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SECTION 5

MAINTENANCE INSTRUCTIONS

5-24

DD-29/31HF/38HF Vibratory Asphalt Compactors

Check Engine Coolant Level

1. Check engine coolant level by observing the level in the coolant recovery bottle

(1, Figure 5-29). Coolant level should be between the "FULL” and "LOW" marks
on the bottle. If required, add a 50-50 mixture of coolant and water to bring
coolant to the proper level.

Figure 5-29

250 HOUR OR QUARTERLY ROUTINE MAINTENANCE

WARNING

Hot oil or components can burn.

Oil must be at normal operating temperature when draining.

Avoid contact with hot oil or components.

Do not allow oil to drain into the ground. Dispose of properly.

Summary of Contents for DD29

Page 1: ...Ref No VOE21A1004089 CPN 43924968 Printed in Sweden 2008 05 Volvo Shippensburg English CST ...

Page 2: ...te of California to cause cancer birth defects and other reproductive harm California Proposition 65 Warning Battery posts terminals and other related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and other reproductive harm Wash hands after handling ...

Page 3: ...L 1 3 SELECTION AND QUALIFICATION OF PERSONNEL 1 4 ORGANIZATIONAL MEASURES 1 4 PRE START INSPECTION 1 5 SAFETY INSTRUCTIONS GOVERNING OPERATION 1 5 Starting 1 7 Operating 1 8 Stopping 1 9 Maintenance 1 9 WARNING OF SPECIAL DANGERS 1 12 TRANSPORTING TOWING AND ROADING 1 12 HAZARDOUS SUBSTANCE PRECAUTION 1 14 SAFETY RELATED DECALS 1 15 U S DECALS 1 16 Crush Area 1 16 Rollover 1 16 Improper Operation...

Page 4: ...opulsion Control Lever 3 7 Vibration ON OFF Switch 3 8 SUSPENSION SEAT 3 8 OPTIONS 3 8 SECTION 4 OPERATING INSTRUCTIONS 4 1 OPERATING INSTRUCTIONS 4 2 GENERAL INFORMATION 4 2 PRE START CHECKS VERIFICATIONS 4 3 STARTING MACHINE AND OTHER CHECKS VERIFICATIONS 4 8 OPERATING THE MACHINE 4 11 Operating Suggestions and Checks While Operating Machine 4 11 Moving the Machine Propulsion Control 4 12 Using ...

Page 5: ... HOUR OR DAILY ROUTINE MAINTENANCE 5 13 Check Engine Oil Level 5 13 Check Engine Coolant Level Clean Radiator and Oil Cooler 5 14 Check Air Cleaner 5 15 Check Air Cleaner Restriction Indicator 5 15 Check Fuel Level 5 16 Check Water Tank Level 5 17 Check Parking Brake 5 18 Clean Water Strainer 5 19 50 HOUR OR WEEKLY ROUTINE MAINTENANCE 5 20 Check Battery Clean and Grease Terminals 5 20 Grease Artic...

Page 6: ...AND FIGURES DD 29 DD 31HF 7 6 MACHINE WEIGHTS AND FIGURES DD 38 HF 7 8 MACHINE DIMENSIONS DD 29 and DD 31HF 7 10 MACHINE DIMENSIONS DD 38 HF 7 11 SECTION 8 FUEL AND LUBRICANT SPECIFICATIONS 8 1 FUEL AND LUBRICANT SPECIFICATIONS 8 2 GENERAL INFORMATION 8 2 SERVICE FUNCTIONS 8 5 FLUID CAPACITIES 8 6 HYDRAULIC OIL REQUIREMENTS AND SPECIFICATIONS 8 7 LUBRICATING OIL GREASE EXCEPT ENGINE 8 8 Extreme Pr...

Page 7: ...t Compactors v TABLE OF CONTENTS TITLE PAGE SECTION 10 SCHEMATICS 10 1 SCHEMATICS 10 2 GENERAL INFORMATION 10 2 Electrical Schematics 10 2 Hydraulic Schematics 10 2 SECTION 11 RECOMMENDED SPARE PARTS 11 1 Recommended Spare Parts 11 2 ...

Page 8: ...vi DD 29 31HF 38HF Vibratory Asphalt Compactors TABLE OF CONTENTS TITLE PAGE ...

Page 9: ...DD 29 31HF 38HF Vibratory Asphalt Compactors 1 INTRODUCTION ...

Page 10: ...TENANCE INSTRUCTIONS Section 6 TROUBLESHOOTING Section 7 TECHNICAL SPECIFICATIONS Section 8 FUEL AND LUBRICANT SPECIFICATIONS Section 9 TORQUE SPECIFICATIONS Section 10 SCHEMATICS Section 11 RECOMMENDED SPARE PARTS Always keep the Operation and Maintenance Manual on the machine and within reach of the operating position If any part of this manual cannot be understood contact your supervisor or loc...

Page 11: ...g inform the freight agent as soon as possible They will inform you regarding how to proceed in order to make a complaint IDENTIFICATION DATA An exact description of the model type and serial number of your machine will facilitate fast and efficient response from our parts and service operations Always provide the model of your machine and its serial number when you contact the local service or pa...

Page 12: ...ine serial number is stamped on a nameplate 1 Figure 2 located on the right side of the engine Figure 2 INSTRUCTION MANUAL STORAGE A manual storage compartment 1 Figure 3 is located next to the operator s seat and provides space for the Operation and Maintenance manual Figure 3 ...

Page 13: ...ost efficient compaction of hot mix asphalt H M A and non cohesive soils DD 29 DD 31HF DD 38HF Compactors feature the Kubota V2203M engine and hydrostatic propulsion and steering systems The hydrostatic propulsion system drives both drums for maximum gradeabilty DRUMS To meet varying job requirements the operator can manually control drum vibration or static and select dual drum or front drum DD 2...

Page 14: ...sitioned for operator convenience The control panel contains the following standard controls and indicators drum selector switch hourmeter emergency stop pushbutton horn button check engine light brake test switch and park brake switch with indicator light In addition to the standard controls there are controls for three options pressurized water spray driving lights and beacon All controls have I...

Page 15: ...repair ROPS SEAT BELT The manufacturer provides ROPS rollover protective structure and seat belts as standard equipment on all compactors A foldable ROPS is available as optional equipment ROPS used in conjunction with seat belts will lessen the possibility of death or serious injury in the event of a rollover WARNING Your life may be endangered if the following are not complied with DO NOT operat...

Page 16: ...8 DD 29 31HF 38HF Vibratory Asphalt Compactors ...

Page 17: ...DD 29 31HF 38HF Vibratory Asphalt Compactors 1 1 SECTION 1 SAFETY ...

Page 18: ...re personal injury or death if the warning is ignored WARNING is used to indicate the presence of a hazard which can cause severe injury or death if the warning is ignored CAUTION is used to indicate the presence of a hazard which will or can cause personal injury or property damage if the warning is ignored NOTICE is used to notify people of installation operation or maintenance information which...

Page 19: ...sive Operators and maintenance personnel must be alert to recognize and avoid potential hazards They should also have comprehensive training required skills and necessary tools to properly perform their functions The machine was built in accordance with state of the art standards and recognized safety rules Nevertheless its misuse may constitute a risk to life and limb of the user or of third part...

Page 20: ...achine is being used OBSERVE AND INSTRUCT the user in all other generally applicable legal and mandatory regulations relevant to accident prevention and environmental protection These compulsory regulations may also deal with the handling of hazardous substances issuing and or wearing of personal protective equipment and traffic regulations SUPPLEMENT operating instructions with detailed working i...

Page 21: ...nk with the engine running while near an open flame or while smoking ALWAYS wipe up any spilled fuel CHECK for any maintenance and repair WARNING tags placed on the compactor by maintenance personnel DO NOT operate the compactor until repairs have been made and the WARNING tags have been removed by authorized personnel CLEAN any foreign material from the operator s platform to reduce the danger of...

