47
5.7.2.4 Oil water separator .............................................. 5-48
5.7.2.5 Lubricant for drum vibration bearing................................ 5-49
5.7.2.6 Reducer........................................................ 5-50
5.7.2.7 Rear axle....................................................... 5-50
5.7.3.1 Engine belt...................................................... 5-51
5.7.3.2 Compressor belt................................................. 5-51
5.8 Initial 250 Hour Maintenance.............................................. 5-51
5.8.1 Replace-lubricant for drum............................................ 5-52
5.9 Every 250 Hour Maintenance............................................. 5-53
5.9.2 Replace-engine oil................................................... 5-53
5.9.3 Replace-engine oil filter element ...................................... 5-54
5.9.4 Replace-fuel filter ................................................... 5-54
5.9.5 Replace-oil water separator........................................... 5-55
5.10 Every 500 Hour Maintenance............................................ 5-56
5.10.1 Secure the machine................................................. 5-56
5.10.2 Fill................................................................ 5-57
5.10.2.1 Propel bearing.................................................. 5-57
5.10.2.2 Central articulation frame........................................ 5-57
5.10.3 Replace........................................................... 5-58
5.10.3.1 Air filter main/safety element ..................................... 5-58
5.10.3.2 Lubricant for drum. ............................................. 5-58
5.10.3.3 Lubricant for reducer ............................................ 5-58
5.10.4 Check............................................................. 5-59
5.10.4.1 Key welding parts/power train parts................................ 5-59
5.10.4.2 Damper........................................................ 5-59
5.11 Every 1000 Hour Maintenance........................................... 5-60
5.11.1 Secure the machine for maintenance . ................................ 5-60
5.11.2 Check/maintain-A/C (if equipped)..................................... 5-61
5.11.2.1 Instructions for using the A/C...................................... 5-61
5.11.2.2 Maintaining intervals for the A/C................................... 5-62

5.11.3 Replace........................................................... 5-66

5.11.3.1 Oil water separator.............................................. 5-66
5.11.3.2 Hydraulic oil. ................................................... 5-67
5.11.3.3 Hydraulic oil filte ............................................... 5-69
5.11.3.4 Coolant........................................................ 5-70
5.12 Others................................................................ 5-71
5.12.1 Clean-fuel tank..................................................... 5-71
5.12.2 Clean-fuel radiator.................................................. 5-72
5.13 Maintenance for long-time storage........................................ 5-73
5.13.1 Engine............................................................ 5-73
5.13.2 Complete machine.................................................. 5-74
5.14 Antifreezing Maintenance ............................................... 5-75
5.15 Check after Maintenance ............................................... 5-76
WARNING
provided with this machine and before
operating or servicing the machine. Failure

5 MAINTENANCE
5.1 Maintenance Information
Do not perform any maintenance and/or
repairs not authorized in this Safety, Operation
& Maintenance Manual or the Shop Manual
for this machine. Always observe and follow
all safety precautions and use the proper tools
when performing any maintenance procedures.
5.1.1 Checks before maintenance

Observe and understand these points to
ensure your safety:
• Read and understand the Safety section of
this manual — including the Lockout/Tagout
procedure — before proceeding with any
inspection or maintenance procedures.
NO TE: See: Section 2.5.2 “Lockout/Tagout
Procedure” on page 2-26.
• Do not perform any maintenance not
authorized in this operator ’s manual
maintenance section for this machine.
If unauthorized maintenance on this
machine must be done, contact your SANY
distributor before proceeding.
• Avoid working on the machine while the
engine is running unless required to do so
in the procedure. If the engine must remain
running during a procedure, always have
a person in the cabin who can correctly
operate the machine and who is in clear
contact with you at all times.
• Contact your SANY distributor if you are
unable to perform the procedures listed in
this manual or if additional procedures are
required.
• Always use the proper tools when
performing any maintenance procedures.
• Obtain the maintenance record for this
machine before proceeding with any repair
work.
• Always use the maintenance record for

this machine to keep a daily record of the
hour meter reading, then refer to it when
determining your schedule of maintenance
procedures.
• Always use genuine SANY parts, coolants
and lubricants when maintaining this
machine. Failure to do so may result in
premature system or component failure.
• Always use clean “EP” (extreme pressure)
grease when lubricating the machine. Avoid
using low viscosity greases.
• If any access covers must be open when
working on this machine, be sure those
covers are properly supported.
5.1.2 Checks after maintenance or

repairs
Always do the following after performing any
maintenance to the machine.
With the machine running:
• Check for any leakage in the system you
have serviced.
• Be sure there are no abnormal sounds
coming from the engine or hydraulic
system.
• Check for any loose or abnormal movement
in the system you have repaired.
• Check for any overheating of the system
you have serviced.
With the engine off:
• Be sure you have completed all the steps in
the maintenance or repair of the machine.
• If necessary, have a coworker inspect your
work for correct and proper completion.
• Be sure the covers are reinstalled, close
tightly and latch securely in place after
completion of maintenance. Be sure that
any locks are properly latched for security.

• Always inventory your tools, parts used

and nuts and bolts after completing
maintenance to ensure that none of these
items were left on or inside the machine.
Failure to do so could result in unexpected
failure or damage to the machine.
• If any hydraulic components have been
replaced or removed, always bleed the air
from the system before resuming and work
operations. Be sure there are no leaks and
the hoses or lines are not twisted and do
not rub on any other components.
• Complete the maintenance record for this
machine and return it to its permanent
storage location.
• Follow the Lockout/Tagout procedure for
returning the unit to service.
NO TE: See: Section 2.5.2 “Lockout/Tagout
Procedures” on page 2-26.
5.1.3 Hour meter reading

Always keep track of the hour meter reading
on a daily basis. Confirm meter readings with
the required maintenance schedule listed in
this manual.
5.1.4 Genuine SANY replacement parts

Always use genuine SANY replacement
parts when repairing or replacing a part on
the machine. Failure to do so may result in
premature system or part failure.
5.1.5 SANY approved lubricants

Never substitute lubricants or coolants with
aftermarket products. System failure or the
service life of the machine may be shortened.
Always use approved SANY coolants and
lubricants. Never mix lubricants of different
brands. System damage or premature failure
may result.

5.1.6 Windshield washer fluid

Use automotive windshield washer fluid only.
Never use flammable liquids that could ignite
or explode. Never use tap water, dirty water
or fluids that could freeze, clog or damage the
system.
5.1.7 Grease
Always use clean grease when greasing the
machine. Avoid using low viscosity greases.
5.1.8 Oil and filter inspection

Always inspect the drained oils and filters for
signs of metal particles and foreign material.
Contact your SANY distributor for an oil
analysis test if any abnormality is found in the
filter or oil
5.1.9 Welding on the machine

Never weld, cut, drill or grind on the work
equipment, hydraulic system or engine system.
Doing so could cause premature component
failure.
• Disconnect all electronic controllers,
monitors and computer controlled systems
that could be damaged during the welding
process.
• Turn off the engine and ignition key switch.
• Set the battery disconnect switch to the
OFF position.
• Never apply more than 300A continuously.
• Connect the ground cable of the welder no
further than 3.3 ft (1 m) away from the place
being welded. If the ground cable is near an
electrical component, remove or disconnect the
component before welding on the machine.
• Avoid welding near bearings, bushings, seals
or sliding surfaces. The possibility of damage
to these components could result.

• Never use hydraulic cylinder components,

cables or hydraulic lines as a grounding
point. Never weld on hydraulic cylinders,
components or lines or cables.
• Never connect ground on opposite side of
the turntable bearing (Ground on carrier and
welding on the superstructure).
5.1.10 Inventory your tools and parts

After performing maintenance or repairs to
the machine, always take time to inventory
your tools, parts used and nuts and bolts to be
sure none of these items were left on or inside
the machine. Failure to do so could result in
unexpected failure or damage to the machine.
5.1.11 Cleaning parts of the machine

• Never clean the machine with caustic
chemicals or steam cleaners. Damage to
the paint or operating systems could result.
Instead, use mild soaps and a pressure
washer to clean the machine.Always
protect electrical parts when cleaning the
machine.
• Never flood or pressure-wash the inside of
the operator’s cabin. Damage to the cabin
electrical system could result.
• Use only nonflammable cleaning solvents.
Never use caustic or flammable liquids to
clean parts or systems.
5.1.12 Adverse work site conditions

If the machine will be operating under dusty or
adverse conditions, always do as follows:
• Clean the radiator and oil cooler core to
avoid any clogging.
• Clean or replace the fuel filters and air filt
more frequently than recommended later
in this section.
• Check and clean any electrical components
to avoid any accumulated corrosion.

• Check and clean any areas where extreme

heat is present, such as the exhaust system,
manifold and turbocharger.
5.1.13 Covers and locks

When servicing the machine with the covers
open, be sure they are properly supported in
place. Also be sure the covers close tightly and
latch securely in place. If a lock is present, be
sure the lock is properly latched for security.
5.1.14 Hydraulic hoses, lines or components

If any hydraulic components have been
replaced or removed, always bleed the air
from the system before resuming operation.
Be sure there are no leaks and the hoses or
lines do not rub on any other components.
5.1.15 Torque values

Always refer to this table if the tightening
torque value is not listed or specified in the
procedure.
Table 5-1 Torque table for T clamp

Bolts Ti g h t e n i n g t o r q u e v a l u e Location
(N.m)
T clamp φ86-φ95 8±2Nm Cooling system assembly
T clamp φ54-φ67 8±2Nm Cooling system assembly
T clamp φ140-φ149 8±2Nm Air inlet and exhaust system assembly
T clamp φ90-φ114 8±2Nm Air inlet and exhaust system assembly
Clamp φ20-φ32JB8870 8±2Nm Hose of AC system

Table 5-2 Torque table for bolts or screws

Bolts or screws Tightening torque value (N.m) Location
Scr ew M1 0 ×3 0 GB 70.1 12.9 9 0 ± 1 0 Nm Linkage disc seat

Scr ew M1 0 ×4 0 GB 70.1 12.9 7 5 ± 5 Nm Crescent-shaped plate
Scr ew M1 2 ×3 0 GB 70.1 10.9 1 2 3 ± 1 0 Nm Elastic leg
Scr ew M1 2 ×3 5 GB 70.1 12.9 1 5 0 ± 1 0 Nm Coupling
Bolt M 1 2 ×3 5 GB 5783 1 0 .9 1 2 3 ± 1 0 Nm Duplex pump
Scr ew M1 2 ×3 5 GB 70.1 12.9 1 2 3 ± 1 0 Nm Damper
Scr ew M1 2 ×4 0 GB 70.1 12.9 1 5 0 ± 1 0 Nm Vibration motor
Scr ew M16×40GB 7 0 .1 1 2 .9 3 0 0 ± 1 5 Nm Cover
Bolt M10×25GB 5 7 8 3 5 0 ± 5 Nm Fan
Bolt M1 0 ×3 0 GB 5783 50±5Nm Steer
Bolt M 1 0 ×3 5 GB 5783 1 0 .9 75±5Nm Compressor bracket
Bol t M1 2 ×1 3 0 GB 5 7 8 2 90±10Nm Elastic leg
Bol t M 16 ×5 0 GB 5783 1 0 .9 300±15Nm Piston motor
Bolt M1 2 ×2 5 GB 5783 90±10Nm Muffler bracke
Bol t M 12 ×3 0 GB 5783 1 0 .9 123±10Nm Damper
Bolt M1 2 ×4 0 GB 5783 90±10Nm Instrument console
Bol t M 12×40GB 5 7 8 3 10.9 123±10Nm Support plate
Bol t M 12×70GB 5 7 8 2 10.9 123±10Nm Radio
Bolt M 16×1 .5×55GB 5 7 8 6 10.9 314±15Nm Seat of damper
Bolt M 16×1.5 ×6 0 GB 5786 1 0 .9 300±15Nm End cover
Bolt M 16×1.5 ×6 0 GB 5786 1 0 .9 314±15Nm Travel support
Bol t M 16×50GB 5 7 8 3 10.9 300±15Nm Mounting seat
Bolt M16×70GB5782 10.9 300±15Nm Bearing cover
Bolt M20×120GB5782 10.9 570±35Nm Compressor
Bolt M20×130GB5782 410±30Nm Bearing baffl
Bolt M20×160GB5782 10.9 570±35Nm Cabin
Bolt M20×170GB5782 10.9 570±35Nm Cabin
Bolt M20×2×80GB5785 10.9 640±35Nm Bearing seat
Bolt M20×260GB5782 595±35Nm Drive axle
Bolt M24×100GB5782 10.9 1030±70Nm Side plate
Bolt M24×60GB5783 10.9 1096±50Nm Side plate

5.1.16 Notes on maintenance

Read all applicable safety instructions when
you service the roller.
The reliability of roller will be increased and
the lifetime of essential components will be
prolonged with thorough machine maintenance.
The faults result from not observing the
safety instructions will cause more effort than
maintenance work.
During maintenance, you should:
• Completely clean the roller and engine
before maintenance.
• Park the roller on level ground for
maintenance.
• When carrying out maintenance work, shut
down the engine.
• Depressurize the hydraulic lines before
working on them.
• Cut off the battery power supply before
working on the electrical parts.
• Collect the effluent lubricant, coolant and
fuel to prevent contamination.
5.1.17 Notes on fuel system

The service life of diesel engine mainly
d e p e n d s o n t h e f u e l p u r i t y. D u r i n g
maintenance, you should:
• Make sure the engine is free of dirt
and water or the injection parts may be
damaged.
• Never use a galvanized iron barrel to store
fuel.
• Before drawing the fuel out from a barrel,
store the barrel for a long time.
• Prevent the fuel suction pipe from churning
the fuel barrel.
• Never draw the fuel out on the bottom of
the barrel.
• The fuel left at the bottom of the barrel
cann't be used by engine. It is used for
cleaning.

5.1.18 Notes on engine performance

The rate between combustion air and fuel
injection of the diesel engine has been carefully
adjusted. Engine’s performance, temperature
level and the quality of the exhaust gas are
determined by that.
You should consult the service department of

our company or engine manufacturer if the
machine has to work with full load in the thin
air (at high altitude).
5.1.19 Notes on hydraulic system

Keep the hydraulic system from contaminating.
Make sure no dirt or any other dirty substance
enters the system, as even tiny particles may
scratch the valve, make pumps to seize or
block the throttle or guide hole, resulting in high
repair cost.
• If the oil level is found to have dropped
during the daily check, check all lines and
hydraulic elements for leaks.
• Seal the external leakage at once. If
necessary, inform the relevant after-sales
service department for repair.
• Never leave the barrel containing hydraulic
oil in the open air. The water may enter
the barrel through the oil outlet because of
weather changes.
• Use oil filling and filtering devices to refill
hydraulic oil. This device is equipped with
a filter that can filter the hydraulic oil and
prolong the lifetime of the filte .
• Before removing the connector and oil tank
cover, clean them and the surfaces around
to prevent dirt from entering the system.
• Unless it is necessary, do not leave the
oil filler of the hydraulic oil tank open.
Otherwise, the dirt may enter the oil tank.

5.2 Requirements on use of oil &

fluids
5.2.1 Introduction of functional oil & fluids
5.2.1.1 Engine oil
Choose engine oil according to the function
and type. Other engine oil meeting the required
specifications also can be chosen
As the viscosity of engine oil varies with the

temperature, the local ambient temperature
is extremely important for the selection of
viscosity grade.
If the ambient temperature is occasionally

lower than the applicable temperature limit
(for example, using SAE 15W/40 engine oil at
-15℃ ), only the engine cold start capability but
not the engine will be affected.
The multi-grade oil does not require frequent oil

change according to the temperature change.
The synthetic oil is better since it can be
used under higher temperature and it is more
reliable.
The maximum allowable duration for the

engine oil is 1 year. If the oil change intervals
exceed 1 year, the oil shall be changed at least
once a year.
The engine oil used by this machine shall be

changed every 250 working hours. This change
interval is only applicable for engine adopting
diesel oil with sulfur content below 0.5% and in
temperature above -10°C.
When the sulfur content is 0.5%~1% or the

temperature is below -10°C, the oil change
interval should be shortened half. If the sulfur
content is 1~1.5%, the engine oil shall contain
TBN, 12 times more sulfur content, with the
change interval shortened half.

5.2.1.2 Fuel
WARNING
• D o not mix diesel with gaso l i n e ,
alcohol or mixture of gasoline and
alcohol, otherwise explosion will be
caused.
NOTICE
• Fuel quality should be controlled
st r ict ly, othe rwise the wate r a n d
impurities in the fuel system will cause
serious damage to engine pump and
nozzle.
Regular diesel oil meeting national and local
emission standard is recommended.
The diesel oils below are permitted:

• GB252
• DINEN590
• BS 2869: A1 and A2
• ASTM D 975-78: 1-D and 2-D
• NATO Code F-54 and F-75
Refill the tank to avoid running out of oil.

Otherwise, the lube filter and injection lines
need to discharge.
Only commercially available diesel fuel can

be used. Ensure that the sulfur content is less
than 0.5% and no contamination when filling
in. Higher sulfur content has negative effect on
oil change intervals.
To avoid blocking caused by paraffin, only

winter diesel fuel can be used in temperature
below 5 ℃ . The mixture of diesel oil and
proper additive can also be used.

