TABLE OF CONTENTS

INTRODUCTION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-2
Procedure When Receiving the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-3
Identification Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-4
Machine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-4
Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-5
Instruction Manual Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-5
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-6
CE Marking, EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-7
CE Marking (Declaration of Conformity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-7
EU EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-7
EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-7
Communication Equipment, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-9
Protection Against Electromagnetic Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-9
Mobile Telephones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-9
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-9
Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-10
Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-10
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-11
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-11
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-11
Drum Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-12
Vibration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-12
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-12
Operator Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-12
Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-12
ROPS/FOPS/Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-13
Identification of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-14

SAFETY
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Be Aware of Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Conventions Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Danger Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Selection and Qualification of Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Organizational Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Mandatory Safety Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Working Within HAZARDOUS Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Safety Instructions Governing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Transporting, Towing, and Roading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Hazardous Substance Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Battery Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

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Warning of Special Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Safety Related Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
U.S. Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
International Decals With Interpretation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

SYMBOL IDENTIFICATION
Symbol Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Machine Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
International Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

OPERATING CONTROLS AND INSTRUMENTS

Operating Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Articulation Lock Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Control Panel, Upper Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Vandalism Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Impactmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Seatbelt Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Grid Heater 'ON' Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Main Water Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Engine Stop Light (RED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Check Engine Light (AMBER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Control Panel, Lower Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Main Water Pump Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Auxiliary Water Pump Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
High/Low Engine Speed Control (Throttle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Park Brake Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Work Lights Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Drum Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Auto/Manual Vibration On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Vibration Control/Eccentric Direction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
High/Low Frequency Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Propulsion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Operator's Console and Seat Adjustment Lever . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Pedestal Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Water Tank Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Vibration Indicator Lamp (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Amplitude Adjusting Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Beacon Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
VPM Meter/Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

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Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Four-Way Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Hydraulic Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Speed Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

OPERATING INSTRUCTIONS
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Pre-Start Checks/Verifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Checks and Verifications of Overall Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Checking and Verifying Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Starting Machine and Other Checks/Verifications . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Starting Procedure and Checks and Verifications with Engine Running . . . . . . . . . . 4-11
Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Operating Suggestions and Checks while Operating Machine . . . . . . . . . . . . . . . . . . 4-16
Moving the Machine (Propulsion Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Using Vibration (Vibration Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Setting the Auto Vibration Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Operating the Machine Using Automatic Vibration . . . . . . . . . . . . . . . . . . . . . . . 4-20
Operating the Machine Using Manual Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Amplitude Adjusting Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Parking, Stopping, and Shutting Down the Machine . . . . . . . . . . . . . . . . . . . . . . 4-24
Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Stopping the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Shutting Down the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Daily Precautions After Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Mounting and Dismounting of Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Movement of Machine Between Work Sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Loading the Machine Under its Own Power (Drive On) for Transporting . . . . . . . . . . 4-26
Loading the Machine by Lifting the Equipment for Transporting . . . . . . . . . . . . . . . . 4-27
Securing the Machine to the Transport Vehicle (Tie-Down) . . . . . . . . . . . . . . . . . . . . 4-27
Towing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Towing the Machine, Maximum 300 Meters (984 Feet) . . . . . . . . . . . . . . . . . . . . . . . 4-30
If The Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
If The Engine Will Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Special Conditions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Precautions to be Taken for Various Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Emergency Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

MAINTENANCE INSTRUCTIONS
Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
General Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Preventive Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Preparations Before Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Fluids and Oil, Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Initial Break-In Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Maintenance for Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Short Term Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

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Long Term Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Prepare Machine for Use Following Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
PREVENTIVE Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Access to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Routine Maintenance - As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Check Air Cleaner Connections and Ducts for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Checking and Removing the Air Cleaner Primary Element . . . . . . . . . . . . . . . . . . . . 5-15
Cleaning the Primary Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Cleaning Air Cleaner Element - Dry Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Cleaning Air Cleaner Element - Wet Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Install the Air Cleaner Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Before Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
After Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Tighten Loose Bolted Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Check all Shock Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
10 Hour or Daily Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Check Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Check Engine Coolant Level, Clean Radiator and Oil Cooler . . . . . . . . . . . . . . . . . . . 5-25
Check Air Cleaner Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Check Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Check Water Tank Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Check Water Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Test Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Check Condition of Drums and Scrapers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Check Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
50 Hour or Weekly Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Check Batteries, Clean and Grease Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Grease Articulation and Oscillation Pin Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Grease Steering Cylinder Pin Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Check Eccentric Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Check Pump Drive Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Check Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Check Air Cleaner System Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
250 Hour or Quarterly Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Change Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Change Engine Fuel Filter and Fuel/ Water Separator . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Clean Pump Drive Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Change Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Clean Drum Carrier Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Grease Console Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Grease Console Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
1000 Hour or Annual Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Change Drum Eccentric and Carrier Housing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Change Pump Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Change Hydraulic Oil and Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Drain and Flush Water Tank and Spray Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Drain, Flush, and Replace Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
Tighten Oscillation Swivel Pin Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Tighten Articulation Swivel Pin Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Check Engine Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
Check Engine Belts and Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

iv
 TABLE OF CONTENTS

TROUBLESHOOTING
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Fuse Block and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Fuse Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Engine Difficult to Start and Has Poor and Irregular Performance . . . . . . . . . . . . 6-5
Engine Making Excessive Fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Engine Overheats - Stop Engine Immediately . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Low Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Voltmeter Indicates Low or Negative Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

TECHNICAL SPECIFICATIONS
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
General Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Machine Weights and Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Variable Amplitude Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

FUEL AND LUBE SPECIFICATIONS

Fuel and Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Symbol Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Lubrication and Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Hydraulic Oil Requirements and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Lubricating Oil/Grease Specifications (Except Engine) . . . . . . . . . . . . . . . . . . . . 8-10
Synthetic Component Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Extreme Pressure Multi-Purpose Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Engine Lube Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Cummins Fuel Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

v
 INTRODUCTION

DD90/DD90HF Intro-1
 INTRODUCTION

INTRODUCTION
This manual is applicable to the DD90/DD90HF asphalt compactor with an engine tier level
designation, Tier 3. Please see Figure 2 to identify the machine engine tier level designation.
The primary purpose of this manual is to provide the operator and site maintenance personnel
with knowledge of the common functions and fundamental rules to be followed for on-site use
and maintenance of DD90 and DD90HF double-drum vibratory roller compactors.

! WARNING
Personal Injury Hazard

Allow no one to operate this machine unless they have read and
understand this Operation and Maintenance Manual, and have been
properly trained in the safe operation of the machine.

Failure to obey this Warning could result in serious personal injury, or

death.

This Operation and Maintenance Manual must have been read and fully understood by the
operator before operating the machine. The information in this manual is divided into the
following sections:

• INTRODUCTION, describing the machine

• Section 1 - SAFETY
• Section 2 - SYMBOL IDENTIFICATION
• Section 3 - OPERATING CONTROLS AND INSTRUMENTS
• Section 4 - OPERATING INSTRUCTIONS
• Section 5 - MAINTENANCE INSTRUCTIONS
• Section 6 - TROUBLESHOOTING
• Section 7 - TECHNICAL SPECIFICATIONS
• Section 8 - FUEL AND LUBE SPECIFICATIONS
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 manufacturer’s
local authorized dealer or distributor. This is an essential condition for working safely with the
machine.
The correct machine operation, use, and regular maintenance are also essential elements to
provide the highest performance and safety.

Intro-2 DD90/DD90HF
INTRODUCTION

The present manual is accompanied with an engine instruction manual. The operator is
therefore advised to follow the operation and maintenance instructions as specified in both the
engine and the machine instruction manuals.
Some illustrations in this manual may show machines with optional equipment installed. This
optional equipment may be purchased from the manufacturer’s local authorized dealer or
distributor.
Each manual is reviewed and revised regularly to include all necessary changes.The
manufacturer reserves the right to modify or make changes within a specific model group
without notice, and without incurring any liability to retrofit machines previously shipped from
the factory. Contact the manufacturer’s local authorized dealer or distributor for non-routine
maintenance that is not covered in this manual.

PROCEDURE WHEN RECEIVING THE MACHINE

The machine has been tested, accurately checked, and prepared for shipment. Every part of
the machine, including the detached parts, has been accurately checked before being shipped
from the factory.
When receiving the machine, and before unpacking the equipment, check if damage has
occurred during transport and if any parts are missing.
Check the equipment by consulting the shipment documents.
If the machine is damaged or has missing parts, inform the freight agent as soon as possible.
They will inform you regarding how to proceed in order to make a complaint.

DD90/DD90HF Intro-3
 INTRODUCTION

IDENTIFICATION DATA
An exact description of the model type and serial number of the machine will facilitate fast and
efficient response from the manufacturer’s parts and service operations.
Always provide the model of the machine and its serial number when contacting the
manufacturer’s local authorized dealer or distributor service or parts office. Enter the machine
identification data for future reference.

Machine Identification Data

Machine Model
Machine Serial Number
Year of Manufacture
Engine Serial Number

MACHINE IDENTIFICATION
The machine serial number is stamped on a nameplate located (1, Figure 1) on the bottom
right hand side of the rear frame.

Figure 1

Intro-4 DD90/DD90HF
INTRODUCTION

ENGINE IDENTIFICATION
The engine serial number is stamped on a nameplate (1, Figure 2) located on top of the
engine. The nameplate also identifies the engine model tier level designation for emission
regulations (1).

Figure 2

INSTRUCTION MANUAL STORAGE

A manual storage compartment (1, Figure 3) is located under the hinged floor panel in the
operator's platform and provides a storage space for the Operation and Maintenance Manual
(2, Figure 3).

Figure 3

DD90/DD90HF Intro-5
 INTRODUCTION

GENERAL INFORMATION
All safety rules in Section 1, SAFETY of this Operation and Maintenance Manual must be
observed.
If further information is required concerning the recommended use on asphalt applications,
contact the manufacturer’s local authorized dealer or distributor, or the following:

Volvo Construction Equipment

312 Volvo Way
Shippensburg, Pennsylvania 17257, USA
(Service and Warranty) Contact your local authorized dealer or distributor
(Customer Service Parts) Contact your local authorized dealer or distributor
The manufacturer reserves the right to make changes or modifications without prior notice and
without incurring any liability to retrofit machines previously shipped from the factory.

Intro-6 DD90/DD90HF
INTRODUCTION

CE MARKING, EMC DIRECTIVE

CE Marking (Declaration of Conformity)

(Applies to machines marked as CE compliant.)
If this machine is CE marked, this means that, when delivered, the machine meets the
applicable “Essential Health and Safety Requirements,” which are given in the EU Machinery
Safety Directive, 2006/42/EC.
Any person carrying out changes that affect the safety of the machine is also responsible for
the same.
As proof of that the requirements are met, an EU Declaration of Conformity and a sound
certificate regarding sound power level in dB(A) are supplied with the machine. The sound
certificate includes both measured external values and guaranteed sound power level. These
declarations are issued by Volvo CE for each CE-marked machine. This EU declaration also
covers attachments manufactured by Volvo CE and supplied for Volvo CE-marked machines.
The documentation is a valuable document, which should be kept safe and retained for at least
10 years. The document should always accompany the machine when it is sold.

EU EMC Directive
The electronic equipment of the machine may in some cases cause interference to other
electronic equipment, or suffer from external electromagnetic interference, which may
constitute safety risks.
The EU EMC directive about “Electromagnetic compatibility,” 2004/108/EC, provides a
general description of what demands can be made on the machine out of a safety point of
view, where permitted limits have been determined and given according to international
standards.
A machine or device which meets the requirements should be CE marked. Our machines have
been tested particularly for electromagnetic interference. The CE marking of the machine and
the declaration of conformity also cover the EMC directive.
If other electronic equipment is fitted to this machine, the equipment must be CE marked and
tested on the machine with regard to electromagnetic interference.

EC Declaration of Conformity
The following is a generic version of the EC declaration of conformity. A signed and dated
version is included with the shipment of the machine.

DD90/DD90HF Intro-7
 INTRODUCTION

EC Declaration of Conformity for Machinery (IIA)

Volvo Construction Equipment Inc, Shippensburg, PA, USA, hereby declares that the product:
Make: Volvo Construction Equipment
Type: Compaction Machine
Product Identification Number (PIN): VCEXXXXXXXXXXXXXXXXX
to which this declaration relates, is in conformity with the relevant provisions of Essential Health and
Safety requirements of the:
Council Directive 2006/42/EC relating to Machinery.
Council Directive 2000/14/EC relating to Noise Emission in the Environment by equipment for use out
doors.
Council Directive 2004/108/EC on electromagnetic compatibility, and their Amendments relating to
machinery, and other applicable Directives.
Harmonized standards applied:
EN 500-1:2006 + A1:2009 Mobile Road Construction Machinery - Safety - Part 1: Common Require-
ments.
EN 500-4:2009 Mobile Road Construction Machinery - Safety - Specific Requirements for Compaction
Machines.
This declaration relates exclusively to the machinery in the state in which it was placed on the market,
and excludes components which are added and/or operations carried out subsequently by the final user.
Signature of the issuer of this declaration:
__________________________________ ____________________________________
Director, Road and Utility Product Platforms Signature
___________________
Date of issue
Signature of the person, established in the Community, authorised to compile the technical file:
__________________________________ ____________________________________
Global Director Laws and Regulations Signature
__________________________________ ___________________
__________________________________ Date of issue
__________________________________
Address
This declaration may include attachments developed, designed/approved, marked and marketed by
above-mentioned manufacturer.