Page 22: ...achine in motion CHECK that braking steering signalling and lighting systems are fully functional before starting work or travelling with the machine CHECK that accessories have been safely stowed away before setting the machine in motion OBSERVE the valid traffic regulations when traveling on public roads and ways and MAKE SURE the machine is in a condition compatible with these regulations ALWAY...

Page 23: ...E starting the engine ENSURE that the parking brake control is in the Applied position START the engine from the operator s position only WARNING NEVER jump start the compactor directly to the starter or starter solenoid Severe injury or death could result from the compactor lurching forward or backward and running over the person s attempting to jump start the compactor Normal safety devices are ...

Page 24: ...to or off of the compactor while it is in motion ALWAYS remain seated with the seat belt on when operating the compactor whether compacting traveling or loading unloading USE EXTREME CAUTION and be very observant when operating in close quarters or congested areas NEVER carry passengers CLOSE all sound baffles during operation KNOW the area in which you are working Familiarize yourself with work s...

Page 25: ...ol to idle RPM pull the fuel shut off control if so equipped turn ignition switch to OFF and lock all lockable compartments USE proper flags barriers and warning devices especially when parking in areas of heavy traffic Maintenance In any work concerning the operation conversion or adjustment of the machine and its safety oriented devices or any work related to maintenance inspection and repair al...

Page 26: ...fter cleaning EXAMINE all fuel lubricant and hydraulic fluid lines for leaks loose connections chafe marks and damage REPAIR or REPLACE defective parts immediately Always TIGHTEN any screwed connections that have been loosened during maintenance and repair Any safety devices removed for setup maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance...

Page 27: ...scorched cables must be rectified immediately Welding flame cutting and grinding work on the machine should only be done if expressly authorized as there may be a risk of explosion and fire Before beginning welding flame cutting and grinding operations clean the machine and its surroundings from dust and other flammable substances and make sure that the premises are adequately ventilated risk of e...

Page 28: ...ve electrical wire Do not leave the machine Do not touch any control or any part of the machine Warn others against approaching and touching the machine Have the live wire de energized Do not leave the machine until the damaged line has been safely de energized Operate internal combustion engines and fuel operated heating systems only in adequately ventilated premises Before starting the machine i...

Page 29: ...and rear of the compactor drum and wheels once loaded onto the transporter Leave the chocks if the unit will be on the transport vehicle for an extended period of time without being moved Always be sure the articulation lock bar lock pin is secured in the locked position before transporting the compactor Position the compactor on the transporter or hauling vehicle centered from side to side and ap...

Page 30: ...mes Hydraulic Oil Avoid ingestion skin contact and breathing fumes Engine Lubricating Oil Avoid ingestion skin contact and breathing fumes Preservative Grease Avoid ingestion skin contact and breathing fumes Rust Preventative Avoid ingestion skin contact and breathing fumes Engine Fuel Avoid ingestion skin contact and breathing fumes Battery Avoid ingestion skin contact and breathing fumes SAE Gea...

Page 31: ... NO REQ D LOCATION 1 WARNING Crush Area 2 Frame both sides 2 WARNING Rollover 1 Console 3 WARNING Misoperation 2 Console and Hood 4 WARNING Rotating Fan Blade 1 Side of radiator inside hood 5 WARNING Hot Fluid Pressure 1 Top of radiator inside hood 6 Checklist 1 Hood 7 WARNING Towing Tag 1 Inside hood on brake release valve ...

Page 32: ...SECTION 1 SAFETY 1 16 DD 29 31HF 38HF Vibratory Asphalt Compactors U S DECALS 1 Crush Area 2 Rollover ...

Page 33: ...SAFETY SECTION 1 DD 29 31HF 38HF Vibratory Asphalt Compactors 1 17 3 Improper Operation 4 Rotating Fan Blade 5 Hot Fluid Pressure ...

Page 34: ...SECTION 1 SAFETY 1 18 DD 29 31HF 38HF Vibratory Asphalt Compactors 6 Check List ...

Page 35: ...achine can cause severe injury or death Do not operate this machine near or on an inclined surface A rollover can occur If this machine has a Rollover Protective Structure ROPS seat belts must be worn to avoid severe injury or death from being thrown out 3 Improper Operation Improper operation of this equipment can cause severe injury or death Read and understand the operator s manual and safety i...

Page 36: ...top machine before performing maintenance 5 Radiator Injury can occur when removing the radiator cap Steam or fluid escaping from the radiator can burn Rust Inhibitor contains alkali Avoid contact with skin and eyes Always shut down the engine and allow to cool before removing the radiator cap Remove the cap slowly to relieve pressure Avoid contact with steam or escaping fluid ...

Page 37: ...SAFETY SECTION 1 DD 29 31HF 38HF Vibratory Asphalt Compactors 1 21 6 Check List ...

Page 38: ...SECTION 1 SAFETY 1 22 DD 29 31HF 38HF Vibratory Asphalt Compactors ...

Page 39: ...DD 29 31HF 38HF Vibratory Asphalt Compactors 2 1 SECTION 2 SYMBOL IDENTIFICATION ...

Page 40: ...r machine No Description No Description 1 Drum Vibration 9 Anti Drum Spin 2 Drum Vibration Control 10 Manual Vibration Control 3 High Amplitude 11 Water System Control 4 Low Amplitude 12 Double Drum Vibration Mode 5 Frequency Vibration 13 Single Drum Vibration Mode 6 Ignition Switch 14 Vibration Control Mode 7 Tie down Point 15 Caution 8 Anti Wheel Spin 16 Auto Vibration Control ...

Page 41: ...SYMBOL IDENTIFICATION SECTION 2 DD 29 31HF 38HF Vibratory Asphalt Compactors 2 3 INTERNATIONAL SYMBOLS NOTE Some symbols shown in this section may not appear on your machine ...

Page 42: ...N 15 Grease 47 Brake OFF 16 Oil Lubrication Point 48 Primer Start Aid 17 Lift Point 49 Hydraulic Oil 18 Jack or Support Point 50 Hydraulic Oil Pressure 19 Filling Emptying 51 Hydraulic Oil Level 20 Read Operator s Manual 52 Hydraulic Oil Filter 21 Engine Oil 53 Hydraulic Oil Temperature 22 Engine Oil Pressure 54 Fuel Diesel 23 Engine Oil Pressure Failure 55 Fuel Level 24 Engine Oil Level 56 Fuel F...

Page 43: ...DD 29 31HF 38HF Vibratory Asphalt Compactors 3 1 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS ...

Page 44: ...N LOCK BAR WARNING During shipment and before performing any checks or service operations place the articulation lock bar in the locked position For compaction operation the lock bar is to be removed from the locked position and placed in the stowed position Figure 3 1 The articulation lock bar is used to prevent accidental articulation of the compactor The lock bar must be in the locked position ...

Page 45: ...action operations Figure 3 2 CONTROLS AND SWITCH LOCATIONS Refer to Figure 3 3 and Figure 3 4 for locations of the following controls Figure 3 3 1 Auto Vibration Switch 7 Indicator Lights 2 Drum Selector Switch 8 Brake Test Switch 3 Water Spray Switch 9 Park Brake Switch 4 Emergency Stop Switch 10 Horn Button 5 Steering Wheel 11 Ignition Switch 6 Hourmeter ...

Page 46: ...8HF Vibratory Asphalt Compactors Figure 3 4 Refer to Figure 3 5 and Figure 3 6 for locations of the following controls Figure 3 5 Figure 3 6 12 Water Flow Control 13 Engine Speed Control Throttle Lever 14 Propulsion Control F S R Lever 15 Vibration ON OFF Switch ...

Page 47: ...er front drum vibration or both drum vibration Auto Manual Water Pump Switch This three position switch 3 is used to control the main water pump In Auto position water spray turns on and OFF when the machine starts and stops respectively In Manual mode water spray operates continuously The switch should be in the OFF center position whenever water spray is not required or when filling the water ta...