5.2.1.3 Lubricant
Lubricant includes engine oil, gear oil,
transmission oil, hydraulic oil, etc.
The proper viscosity grade is determined not

only by the minimum outside temperature
when the machine is started, but also by
the maximum outside temperature while the
machine is operated.
Parts that are continuously operated should

use the oil with higher viscosity in order to
maintain the highest possible oil film thickness.
5.2.1.4 Grease
Use lithium-based high pressured saponifie
grease.
5.2.1.5 Coolant
Antifreeze of organic acid technology (OAT) is

adopted.
NOTICE
• Do not mix coolant with additives of
different types.
• The protective agent of cooling system
must be disposed environmentally.

5.2.2 Oil & Fluids Selection
5.2.2.1 General requirements
1. SANY special oil and fluids are

recommended.
2. Select oil and fluids with proper quality
grade, technical specifications and viscosity
as per latest standard of related authorities
according to this manual.
3. Failing to use the oil and fluids according
to this manual, machine performance may be
affected and fault may be caused to relevant
parts.
4. To ensure machine performance, oil and
fluids of different brands should not be mixed;
otherwise, sediments or layers may be caused,
which lead to performance degradation or
failure, even fault of machine and parts.
5. Disposal of oil and fluids should comply with
local laws and regulations.
6. Viscosity selection
a. Ambient temperature
Ambient temperature refers to the air
temperature surrounding the machine. Do
check the local temperature and possible
air temperature before selection.
Generally, viscosity selection is based
on the higher temperature in the
standard. When the machine starts, the
max. allowable viscosity under ambient
temperature could be selected. In extreme
cold area, it’s better to use parts heating
system a n d o il a n d flu ids o f h ig h e r
viscosity.

b. Viscosity grade
Proper viscosity depends on the min.
ambient temperature, which is the
temperature for machine startup and
operation.
To determine proper viscosity grade under
the min. ambient temperature for startup
and operation, refer to the “Min. Temp.” in
the following tables. To determine proper
viscosity grade under the max. ambient
temperature for startup and operation,
refer to the “Max. Temp.” in the following
tables. Unless specially specified, the max.
allowable viscosity grade under ambient
temperature should be selected for
machine startup.
For long-term operation, oil and fluids of
higher viscosity should be selected for
transmission and differential, so as to
maintain the thickest film
7. Oil and fluids used under low temperature
a. Before start-up of the machine, ensure
engine oil, transmission oil, hydraulic oil
and other fluids are fully flowing. Take out
the dipstick, check that the oil or fluid flows
down the dipstick easily. Oil or fluid diluted
by kerosene is prohibited.
b. If different oil or fluid is replaced under
low temperature, the filter element should
be replaced too. Otherwise, the filter
element and housing will be solidified.
Drain the oil and fluids in hydraulic cylinder
and pipelines. After replacement, run the
machine to circuit the oil and fluid
c. Select proper viscosity according to this
manual.
d. In case of change of temperature,
change proper oil and fluids according to
this manual.

5.2.2.2 Requirements of oil and fluids
Table 5-3 Engine Oil Under Different Ambient Temperature

Type, quality grade & technical Viscosity grade Ambient temp.（℃）
Part/System
spec. of oil & fluids of oil & fluids Min. Temp Max. Temp.
SAE 0W-20 -40 10
SAE 0W-30 -40 30
SAE 0W-40 -40 40
Diesel Engine Oil
SAE 5W-30 -30 30
Engine crankcase • API CI-4
SAE 5W-40 -30 40
• GB 11122
SAE 10W-30 -20 40
SAE 10W-40 -20 50
SAE 15W-40 -15 50
1. Unless specially specified, this machine adopts Diesel Engine Oil CI-4
15W-40 when delivery. It is specially used for SANY machine with applicable
temperature of -15℃ to 50℃ .
2. For engine with emission of China Ⅱ or Euro Ⅱ standard for off-road
Note machine, API CH-4 or lubricant of higher grade should be used.
3. For engine with emission of China Ⅲ or Euro Ⅲ standard for off-road
machine, API CH-4 or lubricant of higher grade should be used.
4. For engine with emission of Euro Ⅳ standard for off-road machine, API CJ-4
or lubricant of higher grade should be used.
Table 5-4 Gear Oil Under Different Ambient Temperature

Part/System
Industrial Enclosed Gear Oil
(mineral oil) 150 -10 40
• DIN 51517 Part 3-group CLP
• ISO 12925-1 CKD
• AIST 224
• AGMA 9005-E02:EP 220 -5 50
Transfer case/Reducer • GB 5903
Industrial Enclosed Gear Oil (PAO)
• DIN 51517 Part 3=>group CLP 150 -40 50
• NF-ISO 6743-6 Category CKD
• AIST 224
• AGMA 9005-E02 220 -40 50
• GB 5903
1. Unless specially specified, this machine adopts Industrial Enclosed Gear
Note Oil L-CKD 220 when delivery. It is specially used for SANY machine with
applicable temperature of -10 ℃ to 50℃ .

Table 5-5 Automotive Gear Oil Under Different Ambient Temperature

Part/System
SAE 75W-90 -40 30
SAE 80W-90 -20 40

Heavy-duty Automotive Gear Oil
Rear axle • API GL-5 SAE 85W-90 -15 40
• GB 13895
SAE 85W-140 -10 50
SAE 90 0 40
1. Unless specially specified, this machine adopts Heavy-duty Automotive

Note Gear Oil GL-5 85W-140 when delivery. It is specially used for SANY machine
with applicable temperature of -10 ℃ to 50℃ .
Table 5-6 Hydraulic Oil Under Different Ambient Temperature

Type, quality grade & technical spec. of Viscosity grade of Ambient temp.（℃）
Part/System
oil & fluids oil & fluids Min. Temp Max. Temp.
Normal Temperature Hydraulic Oil HM /
L-HM Anti-wear Hydraulic Oil 32 -20 5
• AFNOR NF E 48-603 HM
• ISO 11158 L-HM
• CINCINNATI P68、P69、P70
• EATON-VICKERS M-2950 S、I-286 S 46 -20 10
• PARKER-DENISON HF-0、HF-1、
HF-2
• Q/SH303 0550 68 -15 50
• GB 11118.1
Wide-temperature Hydraulic Oil HV / L-HV
Hydraulic system Low-temperature Hydraulic Oil 32 -30 10
• AFNOR NF E-48-603 HV
• ISO 67434/4 HV
• DIN 51524 P3 HVLP 46 -30 15
• CINCINNATI P68、P69、P70
• EATON(VICKERS) M-2950 S、I-286
S
68 -25 50
• Q/SH303 0661
• GB 11118.1
Aircraft hydraulic oil
• SH 0358 10# -40 5
• Q/SH PRD0476
1. Unless specially specified, this machine adopts Normal Temperature Hydraulic Oil HM
Note 68/L-HM Anti-wear Hydraulic Oil when delivery. It is specially used for SANY machine
with applicable temperature of -15 ℃ to 50℃ .

Table 5-7 Grease Under Different Ambient Temperature

Type, quality grade & technical spec. Speed NLGI Ambient temp.（℃）
Part/System
of oil & fluids with load grade Min. Temp Max. Temp.
EP Lithium-based Lubricating Grease
• ISO 6743-9: L-XBCEB 2
2 -25 50
• DIN 51502: MPF2K-25
• SH/T 0587
Motor spline /
• ISO 6743-9: L-XBCEB 3
3 -20 50
• DIN 51502: MPF3K-20
• SH/T 0587
• ISO 6743-9: L-XBCEB 1 High 1 -30 40
• DIN 51502: KP1K-30
EP Lithium-based Lubricating Grease High 2 -25 50
Travelling bearings/
• ISO 6743-9: L-XBCEB 2
articulated frame Mid 2 -20 40
• DIN 51502: KP2K-25
• GB/T 7323 Low 2 -25 40
Tank Lithium-based Lubricating Grease
/ 2 -50 50
GJB 4364
1. Unless specially specified, this machine adopts the following fluid
a. Motor spline: EP Lithium-based Lubricating Grease 3# With Molybdenum Disulfi e.
It is specially used for SANY machine with applicable temperature of -20℃ to 50℃ .
Note
b. Centralized lubricating device and guide device: Extreme Pressure Lithium-
based Lubricating Grease 2#. It is specially used for SANY machine with applicable
temperature of -25℃ to 50℃ .
Table 5-8 Coolant Under Different Ambient Temperature

Part/System
Antifreeze -35 -30 50
Cooling system
• OAT
(Engine radiator) -45 -40 50
• GB 29743
1. Unless specially specified, this machine adopts Antifreeze OAT -45 when
Note delivery. It is specially used for SANY machine with applicable temperature of
-40℃ to 50℃ .

Table 5-9 Diesel Oil Under Different Ambient Temperature

Type, quality grade & technical Grade of oil (as per Ambient temp.（℃）
Part/System
spec. of oil & fluids condensation point) Min. Temp Max. Temp.
Diesel Oil 5# 8 50
Diesel Oil 0# 4 50
Fuel system Regular diesel oil Diesel Oil -10# -5 50
(Diesel engine) GB 252 Diesel Oil -20# -14 50
Diesel Oil -35# -29 50
Diesel Oil -50# -44 50
1. Unless specially specified, this machine adopts Diesel Oil 0# when deliver .
Note
2. Regular diesel oil meeting national and local emission standard is
recommended.
5.2.3 Filling capacities

Table 5-10 Oil & Fluids Filling Capacities
Part/System Type, quality grade & technical spec. of oil & fluids Dosage (L)
Fuel tank Diesel oil 0# about 300

Reducer Industrial enclosed gear oil L-CKD 220 about 3.3
Diesel engine crankcase about 20
Diesel engine oil CI-4 15W-40
Vibratory drum about 10
Heavy-duty vehicle gear oil GL-5
Rear axle about 20
85W-140
Travelling earings/ articulated
EP lithium-based lubricating grease 2# about 3
frame
Normal temperature hydraulic oil
Hydraulic oil tank about 150
HM 68
Water tank of diesel engine Antifreeze OAT -45 about 40
1. Without special requirements, above liquids are used for this equipment;
Note 2. Proper liquid types should be selected according to different
environment temperature

5.3 Test Run Instructions

The maintenance below must be applied for
the new machine or overhauled engine.
Check the engine oil level twice a day after

every 250 working hours.
According to the load, the engine oil

consumption become normal after running for
100-250 h.
After running for 250h, you should do as follows:

• Check the engine for leaks.
• Tighten bolts on the intake/exhaust pipes,
oil sump and engine base.
• Tighten the screws on the machine.
• Change the oil for drum vibration bearing.
• Change the engine oil. Change the engine
oil filter.
• Change engine fuel filter and fuel-water
separator filter element.
After running for 500h, you should do as

follows:
• Change the oil for drum vibrating bearing.
• Change main element and safety element
of air filter .
• Add lubricant for propel bearing and center
articulation frame.
• Check the condition of key welding parts,
power train parts and damping block. In
case of any damage, repair, adjust or
change them.
• Replace the lubricant in vibratory drum
reducer.

5.4 Maintenance
• The technical maintenance for the roller
is divided into three kinds, namely routine
maintenance, regular maintenance and
one-off maintenance (troubleshooting).
• The intervals regulated in regular technical
maintenance are the same with those
specified in the Engine Use ’s Guide.
• The engine shall be maintained in
accordance with the Engine User’s Guide.
N OTE: The time for regular maintenance is
calculated from the engine start.
Every time after 1000h regular
maintenance, the roller enters
into the next new cycle of regular
maintenance.
Prior to any maintenance, confirm the following

items:
• Place the machine on even ground, shut

down the engine, and remove the ignition
switch key.
• Apply the parking brake switch.
• Ensure all components of the roller cool
down.
• Prepare proper container.
N OTE: Only when the engine running is

required during lubrication and
maintenance, can the engine keep
running.

5.5 Roller Maintenance Locations

The following view is a general guide for
service or maintenance locations on the roller.
NOTICE
Failure to perform the outlined
maintenance listed in this maintenance
section will result in shortened service life
of the machine or a system failure during
operation.
1 2 3 4 5 6
●
产品型号
Product Type
整机质量 kg
Gross Mass
额定功率 kW
Rated Power
生产日期
Date of Production
出厂编号
Number
11 12 10 9 8 7
Fig.5-1
1- Cab 7- Rear frame

2- Control system 8- Rear axle assembly
3- Air conditioning system 9- Central articulation frame
4- Electrical system 10- Hydraulic system
5- Hood 11- Front frame
6- Power system 12- Vibratory drum

5.6 Daily Maintenance
NOTICE
Failure to perform the following
procedures when and how directed
will result in shortened service life of
the machine or a system failure during
operation.
5.6.1 Secure the machine for maintenance

1. Park the machine on a level flat surface,
shut the engine down and remove the ignition
key from the ignition key switch.
2. Set the park brake switch in the ON

position.
N O TE: The park brake indicator icon on the

display will light up when the brake is
指示灯
H
M
L
O OFF
set.
Fig.5-2
3. Follow the Lock-out/Tag-out procedure in

the Safety section of this manual and always
DA
allow the systems time to cool down before NG
ER
proceeding with any service.
D
For detailed information, see: Section 2.5.2 OP O N
ER OT
“Lockout/Tagout Procedures” on page AT
E
2-26.
N O TE: Obtain the maintenance record for
this machine and complete it at the
close of all maintenance procedures.
Fig.5-3
4. With the roller secure proceed with the
following items:
Clean:
• Roller
• Air filter

Check
• Safety, Operation & Maintenance Manual
• Operating Functions
• Signal, Running Lights and Horn
• Back-up Alarm
• Brakes(Service and parking)
• Level Indicator
• Hourmeter
• Air Filter
• Engine Oil Level
• Engine Coolant Level
• Hydraulic Oil Level
• Fuel Level
• Tires and Rims
• Oil Leaks
• Electrical Circuit
• Bolts
• Electrical System
• Engine Belt
• Compressor V-belt
• Engine Air Intake Pipeline
• Crankcase Vent Line
• Exhaust Manifold
• Muffler Lines
• Oil Tank and Pipes
• Drum and Damper (see 4.1.2.9 on page
4-5)
• Air Conditioner (see 5.11.2 on page
5-61)
Drain-Oil Water Separator
Fill-Windshield Washer Fluid

5.6.2 Clean
Clean the roller.
• Remove the mud, sands and gravels on
the roller.
• Remove the sands and mud on the engine
and hydraulic elements.
• Remove the sands on the tires.
• Keep all oil fillers clean
Fig.5-4
N O TE: Do not use corrosive detergent for

cleaning. Non-fiber cloth is
recommended.

Clean the air filter.
1. Unlock the left engine hood door and open

it. For the location of the engine hood.
Fig.5-5
2. Remove the end cover of the air filter.
Fig.5-6
3. Clean the end cover and the dust evacuator.
Fig.5-7

5.6.3 Check
5.6.3.1 Safety, Operation & Maintenance
Manual
Be sure the Safety, Operation & Maintenance

manual is with the machine in the cab (1).
N OTE: If damaged or missing, contact your 1
SANY distributor.
Fig.5-8
5.6.3.2 Operating functions
WARNING
Ensure that no one is on or around the
roller when testing operating functions.
Failure to ensure this could result in
serious injury or possible death.
Check that all functions in the operating cabin

work correctly.
N OTE: See section 3 “System Functions”

in this manual.
指示灯
H
M
L
O OFF
Fig.5-9

5.6.3.3 Signal, running lights and horn

Check all lighting systems, be sure all lights
function properly and are not damaged.
Check the function of the horn, be sure it is
operational.
NO TE: If any component is damaged or

inoperable, contact your SANY
distributor.
5.6.3.4 Back-up alarm
Be sure the back-up alarm works when the

engine is running and the roller is place in
reverse direction.
NO TE: If damaged or inoperable, contact
your SANY distributor.
5.6.3.5 Brakes(Service and parking)
WARNING
Ensure that no one is on or around the
roller when testing operating functions.
Failure to ensure this could result in
serious injury or possible death.
Check all equipment braking systems for

proper operation. Be sure they hold the
machine or equipment in place when applied.
NO TE: If any system is inoperable or shows

signs of poor performance, contact
your SANY distributor.

5.6.3.6 Level indicator

Check the level indicators to be sure it is not
missing, damaged or stuck in place. Be sure
it is operational and moves when the machine
position changes.
N OTE: If it is damaged, stuck or missing,

contact your SANY distributor for
repair.
5.6.3.7 Hourmeter
Be sure the hourmeter display on the main

screen is operational when the ignition key is
turned to the ON position.
N OTE: I f t h e h o u r m e t e r i s d e f e c t i v e ,
damaged or not functioning, contact
your SANY distributor for repairs.
5.6.3.8 Air filter
NOTICE
Maintenance work can be done only after
the engine is shut down. Never start the
engine after the air filter is removed.
Otherwise dust will be drawn into the
engine. And this will badly shorten the
service life of the engine.
NOTICE
Never clean the filter element with
gasoline or hot liquid, otherwise it will
damage the air filter. After cleaning, check
the filter element for damage with a pocket
lamp.Replace the filter element if its paper
dedusting ball or seal lip is damaged.

