VOLVO DD24 ASPHALT COMPACTOR Service and Repair Manual

Volvo Double Drum Compactors DD22, DD24

2 Introducing reliable performance in a smaller package The DD22 and DD24 asphalt compactors from Volvo have been designed to help you deliver maximum productivity, density, and smoothness on smaller compaction projects. These reliable double drum machines are simple to operate and are backed by the worldwide Volvo dealer network you know and trust. Move your business and bottom line in the right direction with the DD22 and DD24. Serviceability - Unobstructed daily checkpoints - Easy-to-lift engine enclosure - Ground-level access to engine, radiator, battery, and filters - Service charts with detailed checkpoints, service intervals, and lubricant info - Maintenance-free eccentric bearings Performance Features - 225 l (59 gal) gravity feed water system (not available in all markets) - 260 l (68 gal) pressurized water system (available as option in some markets) - Dual frequency drums - High frequency (67 Hz [4,000 vpm]) for maximum rolling speeds and optimal impact - Machined drum surface with radiused and chamfered edges produce a professional quality finish on each job - Excellent visibility to drum edges in front and rear - Liquid-cooled 24 kW (32 hp), 3-cylinder diesel engine - Urethane wipers to keep water on drum surface - Central lifting Available Options - Offset articulation joint enables operator to shift drum 50 mm (2") - Foldable ROPS - Edge compactor and cutter - Inside urethane wipers - Work and road light packages - Beacon lights - Fuel indicator - Sliding seat with dual levers - Sliding seat with single lever - Loading / unloading traction control - Pressurized water system with interval flow control, four nozzles per drum (standard in some markets)

3 Specifications Product improvement is a continuing goal at Volvo. Designs and specifications are subject to change without notice or obligation. Model DD22 DD24 Machine Weights (w/ ROPS) Operating Weight kg (lb) 2 450 (5,400) 2 600 (5,725) Weight @ Front Drum kg (lb) 1 225 (2,700) 1 300 (2,863) Weight @ Rear Drum kg (lb) 1 225 (2,700) 1 300 (2,863) Shipping Weight kg (lb) 2 300 (5,070) 2 450 (5,400) Machine Dimensions Length mm (in) 2 420 (95) 2 420 (95) Width mm (in) 1 090 (43) 1 290 (51) Height (top of steering wheel) mm (in) 1 909 (75) 1 909 (75) Height (top of ROPS) mm (in) 2 624 (103.3) 2 624 (103.3) Drum Base mm (in) 1 720 (68) 1 720 (68) Curb Clearance mm (in) 490 (19.3) 490 (19.3) Inside Turning Radius (to drum edge) mm (in) 2 800 (110) 2 700 (106) Drum Width mm (in) 1 000 (39) 1 200 (47) Diameter mm (in) 700 (28) 700 (28) Shell Thickness mm (in) 13 (0.5) 13 (0.5) Finish Machined Vibration Frequency Hz (vpm) 55 / 67 (3,300 / 4,000) 55 / 67 (3,300 / 4,000) Nominal Amplitude mm (in) 0,53 (0.02) 0,53 (0.02) Centrifugal Force kN (lb) High 37 (8,318) 40 (8,992) Low 25 (5,620) 28 (6,295) Propulsion Type Closed-loop hydrostatic Drum Drive Radial piston Travel Speed km/h (mph) 0 – 10 (0 – 6.2) 0 – 10 (0 – 6.2) Engine Make / Model Cummins A1700 Engine Type 3-cylinder diesel Rated Power @ Installed Speed kW (hp) 24 (32) 24 (32) Electrical 12 volts, 45 A alternator Brakes Service Hydrostatic Parking Secondary Spring-applied, hydraulic release on each drum Water System Type Gravity Pressurized Gravity Pressurized Nozzles – 4 per drum – 4 per drum Filtration Inlet filter Inlet and nozzle filtration Inlet filter Inlet and nozzle filtration Drum Wipers Spring-loaded, self-adjusting urethane wipers Spring-loaded, self-adjusting urethane wipers Water Tank Capacity l (gal) 225 (59) 260 (68) 225 (59) 260 (68) Miscellaneous Articulation Angle + / - 30° + / - 30° Oscillation Angle + / - 10° + / - 10° Fuel Tank Capacity l (gal) 40 (10.6) 40 (10.6) Hydraulic Oil Capacity l (gal) 27 (7.1) 27 (7.1) Gradeability (theoretical) 30% 30%

Ref. No. VOE 21 C 100 4022 English Printed in Sweden 2008.09-5,0 RM Volvo, Sweden Not all products are available in all markets. Under our policy of continuous improvement, we reserve the right to change specifications and design without prior notice. The illustrations do not necessarily show the standard version of the machine. Volvo Construction Equipment is different. Our machines are designed, built and supported in a different way. That difference comes from an engineering heritage of over 175 years. A heritage of thinking first about the people who actually use the machines. About how to help them be safer, more comfortable, more productive. About the environment we all share. The result of that thinking is a growing range of machines and a global support network dedicated to helping you do more. People around the world are proud to use Volvo. And we’re proud of what makes Volvo different – More care. Built in.