Intro-8 DD90/DD90HF
INTRODUCTION

COMMUNICATION EQUIPMENT, INSTALLATION

! CAUTION
All installation of optional electronic communication equipment must be
performed by trained professionals and in accordance with the Volvo CE
instructions.

Protection Against Electromagnetic Interference

This machine has been tested in accordance with EU directive 2004/108/EC governing
electromagnetic interference. It is therefore very important that all non-approved electronic
accessories, such as communication equipment, should be tested before installation and use,
since they can cause interference to the electronic systems of the machine.

Mobile Telephones
To obtain the best functionality, mobile telephones should be permanently installed in the
electrical system of the machine, with a permanent aerial fixed on the machine and installed
as advised by the manufacturer. If a portable mobile telephone is used, note that it can
constantly transmit information to its base station, even when the telephone is not used. For
this reason, it should not be placed beside electronic equipment in the machine, such as
directly on a control panel, etc.

Guidelines
The guidelines given below must be followed during installation:

• The aerial placement must be chosen to give good adaptation to the surroundings.
• The down lead from the aerial must be of the coaxial type. Make sure that the cable
is undamaged, that the sheath and braid are not split at the ends, the braid covers
the connector ferrules and has good galvanic contact with them.
• The mating surface between the aerial mounting bracket and the bodywork must be
clean metal surfaces, with all dirt and oxide removed. Protect the mating surfaces
against corrosion after installation, to maintain good galvanic contact.
Remember to keep interfering cables and those which may suffer from interference apart.
Interfering cables are the power supply cables and the aerial to the communication equipment.
Cables which may suffer from interference are cables to and from electronic units on the
machine. Install cable harnesses as close to grounded plate surfaces as possible, as these
have a screening effect.

DD90/DD90HF Intro-9
 INTRODUCTION

MACHINE DESCRIPTION
Each compactor model offers the ideal combination of weight, drum width, frequency,
centrifugal force, and amplitude. The combination of these specifications result in the most
efficient compaction of hot mix asphalt (H.M.A.) and non-cohesive soils. Select the model
having drum width which matches the job requirement.
The DD90 and DD90HF feature the Cummins QSB 4.5 T3 engine, hydrostatic propulsion, and
steering systems. The hydrostatic propulsion system drives both drums for maximum
gradeability.
The compactor uses the positioning of the propulsion control lever [Forward-STOP-Reverse
(FSR)] to the STOP position, as an operating brake. Independent spring applied, hydraulically
released drum drive brakes are incorporated on both drums for safety. These brakes actuate
automatically in the event of a power loss or can be activated by the operator and serve the
machine as a parking brake.
Standard equipment includes an emergency stop switch to shut down the engine and apply
the mechanical brakes in an emergency situation. In addition, dual engine speed (rpm)
capability is included.
For a complete listing of currently supplied / available standard and option features, contact
the manufacturer’s local authorized dealer or distributor.

DRUMS
To meet varying job requirements, the operator can manually control drum vibration and select
dual drum, front drum, or rear drum vibration.
The vibration power driving the drums has eight amplitude settings with frequency settings of
1850 to 2500 vpm (31 to 42 Hz) on the DD90 and 2850 to 3800 vpm (47.5 to 63.3 Hz) on the
DD90HF. When placed in the automatic mode, vibration is activated when the machine travel
speed reaches the speed selected on the auto vibration control module and is deactivated at
the same speed on deceleration. Speeds of 1.2, 2.0, 2.8, or 3.2 km/h (0.75, 1.25, 1.75, or 2
mph) may be selected. Refer to "Setting Auto Vibration Control Module" in Section 4,
OPERATING INSTRUCTIONS.
The rotation of the drum eccentric weights automatically changes to coincide with the direction
of machine travel. This added feature ensures consistent, maximum surface smoothness in
both directions. A manual override system is also provided allowing clockwise or
counterclockwise eccentric rotation.

Intro-10 DD90/DD90HF
INTRODUCTION

ENGINE
The DD90/DD90HF series compactors are powered via a 97 kW (130 hp) electronic Tier 3
turbocharged Cummins diesel engine.
Each engine includes a dry type two-stage air cleaner which provides clean air to the engine.
A mechanical air cleaner restriction indicator indicates the air filtration system needs attention.
A dust discharging evacuator valve is provided on the air cleaner.
The 97 kW (130 hp) water cooled Tier 3 engine includes a long screw-on canister style fuel/
water separator with a lift tab drain and a primary fuel filter with a replaceable element. No
in-line fuel filter is required.
Electric start and belt driven alternator charging are standard. Engine shutdown is by a key
operated ignition switch or the emergency stop switch.
Refer to the Cummins Engine Operation and Maintenance Manual and the Engine Parts
Manual supplied with the compactor for additional engine operating and maintenance
procedures.

MAIN FRAME
The machine consists of a front frame and rear frame which are connected by the swivel joint.
The front frame includes a water tank system, fuel tank, battery compartment, seat, and
control console. The rear frame includes a water tank system, engine, and hydraulic oil tank.

CONTROLS
All operator controls, gauges, and indicator lights are located for operator convenience and
comfort.
The machine Forward-Stop-Reverse (FSR) propulsion direction, speed and braking controls
are located to the right of the operator. The emergency stop switch is located on the panel in
front of the operator. The Vibration On/Off button is located on the FSR and actuates vibration
operations.
The control panel on the operator's console includes the ignition switch, voltmeter,
tachometer, hourmeter, engine oil pressure and water temperature gauges, vibration controls,
emergency stop switch, and water system controls. All controls have symbols indicating
particular functions. Refer to Section 3, OPERATING CONTROLS AND INSTRUMENTS.
All models feature a 180° rotating operator's station for better visibility to the drum edges. This
allows accurate operation close to curbs and vertical obstructions. Guard rails, skid resistant
decking, and kick plates promote safety.

DD90/DD90HF Intro-11
 INTRODUCTION

DRUM WATER SYSTEM

For ultimate reliability, two separate, pressurized, water systems are provided. Each system
consists of separate pumps, spray bars, and hand-serviceable nozzles. Water is filtered three
times - once at the water inlet, again at the sediment bowl for each pump, and finally at each
individual nozzle. An electronic flow control permits added productivity over competitive
models by allowing the operator to adjust and conserve water sprayed on the drums, thus,
avoiding costly downtime.

VIBRATION SYSTEM
The vibration system consists of an eccentric mounted in the drum and powered by an
hydraulic motor. This system has an eight-position amplitude adjusting wheel located on the
left side of each drum. High amplitude is recommended for thick lift compaction, low amplitude
for thinner lifts and sensitive compaction areas.

BRAKES
The compactor uses the positioning of the propulsion control lever (FSR) to the STOP position,
as an operating brake. The standard mechanical braking components located in each drum
drive motor assembly are designed for use as a parking brake/ emergency brake. The
mechanical brakes are spring applied and hydraulically released. Loss of engine power for any
reason or loss of hydraulic pressure to the brake circuit will actuate the mechanical brakes.
Placing the propulsion control lever (FSR) to the STOP position acts as a dynamic (operating)
brake.
Refer to Section 4, OPERATING INSTRUCTIONS of this manual, for additional information.

OPERATOR STATION
The operator station is designed for convenience, ease of control, comfort, and safety while
providing maximum visibility to the work area. The operator station is mounted on four
independent vibration isolators and can be equipped with several available options.

SERVICEABILITY
Machine maintenance and service, as described in Section 5, MAINTENANCE
INSTRUCTIONS of this manual, will require raising the spring loaded hood for access to the
engine, air cleaner, oil filter, fuel filters, and related service items. A large, hinged hood allows
easy, ground-level access to the engine and hydraulic components. Items requiring routine
maintenance such as filter, air cleaner, and daily check points are grouped for convenience.
Water spray nozzles are hand-removable for quick cleaning. The spring-loaded, self-
adjusting, drum wipers require little maintenance.
Follow the recommended Preventive Maintenance Schedule located in Section 5,
MAINTENANCE INSTRUCTIONS.

Intro-12 DD90/DD90HF
INTRODUCTION

ROPS/FOPS/SEAT BELT
The manufacturer provides Rollover Protective Structure (ROPS), Falling Object Protective
Structure (FOPS) and a seat belt as standard equipment on the machine. ROPS/FOPS used
in conjunction with a seat belt 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 operate this machine if the Rollover Protective Structure/Falling

Objects Protective Structure (ROPS/FOPS) is structurally damaged,
shows cracks, is not properly secured as originally installed, or has been
involved in a rollover.

DO NOT repair, modify, drill, weld on or add attachments to the ROPS/

FOPS unless authorized in writing by the manufacturer.

DO NOT operate the machine unless the seat belt is fastened. Use only
genuine original equipment manufacturer replacement parts.

Contact the manufacturer’s local authorized dealer or distributor for

complete inspection requirements and maintenance instructions.

Check the seat belt regularly for wear or damage. Inspect belt hardware and fabric. Replace
if hardware is damaged or if strap is nicked, frayed, or loose stitching is found. Seat belt
assemblies should be replaced every 3 years regardless of appearance. Seat belt strength
degrades over time due to use, exposure to weather, ultraviolet radiation (UV) and abrasives
(dirt). Ensure that mounting hardware is tight.

DD90/DD90HF Intro-13
 INTRODUCTION

IDENTIFICATION OF MAJOR COMPONENTS

Figure 4

Intro-14 DD90/DD90HF
INTRODUCTION

1. Engine 13. Vibration Motor

2. Batteries
3. Radiator
4. Steer Console
5. Hydraulic Steering Control
6. Control Panel
7. Operator's Seat
8. Fuel Tank and Fuse Panel
9. Hydraulic Tank
10. Drum
11. Drum Frame
12. Air Cleaner
14. Drum Drive Motor
15. Drum Scraper
16. ROPS/FOPS
17. Hydraulic Filters
18. Articulation and Oscillation Area
19. Water Tanks
20. Emergency Stop Switch
21. Propulsion Control Lever (FSR)
22. Tie-down Points
23. Lift Points
24. Tow Points

DD90/DD90HF Intro-15
 INTRODUCTION

Intro-16 DD90/DD90HF
 SECTION 1 - SAFETY

DD90/DD90HF 1-1
 SECTION 1 SAFETY

SAFETY

BE AWARE OF SAFETY INFORMATION

This section describes the types of safety decals used on the machine and reviews concerns
for safe operation and maintenance.

Conventions Used
The following conventions (special words) are used in this manual for instructions of particular
importance.

This is the SAFETY ALERT SYMBOL. It is used to

alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol
to avoid possible injury or death.

DANGER indicates an imminently hazardous

situation which, if not avoided, will result in
death or serious injury.

(Red Background)

WARNING indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.

(Orange Background)

CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in
minor or moderate injury, or property damage.

(Yellow Background)

NOTICE is used to notify people of installation,

operation, or maintenance information which is
important but not hazard related.

(Blue Background)

1-2 DD90/DD90HF
SAFETY SECTION 1

DANGER ZONE
The DANGER ZONE of this machine is the immediate area or zone surrounding the machine,
machine accessories, or extensions which would allow contact with the machine if the
machine, machine accessories, or extensions were to move. All personnel are to be kept out
of the danger zone during machine operation.

GENERAL INFORMATION
The DD90/DD90HF series of asphalt compactors has been carefully designed and built to
provide a safe working environment when all safety warnings are understood and followed.
PRIOR TO starting, operating, or maintaining the machine, READ and UNDERSTAND this
manual, particularly Section 1, SAFETY, and Section 3, OPERATING CONTROLS AND
INSTRUMENTS.
CONTACT supervisor or manufacturer’s local authorized dealer or distributor with any
questions. NEVER GUESS about how to safely operate and/or maintain this equipment.
MAKE SURE the machine is operated and maintained only by safety-conscious persons who
have been authorized, properly trained, and have the required skills and tools to do their jobs.
All personnel must be alert to, recognize, and avoid potential hazards associated with
performing their work.
ALWAYS wear or use proper personal protective equipment while operating or maintaining the
machine.
OPERATE the machine only when it is in good condition. Any functional disorders, especially
those affecting the safety of the machine, must be corrected immediately.
The machine must be used in accordance with its designated use as described in this
Operation and Maintenance Manual.
MAKE SURE the machine is used only for the compaction of asphalt. Use of the machine for
any other purpose, such as for towing other vehicles/equipment, is contrary to its designated
use. The manufacturer/supplier cannot be held responsible for any damage resulting from
such use. The risk of such misuse lies entirely with the user.