Page 48: ...nt temperature If the Check Engine Light comes on during machine operation shutdown the engine immediately and have service personnel determine the cause of the fault Brake Test Switch The Brake Test Switch 8 is a momentary switch that allows the operator to test the operation of the Park Brake Park Brake Switch This switch 9 turns the park brake ON and OFF Horn Press the horn button 10 to sound t...

Page 49: ... engine RPM Push lever downward gradually to decrease engine RPM Propulsion Control Lever The propulsion control Forward STOP Reverse lever 14 is used to control the forward and reverse movement and stopping of the compactor WARNING Moving the propulsion control quickly may cause loss of machine control lurching or serious injury Move the control slowly To propel the machine in either the Forward ...

Page 50: ... SEAT The machine is equipped with a suspension seat 1 Figure 3 7 that features several adjustments that enhance operator comfort The seat 1 can be moved forward and backward as well as from side to side on the operator s platform Forward and backward seat movement is controlled by a lever 2 Figure 3 7 on the left side of the seat Side to side seat movement is controlled by a lever 3 Figure 3 7 on...

Page 51: ...DD 29 31HF 38HF Vibratory Asphalt Compactors 4 1 SECTION 4 OPERATING INSTRUCTIONS ...

Page 52: ...hich contains safety precautions and guidelines before you perform any maintenance service or repairs GENERAL INFORMATION Observe the following Operational procedures Do not speed engine when it is cold Always chock the drum wheels when parking the machine Do not grease the machine while the engine is running Always perform safety checks prior to starting using the machine Do not control travel sp...

Page 53: ... leaks 2 Condition of engine and machine 3 Bolted assemblies for tightness 4 Inspect entire machine for any loose worn and missing parts Replace as needed 5 Fluid lines hoses fittings filler openings drain plugs pressure cap drum muffler engine safety shrouds and area underneath the machine for signs of leakage WARNING Injury can occur when removing the radiator cap Steam or fluid escaping from th...

Page 54: ...mpactors Coolant level must be maintained Air will enter the coolant system if no coolant is present in the bottle Figure 4 1 7 Check fuel level gauge 1 Figure 4 2 If required add clean filtered fuel through the fill area 1 Figure 4 3 Use 2 diesel fuel Figure 4 2 Figure 4 3 ...

Page 55: ... showing on the dipstick call for service assistance to investigate the cause of oil loss Figure 4 4 9 Check hydraulic oil level at gauge 1 Figure 4 5 Add fresh clean anti wear ISO Grade 46 hydraulic oil through the oil fill area 1 Figure 4 6 The fill area is accessed by opening engine hood Be sure to install the fill plug 10 Be sure water tank is full of fresh clean water before starting compacti...

Page 56: ...ects should be reported to the proper personnel Defects must be corrected before operating the machine Checks and verifications of machine controls must be performed prior to operating the machine 12 Mount the compactor maintaining a three point contact as shown in Figure 4 8 NOTE The machine contains a circuit that will allow machine to start only if the propulsion control 13 Figure 4 9 is in neu...

Page 57: ...curely fasten seat belt 14 Position propulsion control 14 Figure 4 9 to the STOP center position Figure 4 9 15 Place engine speed control lever 13 Figure 4 10 to Low idle position Figure 4 10 16 Apply parking brake by placing park brake switch 9 Figure 4 11 in the ON position Figure 4 11 ...

Page 58: ... STOP position 20 Make sure no personnel are close to the machine with the brake applied turn the ignition key 11 Figure 4 11 to the Start position The engine should not start verifying that the machine will not start with the propulsion control lever in a position other than the STOP position 21 Return ignition switch 11 Figure 4 11 to the stop position 22 Place the propulsion control lever 14 Fi...

Page 59: ...on Engine will not crank if control is out of STOP position Figure 4 13 3 Position the engine throttle switch 13 Figure 4 14 to Low Idle Engine will not crank in Hi Idle position Figure 4 14 4 If applied reset the emergency stop switch STOP 4 Figure 4 12 by pulling outward on the switch Engine will not crank if emergency stop switch is depressed ...

Page 60: ...itch immediately and it will return to the ON position NOTE Run engine for short time to warm up the engine and hydraulic systems but do not run engine at idling speed in excess of 10 minutes 7 Check for correct operation of steering system with engine running by turning steering wheel fully to left and then to right The movement of the steering should be smooth and without hesitation If not notif...

Page 61: ...t down and the parking brake light should illuminate indicating the brakes are applied A restart of the machine will be required after performing the above Also the emergency stop switch must be reset by pulling outward on the knob OPERATING THE MACHINE Operating Suggestions and Checks While Operating Machine 1 Always sound horn before moving the machine in either direction to alert persons Allow ...

Page 62: ...lways check travel and work areas for personnel and obstructions 2 If the articulation lock bar 1 Figure 4 17 is in the locked position move it to the stowed position 3 Place engine throttle control 13 Figure 4 18 to the Hi Up position Figure 4 17 NOTE Never use engine speed control to control the speed of travel Figure 4 18 ...

Page 63: ...tch indicator light goes out Figure 4 19 NOTE Operator must be seated when Park Brake is released or engine will stop after approximately two seconds 5 Slowly move propulsion control 14 Figure 4 20 to achieve desired direction and safe speed of travel as determined by the conditions The further the control is moved from the STOP position the greater the speed in that direction Figure 4 20 ...

Page 64: ...4 21 at the desired setting for Manual OFF or Auto drum spray 2 Press the right side of vibration switch 1 Figure 4 21 to select Auto Vibration 3 Place the drum selector switch 2 Figure 4 21 to front drum vibration 4 Move propulsion control 14 Figure 4 20 in the desired direction and safe speed of travel as determined by the conditions Figure 4 21 5 Place engine throttle control 13 Figure 4 22 to ...

Page 65: ...erating the Machine Using Manual Vibration NOTICE Asphalt mat damage With the engine running and the vibration switch on the machine will vibrate DO NOT vibrate with the machine stationary 1 Position the water spray switch 3 Figure 4 24 at the desired setting for Manual OFF or Auto drum spray 2 Press the right side of vibration switch 1 Figure 4 24 to select Auto Vibration 3 Place the drum selecto...

Page 66: ...fe speed of travel as determined by the conditions 6 Adjust water spray flow control 12 Figure 4 25 for the desired amount of spray on the drums NOTE Only switch vibration ON when machine is moving Always switch vibration OFF before the machine comes to a halt Never allow machine to vibrate when machine is stationary 7 Once the travel of the machine is underway the drum vibration can be selected b...

Page 67: ... destination use the following procedure Stopping the Machine 1 If drum vibration is active press vibration ON OFF switch 15 Figure 4 23 to stop vibration 2 If water spray system is ON move water spray switch 3 Figure 4 24 to the OFF middle position 3 For normal stopping move the propulsion control 14 Figure 4 23 slowly to the STOP position 4 To ensure no machine movement occurs after stopping app...

Page 68: ...re 4 28 in the locked position 3 Allow machine to idle for a few minutes before turning ignition switch to stop position Remove ignition key Figure 4 27 Figure 4 28 DAILY PRECAUTIONS AFTER WORK Perform the following precautions each day after work in addition to the daily routine maintenance on the lubrication chart 1 Fill fuel tank to prevent condensation problems 2 Clean drum scrapers of accumul...

Page 69: ...le 2 Clean the trailer surface and loading ramps 3 Before loading machine chock the wheels of the trailer 4 A signalman must assist the operator with any necessary warnings 5 Approach the transporter loading ramps squarely to make sure machine does not drop off side of ramp 6 Drive machine onto transporter 7 Shut engine OFF apply parking brake and lock all lockable compartments Securing the machin...