Replace the main filter element after being

washed for 3 times. And it must be replaced
after one year regardless of operating hours.
After each cleaning, the cover should be
marked with a cross. It is meaningless to clean
the main lter element if it turns black. Replace
it with a new one. The filter element may be
damaged (crack, for instance) by incorrect
operation which will harm the engine too.
When the engine is in operation, if the air filter

warning lamp on the SYLD controller flashes,
you should maintain the air filter.
Fig.5-10
Take the following steps to maintain the air
filter.
1. Open the covering parts. P
NOTICE
Unlock the clamps at the two sides of the
covering parts before opening it, and then
rotate the rotary lock handle anticlockwise
for 90 degrees. Close the covering parts
and then rotate the rotary lock handle
clockwise for 90 degrees to lock it. It is
forbidden to pull down the covering parts Fig.5-11
when the lock handle is in the horizontal
condition.
2. Take off the cover of the air filte .

1 2
Fig.5-12

3. Clean the end cover and the dust valve.
Fig.5-13
4. Carefully pull the dirty air filter main element

out of the air filter housing, then discard the
dirty air filter main element properly. Pull the
main filter element out of the housing carefully
to avoid contact between the filter elements
and the housing.
N OTE: The main filter is installed on the air

intake port for sealing the interior filter
cover. Take off the element with care
to reduce released dust. Doing so will
damage the element and reduce the
efficiency of the air filter system. If
the air filter element is dirty or looks Fig.5-14
abnormal, it is at the end of its service
life. Replace the element with a new
one. Always read and follow the air
fil er manufactures instructions on the
air filter when servicing the air filt .
If the air filter main element shows no
signs of excess dirt accumulation or
if no abnormalities are found, leave
air filter main element in place. The
safety element will be replaced with
the main element together.
6. Check the used main filter element. The
main filter element used can display foreign
particles causing leakage on the sealing
surface. The linear dust on the air side of
the filter may leak. Clear the items before
fixing a new filt .

7. Use dry compressed air (pressure less than

0.5Mpa) to blow along the inside of the
pleats toward the main filter element, and
then direct the compressed air along the
outside of the pleats to blow from interior
to exterior. It's forbidden to clean the main
fil er element by knocking. The safety filte
element is not allowed to be cleaned.
NOTICE
Never adopt the ways of knocking and
tapping to clean the filter element, Fig.5-15
otherwise it will cause the damage to filter
paper.
Only when the air filter alarm sounds,
can you clean the main filter element.
Otherwise, it will shorten service life and
normal use of the main filter element.
8. It's advised to change the main filter
element if it has been cleaned for three
times. Meanwhile the safety filter element
should be changed as well.
9. If the main filter element is damaged, the
main fi ter element and safety element must
be replaced regardless the cleaning times
is three or not.
Fig.5-16
12. Reinstall the air filte .
1. Insert the filter element. See Fig. 5-16
Check the filter element, especially inside face
of opening for damage due to transportation,
clean and improper hold.
NOTICE
Never install a damaged filter element,
otherwise it will lead to engine fault and
shorten service life of the engine.

2. Install the front housing cover and tighten

the mounting clamps. The dust evacuator is
vertically downwards.
Fig.5-17
N OTE: I n h a r s h e n v i r o n m e n t w i t h h i g h
intensity of dust, shorten the
maintenance and change interval.
It is recommended to inform SANY
service personnel of maintaining air
fil er. Customer is responsible for any
consequences caused by his own
wrong maintenance for air filte .

5.6.3.9 Engine oil level
It is important to check the engine oil level on

a daily basis.
N OTE: Be sure the engine is off and has
cooled down before checking the
engine oil level.
The steps for checking engine oil have been
described. See: Section 4.1.2.1 "Check the
engine oil level" on page 4-1.
CAUTION
If the engine has been just shut down, the
engine oil is still very hot. And you may be
burned by the hot engine oil when draining
the engine oil.
5.6.3.10 Engine coolant level
CAUTION
If you try to start a roller that has been
shut down, wait for the engine to cool
down before you check the coolant level
of the engine. Otherwise you may be
burned by the spilling hot coolant. Before
removing the cover, rotate the cover to
release the pressure inside.
It is important to check the engine coolant level

on a daily basis.
The steps for checking the engine coolant level
have been described. See: Section 4.1.2.2
"Check the engine coolant oil level" on
page 4-2.

5-33
5.6.3.11 Hydraulic oil level
CAUTION
Hydraulic oil is hot and under pressure.
Always wait for the machine to cool down.
Failure to do so could result in possible
injury.
The steps for checking the hydraulic oil level
"Check the hudraulic oil level" on page 4-2.
5.6.3.12 Fuel level
The steps for checking fuel have been

described. See: Section 4.3.2 "Check the
fuel level" on page 4-8.
5.6.3.13 Tires and rims

Check all tires (1) for proper inflation,
excessive wear, damaged or cut surface and
foreign matter penetration.
Check the rims for loose or missing lug nuts
and damaged surfaces.
If any problems with the tires or
N OTE: rims are found, contact your SANY
1
distributor for repairs.
Fig.5-18

5.6.3.14 Oil leaks
• Check under and around all sides of the

roller.
Fig.5-19
• C h e c k t h e p u m p , m o t o r, m u l t i - w a y
valve, valve body, hose, flange and other
connections for leakage.
• Check the engine for leakage.
• Check the A/C lines for leakage.
5.6.3.15 Electrical circuit

• Frequently check the harness connectors
for water and oil. Keep them clean.
• Check the connectors and nuts at lamps,
sensors, horn and brake pressure switch
for looseness.
• Check the harness for short circuit, open
circuit and damage. Keep the harness in
good condition.
• Check the wiring in electric control cabinet
for looseness.
5.6.3.16 Bolts
• Check the tightness of bolts on roller
before the first 50 operating hours, and
then check them every 250 operating
hours. See Table 5-1 on page 5-6 for
detailed tightening torque.

5.6.3.17 Electrical system
(a). Battery
WARNING
Explosion hazard! When working on the
batteries do not use open fire, do not
smoke. There is a possibility of explosion.
CAUTION
Wear proper clothes to avoid skin from
erosion by acid when filling acid to the
batteries.
NOTICE
Never leave tools on the batteries.
Otherwise the batteries may become short
circuit and the electric devices may be
influenced.
• The batteries used in the roller are

maintenance-free. You shall fix it on the
roller firmly and check it frequently for
looseness.
• To install the battery, coat the terminals with
a little of vaseline and connect the wire to
positive pole (+) firs and then to negative
pole (-).
• To take out the storage battery, disconnect
the wire from negative pole (-) first and
then from positive pole (+).
The following maintenance helps to prolong

Fig.5-20
the service life:
• Turn off all consuming electrical appliances
(such as ignition key switch, lamp, cabin
illumination light and radio).
• Check the battery open-circuit voltage
regularly at least once a year.

• When the voltage is 24V or less, recharge the

battery at once instead of supercharging.
• Do not use battery in one hour after each
charging.
(b). Battery maintenance procedures:

1. Open the cover of battery case.
2. Clean the battery case.

3. Clean the battery surface.
4. Clean the electrode and electrode clamp,
and coat some vaseline.
5. Check the tightness of the battery. F ig . 5 -2 1
After-sales support requirement:

1. Disconnect the main switch if the machine
is idle for 2 days. You’d better disconnect
the main switch when you shut off the
machine.
2. Regular check the battery terminal for good
connection isolation and anti-oxidation.
3. Start the engine and charge the battery
every 2 months if the machine is idle:
Shut off the current consuming apparatus,
increase the engine speed to over
1500rpm, charge the battery for over half
an hour, and keep a record.
4. Don’t use electric equipment when the
machine is not started; don’t use too many
current consuming apparatuses when the
engine is idling or at low speed.

(c). Electric box
NOTICE
Keep the electric box dry when maintaining
the electric box. Otherwise the control
modules may become damaged.
Take the following steps to maintain the electric

box.
1. Open the door of the electric box.
2. Use a dry brush to clean out the dust

lightly.
Fig.5-22
3. Check the connection of each electric

contact point.
4. Lock the door of the electric box.
(d) Fuse
Fig.5-23
Check the fuse to see whether they are in good
condition or not.
NOTICE
When replacing a new fuse, the capacity
should be right. Otherwise it will melt again or
not easy to melt when circuit is overloading.
This will influence the electric system.

5.6.3.18 Engine belt
WARNING
Work on the V-belt must only be performed
with the engine shut down. Otherwise
people will be badly hurt by the belts.
Check the condition of the engine belt . If

excessive wear happens, replace the engine
belt at once.
When check the tension of the belt, use the

tester for the work.
1. Press the indicator arm (A) of the tester a
into the gap of the measuring scale.
2. Lay the measuring unit loosely onto the
A
back of the engine belt.
NO TE: To measure the engine belt tension

a free length of at least 20 mm is
required.
Fig.5-24
3. Operate measuring unit B with a finger

(I or II or III), until the pressure spring I II III
disengages audibly or noticeably.
NO TE: The indicator arm (A) remains in the

measured position.
Fig.5-25

4. Remove the measuring unit carefully,

without moving the indicating arm.
5. Read the engine belt tension where the

upper edge of the indicating arm intersects
with the measuring scale
LBS
50
100
150
Fig.5-26
Take the following steps to tension the engine

belt .
1. Unscrew the bolt A.
2. Push the tensioner to the left to proper
position.
3. Screw the bolt A tightly.
Take the following steps to replace the

excessively worn belt (See Fig.5-27).
Fig.5-27
1. Unscrew the bolt A.
2. P u s h t h e t e n s i o n e r t o t h e r i g h t t o
disassemble to belt.
3. Replace the new belt and tension it to
proper position.
4. Screw the bolt A.
5.6.3.19 Compressor V-belt
WARNING

Check the V-belt

1. Inspect the entire circumference of the
V-belt visually for damage and cracks.
Replace damaged or cracked V-belts.
2. Check with thumb pressure whether the
V-belt can be depressed more than 10 to
15 mm (0.4– 0.6 inches) between the V-belt
pulleys, retighten if necessary.
Fig.5-28
Tighten the V-belt
1. Slightly slacken fastening screws 1, 2, 3, 4.
1 4
2. Press the compressor in direction of arrow, 2
until the correct V-belt tension is reached.
3. Retighten all fastening screws.
Fig.5-29
Changing the V-belt
1. Slightly slacken fastening screws 1, 2, 3, 4.
2. Press the compressor against the direction
of arrow completely against the engine.
3. Take the old V-belt off.
4. Fit the new V-belt to the V-belt pulleys.
5. Tension the V-belt as previously described.
6. Check the V-belt tension after a running

time of 30 minutes.

5.6.3.20 Engine air intake pipeline

1. Check the T clamp (1) for looseness. In case 1
of loose clamp, tighten it.
2. Check the rubber hose (3) and steel pipe(2)
for damage or leakage. If any, replace them.
1
1 2
Fig.5-30
5.6.3.21 Crankcase vent line

Check the crankcase vent line for leakage or
blockage. If any, do troubleshooting.
N O TE: If any leakage or blockage in the

crankcase vent line occurs, contact
your SANY distributor. It is forbidden
to perform any maintenance on the
engine by yourself. In reference to any
key parts of the engine and the engine
faults, please consult your SANY
distributor. Otherwise SANY bears no
liability. Fig.5-31
5.6.3.22 Exhaust manifold

Check the exhaust manifold for leakage. If any,
do troubleshooting.
Fig.5-32

5.6.3.23 Muffler lines
Check the muffler lines for leakage. If any, do
troubleshooting.
Fig.5-33
5.6.3.24 Oil tank and pipes
Check oil tank and pipes for damage or leakage.
If any, repair or replace them immediately in
accordance with required safety procedures.
5.6.4 Drain-Oil water separator

The check and water draining method for
oil water separator has been introduced. A
See: Section 4.1.2.3 "Check the oil water B
separator" on page 4-2.
WARNING
Don't use open fire or smoking. There is a
possibility of catching fire.
Take the following steps to exhaust.

1. Unscrew the screw (A) on the filte .
2. Operate the manual pump (B) until the fuel Fig.5-34
runs out from the screw (A) without any
bubble.
3. Tighten the screw (A).
5.6.5 Fill-Windshield washer fluid

Check the fluid level and fill it if necessa .
NOTICE
Add antifreeze into the washer fluid to
avoid freezing of the pipeline.
Fig.5-35
5.7 Initial 50 Hour Maintenance
NOTICE
operation.


position.
指示灯
N O TE: The park brake indicator icon on the

M
L
O OFF

set. Fig.5-36
3. Follow the Lock-out/Tag-out procedure in

DA
ER
D
ER OT
“Lockout/Tagout Procedures” on page AT
E
2-26.
N O TE: Obtain the maintenance record for
Fig.5-37
following items:
Change:
• Engine Oil /Engine Oil Filter Element/
Fuel Filter /Oil Water Separator
Element
• Lubricant for Drum Parts /Rear Axle
Check:
• Engine belt/ compressor belt

5.7.2 Change
5.7.2.1 Engine oil
The steps for checking and refilling engine oil
"Check the engine oil level" on page 4-1.
The following steps show how to change the

engine oil.
1. Place the machine on even ground.
Fig.5-38
2. Start the engine and warm up for a while.

Then switch the ignition switch to the "O"
position to stop the engine.
CAUTION
Protect yourself from the engine oil. Since
its temperature is very high, and it will
badly burned you if it spills onto your skin.
NOTICE
C
Never start the engine when draining the
engine oil. Otherwise it will cause damage
to the engine.
Fig.5-39
3. Place a vessel (volume should be more

than 22L) under the engine oil outlet (C).
Remove the plug on the right side of the
rear frame.

3. Screw the plug back. Then fill the appointed

(See Table 5-10 on page 5-18) engine
oil through the inlet (B).
B
Fig.5-40
4. Start the engine and check the plug for

leakage. If leakage appears, screw the plug
again.
5. Shut down the engine. Wait until the engine
cools down, then check the engine oil level.
5.7.2.2 Engine oil filter element

1. Thoroughly clean the outside of the filte .
2. Use a proper tool (belt spanner) to clamp
the filter element
3. Remove the filter element
CAUTION
badly burn you if it spills onto your skin.
NOTICE Fig.5-41
Never start the engine when the lube filter
is removed. Otherwise engine oil will flow
from the pipeline and make the engine lack
of lubrication.
4. Clean the sealing on the filter carrier from

any dirt.
5. Slightly oil the rubber seal on the new filte .

6. Screw up the new filter element by hand

until the seal contacts.
7. Tighten the filter element for another half
turn.
8. Check the filter element for leak
5.7.2.3 Fuel filter
Fig.5-42
WARNING
Fire hazard! When working on the fuel
system do not use open fire, do not
smoke and do not spill any fuel. There is a
NOTICE
The engine must be shut down before
changing the duplex fuel filter! Or
insufficient fuel will be sucked into the
engine, and it will cause the engine to
work inefficiently or even shut down. This
will shorten the service life of the engine.
Take the following steps to change the fuel

filter
1. Put a container under the filter and
disassemble the filter with a special
spanner.
2. Slightly oil the rubber seal on the new filte .
3. Screw up the new filter element by hand
4. Tighten the filter element for another half
turn.
5. Release the air that possibly mixed in the
fuel pipeline by pressing the manual pump
up and down before starting the engine.
Fig.5-43
6. Check the filter element for leaks after a
short test run.

5.7.2.4 Oil water separator
WARNING
NOTICE
The engine must be shut down before Fig.5-44
changing the oil water separator! Or
Take the following steps to change the oil water

separator.
1. Put a container under the filter and

disassemble the filter with a special
spanner.
any dirt.
3. Unscrew the water separator from the filte
cartridge. Fig.5-45
4. Apply a thin coat of oil to the rubber seal of
the water separator (1). 1 2 3
5. Screw the water separator on by hand (2),

until the seal contacts. Oil +1/2
6. Tighten the water separator for another half

turn (3).
Fuel
7. Fill the filter cartridge with clean fuel (4) 4 5 6
Oil
8. Apply some oil to the rubber seal of the
filter element (5) and screw it on by hand, +1/2
9. Tighten the filter element for another half Fig.5-46
turn (6).


fuel pipeline by pressing the manual pump A
B
Take the following steps to exhaust.

1. Unscrew the screw (A) on the filte .
2. Operate the manual pump (B) until the fuel
runs out from the screw (A) without any
bubble.
3. Tighten the screw (A).
Fig.5-47
5.7.2.5 Lubricant for drum vibration bearing
Take the following step to change lubricant.

1. Set the machine levelly.
2. Turn the vibratory drum assembly to set

one outlet on the drum bearing seat at the 2
lowest position.

than 13L) under the outlet. Undo the oil 1
drain plug, oil level plug and packing plate
to drain the oil.
4. Fit them back.