SELECTION AND QUALIFICATION OF PERSONNEL

MAKE SURE only qualified personnel work on and with the machine. Statutory minimum age
limits must be observed.
DESCRIBE clearly the responsibilities of individuals who operate, setup, maintain, and repair
the machine.

DD90/DD90HF 1-3
 SECTION 1 SAFETY

DEFINE the machine operator’s responsibilities for safe machine operation, including
observing traffic regulations. The operator should have the authority to refuse instructions by
third parties that are contrary to safe practices.
DO NOT allow personnel being trained or instructed in the operation or maintenance of the
machine to work without continuous supervision by an experienced person.
ALLOW ONLY skilled electricians, or persons instructed by them, to work on the electrical
system or electrical components of the machine. All electrical work must be performed in
accordance with electrical engineering guidelines and local regulations.
BE SURE that work on the machine chassis, brake, hydraulic, and steering systems is
performed only by skilled personnel trained to perform such work.

ORGANIZATIONAL MEASURES
ALWAYS make this Operation and Maintenance Manual available where this machine is used.
Stow it in the compartment provided on the machine.
OBSERVE AND INSTRUCT users of the machine in all 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, the issuing
and/or wearing of personal protective equipment, and traffic regulations.
SUPPLEMENT operating instructions with detailed Work Instructions for specific work
activities and locations.
ALWAYS be sure that persons who operate or work on the machine have read the operating
instructions and, in particular, this chapter on safety before beginning work. Reading the
instructions after work has begun is too late. This is especially important for persons who only
occasionally work on the machine, such as during set up or maintenance.
MAKE CERTAIN personnel work in compliance with the operating instructions and are alert to
risks and safety factors.
BE AWARE of personal safety hazards. ALWAYS tie back or otherwise secure long hair, and
wear close-fitting garments. AVOID wearing jewelry such as rings, bracelets, and necklaces.
Injury may result from clothing, hair, or jewelry being caught in the machinery.
USE personal protective equipment whenever required by work circumstances or by law.
OBSERVE all safety instructions in this manual and on decals attached to the machine.
BE SURE all safety Warning and Instruction decals attached to the machine are complete and
legible.

1-4 DD90/DD90HF
SAFETY SECTION 1

STOP the machine immediately in the event of any malfunction. REPORT the malfunction to
the proper authority/person. The continued operation of a machine that is not working properly
may cause extensive damage to the machine or significantly increase hazards to operating
personnel due to abnormal operating conditions.
NEVER perform service or maintenance on the machine in ANY manner other than that which
is described in this manual.
NEVER make any modifications, additions, or conversions to the machine which might affect
safety without the manufacturer’s approval in writing. This applies to the installation and
adjustment of safety devices and valves as well as to welding work on load-bearing
components.
ALWAYS ADHERE to prescribed intervals (as specified in Section 4, OPERATING
INSTRUCTIONS, and Section 5, MAINTENANCE INSTRUCTIONS) for routine checks,
inspections, and maintenance procedures. Performing scheduled preventive maintenance
consistently will extend the life of the machine.
OBSERVE all firefighting procedures.

MANDATORY SAFETY MEASURES

NEVER clean, lubricate, or service the machine when it is running.
DO NOT operate the machine while under the influence of drugs or alcohol.
ALWAYS use personal protective equipment, such as hard hats, safety shoes, eye and ear
protection, while operating or maintaining the machine.
DO NOT wear radio or music headphones while operating the machine.
DO NOT wear jewelry while operating the machine.
REPLACE any guards and shields removed, mount them securely, and clear all maintenance
tools before starting the engine after maintenance.
CONTACT supervisor, or any manufacturer’s local authorized dealer or distributor, if there are
any questions about the operation or maintenance of this machine. NEVER GUESS –
ALWAYS CHECK!
REMEMBER, failure to adhere to these safety instructions may result in serious injury or even
death.

DD90/DD90HF 1-5
 SECTION 1 SAFETY

PRE-START INSPECTION
INSPECT the machine daily. Ensure that routine maintenance and lubrication procedures are
dutifully performed.
REPAIR/REPLACE any malfunctioning, broken, or missing parts. Refer to the Preventive
Maintenance Schedule located in Section 5, MAINTENANCE, of this manual.
VERIFY that all safety Warning and Instruction decals are in place and legible. These
instructions are as important as any other equipment on the machine. Refer to the decal
location drawing in Section 1, SAFETY of this Operation and Maintenance Manual at Safety
Related Decals, 1-18.
ENSURE that all safety and protective devices are in place and in good working order.
USE CAUTION when refueling. NEVER fill the fuel tank with the engine running, while the
machine is located near an open flame, or while operating personnel are smoking. Smoking
is PROHIBITED within 15 m (50 feet) of the machine while refueling.
ALWAYS wipe up any spilled fuel in accordance with local environmental guidelines.
CHECK for any maintenance and repair WARNING tags placed on the machine. DO NOT
operate the machine until repairs have been made and the WARNING tags have been
removed by authorized personnel.
REMOVE any dirt, debris, or foreign material from the operator platform to reduce the danger
of slipping.
KNOW the location of the emergency stop switch.
KNOW the capabilities and limitations of the machine with respect to speed, gradeability,
steering, and braking.
BE AWARE of the dimensions of the machine. This includes the height and width of the overall
machine, as well as the transport vehicle dimensions and weight.

WORKING WITHIN HAZARDOUS AREAS

CHECK for hazardous conditions in the work area, such as holes, banks, underground
culverts, manhole covers, water melt pits, or curb and/or street boxes. Avoid any operation that
might sacrifice safety.
This machine should only be brought into service where the machine is applicable to the
situation and conditions of the construction site. This includes the stability and condition of the
ground, width of the driving lane, and any objects which would interfere with the movement of
the machine both above ground level and below ground level such as curbstones or ditches.

1-6 DD90/DD90HF
SAFETY SECTION 1

SAFETY INSTRUCTIONS GOVERNING OPERATION

AVOID any operating mode or procedure that might sacrifice safety.
AVOID any operation that might risk machine stability.
ENSURE THAT all necessary precautions are taken to ensure that the machine is used only
when in a safe and reliable condition.
OPERATE this machine only if all safety and protective devices originally provided by the
manufacturer are in place and in good condition. This includes removable safety devices,
emergency shut off equipment, soundproofing elements, and exhausts.
MAKE SURE there is sufficient clearance when moving the machine through tunnels,
underpasses, and under power lines.
MAKE SURE bridges are rated to hold the weight of this machine before crossing them.
CHECK the machine at least once each shift for damage and report damage to your
supervisor. If the machine is not operating properly, shut down the machine immediately. The
continued operation of a machine that is not working properly may cause additional damage
to the machine or significantly increase the hazards to operating personnel due to abnormal
operating conditions.
CHECK the surrounding area for pedestrians. MAKE SURE no one is in danger or at risk
before starting the machine or setting it in motion.
CHECK that braking, steering, signalling, and lighting systems are fully functional before
moving the machine.
CHECK that accessories have been safely stowed away before setting the machine in motion.
OBSERVE all the valid traffic regulations when traveling on public roads. ALWAYS MAKE
SURE the machine is in a condition that meets those regulations.
ALWAYS KEEP a safe distance away from the edges of building pits and slopes.
ALWAYS SECURE the machine to prevent inadvertent movement and unauthorized use
before leaving it.
PROVIDE an observer when loading and unloading the machine from a truck or trailer, or
lifting it with a crane.

DD90/DD90HF 1-7
 SECTION 1 SAFETY

STARTING
ALWAYS USE hand rails and steps to get on and off the machine.
ALWAYS MAINTAIN a three-point contact when climbing onto or off of the machine as shown
in Figure 1-1.
Figure 1-1

READ and FOLLOW ALL safety Warning and Instruction decals.

CHECK the surrounding area for pedestrians. MAKE SURE no one is in danger or at risk
before starting the machine or setting it in motion.
BEFORE attempting to start the engine, ENSURE that the Forward-Stop-Reverse (FSR)
Speed Control lever is in the “STOP” position.
WATCH the indicators during start-up and shutdown procedures in accordance with the
operating instructions. See Section 4, OPERATING INSTRUCTIONS of this manual.
TURN ON the lighting system in conditions of poor visibility and after dark.
ALWAYS wear the seat belt when operating the machine.
BEFORE starting the engine, ENSURE that the parking brake control is in the “Applied”
position.
START the engine only while at the operator console.

1-8 DD90/DD90HF
SAFETY SECTION 1

JUMP STARTING

! WARNING
Personal Injury Hazard

Never jump start the machine directly to the starter or starter solenoid.
The machine may lurch forward or backward and run over the personnel
attempting to jump start the machine. Normal safety devices are
bypassed when jump starting directly to the starter or starter solenoid.

Failure to obey this Warning could result in serious personal injury, or

death.

AVOID equipment damage by making sure that the machine being jumped does not come in
contact with the machine supplying the jump.
NEVER jump start a frozen battery, it will explode.
BE AWARE that lead acid batteries generate explosive gases while charging. Keep sparks,
flames, and lighted smoking materials away from batteries.
ALWAYS wear eye protection when working on or near batteries.
FOLLOW these procedures when jump starting the machine.

1. Connect the positive (+) terminal of the booster battery to the positive (+)
terminal of the discharged battery.
2. Connect the negative (–) terminal of the booster battery to the best ground point
on the machine, away from the battery.
3. Follow all recommended engine starting procedures.
4. Remove the jumper cables in the reverse order of their connection as soon as
the engine has started.

DD90/DD90HF 1-9
 SECTION 1 SAFETY

OPERATING
MAKE SURE no person or obstruction is in the line of travel before moving the machine.
LOOK in all directions BEFORE changing the direction of travel.
NEVER CLIMB onto or off of the machine at any time while it is operating/moving.
USE EXTREME CAUTION and be observant when operating the machine in close quarters
or in congested areas.
NO RIDERS. NEVER carry passengers.
KNOW the hand signals used (required) for particular jobs/actions and know who has the
responsibility for signaling.
KNOW the area in which you are working. Become familiar with work site obstructions and any
other potential hazards in the area.
ALWAYS remain seated with the seat belt on when operating the machine whether
compacting, traveling, or loading/unloading.
CLOSE all sound baffles during operation.
DO NOT work in the vicinity of overhanging banks or on grades that could cause the
compactor to slide or roll over.
AVOID side hill travel. ALWAYS operate up and down slopes. NEVER CHANGE to a lower
gear on a slope; always change before reaching it. ALWAYS keep the propulsion control lever
(FSR) in low speed range close to the “STOP” position when climbing or descending hills.
NEVER allow anyone to stand within the machine’s articulation area when the engine is
running.
CONTROL the machine travel speed with the propulsion control lever (FSR).
CONTROL engine speed with the throttle control. When operating the machine maintain the
engine speed at full “Operating rpm.”
DO NOT tow or push the machine except as explained in Section 4, OPERATING
INSTRUCTIONS of this manual.
DO NOT run the engine in a closed building for an extended length of time. EXHAUST FUMES
CAN KILL.
READ and FOLLOW all safety Warning and Instruction decals.

1-10 DD90/DD90HF
SAFETY SECTION 1

STOPPING
ALWAYS park the machine on solid level ground. If this is not practical, park the machine at a
right angle to the slope and chock the drums.
REDUCE the travel speed by moving the FSR Speed control lever before stopping the
machine. To stop the machine, push the FSR Speed control lever back to the STOP position.
Apply the parking brake. Install the articulation lock bar/lock pin. Position the High/Low engine
speed control (throttle) to “low rpm”. Turn ignition switch to OFF, and lock all lockable
compartments.
ALWAYS BE SURE that all control switches are in the OFF (STOP) position and that the
engine is shut off before leaving the machine.
ALWAYS RETRACT the seat belt fully before leaving the operator station.
ALWAYS mount and dismount the machine using walkways, steps, and handrails provided.
Never jump from the operator’s platform to the ground.
ALWAYS maintain a “three-point contact” when climbing on or off the machine. Refer to
Section 1, SAFETY, at Starting, 1-8.
USE proper flags, barriers, and warning devices to warn others of the machine, especially
when parking in areas of heavy traffic.