Page 70: ...being towed Tow only on level ground or up a slight grade Since the compactor braking system has been disabled the towing machine is the only means of restraining the compactor while being towed Chock the disabled compactor whenever towing has stopped Refer to Transporting and Towing Recommissioning in Section 1 SAFETY before transporting the compactor In the event of an engine problem or other ma...

Page 71: ...nd disengage the propulsion pump 1 Figure 4 30 by pressing down on buttons 2 Figure 4 29 Figure 4 30 NOTICE Use only appropriate drawbars for towing requirement Maximum towing speed is 2 5 km h 1 5 mph and maximum towing distance is 300 meters 984 feet 4 Attach an appropriate towing vehicle using appropriate chains drawbar which can be secured in position at the selected tow points on the machine ...

Page 72: ...and wheels of a disabled machine or hitch it to its towing vehicle to prevent accidental movement while preparing the machine for towing This is especially important if machine failure occurs on an incline To tow the machine maximum 300 meters 984 feet use the following procedure CAUTION Towing the compactor is limited to off the job site onto the transporter off the transporter and into the shop ...

Page 73: ...nction valve cartridges used to disengage the propulsion system The spring applied brake will always be applied when the engine is running unless it is manually released 1 Chock the drums 2 Remove plastic plug 1 Figure 4 31 from the center of each drum drive motor housing 2 Figure 4 31 3 Disassemble the brake release bolts 1 Figure 4 32 nuts 2 and bars 3 from the drum support legs 4 4 Assemble the...

Page 74: ...ICE Use only appropriate drawbars for towing requirement Maximum towing speed is 2 5 km h 1 5 mph and maximum towing distance is 300 meters 984 feet 7 Attach an appropriate towing vehicle using appropriate chains drawbar which can be secured in position at the selected tow points on the machine Remove the chocks 8 Tow machine off site at a very slow speed for a short distance maximum 300 meters 98...

Page 75: ...emble the brake release bolts nuts and bars on the drum support legs as shown in Figure 4 32 11 TURN ignition key to the ON position and verify the park brake switch is illuminated to indicate the brake has been applied 12 Check the parking brake using the parking brake test switch procedures identified in Section 5 of these instructions NOTE The propulsion pump will reengage when the engine start...

Page 76: ...SECTION 4 OPERATING INSTRUCTIONS 4 26 DD 29 31HF 38HF Vibratory Asphalt Compactors ...

Page 77: ...DD 29 31HF 38HF Vibratory Asphalt Compactors 5 1 SECTION 5 MAINTENANCE INSTRUCTIONS ...

Page 78: ...s or checks are recommended for the same intervals as the periodic lubrication The purpose of these services or checks are to ensure the uninterrupted and safe operation of the machine by revealing the need for adjustment caused by normal wear Prior to conducting any maintenance work ensure that the following instructions are observed 1 Park the machine on firm level ground 2 Shut down the engine ...

Page 79: ...rvice and the interval at which service should be performed A regular service program should be geared to the items listed under each interval These intervals are based on average operating conditions and manufacturer s recommendations In the event of extremely severe dusty or wet operating conditions more frequent maintenance than specified may be necessary Table 5 1 Maintenance Schedule Function...

Page 80: ... air cleaner system integrity Page 5 23 Check eccentric oil level Refer to Section 8 Page 5 23 Check engine coolant level Page 5 24 SEMI ANNUALLY OR EVERY 250 HOURS Change engine oil and filter Refer to Section 8 Page 5 25 Change fuel filter and in line filter Refer to Section 8 Page 5 26 Purge lube carrier Page 5 28 Change hydraulic oil filter Refer to Section 8 Page 5 29 ANNUALLY OR EVERY 1000 H...

Page 81: ...nated This indicates that the air cleaner is plugged and requires attention Figure 5 1 The air cleaner is a dry type with two elements A primary element that is replaceable or can be cleaned and a safety element that should only be replaced and never cleaned The safety element should be replaced after every third primary element cleaning or change NOTE Dust that gets by the air cleaner system can ...

Page 82: ... two clips 1 Figure 5 2 and remove air filter housing cover 2 to access the filter elements Check vacuator valve 3 to see that it is not inverted damaged or plugged Clean inside housing cover 2 using a clean damp cloth Figure 5 2 2 Gently remove primary filter element 1 Figure 5 3 Figure 5 3 ...

Page 83: ...r Element WARNING When using compressed air water jets or steam cleaning methods ensure that appropriate protective clothing is worn to protect eyes and exposed parts of the body NOTICE Excessive air pressure can damage the primary air element Pressure should not exceed 276 kPa bar 40 psi NOTE No attempt should be made to clean the safety element For maximum engine protection replace the safety el...

Page 84: ...up and down the pleats until no additional dust is being removed Be careful not to rupture the element pleats with the air nozzle Inspect for holes and tears by looking through the primary air cleaner element toward a bright light Check for damaged gaskets or dented metal parts DO NOT REUSE DAMAGED AIR FILTER ELEMENTS 2 To clean the primary air cleaner element using the wet method perform the foll...

Page 85: ...ement before reusing Circulate warm air at LESS than 71 C 160 F DO NOT USE A LIGHT BULB TO DRY THE PRIMARY FILTER ELEMENT Inspect for holes and tears by looking through the primary filter element toward a bright light Check for damaged gaskets or dented metal parts DO NOT REUSE DAMAGED FILTER ELEMENTS Protect the filter from dust and damage during drying Replace the Air Cleaner Elements 1 Examine ...

Page 86: ...5 7 out of the housing Dispose of used element properly 5 Carefully install the replacement safety element by pushing it straight into housing 6 Carefully install the cleaned or replacement primary element 1 Figure 5 8 7 Install air cleaner cover 2 Figure 5 9 and secure with clips 1 Ensure all clips are tight 8 Inspect all air intake piping and joints between air cleaner and engine air inlet to en...

Page 87: ...ater or contaminants may have entered These areas include the articulation and swivel joint pins and bushings console bearings and linkages Refer to Section 8 FUEL AND LUBRICANT SPECIFICATIONS for complete lubrication specification information The complete machine must be given a weekly cleaning Daily cleaning will be required if material is adhering to the drum NOTICE Protect all electrical compo...

Page 88: ...ception of the optional self lubricating bearings 3 Check for defects in the air cleaner ducts and correct as required 4 Check air intake for accumulation of debris that could restrict air flow and clear the air intake 5 Check air cleaner mounting hardware for security and correct as required 6 Check all hoses for cracks chafing or deterioration and replace at the first sign of probable failure To...

Page 89: ...s and nuts as necessary 10 HOUR OR DAILY ROUTINE MAINTENANCE Check Engine Oil Level 1 Park machine on stable level surface and shut down engine 2 Pull out dipstick 1 Figure 5 12 and wipe it clean with a lint free dry cloth Push dipstick back into engine Figure 5 12 3 Pull out the dipstick again The oil level must be between the full top mark and low bottom mark 4 If oil level is low add SAE 15W 40...

Page 90: ... 13 Coolant level should be at the CPLD FILL MIN mark If required add a 50 50 mixture of coolant and water to bring coolant to the proper level Coolant Level must be maintained Air will enter engine coolant system if no coolant is present in the bottle 2 Check for signs of clogging of exposed cooling fins on the radiator 1 Figure 5 14 and oil cooler 2 3 If clogging is dried on dirt use a suitable ...

Page 91: ...ent at this interval Refer to Checking and Removing the Air Cleaner Primary Element on Page 5 5 Check Air Cleaner Restriction Indicator 1 Check the air cleaner restriction indicator 1 Figure 5 15 2 If indicator is red the air cleaner element s are plugged and need replaced or cleaned To replace or clean elements refer to Page 5 9 for details Figure 5 15 ...