Fig.5-48
5. Rotate the drum to make the place marked
with " " at the middle top in the vertical
direction. Remove all plugs and washers of
the two outlets.
1
6. Fill the drum with appointed lubricant (see
Table 5-10 on Page 5-18) through
the higher outlet until lubricant flows out a
little from the lower outlet. 2
7. Clean the plugs, reinstall and tighten them.
Fig.5-49

5.7.2.6 Reducer (if necessary)

The maintenance for the reducer is mainly to
add and drain lubricant.
Lubricant draining
1. When draining the lubricant in the reducer,
first make the outlet at the lowest position.
than 5L) under the outlet. Remove the plug.
3. After draining the lubricant, screw the plug
back tightly.
Fig.5-50
Lubricant adding
1. When adding lubricant to the reducer, firs
make the oil inlet A at the highest position.
2. Remove the plug A and B.
3. Add appointed lubricant (See Table
A
5-10 on page 5-18) through inlet A.
When oil overflows from the port B, then
stop adding oil.
4. Screw the plug B and A back tightly.
B
Fig.5-51
5.7.2.7 Rear axle

2
Fig.5-52 shows the oil filler and the oil drain
Central reducer assembly and main reducer: 1
• Oil drain: unscrew the plug (3) at the
bottom of the shell to drain oil.
6
• Oil filling: unscrew the plug (4) at the rear,
fill oil through the port (2) until oil flows to
3 4
the oil level port (5) at the rear, screw up
the plug (5) and continue to fill until oil flow
to the hole (4) at the rear of the shell. 2
7
Wheel end
• Oil drain: unscrew the plug on the wheel 5
end cover.
• Oil filling: rotate the wheel end to the
position as shown in the figure and make Fig.5-52

the hole (1) upwards. Fill oil through the

port (6) to the hole (7). Pay attention to the
position of the oil level hole and the shaft
hole of the planetary wheel. The oil level
hole shall be between the shaft holes of the
planetary wheel.
Table 5-11 shows the oil brand, change

intervals and dosage.
Table 5-11 Oil change intervals for rear axle
Item Intervals Oil brand and dosage

Main reducer Every month
Level check Central shell Every month
Wheel side reducer Every 250h Heavy-duty
Main reducer Every 1000h, 50h at first tim 2L vehicle gear oil
Oil chang Central shell Every 1000h, 50h at first tim 10 L GL-5 85W-140
Wheel side reducer Every 1000h, 50h at first tim 4 L×2
5.7.3 Check
5.7.3.1 Engine belt
WARNING
The steps for checking the engine belt

have been described. See: Section
5.6.3.18 "Engine belt" on page 5-39.
5.7.3.2 Compressor belt
WARNING
The steps for checking the compressor belt

5.6.3.19 "Compressor V-belt" on page 5-40.

5.8 Initial 250 Hour Maintenance

1. Repeart all items of daily maintenance.
following items:
Replace:
• Lubricant for drum
5.8.1 Replace-lubricant for drum

The steps for replacing lubricant for drum
5.7.2.5 "Lubrication for drum vibration
bearing" on page 5-49.

5.9 Every 250 Hour Maintenance
NOTICE
operation.

1. Repeat all items of daily maintenance.
following items:
Change:
• Engine oil
• Engine oil filter element
• Fuel filter
• Oil water separator element
5.9.2 Replace-engine oil
CAUTION
NOTICE
Never start the engine when draining the
engine oil. Otherwise it will cause damage
to the engine.
NOTICE
Never prolong the interval for changing
engine oil, otherwise it will shorten
service life of the engine due to corrosion,
carbonation and wear.
The steps for replacing engine oil have been

described. See: Section 5.7.2.1 "Engine oil"
on page 5-45.

5.9.3 Replace-engine oil filter element
CAUTION
NOTICE
Never start the engine after the engine
oil filter element has been removed.
Otherwise engine oil will flow out from the
pipe and it will cause lack of lubrication
for the engine.
The steps for replacing engine oil filter element

5.7.2.2 "Engine oil filter element" on
page 5-46. Each time you replace engine
oil, replace engine oil filter element at the
same time.
5.9.4 Replace-fuel filter
WARNING
NOTICE
changing the duplex fuel filter! Or
The steps for replacing fuel filter have been

described. See: Section 5.7.2.3 "Fuel
filter" on page 5-47.

5.9.5 Replace-oil water separator
WARNING
NOTICE
The steps for replacing oil water separator

5.7.2.4 "Oil water separator" on page 5-48.

NOTICE
operation.
5.10.1 Secure the machine


position.
N OTE: The park brake indicator icon on the

指示灯
H
M
L
O OFF
set.
Fig.5-53
3. Follow the Lock-out Tag-out procedure in

DA
ER
D
ER OT
AT
“Lockout/Tagout Procedures” on page E
2-26.
N OTE: Obtain the maintenance record for

Fig.5-54
following items:
Fill:
• Grease for propel bearing
• Grease for central articulation frame

Replace:
• Air filter main element/safety element
• Lubricant for drum
• Lubricant for reducer
Check:
• Key welding parts and power train parts
• Damper
5.10.2 Fill
5.10.2.1 Propel bearing
Take the following step to fill the propel bearing
with grease: 1
1. Set the machine levelly.
2. Remove the plug (2) on the propel bearing.
3. Fill 2/3 of the bearing chamber with

appointed lithium grease through the oil
cup (1)(see Table 5-10 on Page 5-18),
until you can see oil out of the oil port (2).
4. Fit them back. 2
Fig.5-55
5.10.2.2 Central articulation frame
NOTICE
Regularly grease nipples of the central
articulation frame with grease gun to
secure sufficient lubrication for bearings
or it will cause early dysfunction of
bearings.
• See Fig.5-56 for the location of grease

fittings
• Fill them with appointed grease. See Table
5-10 on Page 5-18.
Fig.5-56

5.10.3 Replace
5.10.3.1 Air filter main/safety element
NOTICE
Maintenance work can be done only after
the engine is shut down. Never start the
engine after the air filter is removed.
Otherwise dust will be drawn into the
engine. And this will badly shorten the
service life of the engine.
• Replace the main filter element after being

washed for 3 times.
• And it must be replaced after working for
500 hours.
• After each cleaning, the cover should be
marked with a cross.It is meaningless
to clean the main filter element if it turns
black. Fig.5-57
• The main filter element must be replaced
with the safety element.
The steps for replacing air filter element have

been described. See: Section 5.7.2.2
"Engine oil filter element" on page 5-46.
5.10.3.2 Lubricant for drum

The steps for replacing lubricant for drum
have been described. See: Section Oil filler/outlet plug
5.7.2.5 "Lubrication for drum" on page Fig.5-58
5-49.
5.10.3.3 Lubricant for reducer

The position and way for replacing
lubricant for reducer are shown in Fig.5-57,
Fig. 5-58 and Fig.5-59.
The oil filler/ outlet is on the circle orientation of
reducer. Oil feeding and draining can also be
realized through the rear part of reducer. Filling
capacity is 3.3L.
Fig.5-59

5.10.4 Check
5.10.4.1 Key welding parts/power train parts
• Check welding parts of the frame and the
drum for crack. If any, weld or repair them.
• Check power train parts for deformation.
• If you shall perform welding work on the

machine, pay attention to protection and
treatment of painting, electrical cables or
hydraulic hoses. If the parts to be welded
is close to the fuel tank, be careful of
catching fire
5.10.4.2 Damper
• Check the damper under the compressed
condition. If necessary, adjust it.
• Check the damper for cracks. If there is

any crack more than 15mm, replace it.
• Check the damper for elasticity. Replace

the cracked or deformed damper.
Fig.5-60

NOTICE
operation.


position.
N OTE: The park brake indicator icon on the

指示灯
H
M
L
O OFF

set. Fig.5-61
3. Follow the Lock-out Tag-out procedure in

the Safety section of this manual and always DA
NG
allow the systems time to cool down before ER
proceeding with any service. D

OP O N
For detailed information, see: Section 2.5.2 ER OT
AT
E
“Lockout/Tagout Procedures” on page
2-25.
N OTE: Obtain the maintenance record for
4. With the roller secure proceed with the Fig.5-62

following items:
Check/maintain:
• A/C
Replace:
• Oil Water Separator
• Hydraulic Oil
• Hydraulic Oil Filter
• Coolant
• Lubricant for Rear Axle （See: Section
5.7.2.7 "Rear axle" on page 5-50)
5.11.2 Check/maintain-A/C (if equipped)

5.11.2.1 Instructions for using the A/C
In order to keep good performance, reliability
and prolong the service life of the A/C, pay
attention to the following items when using the
A/C.
• Maintain the A/C according to the
producer's instructions.
• Before turning on the A/C, first you have to
start the engine. Wait a few minutes for the
engine to work smoothly, then you can start
the A/C and choose the proper fan speed
and temperature. (When the temperature
control switch to "COOL" position, the Indicator
fan speed control should be switch to "H" H

COOL
position to avoid the evaporator to frost. ) M
L
O
• Close the window and doors when using Fan speed control switch Temperature control
the A/C. Save the energy.
• When exchanging the air without opening
the window or doors, you can just turn Fig.5-63
on the fan speed control with the heat
exchange valve closed.
• When cooling, the heat exchange valve
should be closed.
O˝ ˝
COOL
L
Fig.5-64

• When the engine is shut down, the A/

C should not be used for a long time.
Because the batteries may be used up
and will cause difficulty in the next engine
startup.
• During the seasons that the A/C may not
be used, the A/C should be turned on every
half a month and run for 5-10 minutes.
NOTICE
Daily cleaning should be done to keep
the cooling capacity of the A/C in dusty
conditions. Otherwise it will affect the
performance of the A/C.
NOTICE
Never use hot water for cleaning, which
can lead to overpressure and damage the
system.
5.11.2.2 Maintaining intervals for the A/C

(a) Compressor
• Check and maintain it once every two years
generally. Mainly check the inlet/discharge
pressure and the fasteners for looseness
and air leak.
• Disassemble the compressor to check
the inlet/discharge valve for damage and
distortion. If any, repair or replace the
relevant valve.
• Replace the seal ring and shaft seal if the Fig.5-65
compressor is disassembled and repaired.
Otherwise, it may cause leak at the
compressor seal.

(b) Condenser and cooling fan

The condenser is installed behind the radiator.
• Check and maintain them once a year
generally. Clean the condenser plate with
compressed air and cold water; rectify
and repair the radiator gill by a pair of flat
nosed pliers; carefully check the condenser
surface for abnormity; check for refrigerant
leak with a leak detector.
• Recoat the antirust paint in case of peeling-
off to prevent leak due to rusting and
perforation.
• Check whether the cooling fan can normally Fig.5-66
run and whether the electric brush of fan
motor is overly worn.
(c) Evaporator
• Generally, check it for leak with a leak
detector once a year.
• Open it to clean the inner and the air duct
once every 2~3 years.
Fig.5-67
(d) Liquid storage drier

Refrigerant level checking procedures: OK
1. Start the engine.

2. Turn on the A/C for refrigeration. Turn on
the temperature control switch to check if
the air is cold.
3. Check the inspection window of the drier/
collector to see if the white float is at the
top.
Fig.5-68

If the white float is at the bottom, inform the

service department.
OK
Fig.5-69
4. Fill the refrigerant. If necessary, check the
A/C system for leakage.
5. Check the water indicator inside the

inspection window of the drier/collector.
OK
Blue: normal drier.
Purple: too much water content.
Inform the service department to replace the Fig.5-70

drier/collector. Check the A/C system.
NOTICE
Before yearly operation season, ask the
service department to replace the drier/
collector. Otherwise it will affect the
performance of the A/C.
WARNING
In case of corrosion or mechanical
damage, replace the drier/collector to
avoid explosion and further damage.

(e) Refrigeration pipeline

• Pipe connectors: Check them once every
year, and check its sealing with a leak
detector.
• Pipes: Check them for collision with other
parts; check the rubber hoses for aging and
crack. Replace the rubber hoses every 3~5
years.
Table 5-12 Checking intervals for the A/C
Item Maintenance Interval

Check the locking nuts for looseness; check the rubber
hoses and connectors for refrigerant leak and oil stain; check
Pipeline connector Once/month
the rubber hoses and pipes for crack, aging, embrittlement,
damage by compression, and collapsing.
Check the fin for distortion and make it in order if any; check
Once/month
Condenser the core for blockage and clean it if any.
Check the fan for damage and abnormity. Once/month
Clean the air-in/out ducts; check the bottom drain pipe for
Evaporator Once/year
blockage and smoothen it if necessary
Check the pressure switch connector for looseness. Once/quarter
Liquid storage Replace the liquid storage after the A/C has been used for
Every 1000 h
some time
Check the refrigerant volume from the inspection window
Refrigerant volume when the A/C runs. There shall be few or no air bubble; Once/month
otherwise, add refrigerant.
Check the fastening bolts for looseness. Once/month
Check the fitting surface and the rotary shaft seal of main
Once/month
shaft for refrigerant leak and oil stain.
Check the compressor belt for wear and replace it if
Compressor Once/month
necessary.
Check the belt for tension and tension it if necessary. Once/month
Start and run the A/C for a few minutes in the seasons when
Once/month
the A/C is unused.

5.11.3 Replace
5.11.3.1 Oil water separator
WARNING
NOTICE
Take the following steps to change the oil water

separator.
1. Disassemble the filter with a special
spanner.
any dirt.
Fig.5-71
3. Unscrew the water separator from the filter

element.
Fig.5-72

4. Apply a thin coat of oil to the rubber seal of

the water separator (1). 1 2 3
5. Screw the water separator on by hand (2),

until the seal contacts. Oil +1/2
6. Tighten the water separator for another half
turn (3).
Fuel
7. Fill the filter element with clean fuel (4) 4 5 6
Oil
8. Apply some oil to the rubber seal of the
filter element (5) and screw it on by hand, +1/2
9. Tighten the filter element for another half Fig.5-73
turn (6).
fuel pipeline by pressing the manual pump
11. Check the filter element for leaks after a
short-time test run.
5.11.3.2 Hydraulic oil

Pay attention to the following items when
changing the hydraulic oil.
NOTICE
Change the hydraulic oil under the working
temperature. Otherwise some impurity
may not be drained out with the hydraulic
oil. And they will cause great damage to
the hydraulic elements.
NOTICE
Except for the regular hydraulic oil change,
replacement should be made as well after
major repairs. Otherwise the hydraulic
elements will be worn more easily.

CAUTION
Protect yourself from the hot hydraulic oil.
Since its temperature is very high, and it
will badly burned your skin if it spills onto
your skin.
The steps for checking and refilling the

hydraulic oil have been described. See:
Section 4.1.2.4 "Check the hydraulic oil
level" on page 4-2.
Changing procedures:
1. Clean around the hydraulic oil tank and oil
fille .
2. Place a container under the hydraulic oil
tank. Remove the oil-drain plug at the
bottom of the oil tank. Drain the oil.
NOTICE
Never start the engine when draining
the hydraulic oil. Otherwise it will cause
damage to the whole hydraulic system.
Fig.5-74
3. Check the seal ring and replace it if
necessary. Tighten it and the oil-drain plug.
4. Add new appointed hydraulic oil (See Table
5-10 on page 5-18).
5. Refill oil to 1/2~2/3 of the level gauge scale
See Fig.5-75.
6. Install the oil filler cap
7. Start the engine and run it for 5 minutes,
and then the oil level shall be within the
range between middle level and full scale.
Fig.5-75

5.11.3.3 Hydraulic oil filter
NOTICE
Replace the hydraulic oil filter element
every time when you change the hydraulic
oil. Otherwise the hydraulic oil may be
contaminated by the impurity on the old
hydraulic oil filter.
Steps of changing the element of oil fill filt .

1. Disassemble the element
Step 1: Loosen the hexagon (Fig. 5-76) at the
bottom of filter by with a special spanner and
then remove it.
Step 2: Pull out the element by hand.
Step 3: Drain off the rest of the hydraulic oil
and clean the filter housing and cove .
2. Install a new element

Step 1: Insert the new filter element into the
filter cove .
Step 2: Screw up the filter housing by S36 Fig.5-76
spanner, and then loosen it in the opposite
direction for 1/4 circle.
Note: Keep the oil fillers and elements clean

in the process of replacement. The old
element should be discarded and can't be
reused after cleaning.
Steps of changing the element of oil suction filte .

1. Disassemble the element
Step 1: Open the tank cover. Loosen the
hexagonal nut at the bottom of filter by with a
special spanner and then remove it.
Step 2: Pull out the filter element when you
hold nut 1.
Step 3: Remove the screw rod by loosening
nut 2 and nut 3.
2. Install a new element

Step 1: Insert the screw rod on the new filter
element. Fig.5-77

Step 2: Adjust total height of the filter to 500m

by adjusting nut 2 and nut 3.
Step 3: Install the tank cover.
5.11.3.4 Coolant
NOTICE
Check the coolant to prevent the engine
from being damaged by corrosion,
cavitations or freezing.
Take the following steps to change the coolant:

1. Unscrew the cover after the coolant cools
down lower than 50 ℃ .
WARNING
Change the coolant only after the engine
cools down. Otherwise people could easily
be burned by the hot coolant spilling from
the radiator.
Fig.5-78
2. Place a vessel (volume should be more than
33L) under the coolant outlet. Remove the
plug on the left side of the rear frame.
Fig.5-79
3. Screw the plug back. Then fill the new
coolant (See Table 5-10 on page
5-18) through the inlet.
4. Screw the cover back.