MAINTENANCE
FOLLOW the start-up and shutdown procedures set forth in Section 4, OPERATING
INSTRUCTIONS, before performing any work on the machine. This includes the operation,
conversion, or adjustment of the machine and its safety oriented devices, and any work related
to maintenance, inspection, and/or repair.
ENSURE that the maintenance area is adequately secured as outlined below.
SECURE the machine against inadvertent starting, if it is completely shut down for
maintenance and repair work, as follows:

• Remove the ignition key, and/or

• Disconnect the battery cables and attach a Warning tag to the battery
CHECK de-energized parts for the presence of power. Ground or short circuit any parts found
to contain residual power. Insulate adjacent live parts and elements.
CHECK and INSPECT machine electrical equipment at regular intervals. Faults, such as loose
connections or scorched cables, must be corrected immediately.

DD90/DD90HF 1-11
 SECTION 1 SAFETY

LIFTING THE MACHINE – When raising the machine off the ground, apply the parking brake
and secure the articulation lock bar in the locked position. Attach the lifting apparatus only to
the machine’s designated lifting points using properly rated lifting straps, cables, or chains.
Use spreader bars to ensure equal weight distribution during lifting as well as avoid contact
with the machine.
USE CARE when attaching and securing lifting tackle to individual parts and large assemblies
being moved for replacement purposes to avoid the risk of accidents. USE lifting gear that is
in proper operating condition and with adequate lifting capacity. NEVER work or stand under
suspended loads.
ALWAYS USE the correct tools and workshop equipment when performing maintenance on
the machine.
PERFORM maintenance and repair work only if the machine is positioned on stable and level
ground and has been secured to prevent movement.
ALWAYS USE the correct tools and workshop equipment when performing maintenance on
the machine.
KEEP all platforms and standing surfaces free from mud, dirt, snow, and ice.
CLEAN the machine at the end of each workday while it is still warm.
CLEAN the machine, especially connections and threaded unions, of any traces of oil, fuel, or
preservatives before carrying out maintenance/repair. NEVER use aggressive detergents.
Use lint free cleaning rags.
COVER OR TAPE all openings which – for safety and functional reasons – must be protected
against water, steam, or detergent penetration before cleaning the machine with water, steam
jet (high pressure cleaning), or detergents. Special care must be taken with electric motors and
switch gear cabinets.
ENSURE that the temperature sensors of the machine do not come into contact with hot
cleaning agents while cleaning the machine.
REMOVE all covers and tapes applied for that purpose after cleaning the machine.
EXAMINE all fuel, lubricant, and hydraulic fluid lines for leaks, loose connections, chafe marks,
and damage after cleaning.
REPAIR or REPLACE faulty parts immediately.
TIGHTEN any screwed connections that have been loosened during maintenance and repair.
REPLACE and CHECK any safety devices removed during setup, maintenance, or repair
activities. Do this immediately upon completion of the maintenance and/or repair activity.
AVOID servicing, cleaning, or examining the machine with the engine running, whenever
possible.

1-12 DD90/DD90HF
SAFETY SECTION 1

DO NOT perform service or maintenance on the machine unless the drums are adequately
chocked, the articulation lock bar/lock pin is in the locked position, and the parking brake is
applied. BE SURE the machine is adequately secured to prevent movement.
NEVER fill the fuel tank of the machine with the engine running. Do not permit sparks, open
flames or smoking within 15 m (50 feet) of the machine while refueling. ALWAYS wipe up any
spilled fuel in accordance with local environmental guidelines.
DO NOT alter the engine governor settings from those indicated in the engine instruction
manual and the engine option plate.
ALWAYS replace damaged or lost Warning and Instruction decals. It is dangerous to operate
the machine without these decals. Refer to the parts catalog for the proper location and part
number of all decals.
DISCONNECT the battery cables when working on the electrical system or when welding on
this machine.
BE SURE the battery area is well ventilated (clear of fumes) should it be necessary to connect
a jump battery or battery charger. Fumes from the battery can ignite by a spark and explode.
BE SURE the battery charger is OFF when making the connections if battery charging is
required.
INSPECT and CHECK the machine’s electrical equipment at regular intervals. Faults, such as
loose connections or scorched cables MUST be corrected IMMEDIATELY.
INSPECT hydraulic hose assemblies visually at regular intervals. Replace them if they show
signs of chafing, cracking, brittleness, deformation, blistering, leakage, fitting separation,
corrosion, or other damages which may affect their function and strength.
INSPECT hydraulic hoses and screwed connections regularly. Look for leaks and signs of
damage. Replace faulty parts immediately.
REMEMBER that hot hydraulic fluid will cause serious burns. WAIT for hot hydraulic fluid to
cool down before disconnecting hydraulic lines.
DO NOT work on hydraulic lines while the engine is running and the system is under pressure.
The hydraulic fluid remains under pressure long after the engine has been stopped. DO NOT
work on any hydraulic hose or fitting until the pressure has been relieved correctly.
NEVER USE YOUR HANDS to check for hydraulic leaks when inspecting an hydraulic
system. Use a piece of cardboard to check for leaks, and always wear gloves and eye
protection while checking.
REMEMBER that fluid penetration from a pin-hole leak can cause serious injury or death. Get
immediate treatment if hydraulic fluid has been injected under your skin.

DD90/DD90HF 1-13
 SECTION 1 SAFETY

DEPRESSURIZE the hydraulic system sections to be serviced before servicing them. Follow
the manufacturer’s instructions for the specific equipment involved.
LAY and FIT hydraulic lines properly. ENSURE that no connections are interchanged. The
fittings, length, and quality of the hoses must comply with the technical requirements.
OBSERVE all product related safety regulations when handling oil, grease, and other
chemical substances.
ENSURE that all consumable and replaced parts are disposed of in an environmentally safe
manner and in accordance with local guidelines and regulations.
USE only original fuses with the specified current rating. Shut down the engine and disconnect
the battery immediately if trouble occurs in the electrical system.
ALLOW only a skilled electrician, or instructed person working under the supervision and
guidance of a skilled electrician, to work on the electrical system of the machine. All work must
be done in accordance with electrical engineering guidelines and local regulations.
REMOVE electrical power to components of the machine before performing inspection,
maintenance, and repair work. Follow established lockout/tagout procedures.
BE CAREFUL when handling hot fluid or parts to avoid burning or scalding. Wear appropriate
personal protective equipment.
ALLOW only qualified and authorized personnel to weld, flame cut, or perform any grinding
work on the machine. There may be a risk of explosion and fire.
CLEAN the machine before starting welding, flame cutting, and grinding operations. Remove
dust and other flammable substances and make sure that the premises are adequately
ventilated to avoid the risk of fire and/or explosion.
MAKE SURE all welding work is carried out by fully trained, instructed, qualified, and
authorized personnel. All regulations and safety stipulations must be strictly adhered to as well
as the generally recognized standards for performing welding work.
ENSURE the clamp on the earth cable (ground) has a good contact near the joint to be welded.
ENSURE that the welding current does not flow through any bearings.
USE only genuine original equipment manufacturer’s replacement parts. This will protect the
warranty and ensure the safe operation and optimum performance of the machine.

1-14 DD90/DD90HF
SAFETY SECTION 1

TRANSPORTING, TOWING, AND ROADING

SECURING THE MACHINE FOR TRANSPORT – When securing the machine for transport,
use only the designated tie-down locations to fasten the machine to the transport vehicle.
Decals on the machine indicate the locations to tie the machine down. Use only properly rated
tie-downs and securing equipment. Place chocks at the front and rear of the machine while
securing to the transport vehicle. If the transport vehicle will be stationary for an extended
period of time without being moved, do not remove the chocks until transporting the machine.
USE only appropriate means of transport and lifting gear of adequate capacity.
Allow only experienced persons to fasten loads and instruct crane operators. The personnel
giving the instructions must be within sight or sound of the operator.
DO NOT attempt to load the machine on the transport vehicle without knowledge and
experience with the operation of the machine.
ALWAYS use a ramp when loading the machine on the transport vehicle. Be sure ramps are
of adequate strength, low angle, and proper height and width.
USE proper chock blocks in front and rear of the wheels of the transport vehicle when loading
the machine.
ENSURE the transport vehicle is on level ground. Approach the transport vehicle loading
ramps squarely to make sure the machine does not drop off the side of the ramp.
KEEP the transport vehicle deck clean of clay, oil, mud, ice, frost, and other material that can
become slippery.
USE proper chock blocks on the front and rear of the drums of the machine once it is loaded
onto the transport vehicle.
Shut down the engine, apply the parking brake, and lock all lockable compartments.
ENSURE the articulation lock bar/lock pin is secured in the locked position before transporting
the machine.
KNOW the overall height of the machine and transport vehicle. Observe height and weight
regulations, and at overhead objects be sure you can safely pass beneath them.
Refer to Section 4, OPERATING INSTRUCTIONS of this manual, for proper brake release
procedures.
OBEY all traffic regulations and be sure that the proper clearance flags, lights, and warning
signs, including the “Slow Moving Vehicle” emblem, are properly displayed when moving the
machine on public access roads.
KNOW the approximate stopping distance at any given speed.
NEVER turn corners at excessive speeds. Look in all directions before reversing direction of
travel.
POSITION the machine on the transport vehicle centered from side to side and apply the
brake.
REFER to Section 4, OPERATING INSTRUCTIONS of this manual, for proper towing
instructions.

DD90/DD90HF 1-15
 SECTION 1 SAFETY

HAZARDOUS SUBSTANCE PRECAUTION

The following information is provided to assist the machine owners and operators. Further
information may be obtained by contacting the manufacturer’s local authorized dealer or
distributor.
The following substances, shown in Table 1-1. are contained in or emitted by this machine and
may be hazardous to health if exposed to or used incorrectly.
Table 1-1:
The following substances are contained in or emitted by this machine and may be
hazardous to health if used incorrectly.

SUBSTANCE PRECAUTION
Antifreeze Avoid ingestion, skin contact, and breathing fumes
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 preventive Avoid ingestion, skin contact, and breathing fumes
Engine fuel Avoid ingestion, skin contact, and breathing fumes
Battery electrolyte Avoid ingestion, skin contact, and breathing fumes
SAE gear oil Avoid ingestion, skin contact, and breathing fumes
The following substances may be produced during the operation of this machine and may
be hazardous to health.

SUBSTANCE
Engine exhaust fumes
Engine exhaust fumes
Electric motor dust (brushes/
insulation)
PRECAUTION
Avoid breathing fumes
Avoid buildup of fumes in confined spaces
Avoid breathing during maintenance.

Battery Disposal
Batteries contain substances dangerous to your health and the environment. Dispose of
batteries marked with the symbol shown in Figure 1-2 according to local and national
regulations. Remember battery electrolyte is corrosive. DO NOT dispose as general trash.
Figure 1-2

1-16 DD90/DD90HF
SAFETY SECTION 1

WARNING OF SPECIAL DANGERS

When operating the machine, maintain a safe distance from overhead electric lines. If work is
to be carried out close to overhead lines, keep the machine away from them.

! DANGER
Electrocution Hazard

Observe the following procedure if your machine comes in contact with

electric power lines:

• Stay in the operator seat.

• Do not touch any part of the machine.
• Warn other workers to stay away and not touch any control or any other
part of the machine.
• If contact can be broken, drive the machine away from the danger zone.
• If contact cannot be broken, stay in the operator seat until told that the
power is OFF.

Failure to obey this Warning could result in electrocution or death.

! DANGER
Suffocation Hazard

Breathing exhaust fumes from internal combustion engines can lead to

loss of consciousness, carbon monoxide poisoning and suffocation.

Never operate internal combustion engines in an enclosed area with poor

ventilation.

Failure to obey this Warning could result in carbon monoxide poisoning

and death.

DD90/DD90HF 1-17
 SECTION 1 SAFETY

SAFETY RELATED DECALS

9 7

8 6
5
5 1

5 5
2 VIEW A-A

4
4 1
VIEW B-B
SM59233817_001

REF. NO. DECAL NO. REQ'D LOCATION

1 Checklist 1 Console
2 WARNING: Rollover 2 Console
3 WARNING: Misoperation 1 Console
4 WARNING: Crushing hazard 2 Machine side frame
5 WARNING: Do not sit on rail 4 Railings
6 WARNING: Rotating fan and belt 1 Top of engine cowling
7 WARNING: Radiator 1 Under engine cowling
8 WARNING: Crush hazard 2 On ROPS support
9 WARNING: Crush hazard 1 On ROPS

1-18 DD90/DD90HF
SAFETY SECTION 1

U.S. DECALS
1. Checklist

DD90/DD90HF 1-19
 SECTION 1 SAFETY

2. Rollover

Rollover of this machine can cause severe injury or death.