Page 92: ... the entire fuel system will require bleeding Fuel tank should always be filled at the end of the shift to prevent condensation 1 Check fuel level gauge 1 Figure 5 16 Figure 5 16 WARNING Fuel is flammable May cause severe injury or death Shut down the engine extinguish all open flames and do not smoke while filling the tank Always wipe up any spilled fuel ...

Page 93: ...7 Check Water Tank Level 1 Check the water level using sight gauge 1 Figure 5 18 Figure 5 18 NOTE During normal operation maintain the tanks full of clean water at all times Do not allow the tanks to become empty for any reason other than for cleaning The water supply for the water spray system is held in tank 1 Figure 5 19 The water tank also functions as the operator platform ...

Page 94: ...tors 2 If water level is low remove the fill cap 2 Figure 5 19 3 Fill tank with clean water 4 Replace fill cap Figure 5 19 Check Parking Brake 1 With the engine running press park brake switch 9 Figure 5 20 to activate the park brake The switch indicator light turns ON Figure 5 20 ...

Page 95: ...tact service personnel and do not operate machine Figure 5 21 Clean Water Strainer Check the water spray system strainer 1 Figure 5 22 clean as necessary at this interval 1 Park the machine on a level surface and turn OFF the engine Turn OFF water flow control 2 Figure 5 18 2 Unthread clear plastic bowl 2 Figure 5 22 and remove strainer 1 Figure 5 22 3 Rinse the strainer and bowl in clean water If...

Page 96: ...battery fluid can cause injury Do not smoke when observing battery fluid level Avoid skin and eye contact with the battery fluid If contact occurs flush area immediately with water The standard battery 1 Figure 5 23 supplied with the DD 29 and DD 31HF 38HF Vibratory Compactors is a maintenance free type battery Figure 5 23 This battery requires only the following maintenance Clean terminals Keep b...

Page 97: ...the articulation pin grease fittings 1 Figure 5 24 2 Apply MPG EP2 grease to each fitting with a grease gun as needed Figure 5 24 Grease Steering Cylinder Pin Bearings 1 Clean the grease fittings 1 Figure 5 25 on the steering cylinder Figure 5 25 2 Apply three shots of MPG EP2 grease to each fitting with a grease gun as needed ...

Page 98: ...e A clean contaminant free system is extremely important to the machine s proper function Take extra care when working around or on the hydraulic system to ensure its complete cleanliness 1 Check hydraulic oil level at gauge 1 Figure 5 26 If required add fresh clean anti wear ISO Grade 46 hydraulic oil through fill area 1 Figure 5 27 Be sure to install fill plug Figure 5 26 Figure 5 27 ...

Page 99: ...Level 1 Park the machine on a level surface with the drum indexes 1 Figure 5 28 in the Twelve o clock and Six o clock positions This places the check plug 2 and fill plug 3 in the proper orientation Figure 5 28 2 Remove check plug 2 Figure 5 28 Oil should be level with the bottom of the hole 3 If additional oil is required remove fill plug 3 Figure 5 28 and add Synthetic Component Lubricant oil as...

Page 100: ...oolant level should be between the FULL and LOW marks on the bottle If required add a 50 50 mixture of coolant and water to bring coolant to the proper level Figure 5 29 250 HOUR OR QUARTERLY ROUTINE MAINTENANCE WARNING Hot oil or components can burn Oil must be at normal operating temperature when draining Avoid contact with hot oil or components Do not allow oil to drain into the ground Dispose ...

Page 101: ...ine drain point remove the plastic plug and drain plug 1 Figure 5 30 Figure 5 30 3 Clean the area around the head of oil filter 1 Figure 5 31 and remove the filter using a filter wrench Catch any escaping oil in a container Figure 5 31 4 Dispose of used oil in accordance with local regulations 5 Wipe the sealing face of the filter head and make sure the used seal is removed before installing the n...

Page 102: ...nge Engine Fuel Filter Element and In Line Fuel Filter WARNING Fuel is flammable May cause severe injury or death Shut down the engine extinguish all open flames and do not smoke while filling the tank Always wipe up any spilled fuel 1 Position the machine on a stable level surface and shut OFF engine 2 Place a container under the fuel filter 1 Figure 5 33 to capture any escaping fuel and remove t...

Page 103: ...fuel filter 2 Figure 5 33 Install the new in line filter and tighten the hose clamps NOTE Air bleeding of the fuel system is required when ever the fuel filters have been removed from the machine 6 Loosen vent plugs 1 Figure 5 34 a few turns Turn the ignition key to the ON position to activate the electric fuel pump Figure 5 34 7 Allow air to escape until bubbles no longer appear Tighten the vent ...

Page 104: ...the ignition key to the STOP position 10 Wipe up any fuel that has escaped and check for leaks Purge Lube Carrier 1 Park the machine on a level surface 2 Clean the area around the protective cap 1 Figure 5 36 on the grease fitting of each drum Figure 5 36 3 Remove the caps and apply MPG EP2 grease to the grease fitting as required 4 Wipe off excess grease and install protective caps ...

Page 105: ...o drain into the ground WARNING Hot exhaust pipe can cause serious burns Avoid contact with exhaust pipe NOTICE Dirt in the hydraulic system will lead to premature component failure A clean contaminant free system is extremely important to the machine s proper function Take extra care when working around or on the hydraulic system to ensure its complete cleanliness 1 Remove hydraulic filter 1 Figu...

Page 106: ...on 8 FUEL AND LUBRICANT SPECIFICATIONS for oil details 4 Apply a film of hydraulic oil to the gasket of the new filter and install filter onto the filter head until gasket makes contact with the filter head Tighten an additional one half turn 5 Check the hydraulic tank level If low fill the hydraulic tank with fresh clean hydraulic oil filtered through a 10 micron filter Refer to Section 8 FUEL AN...

Page 107: ...o drain into the ground NOTICE Dirt in the hydraulic system will lead to premature component failure A clean contaminant free system is extremely important to the machine s proper function Take extra care when working around or on the hydraulic system to ensure its complete cleanliness Drain hydraulic tank as follows 1 Position the machine on stable level surface shutdown the engine and chock the ...

Page 108: ...hydraulic tank Dispose of used hydraulic oil in accordance with local guidelines Figure 5 39 WARNING Hot exhaust pipe can cause serious burns Avoid contact with exhaust pipe 4 Fill the hydraulic tank with fresh clean hydraulic oil filtered through a 10 micron filter Refer to Section 8 FUEL AND LUBRICANT SPECIFICATIONS for oil details 5 Start the machine and check for leaks ...

Page 109: ...the tank Figure 5 40 2 Remove the plugs 1 Figure 5 41 from each end of the spray bars flush out any accumulated sediment 3 Disassemble each of the spray nozzles 2 Figure 5 41 Clean each with a wire brush and reassemble Figure 5 41 4 Remove water tank fill cap 2 Figure 5 42 from tank 1 Figure 5 42 5 Wash the inside of the tank with warm soapy water and rinse with clear water ...

Page 110: ...l cap 2 Figure 5 42 Change Eccentric Lube The eccentric lube oil in each drum must be changed at this interval WARNING The oil must be at operating temperature for draining Use care hot oil and components can burn 1 Run the machine until oil is at operating temperature Position the machine on a level surface with the drum indexes 1 Figure 5 43 and drain plug 2 oriented as shown Figure 5 43 2 Place...

Page 111: ...nt WARNING Injury can occur when removing the radiator cap Steam or fluid escaping from the radiator can burn Inhibitor contains alkali avoid contact with skin and eyes Always shut down the engine and allow to cool down before removing radiator cap Remove cap slowly to relieve pressure Avoid contact with steam or escaping fluid The coolant system of any vehicle should be drained and flushed out at...

Page 112: ...emove the radiator cap 1 Figure 5 45 when draining the system to ensure proper draining Figure 5 45 1 Place a container capable of holding at least 8 quarts 7 6 liters of fluid under the radiator drain petcock 1 Figure 5 46 Open the petcock and drain the coolant from the radiator Figure 5 46 ...