6. Wait until the engine cools down, then
check the coolant level. Add coolant if the
level is below the appointed mark.
Fig.5-80

5.12 Others
During the daily and interval maintenance,
perform the following maintenance according
to your demands.
5.12.1 Clean-fuel tank

Cleaning procedures:
1. Blow the outside of tank with compressed
air to remove the dust and foreign impurity.
Unscrew the drain plug to drain the dirty oil,
collect the drained fuel with a container.
2. Open the cover plate on the tank side.

Blow out the oil and grain materials left in
the fuel tank, esp., the blind corner, with
compressed air.
3. Fill an appropriate amount of clean diesel oil

(or kerosene) into the fuel tank. Use a new
brush to clean the tank up and down. When
the oil gets dirty, change it with new oil and
continue cleaning till no dirt and sediment
are found on the wall and bottom of tank.
4. Paste the wall and bottom of tank with

dough. Never use cotton to clean them in
order to avoid left fibre blocking pipelines.
Carefully clean the fuel tank. Paste them
with different doughs until no impurities can
be seen on dough. After that, wash the fuel
tank with new oil, blow the feul tank, and
install the drain plug.
NOTICE
When filling, clean the filling pipe and oil
tank port to prevent contamination. Close
the oil tank port immediately after filling.
When filling, avoid swashing the oil bucket
and don't insert the filling pipe into the
bottom. Otherwise, impurities will be
sucked into the fuel tank.

5.12.2 Clean-fuel radiator
WARNING
Perform cleaning work only after the
engine has cooled down and with the
engine stopped. Otherwise people could
easily be burned by the radiator.
• Check the radiator core daily and clean
radiator core regularly. It is recommended to
perform cleaning every 1000 working hours.
When lots of sundries exist in the working
site, shorten the cleaning interval by half.
• When the radiator cores are blocked, if

the air from the air outlet of the radiator
is relatively even (at rated speed) but
the foreign substances are loosely
adhered on the radiator, clean the foreign
substances on the surface at first, and
then repeatedly flush the air inlet and
air outlet of the radiator by compressed
air till all dust, weeds, insects and other
foreign substances are blown off and the
air from the air outlet is even. After that,
the radiator may work normally. When the
radiator cores are blocked, if the air from Fig.5-81
the air outlet of the radiator is mild (at
rated speed) but the foreign substances
are tight adhered on the radiator, remove
the coolant radiator, hydraulic oil radiator,
intercooler, and clean them alone.
• If the foreign substances are tightly adhered

on the radiator, or you can’t feel any air when
you put your hand on the air outlet of the
radiator (the engine is running at rated rotation
speed), clean the radiator assembly, hydraulic
oil radiator and engine coolant radiator
separately, and then reassemble them.
• When cleaning the radiator core (fins) the

pressure of the compressed air should
be not more than 0.2 MPa, the distance
between the air outlet face and the radiator

core should be not less than 50 mm, the

pressure of the high pressure water should
be not more than 0.27 MPa, and the
distance between the high pressure water
outlet face and the radiator core should be
not less than 100 mm.
• During the cleaning process, do not spray

water directly to the generator, cables and
electrical parts. After cleaning, start the
engine after the moisture is evaporated.
NOTICE
changing the fuel! Or insufficient fuel will
be sucked into the engine, and it will cause
the engine to work inefficiently or even
shut down. This will shorten the service
life of the engine.
5.13 Maintenance for long-time

storage
5.13.1 Engine
If the engine will not be used for a long time,
we recommend to store the engine according
to the following procedures to prevent
corrosion.
• Clean the engine including the cooling

system with cold detergent and water gun,
or best of all, steam.
• Run the engine until the moisture on the

surface is evaporated.
• Drain the warm engine oil and fill

anticorrosion oil.
• Drain the coolant and fill antifreeze and

coolant.
• Drain the fuel in the fuel tank, mix it with

anti-corrosion oil at a ratio of 10:1 and then
fill the mixed fuel into the tank again
• Run the engine for 10 minutes till the

anticorrosion mixed diesel enters all
pipelines, filters, pumps and nozzles and
the new engine oil is distributed to all parts.
• Turn the engine crankshaft (the engine

not started) for several times to make the
anti-corrosion mixed fuel injected into the
combustion chamber.
• Remove belts, spray anti-rust oil into
the belt pulley oil groove and loosen the
belts of alternator, cooling fan and A/C
compressor. Clear away all anti-rust oil
before restarting the engine.
• Seal the air filter inlet and engine exhaust

port. Reopen the inlet and exhaust port
before restarting the engine.
5.13.2 Complete machine

If the roller is to be stored for 3 months or
even longer, maintain it in accordance with the
following instructions:
• Perform the maintenance for long-time
storage and rust-proof treatment. See:
section 5.13.1 "Engine" on page 5-68.
• Clean the inner and outer surfaces of the
roller. Park it in the garage if available or at
a ventilated place in the open air and cover
it with canvas.
• Block up the front and rear frames in
parallel. Adjust the adjusting pads until the
damp blocks are not under stress. Connect
and fix the front and rear frames with the
limit plate.
• Lubricate the roller through each lubricating
point.
• Clean the surface of vibratory drum. Wipe
it with a piece of cloth and then coat some
anti-rust paint. Apply anti-rust oil on the
exposed machined parts of vibratory drum.
• Remove the storage battery and check the

electrolyte level. Charge the battery once a

month.
• Seal the air filter, dust port and exhaust
pipe outlet with plastic or paper tape to
keep the engine free of moist air.
• Fill up the fuel tank to avoid condensation
and rust.
• Fill the hydraulic oil tank up to the mark
“Max”.
• Turn on/off the A/C for about 10 minutes
monthly.
• Turn on/off the heating system for about 10
minutes monthly.
5.14 Antifreezing Maintenance
NOTICE
In cold weather, always drain the water
from water spraying system and add
antifreeze. Failure to do so may cause
damage to the water spraying system. Pay
attention to water pump, solenoid and filter
which are easily damaged due to frost.
• Dismount the water suction pipe before the

filter in the water spraying system drain the
water.
• Reconnect the water suction pipe properly.
• Add antifreezing coolant.
• Start the water spraying system to spray
water until the antifreezing coolant is
sprayed from the nozzle.
• After the ice period, drain the antifreezing
coolant and dispose it in an environment-
friendly way.

5.15 Check after Maintenance

After maintenance, check the machine.
Check the following items when the machine

runs:
• Ensure the engine or the hydraulic system
has no abnormal noise.
• Check all systems for leakage after
maintenance.
• Check all systems for looseness or
abnormal movements after maintenance.
• Check if all systems are overheating after
maintenance.
Check the following items when the machine

stops:
• Ensure all maintenance items and their
procedures in certain period are performed.
• Ensure all caps or plugs are installed and
tightened in right positions.
• Ensure all locks are locked safely.
• Ensure no tools, replaced parts, nuts, bolts
left on or in the machine.
• If any hydraulic elements are replaced,
exhaust the system. Ensure there is no
leakage in the system and no distortion of
pipelines.
• Record the maintenance notes and put
it back to the original position.Fill the
hydraulic oil tank up to the mark “Max”.

E
G
PA
K
AN
BL

E
G
PA
K
AN
BL

SSR200/220 Series Single Drum Roller Troubleshooting
Troubleshooting
6 Troubleshooting
6.1 Mechanical Parts 6-1
6.1.1 Engine 6-1
6.1.2 Vibratory Drum 6-3
6.1.3 Propel system 6-4
6.1.4 Brake 6-5
6.2 Typical Hydraulic Elements 6-6
6.2.1 Axial Plunger Pump 6-6
6.2.2 Axial Plunger Motor 6-10
6.2.3 Change Valve 6-12
6.2.4 Overflow alve 6-16
6.2.5 Steering Cylinder 6-20
6.2.6 Oil Filter 6-25
6.2.7 Sealing Elements 6-26
6.2.8 Hydraulic Steering Gear 6-28
6.3 Electrical Parts 6-30
6.3.1 Basic Electrical System 6-30
6.3.2 Electrical System of Working Devices 6-32
6.3.3 Fuses 6-33
6.3.4 Radio 6-34
6.4 Air Conditioning System 6-35
6.4.1 System with Poor Cooling 6-35
6.4.2 Insufficient System Cooling 6-36
6.4.3 Abnormal Noise Caused by Cooling System 6-38
6.4.4 Air Heating Device Fault 6-39
6.4.5 Other Faults 6-39
Troubleshooting SSR200/220 Series Single Drum Roller
6.5 Troubleshooting Examples 6-41
WARNING

6 TROUBLESHOOTING
6.1 Mechanical Part
6.1.1 Engine
Table 6-1 Fault Analysis and Troubleshooting for Engine
Fault Symptom Cause Remedy
Fuel used up Fill up fuel and bleed system.
Fuel filter blocke Replace filte .
Engine can not be
Leakage of fuel pipe Check and tighten all connections.
started
Discharge or poor connection of storage
Clamp polar clamp and check cables.
battery
Slow starter rotation speed due to too low

Check storage battery and clean,
voltage, loose or oxidized polar clamps of
reconnect and grease polar clamps.
storage battery
Engine oil with excessive viscosity,

Use appropriate engine oil.
especially in winter
Replace fuel filte , check all oil pipes

Difficult startup or Unsmooth fuel supply; block in fuel system
and use the winter-grade diesel when
unstable working power caused by the paraffin in winte
it turns cold.
of engine
Incorrect valve clearance Adjust valve clearance.
Nozzle with defects Check by the expert.
Turbocharger with defects Check by the expert.
Dirty dry-type air filte Clean or replace dry-type air filte .
Defective vacuum switch Check vacuum switch.
Too tight throttle cable Adjust or replace throttle cable.
Too much engine oil Drain redundant engine oil.
Dirty dry-type air filte Clean or replace dry-type air filte .
Too much smoke
Insufficient compression due to burnt or
discharged Check by the expert.
broken piston
Cylinder or cooling fin of radiator at the top Clean cooling fin of the radiato , esp.
of cylinder blocked by dirt the vertical fin at the top of cylinde .
Engine too hot or shut
down suddenly
Incorrect adjustment of piston pump Check by the expert.
Limited cooling airflo Clean cooling air conveying pipe.
Loose or broken fan belt Adjust or replace fan belt.

Fill up engine oil, immediately shut down

Too much oil consumption or less
Too low oil pressure the equipment and find out the causes,
engine oil
and check oil filter or cooler for leakage
Charging alarm indicator Too low engine speed Check, adjust or replace the belt.
of storage battery lit on Fault in generator or adjuster, and no
Check by the expert.
during operation charge of storage battery
Too much engine oil Discharge redundant engine oil.
Dirty dry-tire air filte Clean or replace dry-type air filte .
Turbocharger with defects Check by the expert.
Insufficient power of
Check and tighten screws and nuts on
engine Leakage of pressure tube
pressure tube.
Loose and eroded wiring of battery Clean and tighten the wiring.
Crankshaft rotates
Insufficient voltage of storage batter Charge storage battery.
slowly and can not be
Change it with the lubricating oil of
started Incorrect lubricating oil model
specified grade
No fuel supply of oil injector Check oil injector and high-pressure lines.
Failure of fuel cut-off solenoid Check the resistance of solenoid.
Check the low-pressure oil circuit and oil

No fuel supply of oil injection pump
Crankshaft rotates tank for fuel.
normally but can not be Abnormal operation of preheating
Check pre-heating system.
started system
Defective preheating plug Replace preheating plug.
Leakage of oil injection tube Re-tighten adaptor or replace fuel tube.
Improper oil injection timing Adjust oil injection timing.
Damaged oil injector or its seat Repair or replace oil injector or its seat.
Improper adjustment of throttle cable Adjust throttle cable.
Too low idling speed Re-adjust idling speed.
Fuel leakage Check, tighten or repair the leaked part.
Improper oil injection timing Adjust oil injection timing.
Unstable idling
Damage or abnormal operation of oil Check, adjust or replace oil injection pump
injector or oil supply valve or oil supply valve.
Insufficient oil supply of oil injection
Check and adjust it.
pump

6.1.2 Vibratory drum

Table 6-2 Fault Analysis and Troubleshooting for Vibratory Drum
Vibration at only one Broken circuit from vibration switch to Check circuit and reconnect
position of vibration switch vibration pump control solenoid broken point.
Broken circuit from vibration switch to Check circuit and reconnect

vibration pump control solenoid broken point.
If the circuit and solenoid are

normal, remove the vibratory
motor from the vibratory drum (not
Damaged nylon sleeve of coupling
including the oil pipe) to check the
No vibration or small nylon sleeve for damage. If any,
vibration at both positions replace it.
of vibration switch
Check for heavy internal wear.
Heavy internal wear in hydraulic pump If necessary, ask professional
personnel for repair.

Heavy internal wear in hydraulic motor If necessary, ask professional
Incorrect position of vibration switch Set switch to position I.
Insufficient oil in hydraulic oil tan Check oil level and refill new oil
Air in hydraulic system Check oil-suction tube and tighten
Oil-suction tube not sealed
connecting elements.
Engine working abnormally due to
Check engine.
insufficient powe

Poor compaction or
Heavy internal wear in hydraulic pump If necessary, ask professional
machine jittering during
vibration
Heavy internal wear in hydraulic motor If necessary, ask professional

Faults in vibratory hydraulic system (e.g.,

low efficiency, oil leakage and improper Check and rectify faults.
pressure)
Abnormal vibration Too much or too less oil in oil chamber of Check oil chamber, and drain or
frequency eccentric block fill oil
Improper throttle control mechanism Check and adjust
Improper engine speed Set to a proper engine speed.
Change in oil pump output Adjust limit screw.
6.1.3 Propel system

Table 6-3 Fault Analysis and Troubleshooting for Propel System
Insufficient engine powe Check and repair engine.
Powerless traveling
Wear in hydraulic pump and hydraulic motor Rectify by professional personnel.
Insufficient oil in hydraulic oil tan Check oil level and refill new oil
Air in hydraulic system Check oil-suction tube and tighten
Oil-suction tube not sealed
connecting elements.
Normal forwarding, but
Failed control valve in pump Rectify by professional personnel.
powerless reversing
Adjust brake lining clearance

Failed park brake Heavily worn or damaged brake lining or replace brake lining by
professional personnel.
Loose throttle control mechanism Re-adjust
Abnormal traveling speed
Improper engine speed Set to a proper engine speed.
Large impact in Heavily worn bearing Replace
transmission system or
torpid steering Insufficient lubricating greas Fill grease.
Damaged pressure relay Replace
No traveling Damaged emergency brake solenoid Replace
Defective circuit Repair or replace

Damaged brake solenoid Repair or replace
Difficult travelin
Damaged reducer Replace

6.1.4 Brake
Table 6-4 Fault Analysis and Troubleshooting for Brake
Check the thickness of brake

disc; adjust the clearance of
Brake disc misadjusted
brake disc if the brake disc is not
heavily worn.
Insufficient braking forc
Check the thickness of brake
Heavily worn brake disc disc, and replace the brake disc
if the brake disc is heavily worn.
Check oil level, and fill or drain

Improper oil level
oil to a proper oil level.
Overheating of brake Small clearance of brake disc Adjust brake disc clearance.
Drain off oil, and fill the proper
Improper lubricating oil
one instead.

6.2 Typical Hydraulic Elements

This section describes the common faults
and the relevant remedies of typical hydraulic
elements.
6.2.1 Axial plunger pump
Table 6-5 Fault Analysis and Troubleshooting for Axial Plunger Pump
Blocked oil suction pipe and oil filter or Unblock oil pipe and clean oil
great resistance filte .
Low oil level in oil tank Check oil level and fill oil
Air in pump body (not filled up with oil Bleed pump (filling oil into pump)
Replace plunger, grind the contact

Wear between plunger and cylinder hole, or face between oil distributor and
between oil distributor and cylinder body cylinder body, and ensure good
contact.
No seal between cylinder body and oil

Insufficient oil discharging
distributor, because plunger returns
or sluggish action of Check and replace center spring.
incompletely or can not return due to broken
actuator
center spring
Check variable mechanism:

Failure of variable mechanism failing to check whether variable piston or
meet the working requirements variable mechanism is agile, and
correct their adjustment error.
Select suitable oils according

Internal leak or difficult oil suction due to
to the actual condition of
improper oil temperature or air suction of
temperature rise and fix the joint
hydraulic pump
where the air leak may occur.