Do not operate this machine near or on an inclined surface. A rollover can
occur.
With a Rollover Protection Structure (ROPS), seat belts must be worn to avoid
severe injury or death from being thrown out.
3. Misoperation

Improper operation of this equipment can cause severe injury or death.

Read Operation and Maintenance Manual supplied with this equipment before
operating or servicing.

1-20 DD90/DD90HF
SAFETY SECTION 1

4. Crush area

Crush area can cause severe injury or death.

Stay clear or install articulation lock before entering area.
5. Do not sit on rail

Do not sit on rail.

DD90/DD90HF 1-21
 SECTION 1 SAFETY

6. Rotating fan and belt

Rotating fan blades can cause serious injury.

Do not operate with guard removed.
7. Radiator warning

Hot pressurized fluid can cause serious burns.

Do not open radiator while hot.

1-22 DD90/DD90HF
SAFETY SECTION 1

8. Crush hazard warning

Crush hazard can cause serious injury or death.

Stay alert when approaching paver. Do not come closer than 50 feet from an
operating paver.
If it is necessary to closely approach a stationary paver, clear personnel from
the screed area and proceed slowly and cautiously.
9. Crush hazard warning

Crush hazard can cause serious injury or death.

Stay alert when approaching paver. Do not come closer than 50 feet from an
operating paver.
If it is necessary to closely approach a stationary paver, clear personnel from
the screed area and proceed slowly and cautiously.

DD90/DD90HF 1-23
 SECTION 1 SAFETY

10. Towing tag

WARNING: Attach this tag to steering wheel prior

to starting towing procedures. Runaway machine
can cause serious injury or death. Brakes have
been manually released. Propulsion pump has
been shunted. This machine will roll freely if not
chocked or restrained by another machine.
Consult Operator and Maintenance Manual for
towing instructions. Return this tag to its storage
position only after brakes and propulsion pump
have been returned to normal conditions.

1-24 DD90/DD90HF
SAFETY SECTION 1

INTERNATIONAL DECALS WITH INTERPRETATION

1. Rollover

Rollover of this machine can cause severe injury or death. Do not operate this
machine near or on an inclined surface. A rollover can occur. If this machine
has a Rollover Protective Structure (ROPS), seat belts must be worn to avoid
severe injury or death from being thrown out.
2. Misoperation

Improper operation of this equipment can cause severe injury or death. Read
and understand the Operation and Maintenance Manual and safety instructions
before operating or servicing.
3. Crush area

Crush area. Can cause severe injury or death. Stay clear. Install lock pin before
servicing.

DD90/DD90HF 1-25
 SECTION 1 SAFETY

4. Do not sit on rail

Never sit on railing around operator's compartment.

5. Rotating fan and belt

Rotating blade. Can cause severe injury. Do not operate with guards or shields
removed. Stop machine before performing maintenance.
6. Radiator

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 before removing the radiator
cap. Remove the cap slowly to relieve pressure. Avoid contact with steam or
escaping fluid.

1-26 DD90/DD90HF
 SECTION 2 - SYMBOL
IDENTIFICATION

DD90/DD90HF 2-1
 12 SYMBOL IDENTIFICATION

SYMBOL IDENTIFICATION

MACHINE SYMBOLS

NOTE: Some symbols shown in this section may not appear on your machine.

No. Description No. Description

Drum vibration Anti-drum spin

Manual vibration
Drum vibration control
control

Automatic vibration
High amplitude
control

Double drum vibration

Low amplitude
mode

Single drum vibration

Frequency (vibration)
mode

Ignition switch Vibration control mode

Tie-down p Caution

Anti-wheel spin

2-2 DD90/DD90HF
SYMBOL IDENTIFICATION 12

INTERNATIONAL SYMBOLS

NOTE: Some symbols shown in this section may not appear on your machine.

No. Description No. Description

ON/Start Seat (lap) belt

OFF/Stop Linear

ON/OFF Rotational

Plus/Positive Volume empty

Minus/Negative Volume half-full

Horn Volume full

Battery condition Grease

Hourmeter Oil lubrication point

DD90/DD90HF 2-3
 12 SYMBOL IDENTIFICATION

No. Description No. Description

Lift point Engine oil temperature

Jack or support point Engine coolant

Filling/Emptying Engine coolant level

Read Operation and

Coolant temperature
Maintenance Manual

Engine oil Engine rotations (rpm)

Engine oil pressure Gas inject (cold start)

Engine oil pressure –

Engine air filter
failure

Engine air filter –

Engine oil level
failure

Engine oil filter Fan belt – failure

2-4 DD90/DD90HF
SYMBOL IDENTIFICATION 12

No. Description No. Description

Emergency stop
switch
Reverse direction
Engine stop light

Engine start Parking brake

Engine ON/Run Brake ON

Start switch Brake OFF

Transmission Primer (start aid)

Transmission oil level Hydraulic oil

High gear Hydraulic oil pressure

Low gear Hydraulic oil level

Forward direction Hydraulic oil filter

DD90/DD90HF 2-5
 12 SYMBOL IDENTIFICATION

No. Description No. Description

Hydraulic oil Control lever – multi

temperature direction

Fuel (diesel) Clockwise rotation

Counterclockwise
Fuel level
rotation

Engine electrical
Fuel filter
preheat

Work light Fast speed

Flashing beacon Slow speed

Control lever – dual

direction

2-6 DD90/DD90HF
 SECTION 3 - OPERATING
CONTROLS AND INSTRUMENTS

DD90/DD90HF 3-1
 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS

OPERATING CONTROLS AND INSTRUMENTS

! WARNING
Allow no one to operate or maintain this machine unless they have read
and understand this Operation and Maintenance Manual, especially
Section 1, SAFETY, and Section 3, OPERATING CONTROLS AND
INSTRUMENTS, and have been trained in the proper operation and
maintenance of this machine.

ARTICULATION LOCK BAR

! WARNING
Unexpected machine motion or moving parts can cut or crush.

During shipment, and before performing any checks or service

operations, place the articulation lock bar into its locked position.

For compaction operation, the lock bar is to be removed from its locked
position and placed in its stowed position.

The articulation lock bar (1, Figure 3-1) is used to prevent accidental articulation of the
compactor. Prior to shipment, and before performing any checks or service operations, place
the lock bar in the locked position. Secure the lock bar with pin (2).

Figure 3-1

3-2 DD90/DD90HF
OPERATING CONTROLS AND INSTRUMENTS SECTION 3

For machine operation, place the lock bar in the stowed position (1, Figure 3-2).

Figure 3-2

DD90/DD90HF 3-3
 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS

CONTROL PANEL, UPPER SECTION

The following descriptions refer to operator controls on the upper section of the control panel,
see Figure 3-3.

Figure 3-3

1. Impactmeter 6. Engine oil pressure gauge

2. Seatbelt lamp 7. Main water flow control
3. Grid heater 8. Water temperature gauge
4. Voltmeter 9. Engine stop light
5. Ignition switch 10. Check engine light

VANDALISM PROTECTION
The machine is equipped with a vandalism protection package. When leaving the machine
unattended, lock all lockable compartments.

IMPACTMETER
The impactmeter (1, Figure 3-3) displays the vibration of the drum and is calibrated in impacts
per foot and impacts per minute. The green area on the dial of the gauge indicates the
"compaction zone" for normal operation.
NOTE: The impactmeter is calibrated to be accurate at maximum VPM ONLY.

3-4 DD90/DD90HF
OPERATING CONTROLS AND INSTRUMENTS SECTION 3

SEATBELT LAMP
The seatbelt lamp (2, Figure 3-3) turns on to remind the operator to fasten the seat belt.

GRID HEATER 'ON' INDICATOR

The grid heater “on” indicator (3, Figure 3-3) illuminates with the ignition switch in the Run
position when the engine temperature is below starting temperature.

! WARNING
Personal Injury Hazard

Do not use ether. Intake manifold grid heater starting aid has a high
temperature element. Ether may cause explosion and serious injury.

Starting aids are extremely flammable and can explode.

Failure to obey this Warning could result in serious personal injury, or

death.

The illuminated light indicates that the grid heater is heating the air in the engine air intake
chamber. The indicator will go out when the air intake temperature is high enough to assist in
starting the engine.

VOLTMETER
The voltmeter (4, Figure 3-3) indicates the battery voltage when the ignition switch is at the
Run position. The normal operating range is 13.5 to 14.5 volts. If the display is outside this
range, shut down the machine, and correct the problem before continuing operation.

IGNITION SWITCH

The key operated, 3-position (Stop, Run, Start) switch (5, Figure 3-3) controls the engine
stopping, starting and run operations by selecting:

• Stop position =
• Run position =
• Start position =
Turn switch clockwise from Stop position to Run position to energize electrical system.
Continue turning switch to Start position for engine start. Once engine starts, release switch
immediately and it will automatically return to Run position. If engine will not start, attempt to
restart.

DD90/DD90HF 3-5
 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS

NOTICE
Starter may overheat if operated longer than 30 seconds.

If engine does not start, allow the starter to cool for 2 to 3 minutes before
trying again.

NOTE: The propulsion control lever (FSR) must be in the STOP position, the
High/Low engine speed switch (throttle) in Low RPM, the park brake switch in
the on position, and the emergency stop switch pulled up before the engine will
start.

Always remove ignition switch key when leaving machine unattended to

prevent unauthorized personnel from starting or operating the machine.

ENGINE OIL PRESSURE GAUGE

The engine oil pressure gauge (6, Figure 3-3) displays engine oil pressure on a dual scale
calibrated from 0 - 700 kPa or 0 - 100 psi.
At normal operating speeds, pressure should read between 276 - 414 kPa or 40 - 60 psi. At
idle speed, gauge should display between 172 - 207 kPa or 25 - 30 psi. If gauge reads outside
these ranges, shut down the machine and correct the problem before continuing operation.

MAIN WATER FLOW CONTROL

The main water flow control is a variable knob control (7, Figure 3-3) that allows the operator
to regulate water flow from the water system to the drums.
Turn control clockwise, away from OFF position, to increase water flow to maximum from the
main water system. Turn control counterclockwise, towards OFF position, to decrease the
water flow. Positioning this control does not affect the auxiliary water system.

WATER TEMPERATURE GAUGE

The water temperature gauge (8, Figure 3-3) displays the engine water temperature on a dual
scale calibrated from 38 °C to 138 °C (100 °F to 280 °F).
The normal operating temperature is 72 °C to 88 °C (160 °F to 190 °F). If the display is outside
this range, shut down the machine, and correct the problem before continuing operation.

ENGINE STOP LIGHT (RED)

The engine stop light (9, Figure 3-3) displays to advise the operator to STOP the engine as
soon as possible following all safety precautions. An illuminated light indicates serious areas
of concern.

3-6 DD90/DD90HF
OPERATING CONTROLS AND INSTRUMENTS SECTION 3

CHECK ENGINE LIGHT (AMBER)

The check engine light (10, Figure 3-3) displays when the engine sensors detect areas of
concern which should be investigated by the maintenance personnel.

CONTROL PANEL, LOWER SECTION

The following descriptions refer to operator controls on the lower section of the control panel,
see Figure 3-4.

Figure 3-4

1. Main water pump switch 6. Work lights (optional)

2. Auxiliary water pump switch 7. Drum selector switch
3. High/Low engine speed (throttle) 8. Auto/Manual vibration on/off switch
4. Park brake test switch 9. Vibration control/eccentric direction switch
5. Park brake switch 10. High/Low frequency switch

MAIN WATER PUMP SWITCH

The On/Off switch (1, Figure 3-4) is a three-position switch 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 tanks.

DD90/DD90HF 3-7
 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS

AUXILIARY WATER PUMP SWITCH

The On/Off rocker switch (2, Figure 3-4) is used to activate the water pump for the auxiliary
water system.
Move switch to ON position to activate the auxiliary water pump and to OFF position when
pump use is not required. The auxiliary pump is used as a back-up system in case the main
water pump fails.

HIGH/LOW ENGINE SPEED CONTROL (THROTTLE)

This two-position engine speed control switch (3, Figure 3-4) is used to select engine speed
to HIGH RPM or LOW RPM. Compacting operations are performed at HIGH RPM engine
speed.

NOTE: Do not allow engine to idle for more than 10 minutes.

Always ensure that the engine speed switch is at the HIGH RPM position before performing
compacting operations. Full engine power is necessary to obtain the proper component
operation and maximum VPM for greatest efficiency.