Page 113: ...ine Figure 5 47 3 Check for damaged hoses and loose or damaged hose clamps Replace as required Check radiator for leaks damage and buildup of dirt Clean and repair as required 4 Clean the cooling system using a commercial radiator flushing product Follow the manufacturer s recommendations 5 After cleaning and flushing operations are completed close the drain valve 1 Figure 5 47 and petcock 1 Figur...

Page 114: ...reezing 6 Refill the coolant system 7 Drain and clean overflow bottle 1 Figure 5 48 Refill the overflow bottle with a 50 50 mixture of antifreeze and water Fill coolant bottle to COLD FILL MIN mark on the bottle Coolant Level must be maintained Air will enter engine coolant system if no coolant is present in the bottle Figure 5 48 8 Install radiator cap 1 Figure 5 45 and cap on coolant recovery bo...

Page 115: ...r service the air cleaner while the engine is running 1 Open two clips 1 Figure 5 49 and remove air filter housing cover 2 to access the filter elements Check vacuator valve 3 to see that it is not inverted damaged or plugged Clean inside housing cover 2 using a clean damp cloth Figure 5 49 2 Gently remove primary filter element 1 Figure 5 50 Figure 5 50 ...

Page 116: ...it straight into housing 6 Install new primary element 1 Figure 5 50 7 Install filter housing cover 2 Figure 5 49 and secure with two clips 1 8 Inspect all air intake piping and joints between the air cleaner and the engine air inlet to ensure that unfiltered air cannot enter the system 9 Ensure that all clamps are tight Clean Fuel Tank WARNING Fuel is flammable May cause severe injury or death Sh...

Page 117: ...acity is approximately 18 gallons 68 1 liters Figure 5 52 NOTICE Do not reuse the fuel that has been drained from the fuel tank Always refill with fresh diesel fuel Discard drained diesel fuel in accordance with local guidelines 3 Remove the drain plug and drain the fuel tank Discard drained diesel fuel 4 Rinse the tank with fresh clean diesel fuel 5 Install the drain plug and refill the tank with...

Page 118: ...SECTION 5 MAINTENANCE INSTRUCTIONS 5 42 DD 29 31HF 38HF Vibratory Asphalt Compactors ...

Page 119: ...DD 29 31HF 38HF Vibratory Asphalt Compactors 6 1 SECTION 6 TROUBLESHOOTING ...

Page 120: ...nd maintenance is the most frequent cause of machinery failures and problems In the event of a failure it is recommended to read through this manual If you are unable to determine the cause of the problem or are unable to find a solution when following the troubleshooting chart below contact your local service office The troubleshooting chart is limited to machine control operational problems whic...

Page 121: ... Wait to crank until console indicator lights and gauges have completed system check Controller sensing parking brake is released Toggle Parking Brake Release switch Turn ignition key ON and OFF Propulsion control lever NOT in STOP position Move lever to STOP Fuse F1 defective Check console fuse and replace Battery discharged Check Battery charge if necessary Battery cable connections loose corrod...

Page 122: ...due to wax separation in winter Change fuel filters and bleed fuel system check for fuel line leaks and loose connections Always use winter grade fuel in winter Turn ignition key ON and OFF Vibration turned ON Turn vibration OFF Blocked air cleaner element Clean or replace element Incorrect valve clearances Call for service to adjust Defective fuel injectors Call for specialist service Electric fu...

Page 123: ...ling fins Blocked cooling air flow Call for service to correct fault Fan on radiator or radiator cap defective Replace defective component Thermostat defective Check thermostat Replace if defective SYMPTOM POSSIBLE CAUSE SOLUTION Low Engine Oil Pressure Red Warning Light Illuminates Low engine oil level low engine oil pressure warning light should illuminate Fill oil level to dipstick mark Lubrica...

Page 124: ...UNCTION POSSIBLE CAUSE SOLUTION Start Relay Fuse F1 Replace Vibration Solenoids Power Relay Coil Fuse F2 Replace Emergency Stop Brake and Shunt Solenoids Fuel Pump 2 Second Timer Fuel Shut OFF Fuse F3 Replace Horn Indicator Lamps Fuse F4 Replace Water Pump Fuse F5 Replace Work Lights Option Fuse F6 Replace Back Up Alarm Option Fuse F7 Replace Beacon Option Fuse F8 Replace Turn Stop Lights Option F...

Page 125: ...DD 29 31HF 38HF Vibratory Asphalt Compactors 7 1 SECTION 7 TECHNICAL SPECIFICATIONS ...

Page 126: ...CIFICATIONS GENERAL IDENTIFICATION Name of machine DD 29 DD 31HF DD 38HF Type of machine Double drum vibratory compactor Serial number and product range Effective with initial production Name and address of manufacturer Volvo Construction Equipment 312 Volvo Way Shippensburg Pennsylvania 17257 1295 ...

Page 127: ... 98 37 EC the following values were measured Arms hands The weighted root mean square acceleration value to which the hands are subjected Aeq does not exceed 4 69 m s Body posterior The weighted root mean square acceleration value to which the posterior is subjected Aeq does not exceed 0 13 m s These measurements were recorded in accordance with ISO 5349 and ISO 2631 with the machine operating at ...

Page 128: ...llowing values were measured Arms hands The weighted root mean square acceleration value to which the hands are subjected Aeq does not exceed 6 47 m s Body posterior The weighted root mean square acceleration value to which the posterior is subjected Aeq does not exceed 0 34 m s These measurements were recorded in accordance with ISO 5349 and ISO 2631 with the machine operating at maximum vibratio...

Page 129: ...ion ON These measurements were recorded in accordance with ISO 6394 ISO 6396 and ISO 6395 with engine at manufacturer s rated speed Operator s Exposure to Vibration In accordance with the requirements of clause 3 6 3 a of Annex 1 of Council Directive Relating to Machinery 98 37 EC the following values were measured Arms hands The weighted root mean square acceleration value to which the hands are ...

Page 130: ...ssion Type of system Closed loop hydrostatic parallel circuit to drums Closed loop hydrostatic parallel circuit to drums Drum drive both Pump axial piston Motor radial piston low speed high torque Pump axial piston Motor radial piston low speed high torque Travel speed max 10 6 km h 6 6 mph 10 7 km h 6 6 mph Theoretical Gradeability 44 6 41 7 Brakes Service Dynamic hydrostatic through propulsion s...

Page 131: ...ine Model Kubota V2203M Kubota V2203M Cylinders 4 4 Displacement 2197 cc 134 07 cu in 2197 cc 134 07 cu in Bore 87 0 mm 3 43 in 87 0 mm 3 43 in Stroke 92 4 mm 3 64 in 92 4 mm 3 64 in Capacity 9 5 liters 10 quarts 9 5 liters 10 quarts Rated Power 32 8 Kw 44 hp 2450 RPM 104 FT LB 1700 RPM 32 8 Kw 44 hp 2450 RPM 104 FT LB 1700 RPM Engine Oil Filtration Type Spin on Type Spin on Fuel Filtration Type S...

Page 132: ... Capacities liters gal Fuel 68 0 18 0 Hydraulic 84 9 22 4 Water 299 0 79 0 Propulsion Transmission Type of system Closed loop hydrostatic parallel circuit to drums Drum drive both Pump axial piston Motor radial piston low speed high torque Travel speed max 10 1 km h 6 3 mph Theoretical Gradeability 41 8 Brakes Service Dynamic hydrostatic through propulsion system Secondary Parking Spring applied h...

Page 133: ...de mm in 0 34 0 013 Centrifugal Force kN lb 55 12400 Engine Model Kubota V2203M Cylinders 4 Displacement 2197 cc 134 07 cu in Bore 87 0 mm 3 43 in Stroke 92 4 mm 3 64 in Capacity 9 5 liters 10 quarts Rated Power 32 8 Kw 44 hp 2450 RPM 104 FT LB 1700 RPM Engine Oil Filtration Type Spin on Fuel Filtration Type Spin on Fuel System Type Bosch Type Air Cleaner Dry 2 stage Starting System 12 volt Coolin...