Air cleaner, description The three-stage air cleaning system is of crucial importance to the operational reliability and durability of the engine. In the first stage, a cyclonic filter separates out the heavier particles in the air and these are expelled automatically by a dust ejection valve. A considerable amount of impurities are eliminated at this preliminary stage, which reduces the demands on the main filter. The main filter (stage 2) is a paper filter that needs to be exchanged at regular intervals. The safety filter (stage 3) is effective when the main filter is damaged and allowing impurities through. As it traps impurities, it clogs quickly. The safety filter cannot be cleaned. Instead, the filter must be renewed as soon as it has become clogged or the renewal date has been reached.

Battery disconnector switch, description Battery disconnect switch Figure 1 Battery The battery main switch (1) is on the right-hand side next to the battery under the engine bonnet. (Refer to Battery, description ) It is connected to the positive terminal of the battery (12 V). The purpose of the battery main switch (1) SW3101 is to isolate the electrical system from the battery whenever the machine is out of use. NOTE! It should be noted that the battery main switch does not have an emergency STOP function. The battery main switch cannot be used to stop the engine when it is running. Refer to Wiring diagram 1 . Emergency stop switch Figure 2 Control panel Emergency STOP switch (1) SW3305 is located on the control panel, refer to Instruments and controls, overview . Whenever the emergency STOP switch is pressed, the machine's on-board power supply is interrupted. The engine and all functions stop immediately. If the emergency STOP switch has been operated, it must be reset before the machine can be restarted. Refer to Wiring diagram 1 .

Battery, charging WARNING Hydrogen gas is formed during battery charging. Hydrogen gas is flammable and may be explosive. A short circuit, open flame or spark near the battery can cause a powerful explosion. Therefore, ventilate well. Never smoke near batteries.    Batteries must only be charged using a battery charger. Check the battery terminal connections and make sure that they are adequately tightened and free from corrosion and dirt. Check the battery voltage when the batteries are at rest (before starting). Each battery must be at least half-charged. NOTICE Always turn off the current to the battery charger before disconnecting the charging clamps. WARNING Corrosive sulphuric acid The battery electrolyte includes corrosive sulphuric acid. Electrolyte spilled on bare skin must be removed immediately. Wash with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately with plenty of water and seek immediate medical attention.

Battery, description The battery master switch is next to the battery on the left-hand side under the engine bonnet. Figure 1 Battery Position Description 1 Positive terminal 2 Negative terminal 3 Attaching frame The battery is on the left-hand side under the engine bonnet. The original battery fitted in the machine in production is completely maintenance-free. If the battery does need to be replaced, the replacement battery must have identical power characteristics. Before trouble shooting is carried out on the electrical system, the battery must have sufficient charge. If necessary, recharge the battery using a battery charger.

Brake system, description During operation, the machine is braked by the hydrostatic travel drive. The parking brake, or holding brake, is a wet hydraulic-release multi-disc brake integrated into the travel motors. It is held closed by spring force and opened hydraulically by the supply of compression oil. The multi-disc brake also acts as an emergency brake in the event of hydrostatic travel drive failure. Braking A closed circuit can be operated with four-quadrant control. This means that it can drive in the forwards or reverse direction of rotation and transmit either positive or negative torque in the process. Whenever the drive lever is used to reduce travel speed, the mode of operation changes from positive torque to negative torque. In this state, the hydraulic pump of the travel drive attempts to drive the diesel engine. The travel drive and brake are controlled by means of the drive lever. The spring brake in the travel motors opens first. Any further movement of the drive lever forwards (forward travel) or backwards (reverse travel) causes the machine to accelerate to the selected speed. When the drive lever is moved towards neutral position, the amount of hydraulic oil displaced by the travel pump is reduced; the drive changes from positive torque to negative torque and the machine decelerates. Any further movement towards neutral results in braking by the hydraulic system and, if necessary, actuation of the pressure limiting valves. This ensures safe braking in all situations:     During normal operation, braking is hydrostatic and completely wear-free. Under hard deceleration, the high-pressure limiting valves may be actuated if necessary. If the emergency STOP switch has been pressed, hydrostatic braking no longer functions and the multi-disc brake in the travel motors would intervene instead. The multi-disc brake would also intervene automatically if, for example, fluid were leaking from the travel drive due to a line break. In this situation, the pressure on the feed side would collapse. For this reason, pneumatic pressure for the brake would be tapped from the feed side.

Cleanliness in hydraulic systems The greatest possible cleanliness must be observed when carrying out any work on the different hydraulic systems. Wipe all pipes and hose connections clean before disconnecting them, remove all flakes of paint, etc. Plug all pipes, hoses, cylinders, etc. immediately after disconnecting them. Never attach an unplugged hydraulic hose without first cleaning it.

VOLVO DD24 ASPHALT COMPACTOR Service and Repair Manual

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