PARK BRAKE TEST SWITCH

The park brake test switch (4, Figure 3-4) is a momentary switch. When held in the test
position, it allows the operator to test the operation of the parking brake by positioning the
propulsion control lever (FSR) forward. See Section 4, Operating Instructions, for details on
testing the parking brake.

PARK BRAKE SWITCH

The park brake switch (5, Figure 3-4) controls the spring applied, hydraulically released
parking brake. Apply the parking brake by pressing the top of the switch. When the brake is
applied, the parking brake red warning light will be illuminated except following an emergency
stop switch. Release the park brake by pressing the bottom of the switch and the red warning
light will extinguish.

NOTE: Brakes can only be released by this switch when the engine is running.

WORK LIGHTS SWITCH (OPTIONAL)

The work lights switch (6, Figure 3-4) turns the optional working lights ON and OFF.

DRUM SELECTOR SWITCH

The 3-position switch (7, Figure 3-4) is used to select independent or dual drum vibration.
Position switch to BOTH and front and rear drums will both vibrate. Select FRONT or REAR
to obtain front or rear drum vibration.

3-8 DD90/DD90HF
OPERATING CONTROLS AND INSTRUMENTS SECTION 3

AUTO/MANUAL VIBRATION ON/OFF SWITCH

The 3-position vibration switch (8, Figure 3-4) is used to select automatic or manual drum
vibration or the off position.
In AUTO VIB position, drum vibration automatically begins when machine travel speed
reaches a preset speed and stops once travel speed drops to the same preset speed. The
speeds can be set to 1.2, 2.0, 2.8, or 3.2 km/h (0.75, 1.25, 1.75, or 2 mph). Refer to "Setting
Auto Vibration Control Module" in Section 4, OPERATING INSTRUCTIONS.
Position the switch to OFF (center) and all vibration stops.

NOTE: The vibration mode selector switch must be used in conjunction with the
drum selector switch.

VIBRATION CONTROL/ECCENTRIC DIRECTION SWITCH

The three position switch (9, Figure 3-4) controls the direction the eccentrics will operate.
With the switch positioned to the left, the drum eccentrics will rotate in the clockwise direction,
viewed looking at the amplitude setting hand-wheel.
With the switch positioned to the right, the drum eccentrics will rotate in the counterclockwise
direction, viewed looking at the amplitude setting hand-wheel.
With the switch positioned to AUTO (center), the eccentrics will rotate automatically (change
direction of rotation) as the direction of the machine is reversed.

HIGH/LOW FREQUENCY SWITCH

The 2-position switch (10, Figure 3-4) is used to select the drum vibration frequency required
for the job.
The switch can be turned to minimum (LO) frequency, OFF. or maximum (HI) frequency
position. The minimum frequency setting for the DD90 is 1850 VPM and 2850 VPM for the
DD90HF. Maximum frequency setting for the DD90 is 2500 VPM, and for the DD90HF, 3800
VPM. If drum vibration is not required, move auto/off/manual switch to OFF position or push
the vibration switch once to turn vibration off.

DD90/DD90HF 3-9
 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS

STEERING WHEEL
The steering wheel (1, Figure 3-5) is used to turn the machine left and right during operation.

Figure 3-5

PROPULSION CONTROL
The propulsion control lever (FSR) (Figure 3-6) controls machine direction, speed of travel,
and braking function. The vibration on/off button (1, Figure 3-6) on the propulsion control lever
actuates the vibration control module for compaction operations. This button must be pressed
to actuate power to the vibration control modules.

Figure 3-6

3-10 DD90/DD90HF
OPERATING CONTROLS AND INSTRUMENTS SECTION 3

! WARNING
Loss of machine control.

Moving the propulsion control lever (FSR) quickly may cause loss of
machine control, lurching or serious injury.

Move the propulsion control lever slowly.

To propel the machine in either Forward or Reverse direction, grasp the propulsion control
lever (FSR) and pull toward you, out of the detent, then slowly move the control in the required
direction.
To slow and stop machine travel, slowly move the propulsion control lever towards the STOP
position, arriving at the STOP position to halt machine travel.

NOTE: There is also an electrical interlock switch in the propulsion control

which only permits engine starting when the control is in the STOP position.

OPERATOR'S SEAT
The operator's seat can be adjusted forward and backward by moving the lever on left side of
the seat (1, Figure 3-7) and sliding seat in the desired direction. The operator’s seat can also
be adjusted for the weight of the operator by adjusting the knob (2) at the front of the seat.

NOTE: The machine contains a circuit that will allow the machine to start only
if the propulsion control lever (FSR) is in the STOP position, the parking brake
is applied, the engine speed control switch is in the low idle position, and the
emergency stop switch is reset.

Figure 3-7

DD90/DD90HF 3-11
 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS

OPERATOR'S CONSOLE AND SEAT ADJUSTMENT LEVER

The operator’s console and seat adjustment lever (1, Figure 3-8) is used to swivel the operator’s
console and seat as one unit. The operator’s console and seat swivels 180 degrees and can be
locked in any of five positions for ease of operation and to observe work being performed.

Figure 3-8

To change the operator’s console and seat position, pull lever backward and hold. Swivel the
operator’s console and seat to one of five positions and release the lever. This action locks the
unit at the desired location.

3-12 DD90/DD90HF
OPERATING CONTROLS AND INSTRUMENTS SECTION 3

PEDESTAL CONTROL PANEL

The following descriptions refer to Figure 3-9.

Figure 3-9

1. Horn button 4. Emergency stop switch

2. Water tank level indicator 5. Hourmeter
3. Vibration indicator (option)

HORN BUTTON
The horn button (1, Figure 3-9) is used to alert personnel of the approach of the machine or a
change in its direction.

WATER TANK LEVEL INDICATOR

The water tank level indicator panel (2, Figure 3-9) illuminates when the button in the center
of the panel is pushed. The panel displays water levels for the front and rear water tanks.

VIBRATION INDICATOR LAMP (OPTION)

The optional vibration indicator lamp (3, Figure 3-9) illuminates when the vibration speed
reaches 1700 vpm.

DD90/DD90HF 3-13
 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS

EMERGENCY STOP SWITCH

The emergency stop switch (4, Figure 3-9) is a latching type switch that, when pressed, shuts
down the engine and all other machine functions in the event of an emergency and applies the
parking brake.
Push in on red knob to shut down the engine and all machine functions. Reset switch by pulling
out on the red knob. This activates the switch for future use.

HOURMETER
The hourmeter (5, Figure 3-9) displays the engine running time in hours and tenths.

NOTE: To ensure minimal machine downtime, it is important that the hourmeter

be used with the machine lubrication chart and maintenance records. It is
important that servicing of the machine be performed at the correct time
intervals.

3-14 DD90/DD90HF
OPERATING CONTROLS AND INSTRUMENTS SECTION 3

AMPLITUDE ADJUSTING WHEEL

! WARNING
The amplitude wheels turn with the drum eccentric weights.

SERIOUS INJURY can occur while making adjustments with the engine
running, if the machine's system is energized allowing drum movement
to occur.

ALWAYS make sure engine is shut down, machine is chocked and the
articulation lock bar is in the locked position before performing any
adjustments or service to the amplitude wheel and drum area.

One adjusting wheel (1, Figure 3-10) is located on the left side of each drum. The amplitude
adjusting wheel has eight positions that control variable amplitude by repositioning the
eccentrics. Each drum is controlled independently of the other.

Figure 3-10

To turn the amplitude adjusting wheel, shut down the engine. Pull the spring-loaded wheel to
release it from its detent. Turn the adjusting wheel clockwise to increase drum amplitude
(dynamic force) and counterclockwise to decrease amplitude. When the desired drum
amplitude has been determined, release wheel to engage the mechanism.

DD90/DD90HF 3-15
 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS

OPTIONAL EQUIPMENT

BEACON LIGHT SWITCH

The On/Off switch (1 Figure 3-11) located on the pedestal control panel, operates the rotating
beacon. The beacon provides increased visibility of the machine during operations.

Figure 3-11

VPM METER/TACHOMETER
The optional VPM meter (1, Figure 3-12) located on the pedestal above the steering wheel, is
available to measure and display the selected drum vibrations per minute (VPM). The
selection of the drum is performed by the three position toggle switch (2, Figure 3-12). Placing
the switch to the left position selects the front drum, while the right position selects the rear
drum. Center position removes all input to the meter.

3-16 DD90/DD90HF
OPERATING CONTROLS AND INSTRUMENTS SECTION 3

Figure 3-12

The optional speedometer (3, Figure 3-12) is available to measure machine ground speed
(km/h / mph). The speedometer is calibrated in mph with a range of 0 to 10.

TURN SIGNAL SWITCH

The optional 2-position selector switch (1, Figure 3-13) is turned to the right or left to cause the
turn signal lights to flash indicating a machine turn.

Figure 3-13

DD90/DD90HF 3-17
 SECTION 3 OPERATING CONTROLS AND INSTRUMENTS

FOUR-WAY FLASHER
The optional 2-position selector switch (1, Figure 3-14) activates the 4-way flasher signal
lights.

Figure 3-14

HYDRAULIC OIL TEMPERATURE GAUGE

The optional gauge provides a visual indication of the hydraulic oil temperature.
Under normal operation, gauge should read from 82 - 93 °C (180 - 200 °F).

SPEED LIMITER
The optional speed limiter, located at the propulsion control lever (FSR), is used to prevent the
machine from operating at a greater speed in forward or reverse than desired. The limiter can
be adjusted to different locations which alters the maximum speed.

3-18 DD90/DD90HF
 SECTION 4 - OPERATING
INSTRUCTIONS

DD90/DD90HF 4-1
 SECTION 4 OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS
If you are not experienced with the machine's operation and control, before operating the
machine, read Section 3, OPERATING CONTROLS AND INSTRUMENTS.

! WARNING
Ensure the articulation lock bar is in the stowed position before operating
the machine. The articulation lock bar, in the installed position, will
prohibit the vehicle from steering.

! WARNING
Allow no one to operate or maintain this machine unless they have read
and understand this Operation and Maintenance Manual, especially
Section 1, SAFETY, and have been trained in the proper operation and
maintenance of this machine.

Read and understand Section 3, OPERATING CONTROLS AND

INSTRUMENTS, before you operate this machine.

GENERAL INFORMATION
Adhere to the following operational procedures:

• Allow the machine to warm up for 3 to 5 minutes before operating with a load. After
starting a cold engine, increase the engine speed (rpm) slowly to provide adequate
lubrication to the bearings and to allow oil pressure to stabilize.

• Always chock the drums when parking the machine. There is a possibility of
uncontrolled movement.

• Do not grease the machine while the engine is running.

• Always perform safety checks prior to starting/using the machine.

• Do not control travel speed using the high rpm/low rpm engine speed control.

• Always operate the machine at full engine speed when compacting or traveling the
machine.

• Never operate the machine across slopes. Travel up and down slopes.

• On machines equipped with a Rollover Protective Structure (ROPS), wear seat belt
at all times.

4-2 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

• Before starting engine, position the propulsion control lever to the STOP position,
position vibration controls to the OFF position, and position the parking brake switch
to the applied position.

• Always sound the horn before moving the machine in either direction to alert
personnel, and to allow sufficient time before putting the machine into motion.

• Always use personal protective equipment such as gloves, goggles, and safety
helmet when performing service maintenance. Do not wear oil stained or damaged
garments.

PRE-START CHECKS/VERIFICATIONS

Checks and Verifications of Overall Machine

Checks and verifications of overall machine performed prior to starting (these are in
addition to the 10 hour daily routine maintenance):

1. Inspect fuel tank and fuel lines for any leaks.

2. Check condition of engine and machine.
3. Check bolted assemblies for tightness.
4. Inspect entire machine for any loose, worn and missing parts. Replace as needed.
5. Inspect fluid lines, hoses, fittings, filler openings, drain plugs, pressure cap, drums,
muffler, engine safety shrouds for signs of leakage.
6. To unlock the hood, pull down the two draw latches (1, Figure 4-1) on both
sides of the machine.

Figure 4-1

7. To open the hood, pull up the handles (2, Figure 4-1).

8. To close the hood, push the handle until the hood is down.

DD90/DD90HF 4-3
 SECTION 4 OPERATING INSTRUCTIONS

9. Pull up the two draw latches (1, Figure 4-1) on both sides of the machine.

! WARNING
Personal Injury Hazard

Injury can occur when removing the coolant recovery bottle 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 it to cool down before removing
the engine coolant recovery bottle cap. Remove the cap slowly to relieve
pressure. Avoid contact with steam or escaping fluid.