Unblock oil suction port and

Blocked oil suction port or narrow oil
widen the cross section for oil
passage
passage.
Control oil temperature, and

High oil temperature, low oil viscosity and
change oil with new one of
more internal leak
greater viscosity.
Trim the contact face between

Large internal leak due to wear between cylinder body and oil distributor,
cylinder body and oil distributor, or between and replace the plunger. In case
plunger and cylinder hole of heavy wear, sent them to the
Insufficient pressure or factory for repair.
strong pressure pulse
Small flow as a result of small deflection Widen deflection angle of variab e
angle of variable mechanism mechanism.
Increasing internal leak due to fatigued
Replace center spring.
center spring
For occasional pulsations, change

oil; for frequent pulsations,
Incoordination of variable mechanism (e.g.,
remove and repair the mating
large pulse due to incoordination between
elements, as whose damage or
servo piston and variable piston.)
incoordination is likely to cause
such pulse.
Bleed pump and check the part

Air in pump
into which the air may enter.
Bearing improperly assembled, or abraded Check bearing for damage, and
or damaged at one side replace it in time.
Difficult oil suction due to blocked oil filt Clean oil filte .
Check oil by sampling and
Dirty oil
change it with clean oil.
Large oil suction resistance due to high oil C h a n g e i t w i t h o i l o f l o w e r
Excessively loud noise
viscosity viscosity.
Low oil level or air suction in hydraulic Fill oil to the specified level and
pump check the sealing.
Pump not fitted concentrically with motor, Readjust them to the allowable
which increases the axial load range.
Lines vibrate; connector between plunger Take measures for insulation

and ball head of sliding boot seriously and vibration absorption. Check,
loosen or flaking o f repair or replace components.

Wear between cylinder body and oil

Trim contact face.
distributor
No seal between cylinder body and oil

Replace center spring.
distributor due to damaged center spring
Internal leak Adjust axial clearance to specifie

Large axial clearance
value.
Replace plunger and regrind the
Wear between plunger and cylinder hole
contact face.
Change it with oil of proper
Internal leak due to low oil viscosity
viscosity.
Damaged seal on drive shaft Replace seal ring.
Nuts and bolts on joint surfaces and
External leak Tighten them and check and
pipe connectors not tightened, and seal
replace the seal.
damaged
Check and grind relevant seal

Serious internal leak
surfaces.
Check and seal relevant sealing
Serious air suction in hydraulic pump
parts.
Wear in matching contact faces (e.g. Trim or replace the worn parts,
Too hot hydraulic pump
between cylinder body and oil distributor, or such as oil distributor and sliding
between sliding boot and swashplate) boot.
Change oil, increase capacity of

High oil viscosity, small capacity of oil tank,
oil tank or set a cooling device, or
or high rotation speed of hydraulic pump
lower rotation speed.
Filter oil, and flush oil circuit (if

Blockage in control oil circuit
necessary).
Wear between variable piston and variable
Trim, grind, or replace them.
shell
Fault of variable
Servo piston, variable piston and spring For the mechanical seizure, grind
mechanism
element shaft get stuck moving parts; change dirty oil.
Replace dirty oil; change oil of

Spring on one-way valve in the control oil
low viscosity if the oil temperature
circuit damaged
is too low.

Change dirty oil; in the event of too

Seizure of plunger and cylinder hole
low oil temperature, change oil with
as a result of dirty oil, the change in oil
new one of lower viscosity; or use a
temperature, or the adhesion due to high
scrapper to scrape away the metal
temperature
crumbs.
No rotation (i.e. seizure) of
pump
Sliding boot flaking off due to stuck or
Replace or refit sliding boot
flaked o f plunger or loaded startup
Broken plunger ball due to stuck plunger

Replace plunger ball.
or loaded startup

6.2.2 Axial plunger motor
Table 6-6 Fault Analysis and Troubleshooting for Axial Plunger Motor
Try to improve oil supply

Insufficient oil supply of hydraulic pum
condition.
Find out the causes and carry out
Low rotation speed of motor
adjustment.
Blocked filtration screen of oil filt Clean or replace filter core
Fill oil, and properly increase pipe
Difficult oil suction due to insufficient oil in
diameter to ensure smooth oil
oil tank or small pipe diameter
suction.
Ti g h t e n r e l e v a n t j o i n t s , a n d
Internal air leak due to poor seal properly increase pipe diameter
to ensure smooth oil suction.
Change oil with new one of lower

High oil viscosity
viscosity.
Low Large axial and radial clearances, great

Repair hydraulic pump.
rotation leak volume, and low volumetric efficienc
speed and Insufficient input pressure of hydraulic
Try to increase the pressure.
small pump
torque Check and rectify the fault of
Low efficiency of hydraulic pum
hydraulic pump.
Check and rectify the fault of

Insufficient adjusting pressure or failure in
overflow valve, and increase the
overflow valv
pressure.
Increase diameter of line and

Slender line and great resistance
adjust the layout.
Check causes for oil temperature

High oil temperature, low oil viscosity, and
rise, cool down oil and change oil
more internal leak
with new one of higher viscosity.
Tighten connecting bolts on

Serious leaks on joint surfaces of hydraulic
each joint surface and check the
motor
sealing condition.
Serious leak due to heavily worn internal Check damaged parts, and grind
hydraulic elements or replace these elements.

Large axial clearance due

Grind end faces of oil distributor
to wear in end faces of oil
and cylinder body.
distributor and cylinder body
Internal leak
Fatigued spring Replace spring.
Heavy wear between plunger Grind cylinder hole and refit
Leak and cylinder hole plunger.
Poor seal at shaft end or
Replace seal ring.
damaged seal ring
External leak Bolts on joint surfaces and Ti g h t e n t h e b o l t s a n d p i p e
pipe connectors loosen or not connectors at relevant connecting
tightened positions.
Bearing improperly fitted or worn ou Refit or replace bearing
Check seal of air inlets and
Air in pump due to poor seal
tighten connecting parts.
Dirty oil or air bubble in oil Change it with clean oil.
Coupling not concentric Calibrate its concentricity.
Change oil with new one of lower
Abnormal noise High oil viscosity
viscosity.
Grind cylinder hole and refit
Heavy wear at radial side of hydraulic motor
plunger.
Take measures (e.g. adding an

External vibration insulating cover) to insulate the
external vibration source.

6.2.3 Change valve

Table 6-7 Fault Analysis and Troubleshooting for Change Valve
Valve core stuck due to oil port of electromagnetic Check, connect oil port to oil
change valve not connected to oil return tank or high return tank, and reduce counter
counter pressure in oil drain pipeline pressure.
Electromagnetic change valve affected by gravity of Install electromagnetic change

parts such as valve core and armature caused by its valve with its axis in horizontal
vertical installation position.
Valve core stuck in hole and not

acting or acting torpidly due to Check clearance and repair or
small clearance between slide replace valve core.
valve (valve core) and valve body
Axial hydraulic seizure due to valve Check, grind or refit valve core.
core (or valve body) bruised, or C h a n g e o i l w i t h n e w o n e , i f
Seizure of slide stuck by dirt or particles necessary.
valve
Axial hydraulic seizure due to
geometric over-deviation in opening
Check and correct geometric over-
No switch and closing of valve core or non-
deviation and non-concentricity.
concentricity of valve core and
valve hole
Valve core stuck due to distorted Refit, tighten and overhaul valve
valve body or valve core body and valve core.
Check supply voltage and make

Insufficient power for electromagnet
it as per requirements (i.e. within
to propel the valve core due to low
+10% ~ -15% of the specified
supply voltage
voltage).
AC electromagnet burnt out as a

Fault of
result of electromagnet element not Rectify the stuck slide valve and
electromagnet
attracted to the end due to blocked replace electromagnet.
slide valve.
Difficult to propel the valve core as

Find out the causes for magnetic
a result of insufficient at raction due
leak and replace electromagnet.
to magnetic leak

Increase control pressure,

Low pressure of hydraulic control oil check whether the spring is
to propel valve core too rigid, and replace spring (if
necessary).
F a u l t o n Throttle valve on the hydraulic Check, adjust and clean

c o n t r o l o i l change valve closed or blocked throttle orifice
No switch circuit of
h y d r a u l i c Oil ports at both ends of hydraulic Check and connect oil ports
change valve slide valve not connected with oil with oil return tank, and clean
return tank, or oil drain pipe blocked and unblock oil return pipe.
Slide valve can not switch or reset

due to broken, omitted, or too soft Check, replace or fit spring
spring
Insufficient stroke of valve core, lower opening of

Lower action speed valve and small flow, which are resulted by the
Replace push rod or
o f a c t u a t o r t h a n shortened switch push rod (as a result of abrasion
electromagnet.
specified on due to long-term knocking), or the worn contact point
of armature
Oil leak due to heavy wear at seal ring of push rod Replace seal ring.
Oil leak at the
If the counter pressure is too
push rod of dry Oil leaking at push rod due to large counter pressure
high, respectively connect
electromagnet at oil drain (oil return) chambers at both ends of
these chambers to the oil
change valve solenoid
return tank.
Sluggish attracting There are two sealing screws at the rear end of
Screw off these sealing screws,
a n d r e l e a s i n g o f electromagnet, and the air enters into the rear
fill sufficient oil, and then screw
wet electromagnet chamber during the initial installation of these
down the screws for sealing.
change valve screws.
Loose mounting screw Tighten mounting screw.

Trim the surface of bottom
Poor processing precision of surface of bottom
mounting plate to get a good
Oil leak at the joint mounting plate precision.
surfaces of plate
Seal ring for bottom face aged or of poor sealing
change valve Replace seal ring.
effect
Screw made of material not as per requirements, Replace and tighten screw in
thus screw distorted after being stretched accordance with requirements.

Check supply voltage, and make

Overheating of coil due to supply voltage it as per requirements (i.e. within
higher than the specified valu +10% ~ -15% of the specified
voltage).
Poor insulation of electromagnetic coil Use wet DC electromagnetic coil.

Overheating of coil due to frequent switch Check and refit coil
Poor contact due to defective welding of
Remove and refit wires
wires
Overheating or burnout of Electromagnet element not concentric with
Replace electromagnet.
electromagnet the axis line of slide valve.
Overheating and burnout of coil due to large

current as a result of failure to attract the
electromagnet element, which is caused by Repair push rod.
the length of push rod not in proportion to
the stroke of electromagnet
Check and rectify the fault of oil

Burnout of coil due to oil entering dry
leak at push rod, or replace seal
electromagnet
ring.
Slide valve stuck by dirt in oil Clean slide valve and change oil.
Large or small force of spring Replace spring with a proper one.
Dirt at the contact part of electromagnetic
Remove dirt.
element.
Large or small clearance between slide
Torpid switch Face up or replace slide valve.
valve and valve body
Incomplete or torpid steering due to short

movement of valve core as a result of Check and repair push rod, or
insufficient length or incorrect stroke of replace it (if necessary).
worn push rod of electromagnet

Diminish the orifice of one-

Rapid movement of slide valve of hydraulic way throttle valve on hydraulic
change valve change valve, and slow down the
movement of slide valve.
Large fitting clearance between hole and

element of one-way throttle valve (on the
Check and adjust the clearance
hydraulic change valve), omitted installation
to a proper value and fit a spring
of spring for one-way valve and ineffective
resistance
Uneven contact face or poor contact of Remove foreign materials, and

electromagnet element repair electromagnetic element.
Impact and noise during
switch Control pressure difference of two
Vibration of piping and other elements due
circuits; under worse conditions,
to hydraulic impact (the two circuits with
use wet AC change valve, or
great pressure difference instantaneously
the change valve with buffering
connected)
function.
Slide valve acting fitfully or high local

Grind or replace slide valve.
pressures
Tighten bolt, and fit a locking
Bolt fixing electromagnet loose
washer.
Long or short push rod of electromagnetic R e p a i r o r r e p l a c e p u s h

change valve; strong or weak attraction of r o d ; o v e r h a u l o r r e p l a c e
electromagnet electromagnet.

6.2.4 Overflow valve

Table 6-8 Fault Analysis and Troubleshooting for Overflow alve
Noise of liquid Check and rectify it.

Noise of cavitation, swirling and intercepted
Replace overflow valve
liquid after the overflow valve releases liquid
Prolong unloading time and

Impactive noise of pressure wave when the
gradually open or close change
overflow valve is unloadin
valve which controls unloading.
Repair leading valve and main

slide valve to enhance their
Uneven pressure distribution for leading geometric precision; increase
valve and main slide valve diameter of oil return pipe; and
use softer spring for main slide
valve and oil of proper viscosity.
Air in oil return line Check, seal and bleed the line.
Increase diameter of oil return
Vibration and noise Great counter pressure in oil return line pipe and separately set the oil
return pipe.
Air in inner pressure control area of overflow

Check, seal and bleed the area.
valve
Use overflow valve suitable for
Flow exceeds the allowable value
the flo .
Mechanical noise Check and rectify it.
Tight or loose fitting of slide valve and valve
Repair slide valve and valve hole.
hole
Too soft or distorted pressure adjusting Replace pressure adjusting
spring spring.
Loose pressure adjusting nut Tighten pressure adjusting nut.
Worn cone valve Grind and face up cone valve.
Diagnose and rectify the vibration
Resonance with other elements of system
and noise of system.

Control oil lacks of pressure due to plug at

unloading port of leading overflow valve Fit and seal plug.
not fitte
Control oil flowing back to oil tank due to oil Check remote control circuit,
circuit connecting with remote control port and close oil circuit for control oil
of overflow valve getting opene flowing back to oil return tank
Failure in raising system No pressure in overflow valve unloading

Clean damping hole and change
pressure, or no pressure system due to blocked damping hole of
oil.
(reading of pressure gauge leading overflow valv
almost equals to 0), and Cone valve, steel ball or pressure adjusting
useless adjustment Fit it.
valve not fitte
Overflow valve stuck at full opening
Clean overflow valve
position by dirt
Diagnose and rectify the fault of
No pressure in hydraulic pump
hydraulic pump.
Serious oil leak due to damaged elements
Check, repair or replace them.
and line of system
Leading valve lacks of control pressure oil

Check and unblock control oil
due to blocked control oil circuit from main
circuit.
valve to leading valve
Inner oil drain port of leading valve for Clean inner oil drain port of
returning oil blocked by dirt leading valve.
Too high system pressure
and failed adjustment Slide valve can not be opened due to even
Insert a stainless steel slice or
oil pressures at both sides of main valve
a slender soft wire into damping
core as a result of heavy wear in damping
hole to plug up a part of this hole.
hole
Slide valve stuck at closing position due to Clean slide valve and valve hole,
dirty oil and change oil.

Check oil leak and oil trickle at

Oil leak or defective seal at remote control remote control port of leading
port of leading overflow valv overflow valve, and seal leaking
parts.
Oil leak or defective seal at control valve Find out the causes of oil leak or
and line of remote control oil circuit for internal leak of remote control oil
leading overflow valv circuit, and seal leaking parts.
Oil at oil return port when the pressure had

not reached the setpoint value, as a result
Overhaul, ream, repair or replace,
of serious internal leak at slide valve or
Failure in raising system internal leak and oil overflowing at overflo and grind slide valve.
pressure and useless valve
adjustment
Clean slide valve and valve hole,
Slide valve stuck due to dirty oil
and change oil.
Face up cone valve and valve

seat, replace steel ball or cone
Internal leak due to improper fitting betwee
valve, or slightly tap cone valve
cone valve/ball valve and valve seat
to make it pressed against valve
seat.
Pressure rises slowly or no longer rises due

Clean damping hole, and change
to small flow of leading valve as a result of
oil.
partially blocked damping hole

Failure to maintain a stable working

Replace it with a new one of
pressure as a result of too soft or distorted
proper pressure grade according
pressure adjusting spring for control valve
to the pressure control range.
core
Face up cone valve and valve

seat, replace steel ball or
Fluctuant pressure due to improper fitting cone valve, and clean valve.
between cone valve/steel ball and valve Alternatively, lay cone valve or
seat as a result of seizure by dirt or wear steel ball on valve seat; tap it with
a wood plate to make it pressed
against valve seat.
Fluctuant pressure
(fluctuant or jumpy reading Check damping hole on
Damping hole on main valve sometimes
on pressure gauge) main valve, and change oil (if
blocked by dirty oil
necessary).
Slide valve acts torpidly due to slide valve Overhaul or replace slide valve,
scored, distorted, or seized by dirt, or and repair valve hole or slide
having ellipses, or valve hole bruised or valve to make its ellipses less
having ellipses. than 5 μm.
Diagnose and rectify the fault

Change valve remotely connected with
of change valve, and seal the
overflow valve out of control, or constantly
remote control port of overflow
leak (large or small) at remote control port
valve, the change valve and the
and change valve
line.
Check and rectify such

Fluctuant pressure and large noise
phenomena.
Improper fitting between cone valve/steel Clean them, grind cone valve,
ball and valve seat due to wear or seizure face up valve seat, or replace
by dirt steel ball.
Large fi ting clearance between slide valve

Leak Replace slide valve core.
and valve body
External leak Check seals.
Screw down pipe connector, or
Loose pipe connector or defective seal
replace seal ring.
Defective or ineffective sealing on relevant Trim joint surfaces, or replace
joint surfaces sealing elements.