Page 134: ...04 8 51 7 35 3 71 8 5 9 47 47 2 2 2 24 1 Units K L M N O P R S T U Millimeters 732 862 23 1725 2556 392 2619 3819 481 Inches 28 8 33 9 68 9 100 6 15 4 103 1 150 4 18 93 DD 31HF Units A B C D E F G H I J Millimeters 2533 2665 1313 899 1826 105 14 1200 57 614 Inches 99 7 104 9 51 7 35 5 71 9 4 13 55 52 2 24 24 17 Units K L M N O P Q S T U Millimeters 736 483 23 1725 2556 392 2559 3879 483 Inches 29 ...

Page 135: ...ENSIONS DD 38 HF Figure 7 2 DD 38HF Units A B C D E F G H I J Millimeters 2536 2668 1435 901 1828 107 16 1320 57 616 Inches 99 8 105 56 5 35 5 72 4 2 63 52 2 2 24 25 Units K L M N O P R S T U Millimeters 740 862 19 1725 2556 392 2559 3879 608 Inches 29 13 33 9 19 67 9 100 6 15 4 100 75 152 7 23 9 ...

Page 136: ...SECTION 7 TECHNICAL SPECIFICATIONS 7 12 DD 29 31HF 38HF Vibratory Asphalt Compactors ...

Page 137: ...DD 29 31HF 38HF Vibratory Asphalt Compactors 8 1 SECTION 8 FUEL AND LUBRICANT SPECIFICATIONS ...

Page 138: ...d under each interval These intervals are based on average operating conditions In the event of extremely severe dusty or wet operating conditions more frequent lubrication than specified may be necessary All oil levels are to be checked with the machine parked on a level surface and while the oil is cold unless otherwise specified On plug type check points the oil levels are to be at the bottom e...

Page 139: ...rd to capscrews nuts and pins being properly secured 4 Spot check several capscrews and nuts for proper torque If any are found loose a more thorough investigation must be made 5 If a defect is detected which requires special maintenance service stop the machine operation until the defect has been corrected If necessary contact the local distributor for assistance 6 This symbol represents an area ...

Page 140: ...ilter Engine Coolant Engine Oil Filter Hydraulic Oil Hydraulic Oil Filter Refer to Page 8 7 for specific oil grades This lubrication schedule is supported by the Maintenance Schedule chart found in Section 5 MAINTENANCE INSTRUCTIONS of this manual LCDDSNAP 002 250h semi annual 10h or shift 50h or 1 week 1000h annual 1 3 11 12 13 16 16 19 21 24 23 22 25 25 26 24 23 31 33 33 34 35 36 ...

Page 141: ...pstick Full AR 50 HRS OR WEEKLY 11 12 13 16 19 STEERING CYL BEARINGS SWIVEL PINS HYDRAULIC OIL ECCENTRIC OIL ENGINE COOLANT G G S A S A S A MPG EP2 GREASE MPG EP2 GREASE See 3 next page See 4 next page Water Anti freeze 3 SHOTS EACH 3 SHOTS EACH FILL TO SIGHT GLASS FILL TO LEVEL HOLE FILL TO FULL MARK 250 HRS OR SEMI ANNUALLY 21 22 23 24 25 26 ENGINE OIL ENGINE OIL FILTER FUEL FILTER CARTRIGE IN L...

Page 142: ... These capacities will give the servicing personnel an approximation of the fluid capacities of the components to be serviced Always ensure that the specified method of checking for accurate fluid levels is used Table 8 3 Fluid Capacities FLUID OIL APPROXIMATE CAPACITY DD 29 31HF 38HF Diesel Fuel 68 liters 18 0 gallons Hydraulic Oil 84 9 liters 22 gallons Engine Oil 9 5 liters 10 quarts Engine Coo...

Page 143: ...at operating temperature 7500 SUS minimum at starting temperature 150 to 225 SUS at 100 F generally 44 to 48 SUS at 210 F generally Viscosity Index 90 minimum Aniline Point 175 minimum API Gravity 28 minimum Parafinic oils 28 or more Mixed base 24 to 28 Naphthalic or asphaltic base 24 or less Recommended Additives Rust and oxidation inhibitors Foam Depressant Desirable Characteristics Stability of...

Page 144: ... for year round service Low temperature usage is restricted as follows Table 8 5 Viscosity Temperatures Extreme Pressure Multipurpose Grease This is a lithium soap base grease with a high load carrying capacity The following properties are recommended Table 8 6 Multipurpose Grease Properties SAE VISCOSITY NO MIN AMBIENT TEMP F C 75W 40 F 40 C 80W 15 F 26 C 85W 10 F 12 C 90 20 F 7 C 140 40 F 4 C 25...

Page 145: ...nal mineral oils The lubricant has naturally high viscosity indexes compared to mineral oils providing lower viscosity at lower temperatures and higher viscosity at higher temperatures Table 8 7 Table 8 8 AMBIENT TEMPERATURE F C CONSISTANCY GRADE Below 0 F Below 18 C NLGI No 0 0 to 100 F 18 to 38 C NLGI No 1 or No 2 Over 100 F Over 38 C NLGI No 2 or No 3 PROPERTY SPECIFICATION ISO Viscosity Grade ...

Page 146: ... high energy content and generally lower cost of No 2 Diesel Fuels Refer to the specifications shown in Table 8 8 Table 8 9 Fuel Oil Specifications Flash Point 125 F 52 C minimum Water and sediment volume 0 05 maximum Carbon residue on 10 percent residum 0 35 maximum Ash Weight 0 01 maximum Distillation Temperatures 90 Point 540 F 282 C minimum 640 F 338 C maximum Viscosity kinematic cSt or mm s a...

Page 147: ...ring maintenance Brake Lining Dust Avoid breathing during maintenance Only on machines with dry axle brakes The following substances are contained in or emitted by this machine and may be hazardous to your health if used incorrectly SUBSTANCE PRECAUTION Antifreeze Water cooled engine Avoid ingestion skin contact and breathing fumes Hydraulic Oil Avoid ingestion skin contact and breathing fumes Eng...

Page 148: ...SECTION 8 FUEL AND LUBRICANT SPECIFICATIONS 8 12 DD 29 31HF 38HF Vibratory Asphalt Compactors ...

Page 149: ...DD 29 31HF 38HF Vibratory Asphalt Compactors 9 1 SECTION 9 TORQUE SPECIFICATIONS ...

Page 150: ...tween the engaged bolt and nut threads All thread fasteners will be Loctited except the following 1 Nylon insert nuts 2 Whizlock bolts and nuts 3 Fasteners less than inch 6 mm diameter 4 If instructed not to apply Loctite BOLT COURSE TORQUE BOLT FINE TORQUE lbs ft N m lbs ft N m 1 4 20 9 12 1 4 28 1 1 5 16 18 19 26 5 16 24 1 2 3 8 16 37 50 3 8 24 2 5 7 16 14 59 80 7 16 20 6 8 1 2 13 90 122 1 2 20 ...

Page 151: ...Use Loctite 271 on all bolts larger than M8 Use Loctite 242 on bolts M8 and smaller Apply enough Loctite to fill all gaps between the engaged bolt and nut threads All thread fasteners will be Loctited except the following 1 Nylon insert nuts 2 Whizlock bolts and nuts 3 Fasteners less than inch 6 mm diameter 4 If instructed not to apply Loctite BOLT SIZE TORQUE lbs ft N m M6 X 1 0 9 12 M8 X 1 25 21...