10. Check engine coolant level in the coolant recovery bottle (1, Figure 4-2).
Maintain the coolant level to within 25 mm (1 inch) from the bottom of the cap.
If required, add a mixture of 50% coolant and 50% water to bring coolant to the
proper level.

Figure 4-2

4-4 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

11. Check fuel level in fuel tank. If required, add clean, filtered fuel through the fill
area (1, Figure 4-3). Refer to Section 8, FUEL AND LUBE SPECIFICATIONS.

Figure 4-3

12. Check engine oil level on dipstick (1, Figure 4-4). If required, add engine
oil through fill area (2, Figure 4-4) to bring to Full level on dipstick. If no oil is
showing on the dipstick, call for service assistance to investigate the cause of
oil loss. Refer to Section 8, FUEL AND LUBE SPECIFICATIONS.

Figure 4-4

DD90/DD90HF 4-5
 SECTION 4 OPERATING INSTRUCTIONS

13. Check hydraulic tank oil level by viewing the sight level gauge (1, Figure 4-5)
on the side of the tank. Add fresh, clean, anti-wear hydraulic oil through the oil
fill area (2). Refer to Section 8, FUEL AND LUBE SPECIFICATIONS.

Figure 4-5

14. Check the water spray system tanks (1, Figure 4-6) located at the front and rear
of the machine. Maintain the water tanks full of clean water at all times. If water
level is low, remove the fill cap and add clean water to the full level.

NOTE: NEVER allow the water tanks to become empty for any reason other
than for cleaning.

Figure 4-6

4-6 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

Checking and Verifying Machine Controls

Checking and verifying machine controls prior to operating the machine.

! CAUTION
Any machine faults must be corrected before operating the machine.

Checks and verifications of machine controls must be performed prior to

operating the machine.

1. Mount the compactor maintaining a three-point contact.

2. Adjust the seat to a comfortable position with the lever (1, Figure 4-7).

Figure 4-7

NOTE: The machine contains a circuit that will allow the machine to start only
if the propulsion control lever (FSR) is in the STOP position, the parking brake
is applied, the engine speed control switch is in the low idle position, and the
emergency stop switch is reset.

3. Securely fasten seat belt across hips.

DD90/DD90HF 4-7
 SECTION 4 OPERATING INSTRUCTIONS

4. Move the propulsion control lever (1, Figure 4-8) to the STOP
position.

Figure 4-8

5. Reset the emergency stop switch (1, Figure 4-9), by pulling out on switch.

Figure 4-9

4-8 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

6. Press engine speed switch (1, Figure 4-10) to LOW RPM position.
7. Press the top of the parking brake switch (2, Figure 4-10) to the applied
position.

Figure 4-10

8. Turn ignition switch (3, Figure 4-10) to position, and verify that the following
occurs:

a. Red brake lamp on parking brake indicator (2, Figure 4-10) illuminates.
b. Voltmeter (1, Figure 4-11) registers.

Figure 4-11

DD90/DD90HF 4-9
 SECTION 4 OPERATING INSTRUCTIONS

9. Press the horn button (1, Figure 4-12) to verify that the horn operates properly.

Figure 4-12

10. To confirm that the engine will only start with propulsion control lever in the
STOP position, move lever from the STOP position in any direction.
11. Make sure no personnel are close to the machine. With the brake applied, turn
ignition switch to position. The engine starter motor should NOT engage,
confirming the engine will only start with the propulsion control lever in the
STOP position.
12. Return ignition switch to position.
13. Return propulsion control lever to STOP position.

4-10 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

STARTING MACHINE AND OTHER CHECKS/VERIFICATIONS

Starting Procedure and Checks and Verifications with Engine Running

NOTE: If any controls or devices do not function correctly, refer to Section 6,

TROUBLESHOOTING. When carrying out troubleshooting, refer to the safety
instructions in Section 1 of this manual. Do not operate the machine until the
condition(s) is corrected.

1. Position propulsion control lever (1, Figure 4-13) to the STOP position.

Figure 4-13

2. If applied, reset the emergency stop switch (1, Figure 4-14), by pulling out
on switch.

Figure 4-14

DD90/DD90HF 4-11
 SECTION 4 OPERATING INSTRUCTIONS

3. Position the water control switches (1 and 2, Figure 4-15) to the OFF position.

Figure 4-15

4. Position the engine speed control (3, Figure 4-15) to LOW RPM position.
5. Position park brake switch (4, Figure 4-15) to the applied position.
6. Turn ignition switch (5, Figure 4-15) to run position. Wait until the grid heater
light (6, Figure 4-15) goes out.

NOTICE
Starter may overheat if operated longer than 30 seconds.

If the engine fails to start, allow the starter to cool 2 to 3 minutes before
trying again.

4-12 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

7. Start engine by turning ignition switch to position. When the engine starts,
release switch immediately, and it will return to position.
8. 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.
9. 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, notify appropriate personnel.
10. Check wear conditions on the steering cylinder mounting pins and bushings
(1, Figure 4-16). Any wear in the pins and bushings should be noted and proper
personnel notified.

Figure 4-16

11. Check water level in front and rear water tanks from the operator’s seat by
pressing button (1, Figure 4-17) on center of water tank level indicator panel
and reviewing light readout. Fill tanks as necessary. Keep water tanks as full
as possible during compacting operations.

Figure 4-17

DD90/DD90HF 4-13
 SECTION 4 OPERATING INSTRUCTIONS

12. With engine running, turn off parking brake switch and ensure brake light
goes out. Observe area around machine for personnel and/or obstructions.
13. Move propulsion control lever (1, Figure 4-18) in reverse direction to
ensure the back-up alarm is operational. Alarm should sound even before
machine begins movement. Return propulsion control lever to STOP position.
If alarm is not operational or does not sound immediately, contact appropriate
personnel.

Figure 4-18

14. Check for correct operation of brake systems by driving machine in forward and
reverse directions using propulsion control lever (1, Figure 4-18) to alternately
accelerate and brake machine movement. Return propulsion control lever to
STOP position. If brake system is questionable, contact appropriate personnel.

NOTE: Braking should be smooth and capable of bringing machine to a

complete stop when propulsion control lever is placed in STOP position.

15. Turn the parking brake switch on.

4-14 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

16. Check for correct operation of the emergency stop switch. While the propulsion
control lever (1, Figure 4-18) is in the STOP position, depress the red
emergency stop knob (1, Figure 4-19).

Figure 4-19

NOTE: The engine should immediately shut 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 out on the switch.

DD90/DD90HF 4-15
 SECTION 4 OPERATING INSTRUCTIONS

OPERATING THE MACHINE

Operating Suggestions and Checks while Operating Machine

1. Always sound horn before moving the machine in either direction to alert
personnel. Allow sufficient time before putting the machine into motion.
2. Monitor all instruments and warning lights. If instruments or lights indicate a
fault or problem, contact appropriate personnel.
3. Monitor and ensure that the horn and back-up alarm function properly and that
optional working lights give good illumination of the working area.
4. Monitor working area for obstruction and personnel.
5. Always remove the ignition switch key and ensure that the parking brake is
applied when leaving the operator’s station.
6. Always move the steering wheel slowly and monitor the steering action.

Moving the Machine (Propulsion Control)

1. Always check travel and work areas for personnel and obstructions.
2. Install articulation lock bar (1, Figure 4-20) to the stowed position as shown.

Figure 4-20

3. Position engine speed control switch to HIGH RPM position.

NOTE: Never use engine speed control to control the speed of travel.

4-16 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

4. Turn off the parking brake switch .

5. Slowly move propulsion control lever (1, Figure 4-21) 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 4-21

WARNING!! Crush hazard can cause serious injury or death. Stay alert when approaching
paver, Do not come closer than 15 m (50 ft) from an operating paver. If it is necessary to
closely approach a stationary paver, clear personnel from the screed area and proceed slowly
and cautiously.
During the paving and compacting operation, the compactor should not approach the paver
closer than 15 m (50 ft) unless the paver has stopped and all paver crew members have
moved safely away from the paver screed area. The compactor operator should then
approach the paver cautiously, taking care not to bump the paver screed. There is no
significant quality or performance advantage to bringing the compactor “up close” to the paver
screed on every pass. Of course, if the paver has stopped because it has reached the end of
the run or has run out of asphalt, the compactor must then closely approach the paver.
However, a stopped paver does not require crew members on or near the paver screed. Under
these circumstances, the compactor operator should make sure the paver screed crew
members have moved away before closely approaching the paver.

DD90/DD90HF 4-17
 SECTION 4 OPERATING INSTRUCTIONS

Using Vibration (Vibration Controls)

NOTE: When auto vibration mode is selected, drum vibration will automatically
begins when machine travel speed reaches the speed selected by the dip
switch setting on the auto vibration control module.

There are four dip switches settings available: 1.2, 2.0, 2.8, and 3.2 km/h
(0.75, 1.25, 1.75, or 2 mph). As shipped from the factory, the control is set at
1.2 km/h (0.75 mph).

Setting the Auto Vibration Control Module

1. Set AUTO VIB/MANUAL VIB mode selector switch (1, Figure 4-22) to the
AUTO VIB position.

Figure 4-22

2. Place the machine on a level surface and shut down the engine.

4-18 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

3. Open the fuel access door. The auto vibration control module (1, Figure 4-23)
is located to the right of the fuse panel.

Figure 4-23

4. Remove the protective plastic covers from the dip switches (1 and 2,
Figure 4-24).

Figure 4-24

5. Place the SPEED SETTING dip switch (1, Figure 4-24) for the desired speed
in the ON position. Be sure the other speed setting switches are not activated.
6. Check the dip switch (2, Figure 4-24) labeled VEHICLE TYPE to ensure the
correct machine is selected. If the correct vehicle type is not selected, place the
dip switch for the correct vehicle in the ON position. Be sure the other VEHICLE
TYPE switches are not activated.

NOTE: If more than one speed setting is set to the ON position, the default

DD90/DD90HF 4-19
 SECTION 4 OPERATING INSTRUCTIONS

setting of 1.2 km/h (0.75 mph) will be set. When the machine is started, the LED
will flash rapidly for approximately 5 seconds.

7. Install the protective covers on the switches. Have an associate observe the
LED and start the machine. The LED should illuminate to show power is ON but
should not be flashing.
8. Close the fuel fill access door.

Operating the Machine Using Automatic Vibration

The FSR vibration on/off switch, located on the FSR, powers up the vibration control module
of the machine for compaction operations.

NOTE: When AUTO VIB/MANUAL VIB switch is set to AUTO VIB, the drum
vibration automatically begins when machine travel speed reaches the speed
selected by the dip switch setting on the auto vibration control module.

1. Position the main water switch (1, Figure 4-25) for drum spray, if desired. Place
the auxiliary water switch (2) in the OFF position.

Figure 4-25

2. Release the parking brake by switching the brake switch to OFF (3, Figure
4-25).
3. Place the FREQUENCY switch (4, Figure 4-25) to the desired settings.
4. Place the drum selector switch (5, Figure 4-25) to either both, front or rear drum
vibration.
5. Place the eccentric direction selector switch (6, Figure 4-25) to AUTO position.
6. Place the AUTO VIB/MANUAL VIB mode selector switch (7, Figure 4-25) to
AUTO VIB position.
7. Move propulsion control lever in the desired direction and safe speed of travel
as determined by the conditions.
8. Press the vibration switch on the FSR to actuate vibration operations.

4-20 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

Operating the Machine Using Manual Vibration

! CAUTION
Asphalt mat damage.

With the engine running and the vibration mode selector switch in one of
the manual positions, the machine will vibrate.

DO NOT vibrate with the machine stationary.

The FSR vibration on/off switch, located on the FSR, powers up the vibration control module
of the machine for compaction operations.

NOTE: Only switch on drum vibration when machine is moving. Always switch
off drum vibration before machine comes to a halt. Never allow drums to vibrate
when machine is stationary.

1. Position the main water switch (1, Figure 4-26) for automatic or manual drum
spray, as desired. Place the auxiliary water switch (2) in the OFF position.

Figure 4-26

2. Release the parking brake (3, Figure 4-26).

3. Position the FREQUENCY switch (4, Figure 4-26) to the desired
setting.
4. Place the drum selector switch (5, Figure 4-26) to either both, front or rear drum
vibration.
5. Place the eccentric direction selector switch (6, Figure 4-26) to MANUAL
position.
6. Position the AUTO VIB/MANUAL VIB selector switch (7, Figure 4-26) to
MANUAL VIB position.