6.2.5 Steering cylinder

Table 6-9 Fault Analysis and Troubleshooting for Steering Cylinder
Set an exhaust device;

alternatively, start hydraulic
Air in hydraulic cylinder and line leads to: device and make it run at its
normal or slightly low reading on pressure maximum stroke for several times
gauge, and creeping at two ends of to compulsorily discharge the air.
hydraulic cylinder In addition, seal the system and
line to prevent oil leak and air
intrusion.
Negative pressure at certain part of

hydraulic cylinder leads to: slightly low Locate and seal the part with
reading on pressure gauge, no or few negative pressure to prevent air
air bubbles in oil tank, and the creeping intrusion; and discharge the air.
gradually aggravating
Air suction of hydraulic pump leads to: quite Bleed the hydraulic pump and oil
low reading on pressure gauge, powerless suction pipe if the fault is caused
Creeping hydraulic cylinder, air bubbles in oil tank, by air suction of hydraulic pump
and useless exhaust and oil suction pipe.
Excessively tightened seal ring leads to: Adjust seal ring to be neither very
normal or slightly low reading on pressure loose nor very tight, and ensure
gauge, and the surface of piston rod that the piston rod can be pulled
whitening with creaks by hand and without oil leak.
Fit two piston rods together, and

Non-concentricity of piston rod leads to:
calibrate them on a V-shaped
slightly high reading on pressure gauge,
iron plate to keep the non-
and the creeping at two ends of hydraulic
concentricity within 0.04 mm; or
cylinder gradually aggravating
else, replace pistons.
Put a single piston rod, or a piston

Bent piston rod leads to: slightly high
rod along with a piston, on the
reading on pressure gauge, regular
V-shaped iron plate; straighten it
creeping positions, and partially whitened
or them by a press machine or a
piston rod
micrometer.

Adjust the tightness of pressing

block (bar) of guide rail or sliding
Excessively clamped guide rail/sliding
block to ensure the precision of
block or uneven hydraulic cylinder leads to:
acting elements and reduce the
slightly high reading on pressure gauge,
sliding resistance. If it doesn't
regular creeping positions, jutter at moving
work, check the parallelism
parts, and whitened surface of guiding
between hydraulic cylinder and
device
guide rail, trim and calibrate their
contact faces.
Confliction between hydraulic cylinder and

Adjust the tightness of nuts to
moving parts due to excessively tightened
keep piston rod not tight or loose.
nuts at both ends of two piston rods
Check and readjust the pressure

Creeping and flow of lubricating oil.
Poor lubrication leads to: the normal
Otherwise, check whether the
reading on pressure gauge, slight shake
oil hole is blocked and the oil
or vibration at moving parts (e.g. the work
viscosity is too high or lubricating
bench), or whitened surface of guide rail
performance is ineffective; and
timely change oil (if necessary).
Score at inner wall of hydraulic cylinder

or surface of piston, or heavy wear or
Bore cylinder, and refit a new
corrosion at certain parts leads to: fluctuant
piston.
reading on pressure gauge, and regular
creeping
Serious internal leak of hydraulic cylinder

Replace (aged and damaged)
leads to: very low reading on pressure
seal ring on piston.
gauge, and slow or difficult pressure risin

Defective seal ring on piston rod due to Check piston rod for damage. If
damaged surface of piston rod or damaged any, repair it. Replace damaged
or aged seal ring or aged seal ring.
Check seal ring and contact face

Oil leak due to poor sealing of pipe
for scratch. If any, replace or
connector
repair them.
Check the processing precision

Defective seal at cylinder cover due to poor
of contact face and the aging
processing precision of contact face or
condition of seal ring, and timely
External leak aged seal ring
replace or repair them.
Oil leak due to seal ring damaged by local

high temperature, which is caused by air Add exhaust device and timely
insulation compression as a result of poor discharge the air.
exhaust
Check the processing precision

Oil leak at buffering device due to poor of contact face and the aging
processing precision or aged seal ring condition of seal ring, and timely
replace or repair them.
If the piston is heavily worn, bore
Internal leak and interchange between high/ the cylinder, lathe the piston to be
low-pressure chamber due to excessively thinner with several grooves, and
large fit clearance between worn cylinder then fit a seal ring to the piston
hole and piston for sealing, or fit a new piston
instead.
Internal leak and interchange between
Replace damaged or aged seal
high/low-pressure chamber due to worn or
ring in time.
Internal leak aged seal ring on piston
Internal leak due to inclined or deflec ively Check concentricity of cylinder

worn piston as a result of non-concentricity body, piston, and hole of piston
or eccentric load on cylinder body and rod for cover, and make them
piston align with each other.
Internal leak due to local drum shape

Bore hydraulic cylinder, and
caused by poor processing linearity of
replace piston.
diameter of cylinder hole or local abrasion

Replace seal ring in time if the

aged seal ring brings on serious
Serious internal leak due to large fit
internal leak and the hydraulic
clearance between piston and hydraulic
cylinder moves downward. In
cylinder (caused by wear), or defective
case of large clearance, lathe
sealing (caused by damaged or aged piston
the piston with several grooves,
seal rings due to fitting and abrasion
and then fit a seal ring or replace
piston.
Internal leak in high/low-pressure chamber

at local sections due to defective seal Bore hydraulic cylinder, repair
caused by error in local geometric shape the diameter of cylinder hole, and
as a result of uneven wear at local sections replace piston.
of hydraulic cylinder
Confliction due to increasing friction or Adjust the tightness of seal ring

resistance caused by excessively pressed for piston rod (to the extent that
seal ring of piston rod at cylinder end or no oil leak occurs), and straighten
Insufficient propulsion, bent piston rod piston rod.
decreasing speed and
unstable operation Lower operating speed and unstable
operation due to large sliding resistance Change oil.
caused by dirt in oil entering sliding parts
Lower operating speed of hydraulic cylinder F i n d o u t t h e c a u s e s f o r o i l

due to high oil temperature, lower oil t e m p e r a t u r e r i s e , a n d t a k e
viscosity and increasing leak radiating and cooling measures.
In case of insufficient capacity,

Low working pressure or capacity of replace accumulator; in case
accumulator, which is used for enhancing of insufficient pressure, apply
the operating speed of hydraulic cylinder enough air pressure to the
accumulator.
Adjust the pressure of overflow

Insufficient propulsion due to low system valve as per the requirements
pressure cause by lower pressure of of propulsion; check pressure of
overflow valve or leak in pressure control overflow valve; check overflow
area of overflow valv valve for internal leak, if any,
repair or replace overflow valve

Unstable operation due to air in hydraulic Rectify this fault by the method for
Insufficient propulsion, cylinder faults on air suction and creeping.
decreasing speed and Lower operating speed and unstable Check the hydraulic pump or flow
unstable operation operation due to insufficient oil supply of adjusting valve, diagnose and
hydraulic pump rectify the fault.
Adjust steering time, slow down

Fast moving speed and hydraulic cylinder movement of hydraulic cylinder;
without a buffering device alternatively, add a buffering
device.
Replace buffering plunger or set

Serious leak due to large clearance
Impact a sleeve in the hole to adjust the
between plunger and hole in buffering
clearance to the specified value;
device, and ineffective throttle valve
check throttle valve.
Ineffective buttering of one-way valve which

Repair and grind one-way valve
buttering at the end as a result of serious
and valve seat, or replace them.
leak
Stop the machine for checking,

Friction sound of sliding metallic surface
avoid the sintering of sliding
due to poor lubrication caused by damaged
surface and improve the
oil film of sliding surface or high pressur
lubrication.
Improve the lubrication, and in

case of serious scratch of seal
Abnormal sound around seal ring due
ring, polish the lip edge with sand
to damaged oil film of sliding surface or
paper or sand cloth, or adjust
Abnormal sound and noise serious scratch of seal ring
the tightness to eliminate the
abnormal sound.
Move the piston slowly to the

Shake and huge noise resulted from the
top for several times in order
insulated and compressed air under the
to discharge the air in cylinder,
piston when the piston is moving to the end
which can eliminate this serious
of hydraulic cylinder (especially for vertical
noise and prevent burnout of seal
hydraulic cylinder).
ring.

6.2.6 Oil filter

Table 6-10 Fault Analysis and Troubleshooting for Oil Filter
If the oil filter is not strong and seriously

blocked, the oil-passed clearance
decreases greatly, and the resistance
Deformation of oil filter
increases to a great extent, the filter Use a stronger skeleton instead,
core (usually on sintering
core, under the effect of large pressure and filter or change oil
oil filter or screen oil filte
difference, will be deformed, and even
c r u s h e d . ( T h e s k e l e t o n o f o i l f i l t e r,
sometimes, will be damaged, too.)
Replace filter core, and check

the new filter core, to which the
requirements are listed as follows:
Under the vibration at an
acceleration of 10 g, the filter core
shall not shed granules;
Sintering oil filter shedding The quality of sintering oil filter not in Under the effect of a pressure at
granules accordance with requirements. 21 MPa, the filter core shall not
shed granules within 1 hour;
During the impact load test by
a manual pump, the filter core,
under the accelerated pressure of
10 MPa, shall not be damaged.
Such a phenomenon usually appears on

the grid oil filter which is fitted at the inlet
of high-pressure pump. The reason of this
is as follows: when the melting point of Replace the plumbum-stannum
Solders breaking away
plumbum-stannum electrode is 183°C, and e l e c t r o d e b y t h e a r g e n t u m -
from metallic grid and
the temperature at the inlet of oil filter has cadmium electrode, which has a
skeleton of grid oil filte
reached 117°C, the strength of electrode higher melting point.
will consequently decrease to a great
extent and finally the electrode will break
away under the impact of high-pressure oil.

6.2.7 Sealing elements

Table 6-11 Fault Analysis and Troubleshooting for Sealing Elements
Lower the pressure; set

High pressure
supporting rings or retainer rings.
Overhaul or replace sealing
Large clearance
elements.
Pulled clearance
Improper size of groove, etc.
elements.
Refit, overhaul, or replace sealing
Sealing element fit improperl
elements.
Sealing elements not compatible with Replace seal ring or change
hydraulic oil hydraulic oil.
Strictly keep sealing elements

Expansion (frothing)
Sealing elements dissolved by solvents away from solvents (e.g. kerosene
and petroleum).
Aged hydraulic oil Change hydraulic oil.
Check oil temperature; in case

of serious friction or overheating
High temperature (poor lubrication or excessively
tight mating), timely overhaul or
replace seal elements.
Aging and cracking Naturally aged and deteriorated sealing

elements as a result of being stored or
elements.
used for a long term
Find out the cause, and improve

Sealing elements hardened under low
the lubrication on sealing
temperature
elements.
Sealing elements distorted due to lateral (or Use retainer rings to obviate
Distortion
longitudinal) load distortion.


Check the impurities in oil, the
process quality of fi ting surfaces
Fitting surfaces of sealing elements
and the quality of seal rings, and
damaged due to movement and friction
timely overhaul or replace sealing
Wear and damage on elements.
surface Sealing elements damaged due to cutting Overhaul or replace sealing
during installation elements.
Find out the cause, and improve
Sealing elements worn due to poor
the lubrication on sealing
lubrication
elements.
High pressure, heavy load, and poor Set additional supporting rings or
working conditions retainer rings.
Check the quality of sealing
Damage, adhesion and Poor quality of sealing elements
elements.
deformation
Poor lubrication Improve the lubrication.
Refit, overhaul, or replace sealing
Improper installation
elements.
Sealing elements not compatible with Replace seal ring or change
hydraulic oil hydraulic oil.
Shrinkage
Age hardening or drying shrinkage due to
Replace sealing elements.
closed storage

6.2.8 Hydraulic steering gear

Table 6-12 Fault Analysis and Troubleshooting for Hydraulic Steering Gear
Oil leak at joint surfaces

between stator of valve Damaged seal ring Replace seal ring.
body and rear cover
Oil leak at joint surfaces

Oil between valve block and Dirt at joint surfaces Remove the dirt.
leakage steering gear
Oil leak at adjusting bolt for
Fixing bolt not rigid enough Replace bolt.
safety valve
Oil leak at bolt of steering
Uneven washer Grind or replace washer.
gear
Easy steering when turning

Check whether the pump is
the wheel slowly; hard
Insufficient oil supply of pum normal. If not, replace or repair
steering when turning the
pump.
wheel quickly
If steel ball is lost, fit a new Φ8

Hard steering when turning
Defective one-¬way valve with one; if the valve is seized by
the wheel slowly or quickly;
steel ball inside the steering gear dirt, clean it; if the crown bar is
feeble turning
Heavy deformed, calibrate or replace it.
steering E a s y s t e e r i n g u n d e r
Set pressure of overflow valve
no load or light load, Adjust set pressure of overflow
lower than working pressure, or
but hard steering under valve, or clean overflow valve
stuck overflow valv
heavier load
Bubble in oil and abnormal

Discharge the air, and check oil
sounds; steering cylinder Air in steering system, low oil
suction pipe for air leak, or add oil
acting fitfully when the level, and high oil viscosity
(i.e. recommended hydraulic oil).
steering wheel is turned

Steering wheel can not

return back to center
automatically, and pressure Broken spring Replace spring.
drop increases at the
center position
Pressure fluctuation
obviously increases and Pin or opening of universal Replace pin and shaft (do not use
steering wheel can not be driving shaft broken or distorted other substitutes).
Failed turned
steering S t e e r i n g w h e e l
Rotor fitted at incorrect position Replace bolt.Make tooth A on
automatically turns or
in relation to universal driving driving shaft due aligned with a
wobbles leftwards and
shaft gear root of rotor.
rightwards
The roller travels

d e f l e c t i v e l y ; s t e e r i n g Defective two-way buffering
Replace spring or clean two-way
cylinder does not act or valve, or spring or steel ball stuck
buffering valve.
acts sluggishly when the by dirt
steering wheel is turned
Broken spring
Steering wheel can not turn back Va l v e c o r e a x i a l l y s t u c k b y
to center automatically: when the steering shaft
pressure drop increases at the center Rectify the fault according to the
Large coaxiality error between
position or steering wheel stops corresponding causes.
axes of steer shaft and valve
turning, steering gear does not unload
(i.e. the roller travels deflectivel .). Large rotation resistance of
steering shaft
Failure in switching to manual

steering: during power steering, the
driver can not feel he has turned the
steering wheel to the limit when the Large axial or radial clearance
Replace rotor and stator.
piston of steering cylinder is already between rotor and stator
at the limit; during manual steering,
the steering cylinder doesn't switch
when the steering wheel is turned

6.3 Electrical Parts

6.3.1 Basic electrical system
Table 6-13 Fault Analysis and Troubleshooting for Basic Electrical System
Fuse burnt Replace fuse.
When the machine is blocked,

No power supply of dismantle it for coating lubricant;
Damaged ignition key switch
complete machine replace ignition key switch when
the contact is damaged.
Damaged DC contactor Replace DC contactor
Check whether the indicator

light HL1 and resistance R3 are
Failure of charging lines
normal and in good connection;
replace it if necessary.
Charge it when the indicator

I n s u f f i c i e n t p o w e r i n Damaged storage battery of storage battery turns black;
storage battery replace it if it turns white.
If the voltage on terminal B+ is

less than 26 V after starting the
Fault of engine engine, the generator is damaged.
Send it for maintenance by
professional personnel.
Set traveling handle and vibration

Traveling handle and vibration selection
selection switch to the neutral
switch not set at neutral position
position.
Replace starter relay K1 if the

Damaged starter relay K1
circuit is normal.
Confirm if there is short circuit

Failure of engine startup
on lines firstly; if not, start it after
replacing it with the fuse of the
same type.
Fuse FU1 burnt; defective starter motor
It is usually caused by the seizure
of clutch mechanism and bad
performance of control contact;
the professional repair is needed.

Check the lines, in particular

Poor contact of lines
terminal W of generator.
No display of engine speed
In case of damaged engine or no
signal
Defective engine output from terminal W, ask for
professional repair.
Failure in engine No engine speed indication at auto gear Check as per step 4.
Check relevant circuit, esp. the
Poor contact in circuit plug connecting to linear stepper
motor.
Dismantle and clean spline

speed control Linear stepper motor stuck push rod mechanism, or replace
bearing.
Check resistance of the 2 coils. If

Defective linear stepper motor it not 2Ω, the motor is damaged.
Replace it.
Pointer always at “max.” mark Short circuit. Check and repair
Broken circuit. Check and repair.
A b n o r m a l f u e l g a u g e Pointer always at “min.” mark
Damaged sensor. Replace it.
indication
No response of pointer after turning on/off
Damaged fuel gauge. Replace it.
the power.

6.3.2 Electrical system of working

devices
Table 6-14 Fault Analysis and Troubleshooting for Electrical System of Working Devices
Brake switch and emergency stopping R e s e t b r a k e s w i t c h a n d

switch not reset emergency stopping switch.
If the machine still travels with the

pressure relay plugged off, the
Defective pressure relay
relay is damaged. Replace the
No traveling or sluggish relay.
traveling
Check for short circuit or poor
Defective wiring contact of solenoid socket. Rectify
it.
Damaged brake/brake release solenoid; stuck Replace solenoid or clean valve

valve core core.
Reset emergency stopping
Emergency stopping switch not reset
switch.
Damaged vibration selection

No vibration at manual gear switch or toggle switch. Replace
it.
No vibration
Check for poor contact in circuit.
Rectify it.
When traveling speed is over 1.5
No vibration at auto gear
km/h, the vibration button must
be pressed down. Stop vibration
forcibly.
Check the wiring, esp. the sensor
Defective wiring harness for damage or poor
contact of connectors.
No speed signal
Large clearance between sensor and motor Re-adjust the clearance to 0.4~0.6
flywheel gea mm.
Damaged sensor Replace sensor.