Page 152: ...ER FASTENER SIZE TORQUE USE LOCTITE N m lbs ft Rear Frame Filter Plate Attaching Bolt M8 X 1 25 13 9 5 ROPS Attaching Bolt M20 X 90 271 200 271 Drum Drive Motor to Drive Plate Attaching Nut M10 X 1 5 170 125 271 Vibration Motor Attaching Bolt M10 70 52 271 Eccentric Bearing Cover Attaching Bolt M10 X 25 41 30 271 Eccentric Bearing Housing Attaching Bolt M12 X 1 75 X 35 108 80 271 Hood Grab Handle ...

Page 153: ...DD 29 31HF 38HF Vibratory Asphalt Compactors SECTION 10 SCHEMATICS ...

Page 154: ...e and maximum performance we recommend the use of genuine manufacturer brand parts The electrical and hydraulic schematics included herein that are applicable to the DD 29 31HF 38HF Vibratory Asphalt Compactors are outlined below Electrical Schematics Electrical Schematic for the DD 29 31HF 38HF Vibratory Asphalt Compactors Drawing No 13305313 page 10 3 Hydraulic Schematics Hydraulic Schematic for...

Page 155: ...SCHEMATICS SECTION 10 DD 29 31HF 38HF VIBRATORY ASPHALT COMPACTORS 10 3 Electrical Schematic for DD 29 31HF 38HF Vibratory Asphalt Compactors 13305313 OM13305313_0B01 ...

Page 156: ...SECTION 10 SCHEMATICS 10 4 DD 29 31HF 38HF VIBRATORY ASPHALT COMPACTORS Hydraulic Schematic DD 29 Vibratory Compactors 59223479 OM59223479_0D01 ...

Page 157: ...SCHEMATICS SECTION 10 DD 29 31HF 38HF VIBRATORY ASPHALT COMPACTORS 10 5 Hydraulic Schematic for DD 31HF 38HF Vibratory Compactors 59223487 OM59223487_0B01 ...

Page 158: ...SECTION 10 SCHEMATICS 10 6 DD 29 31HF 38HF VIBRATORY ASPHALT COMPACTORS ...

Page 159: ...DD 29 31HF 38HF Vibratory Asphalt Compactor 11 1 RECOMMENDED SPARE PARTS ...

Page 160: ...ation Motor DD 29 1 13357322 Vibration Motor DD 31HF 38HF 1 59402537 V Ring Seal 2 59027755 Seal 2 59133900 Drive Motor DD 29 1 13402276 Drive Motor Front DD 31HF 38HF 1 59243017 Drive Motor Rear DD 31HF 38HF 1 59240309 Magnetic Plug 2 59144428 Shock Mount 6 59600205 Shock Mount DD 31HF 38HF 3 59269688 Drum Skirt Hydraulic Filter 2 2 2 59075440 Battery Hold Down 1 58870627 Engine Effective with Al...

Page 161: ...5 Pin 1 59265959 Pin 1 59265942 Breather Filtered Vent 1 59093351 Sight Plug 1 59121954 Cable 1 59436741 Bearing 1 50268127 Cap 1 59180992 Steering Cylinder 1 59269563 Hydraulics Pressure Switch 1 59090878 Vibration Steering Pump 1 59227041 Propulsion Pump 1 13219175 Brake Valve 1 59225573 Vibration Valve 1 59212886 Instrument Panel Parking Brake Switch 1 13305420 Water System Switch 1 59226597 Oi...

Page 162: ...destal Ignition Key 1 1 1 58917261 Horn Button 1 1 1 58858572 Blank Switch 1 58835398 Top Dust Boot 1 59108100 Bottom Dust Boot 1 59108605 Ignition Switch 1 13305180 Shock Mount 2 59653543 Steering Control Valve 1 59212860 Steering Wheel 1 58858564 Steering Column 1 58858580 Side Console Drum Vibrate Switch 1 59214718 F Stop R Control 1 13316385 F Stop R Cable 1 54520986 Clevis Assembly 1 59662312...

Page 163: ...199807 Water Pump 1 59262410 Electrical Receptacle 1 59436865 Connection 1 59572867 Drain 1 95250692 Ball Valve Two Way 1 59226076 Wedge 1 59436873 Water Tank Cap 1 54489000 Water Strainer 1 1 1 59044321 Ball Valve 1 58825498 Check Valve 1 58848755 Kits Vibration Motor Seal Kit DD 29 1 59489658 Vibration Motor Seal Kit DD 31HF 38HF 1 59402537 Drive Motor Seal Kit DD 29 1 54505383 Drive Motor Brake...

Page 164: ...raper 47 Drum 1 59272419 Inside Scraper 49 Drum 1 13171954 Inside Scraper 52 Drum 1 59272443 Inside Scraper 54 Drum 1 13212725 Urethane Scraper Rubber Scraper 47 Drum 1 13166996 Rubber Scraper 49 Drum 1 13172044 Rubber Scraper 52 Drum 1 13167002 Rubber Scraper 54 Drum 1 13212733 Urethane Inside Scraper Inside Scraper 47 Drum 1 13213202 Inside Scraper 49 Drum 1 13213210 Inside Scraper 52 Drum 1 132...

Page 165: ...ulated Module 1 59262469 LUBRICANTS 1 Qt 1 Gal 5 Gal 55 Gal All Season Premium Hydraulic Oil n a n a 59045179 59045187 Multi Purpose Premium Engine Oil 59022343 59023507 57022327 59022335 Premium Limited Slip Component Lubricant 13248455 13248463 59022418 59022426 Premium Multi Purpose ATF 13248471 13248489 59023572 59023580 Synthetic Component Lubricant 13248430 13248448 59877597 59022459 Synthet...

Page 166: ...SECTION 11 RECOMMENDED SPARE PARTS 11 8 DD 29 31HF 38HF Vibratory Asphalt Compactors ...

Page 167: ...Cleaner Element 5 7 Clean Water Strainer 5 19 Consistancy Grades 8 9 CONTROLS 6 Crush Area 1 16 1 19 D DAILY PRECAUTIONS AFTER WORK 4 18 DD 24 30 28HF 34HF SPECIAL TORQUE VAL UES 9 4 Decal Location 1 15 DIESEL FUEL SPECIFICATIONS 8 10 Difficult Starting Poor Irregular Performance 6 4 Drain and Flush Radiator Replace Engine Cool ant 5 35 Drain and Flush Water Tank and Spray Bars 5 33 Drain hydrauli...

Page 168: ...neous Areas 9 4 MOUNTING AND DISMOUNTING OF ATTACH MENTS 4 19 MOVEMENT OF MACHINE BETWEEN WORK SITES 4 19 Moving the Machine Propulsion Control 4 12 Multipurpose Grease Properties 8 8 N NOTE 1 3 NOTICE 1 3 O Operating 1 8 OPERATING INSTRUCTIONS 4 2 Operating Suggestions and Checks While Oper ating Machine 4 11 OPERATING THE MACHINE 4 11 Operating the Machine Using Manual Vibration 4 15 operational...

Page 169: ...olted Connections 5 12 TORQUE SPECIFICATIONS 9 2 TOWING THE MACHINE MODELS DD 24 DD 30 4 20 MODELS DD 28 DD 34HF 4 22 TRANSPORTING TOWING AND LOADING 1 12 TROUBLESHOOTING 6 2 U UNDERSTAND SIGNAL WORDS 1 2 US DECALS 1 16 Using Vibration Controls 4 15 Operating the Machine Using Auto Vibration 4 14 V Viscosity Temperatures 8 8 Voltmeter Indicates Low Or Negative Value 6 5 W WARNING 1 3 WARNING OF SP...

Page 170: ...SUBJECT INDEX Index 4 DD 29 31HF 38HF Vibratory Asphalt Compactors ...

Page 171: ...The warranty statement is provided within the manual kit shipped with the machine ...

Page 172: ...Ref No VOE21A1004089 English CPN 43924968 Printed in Sweden 2008 06 CST Volvo Shippensburg ...

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