6.3.3 Fuses
Table 6-15 Fuses
Code Part Current Code Part Current
F11 Starter 30A F50 Front working light 10A
F12 Ignition switch 15A F51 Rear working light 10A
F13 Backup 15A F52 Backup 10A
F14 SYCD (resting) 5A F53 Excess fuel valve 30A
F36 Dome light 10A F34 A/C 15A

Horn & reversing
F37 Radio 10A F31 10A
alarm
F38 Front wiper 10A F32 Steering light 5A
F41 Backup 10A F21 Controller load 20A
Controller input
F24 5A F22 SYCD 5A
power 1
Controller input
F25 5A F23 Controller power 5A
power 1
F54 Excitation & parking 10A

6.3.4 Radio
Ta b l e 6 - 1 6 d e s c r i b e s t h e f u s e s o f t h e
pneumatic tire roller.
Table 6-16 Radio
Symptom Possible Cause Suggested Action

Method 1: press SEL and DISP keys, and
hold them for 3 seconds to reset the radio.
Any abnormality Wrong setting or halted CPU. Method 2: disconnect the power supply of
the radio at the harness connector, and
then connect it to reset the radio.
•The power supply ACC of ignition
1. Check the red wire for power supply at
switch has no circuit, meanwhile date
the rear harness connector of the radio.
Radio can't be appears on the display.
2. Check the yellow wire for power supply
started. • The power supply B+ (yellow) of the
at the rear harness connector of the
battery has no circuit, meanwhile no
radio.
date appears on the display.
Press SEL and DISP keys, and hold them
Abnormal display Halted CPU
for 3 seconds to reset the radio.
Inferior U disc may be read on a computer
U disc can't be
because the drive current through the U
read or be played
disc connector of the computer is enough. Replace it with qualified U disc
after a certain
However, inferior U disc could make the U
time.
disc connector of the radio heat severely.
SD card can't be
read or be played
Inferior SD card Replace it with qualified SD card
after a certain
time.
The radio can
receive no or 1. Check the antenna connector of the
1. The signal of antenna has short or
few stations. radio; check if there is short circuit
open circuit.
Frequencies between the antenna at top of cabin
2. Stations are in repair and their signals
change as manual and the iron roofing
are weak.
or auto search 2. Try it in another time or place.
functions.
1. The horn is broken or the harness is
Normal display but inferior. 1. Check the horn and the harness.
no sound 2. The radio can receive no or few 2. Refer to the above one.
stations with MP3 playing normally.

6.4 Air Conditioning System

The common faults of air conditioning system
generally are electrical faults, mechanical faults
and refrigerant and freezing lubricant failures.
The symptoms are no cooling or insufficient
cooling or abnormal noise.
6.4.1 System with poor cooling

Failure symptom: Start the engine and keep
medium speed for about 3 mins. Turn on the
blower and air conditioner switches, but there
is no cold air blown out. For fault checking and
handling, see Table 6-17.
Table 6-17 Fault Analysis and Troubleshooting of Poor Cooling

Fuse burnt Change
Bad switch connection Repair or change
Bad rheostat Repair or change
Bad motor Repair or change
Open circuit in conductor Repair or change
Bad idle speed control Repair or change
Bad temperature control Repair or change
Electromagnetic
Bad pressure switch Repair or change
clutch not engaged
Bad solenoid Repair or change
No rotating of Open circuit in conductor Repair or change
evaporator fan
Compressor not Loose or damaged belt Adjust or change
rotated
Compressor fault Remove and check
Refrigerant leaked or
Make up or discharge
Electromagnetic filled too muc
clutch engaged
C o m p r e s s o r Expansion valve plugged Change
rotated
Dry filter plugge Change
Pipe plugged Change
Compressor fault Remove and check

6.4.2 Insufficient system cooling

Causes: Insufficient cooling can be caused
by many reasons. All factors that reduce the
refrigerant flow at the expansion valve outlet
may decrease the system cooling capacity; all
factors that can cause excessive temperature
and low pressure at high or low sides in the
system can also lead to insufficient system
cooling. For the specific cause and inspection
of the faults, and troubleshooting methods, see
Table 6-18.
Table 6-18 Analysis and Troubleshooting of Insufficient System Coolin
Air filter blocke Clean filte
Break of thermistor Repair
Blower could rotate
N o r m a lFrosted
Low battery voltage Check battery
operation evaporator
Thermistor fault Change
Displacement of air duct Check and repair
Loose or corroded battery
Check and repair
Slow rotation terminals
Blower motor fault Check and repair or change
Insufficient air fl
Rotating at high
speed but no
rotating at low Rheostat fault Change
and medium
Blower does not rotate
speeds
Adjustable resistance fault and
Check, repair or change
fuse blown
N o r o t a t i n g a t Blower motor fault Repair or change

h i g h , m e d i u m Blower switch fault Repair or change
and low speeds Blower relay fault Check or change
Improper wiring or connection
Check or change
falling


Outside air infiltratio Check vents
Normal pressure Check and change related
Temperature control system fault
parts
Discharge proper refrigerant
Excessive refrigerant
Pressures on from low-pressure valve.
both high and Discharge refrigerant,
l o w s i d e s a r e Air in the cooling cycle vacuumize and then fill
too high refrigerant.
Bad condenser Check and repair it.
High pressure is Find out reason and repair or

Condenser pipe blocked
Compressor operates normally
too high and low change

pressure is too Expansion valve opening
Adjust or replace
low is too large
E v a p o r a t o r i n l e t Check vents and access
High pressure temperature too high opening, etc.
A b n o r m a l
is normal; low Improper installation of
Normal wind
pressure
pressure is too t e m p e r a t u r e s e n s i n g Check and repair
high bulb for expansion valve
Compressor fault Check and repair or change
Find out leaks, repair and
High pressure is Insufficient refrigeran then refil
slightly low; low
Air filter blocke Clean
pressure is too
high Expansion valve screen
Clean or repair.
blocked
Refrigerant leaked Find out leaks and repair
Both high and
Temperature sensing
low pressures
bulb for expansion valve Check, repair or change
are too low
faulted
Compressor operates
Compressor fault Check, repair or change

abnormally
Electromagnetic clutch fault Check, repair or change
Driving belt damaged or slipping Check, repair or change
Pressure switch fault Check, repair or change

6.4.3 Abnormal noise caused by cooling

system
Causes: Normally, it belongs to mechanical
faults, such as looseness fasteners, over-
worn moving parts, poor lubrication for relative
moving parts. See Table 6-19.
Table 6-19 Analysis and Troubleshooting of Abnormal Noise Caused by Cooling System
Too loose conveyor belt Adjust belt tightness
Over-worn conveyor belt Change
Conveyor belt part
Loose bracket Repair
Tension wheel bearing Change
Check the fan for debris, or repair
Abnormal sound in blower fan
Blower part and change
Motor worn too much Repair or change
Electromagnetic clutch slipping Repair
Improper coil installation Repair
Skew pulley Adjust
Electromagnetic clutch part
Excessive refrigerant Discharge
Insufficient freezing lubrican Refuel
Compressor fault Remove and check.

6.4.4 Air heating device fault

There are usually faults such as no heating
or the heating cannot be shut off, for air
conditioning system with heating function. See
Table 6-20.
Table 6-20 Analysis and Troubleshooting of Heating Fault
Check and replace the fuse. Use a

Burnt fuse or damaged circuit
multimeter to check the circuit.
No air flo
Use a multimeter to check the fan;
Damaged fan
repair or replace the fan.
Solenoid cannot be switched on Use a multimeter to check the
No heating
due to de-energizing circuit.
Normal air flo Turn on the heating switch. You

Solenoid cannot be switched on
can feel the solenoid action. Repair
due to damage
or replace solenoid.
Heating cannot be Normal air flow Solenoid is internally stuck, which

Check, repair or replace solenoid.
shut off with heating cannot be closed
6.4.5 Other faults

In addition to the above faults, the other
faults for air conditioning system of the roller
are: good and bad cooling effect at times,
evaporator frosting, etc. See Table 6-21.
Table 6-21 Analysis and Troubleshooting of Other Faults

Better system cooling at first,
but inadequate cooling after
Find out the leak with a leak
using a period of time; there are Joints loose due to vibration,
detector; carefully tighten
bubbles in observation hole of Leading to improper use in
the loose parts and make up
the storage bottle; “reading” of case of leakage
R134a.
high and low pressure gauges
are slightly low

System does not refrigerate;

hot air flows out of the vent; Temperature sensing bulb of
t h e r e i s n o t e m p e r a t u r e expansion valve leaks due to Replace expansion valve and
difference at inlet and outlet of damage, resulting in the valve recharge R134a.
expansion valve; “reading” from hold closed
low pressure gauge is low
Start the air conditioning system

Air from vent is not cold, and the
intermittently, which can eliminate
compressor temperature rises. There are impurities in the system;
the transient clogging if it is not
The pointer of low pressure gauge expansion valve screen is clogged;
serious. Remove the expansion
decreases rapidly, close to 0; thin frost or "sweating" occurs in
valve and clean with alcohol.
and “reading” from high pressure the expansion valve
Recharge R134a after emptying
gauge is slightly high
the system.
Insufficient cooling capacity;

evaporator frosted; “readings” of Throttle orifice in expansion valve Drain off the system, replace the
high and low pressure gauges are does not work expansion valve and re-fill R134a
slightly low
After running for some time,

system cooling capacity
The desiccant in storage bottle Empty the system, replace the
decreases; “reading” of high
saturated; throttle orifice blocked liquid storage bottle and recharge
pressure gauge is slightly high,
by ice R134a.
and “reading” of low pressure
gauge is less than 0.2 MPa
Check if the temperature

After starting the cooling system, B a d c o n t a c t o f t e m p e r a t u r e
control switch is damaged
there is only air instead of cold air; control switch or the compressor’s
with a multimeter; replace the
readings of high and low pressure e l e c t r o m a g n e t i c c l u t c h c o i l
compressor ’s electromagnetic
gauges are stationary damaged
clutch.
Compressor electromagnetic O p e n i n g o f t e m p e r a t u r e
Check temperature control switch
clutch operates frequently, with c o n t r o l s w i t c h i s t o o s m a l l ,
to make it turn to the position close
short engaging time; cold air in which automatically forces the
to the electromagnetic clutch as
vehicle, and normal readings of compressor to stop, resulting in
much as possible.
high and low pressure gauges insufficient cooling capacit

6.5 Troubleshooting Examples

Example 1: Vibration fault
Fault symptom:
No vibration at low vibration frequency.
Fault cause:
• Fault in low-frequency vibration control
circuit.
• Defective low-frequency vibration solenoid.
• Pump failing to change angle due to

defective 3-position switch of vibration pump.
Remedy:
Set to the vibration frequency and the drum
vibrates. It means the mechanical part,
vibration pump, and vibratory motor are
normal. Check the low-frequency vibration
control circuit and the electrical connections
are good. Replace the low-frequency vibration
solenoid, and the drum vibrates at low
frequency. It indicates the solenoid is in trouble.
Test the valve, and the valve core does not act
no matter the valve is energized or not. There
is mechanical fault. In this case, replace the
valve.
Example 2: Gear speed fault

Fault symptom:
Same speeds at gear I and gear II; same
speeds at gear III and gear IV.
Fault cause:
The fault must lie in the front axle motor speed
governing. The possible fault causes are as
follows:
• Broken circuit of drum motor solenoid coil.
• Broken circuit.
• Relay damaged or not energized.

Example 3: No traveling
Fault symptom:
No traveling or sluggish traveling
Fault cause:
• Brake switch and emergency stopping
switch not reset
• Defective neutral position switch
• Defective brake release valve circuit
• Damaged brake release solenoid or stuck

valve core
Remedy:
Reset brake switch and emergency stopping
switch. Check the neutral position switch, and
the circuit is normal. Check the voltage of
brake release valve, and the valve is properly
grounded. Replace the solenoid, and the
machine travels normally. Clean the valve
core, and the machine works normally. Thus,
the fault is caused by the dirty solenoid core.
Regularly check and maintain the valve core.

E
G
PA
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BL

E
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BL

SSR200/220 Series Single Drum Roller Specifications
Specifications
7 Specifications
7.1 Dimension of the Equipment 7-1
7.2 Specifications of the Equipment 7-2

Specifications SSR200/220 Series Single Drum Roller
WARNING

7 SPECIFICATIONS
7.1 Dimension of the Equipment
E
C
D
G
H
F
A B
Table 7-1 Dimension of the equipment
Item Unit SSR200 SSR220
A Length mm 6797 6797
B Width mm 2318 2318
C Height mm 3330 3330
D Vibratory drum diameter mm 1600 1600
E Thickness of vibratory drum mm 40 40

rim
F Vibratory drum width mm 2130 2130
G Min. ground clearance mm 410 410
H Wheel base mm 3182 3182
Note: The above data are specifications of

standard machine. Materials and specifications
are subject to change without notice in
accordance with our continuous technical
innovations.

7.2 Specifications of the Equipment

Table 7-2 Technical Specification
Product Model
Technical SSR200 SSR220
Parameters
Operating mass (kg) 20000 22000
Mass and load
Distributing mass of vibratory drum (kg) 13600 14600
Distributing mass of drive axle (kg) 6400 7400
Static linear load of vibratory drum (N/cm) 638 678
Vibration frequency (Hz) 29/35 29/35

Compaction
mechanism
Nominal amplitude (mm) 2.0/1.0 2.0/1.0
Exciting force (kN) 380/275 410/300

0 ～ 3.5 0 ～ 3.5
Low speed
Power-driving performance
Travel 0 ～ 4.5 0 ～ 4.5

speed
(km/h) 0 ～ 5.5 0 ～ 5.5
High speed
0 ～ 7.5 0 ～ 7.5
Theoretical gradeability (%) 45 45
Steering angle (°) ±35 ±35

Swing angle (°) ±12 ±12
Min. turning outside diameter (mm) 12350 12350

Tire
Tire spec. 23.1-26-8 23.1-26-8
Manufacturer WEICHAI WEICHAI

Engine
Model WP6G200E331 WP6G200E331

Rated power (kW) 147 147
Battery (VxAh) 24×120 24×120
Capacity
Fuel tank (L) 300 300
Hydraulic oil tank (L) 150 150
Note: The above data are specifications of

standard machine. Materials and specifications
are subject to change without notice in
accordance with our continuous technical
innovations.

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www.sanyglobal.com
SANY AUTOMOBILE MANUFACTURING CO., LTD

Address: SANY Industry Town, Economic and Technological Development Zone,
Service Hotline: 0086 4006098318

E-mail: [email protected]
Website: www.sanyglobal.com

Single Drum Roller: SSR200C-8H SSR220C-8H

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Quality Changes the World

Single Drum Roller

Safety, Operation & Maintenance Manual

SSR200/220 Series Single Drum Roller

Safety, Operation and Maintenance Manual- January 2019

Scan here to download the Service Cloud APP

Safety, Operation and Maintenance Manual- January 2019

Duty of owners or other authorized personnel

Safety, Operation & Maintenance Manual - January 2019

• Periodically check related personnel's safety consciousness during working.

Duty of all working personnel

Safety, Operation & Maintenance Manual - January 2019

2.2.5.2 Safety Symbols 2-7

II Safety, Operation & Maintenance Manual - January 2019

2.5.9 Working in Noisy Environment 2-31

4.1.2.10 Check the Cables 4-5

IV Safety, Operation & Maintenance Manual - January 2019

5.6.3 Check ............................................................. 5-26

VI Safety, Operation & Maintenance Manual - January 2019

5.8 Initial 250 Hour Maintenance ............................................. 5-52

5.13 Maintenance for long-time storage ....................................... 5-73

VIII Safety, Operation & Maintenance Manual - January 2019

Safety, Operation & Maintenance Manual - January 2019

Safety, Operation & Maintenance Manual - January 2019

Always keep this manual nearby and have all

Safety, Operation & Maintenance Manual - January 2019 1-1

1.2 Your Documentation Package

1.2.1 Recommendations on using the

1.2.2 Documentation storage

1.2.3 Organization of this manual

1-2 Safety, Operation & Maintenance Manual - January 2019

1.2.3.3 System functions

Safety, Operation & Maintenance Manual - January 2019 1-3

1.3 Your SANY Equipment A

1.3.1 Equipment directions

During the break-in period:

1-4 Safety, Operation & Maintenance Manual - January 2019

1.3.3 Equipment information

Product identification plate is riveted on the left

中国制造 / Made in China

Safety, Operation & Maintenance Manual - January 2019 1-5

1.3.4 Serial number and distributor information

1-6 Safety, Operation & Maintenance Manual - January 2019

1.4 Contact Information

Tel: 0086 4006098318

Safety, Operation & Maintenance Manual - January 2019 1-7

1-8 Safety, Operation & Maintenance Manual - January 2019

Safety, Operation & Maintenance Manual - January 2019

2.4.1 Safe Starting 2-15

Safety, Operation & Maintenance Manual - January 2019

2.5.21 Safe Treatment of Liquid 2-37

Safety, Operation & Maintenance Manual - January 2019

Safety, Operation & Maintenance Manual - January 2019

It contains technical and safety information

Always operate your equipment according to

SANY cannot anticipate every possible

Equipments covered by this manual are used

Never use the equipment in flammable or

Select a SANY single drum roller with a