DD90/DD90HF 4-21
 SECTION 4 OPERATING INSTRUCTIONS

7. Move propulsion control lever in the desired direction and safe speed of travel
as determined by the conditions.
8. Press the vibration switch on the FSR to actuate vibration operations.
9. Press the vibration switch on the FSR again to stop vibration operations.

Amplitude Adjusting Wheel

! WARNING
The amplitude wheels turn with the drum eccentric weights.

SERIOUS INJURY can occur while making adjustments with the engine
running, if the machine's system is energized allowing amplitude wheel
or drum movement to occur.

ALWAYS make sure engine is shut down, machine is chocked and the
articulation lock bar is in the locked position before performing any
adjustments or service to the amplitude wheel and drum area.

One amplitude adjusting wheel (1, Figure 4-27) is located on the left side of each drum.
The eight position (1-8) wheel (2, Figure 4-27) is adjustable and controls variable amplitude
by repositioning the eccentrics. Each drum is controlled independently of the other.

Figure 4-27

To turn the adjusting wheel:

1. Shut down the engine.

2. Pull the spring-loaded wheel to release it from its detent.
3. Turn wheel clockwise to increase drum amplitude (dynamic force) and
counterclockwise to decrease amplitude.

4-22 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

4. When the desired drum amplitude has been determined, release wheel to
engage the mechanism.
Use the recommended settings in Table 4-1 and Table 4-2 when a test strip is being
established in conjunction with some type of density testing as a starting point. Make actual
adjustments according to density test results and production requirements. The day-to-day
variation in hot mix asphalt applications requires attention to the amplitude setting.
Table 4-1

RECOMMENDED VARIABLE AMPLITUDE SETTINGS FOR HOT MIX ASPHALT

TOP, INTERMEDIATE, AND BASE COURSES, DD90
LIFT 25.4 - 63.5 mm 63.5 - 101.6 mm 101.6 - 152.4 mm 152.4 mm ±
THICKNESS 1.0 - 2.5 in. 2.5 - 4.0 in. 4.0 - 6.0 in. 6.0 in. ±
AMPLITUDE
1, 2, 3 2, 3, 4 4, 5, 6, 7 5, 6, 7, 8
SETTING

Table 4-2

RECOMMENDED VARIABLE AMPLITUDE SETTINGS FOR HOT MIX ASPHALT

TOP, INTERMEDIATE, AND BASE COURSES, DD90HF
LIFT 25.4 - 50.8 mm 50.8 - 76.2 mm 76.2 - 101.6 mm 101.6 mm ±
THICKNESS 1.0 - 2.0 in. 2.5 - 3.0 in. 3.0 - 4.0 in. 4.0 in. ±
AMPLITUDE Not
1, 2, 3 2, 3, 4 4, 5, 6, 7
SETTING Recommended

DD90/DD90HF 4-23
 SECTION 4 OPERATING INSTRUCTIONS

PARKING, STOPPING, AND SHUTTING DOWN THE MACHINE

Parking the Machine

1. To park the machine, move to firm, level ground. If circumstances require

parking the machine on other than level ground, chock the drums.
2. To stop the machine upon reaching destination, use the following procedure.

Stopping the Machine

1. Stop the drum or drums from vibrating.

• If drum vibration mode is set to AUTO VIB (automatic), drum vibration stops when
the machine speed is less than the preselected value.

• If drum vibration mode is set to MANUAL VIB, press the vibration switch on the
FSR (1, Figure 4-28) to stop drum vibration.

Figure 4-28

2. For normal stopping, move the propulsion control lever (1, Figure 4-28) slowly
to the STOP position.
3. To ensure no machine movement occurs after stopping, turn the parking brake
switch to ON to apply the brakes.

4-24 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

Shutting Down the Machine

1. Stop the water flow by turning the water control switch (1, Figure 4-29) to the
OFF position. If the auxiliary water pump has been activated, turn auxiliary
water switch (2) to the OFF position.

Figure 4-29

2. Insert the articulation locking bar (1, Figure 4-30) to the locked position. Secure
with pin (2).

Figure 4-30

3. Allow machine to idle for a few minutes before turning ignition switch to the
STOP position. Remove ignition key.

DD90/DD90HF 4-25
 SECTION 4 OPERATING INSTRUCTIONS

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 accumulated material.
3. Lock all vandal protection devices on the machine.

MOUNTING AND DISMOUNTING OF ATTACHMENTS

NOTE: All optional equipment mounting and dismounting on this machine must
only be undertaken by trained service personnel.

MOVEMENT OF MACHINE BETWEEN WORK SITES

Before driving machine on public roads, check with your supervisor for instructions and
information in respect to traffic regulations regarding construction machinery.

NOTE: For more information on transporting, refer to Section 1, SAFETY.

Loading the Machine Under its Own Power (Drive On) for Transporting

1. Choose level ground which will solidly support the transport vehicle.
2. Clean the transport vehicle surface and loading ramps.
3. Before loading machine, chock the wheels of the transport vehicle.
4. A signalman must assist the operator with any necessary warnings.
5. Approach the transport vehicle loading ramps squarely to make sure machine
does not drop off side of ramp.
6. Drive machine onto transport vehicle.
7. Shut down the engine, apply parking brake, and lock all lockable
compartments.

4-26 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

Loading the Machine by Lifting the Equipment for Transporting

1. Always use four lift points and proper lifting tackle. Refer to weight distribution
in Section 7, TECHNICAL SPECIFICATIONS. The total weight is indicated on
the machine identification plate located on the machine.
2. Insert the articulation lock bar into the locked position.
3. Attach the lifting frame using the four lift points marked with symbol (1 and
2, Figure 4-31).

Figure 4-31

4. Ensure appropriate lifting equipment is rated to the machine before lifting.

Securing the Machine to the Transport Vehicle (Tie-Down)

5. After loading the machine to the transport vehicle, place the articulation lock bar
in the locked position (2, Figure 4-33). Secure with pin (2).

Figure 4-32

6. Shut down engine and remove ignition switch key.

DD90/DD90HF 4-27
 SECTION 4 OPERATING INSTRUCTIONS

7. Chock the drums.

8. Tie-down machine using a chain and tensioning device or other appropriate
equipment to the four tie-down points marked (1 and 2, Figure 4-33).

Figure 4-33

9. The driver of the transport vehicle must be aware of its total weight, load on the
axles, and the overall dimensions of the machine. For dimensions, refer to
Section 7, TECHNICAL SPECIFICATIONS.

4-28 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

TOWING THE MACHINE

! WARNING
Personal Injury Hazard Flying Objects

Special care must be taken in attaching the tow bars, chains, or cables to
the towed vehicle and the towing vehicle(s). Release or breakage of the
tow bar, chains, or cables during the towing process could result in
serious injury or death.

! WARNING
Machine runaway condition could occur.

Always chock the drums of a disabled machine or hitch it to its towing

vehicle to prevent accidental movement while preparing the machine for
towing.

Especially if machine failure occurs on an incline.

! WARNING
Towing the compactor is limited to off the job site, onto the transport
vehicle, off the transport vehicle, and into the shop and maximum speed
while towing is 2 km/h (1.24 mph).

Ensure the machine used to tow the compactor is heavier than or equal
to the weight of the compactor being towed and has sufficient power and
braking capacity to tow and stop both machines.

When towing, use tow bars rated for a minimum of 1.5 times the weight of
the towing vehicle. Attach bars to the towed vehicles at the tie down
points only. Use of cable or chain will not allow control of the towed
vehicle when going downhill unless a second tow vehicle is used on the
other end of the compactor.

Forces on the tow points must not exceed 89,142 N (20,040 lb)
horizontally or 32,427 N (7290 lb) vertically.

DD90/DD90HF 4-29
 SECTION 4 OPERATING INSTRUCTIONS

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 when towing has stopped.

Refer to Section 1, SAFETY, at Transporting, Towing and Roading in this

Operation and Maintenance Manual, before transporting the compactor.

Towing the Machine, Maximum 300 Meters (984 Feet)

If The Engine Will Not Start

1. Chock the drums.

2. Locate the towing tag from the Operation and Maintenance Manual storage
pouch, and secure the towing tag to the steering wheel.
3. To manually disengage the brakes, remove the tow bolts and washers
(1, Figure 4-34) from the compartment under operator console. Tow bolts are
located next to the fuel fill.

Figure 4-34

4-30 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

4. Remove rubber cap from center of both front and rear drive motors (1, Figure
4-35) of the drums.

Figure 4-35

5. Using washer as spacer, engage tow bolt into both motors and tighten to
140 Nm (103 lbf ft).
6. Disengage the propulsion system by using a wrench to turn the middle nut on
the propulsion pump bypass valve a maximum of three revolutions
counterclockwise. Refer to 1, Figure 4-36.

Figure 4-36

7. Move the propulsion control lever from the STOP position to the full
forward or reverse position.

DD90/DD90HF 4-31
 SECTION 4 OPERATING INSTRUCTIONS

! CAUTION
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).

8. Attach an appropriate towing vehicle using appropriate chains/drawbar which

can be secured in position at the selected tow points on the machine marked
with symbol . Remove the chocks.
9. Tow machine off site at a very slow speed for a short distance (maximum
300 meters [984 feet]).
10. Apply the parking brake control .
11. Once the machine has reached its destination, engage the brakes by removing
tow bolts and washers. Return tow bolts and washers to compartment under
operator’s console. Obtain two new rubber caps and install in drive motor.

! CAUTION
Do not reinstall rubber caps removed for releasing brakes into the drive
motor. Obtain and install new rubber caps.

12. To restore the propulsion system, use a wrench to turn the middle nut of the
propulsion pump by-pass valve three revolutions clockwise until it seats.
13. Remove the tow tag from the machine steering wheel and place back in the
Operation and Maintenance Manual pouch.
14. Correct the malfunction.

If The Engine Will Start

1. Release the parking brake control .

2. Chock the drums.
3. Locate the towing tag from the Operation and Maintenance Manual storage
pouch, and secure the towing tag to the steering wheel.
4. Remove rubber cap from center of both front and rear drive motors (Figure 4-
37) of the drums.

4-32 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

Figure 4-37

5. Using washer as space, engage tow bolt into both motors and tighten to
140 Nm (103 lbf ft).

! CAUTION
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).

6. Attach an appropriate towing vehicle using appropriate chains/drawbar which

can be secured in position at the selected tow points on the machine marked
with symbol Remove the chocks.
7. Tow machine off site at a very slow speed for a short distance (maximum 300
meters [984 feet]).
8. Apply the parking brake control .
9. Once the machine has reached its destination, engage the brakes by removing
tow bolts and washers. Return tow bolts and washers to compartment under
the operator’s console. Obtain two new rubber caps and install in drive motor.

! CAUTION
Do not reinstall rubber caps removed for releasing brakes into the drive
motor. Obtain and install new rubber caps.

10. Remove the tow tag from the machine steering wheel and place back in the
Operation and Maintenance Manual pouch.

DD90/DD90HF 4-33
 SECTION 4 OPERATING INSTRUCTIONS

11. Correct the malfunction.

SPECIAL CONDITIONS OF USE

Precautions to be Taken for Various Conditions

1. Precautions to be taken during cold weather:

• Refer to lubrication instructions in Section 8, FUEL AND LUBE

SPECIFICATIONS regarding lubricants, hydraulic fluids, coolants etc.

• Use winter-grade diesel fuel for operation at temperatures below -18 °C (0 °F).

• Be extremely careful when using cold starting aids. Starting aids are very
flammable and should only be used if needed.

• Remove batteries and store in a warm area to about +20 °C (+68 °F).
2. Precautions for use in hot weather:

• Monitor temperature gauges.

• Keep cooling fins on radiator and oil cooler clean and free of accumulated dirt.
3. Precautions for use in water and muddy conditions:

• Clean machine of accumulated material and thoroughly grease all lubrication

points. Refer to lubrication chart on machine or in Section 8, FUEL AND LUBE
SPECIFICATIONS.
4. Precautions for use in dusty conditions:

• Keep air cleaner elements clean and free of accumulation of dirt.

• Wear protective mask.

5. Precautions for use in high altitude conditions:

• Be aware that engine power will be reduced.

• Keep cooling fins on radiator and oil cooler clean and free of accumulated dirt.

4-34 DD90/DD90HF
OPERATING INSTRUCTIONS SECTION 4

EMERGENCY JUMP STARTING

To avoid personal injury or machine and battery damage, follow these directions and warnings
when using jumper cables.

! WARNING
Personal Injury Hazard

Never jump start the machine directly to the starter or starter solenoid.
The machine may lurch forward or backward and run over the personnel
attempting to jump start the machine. Normal safety devices are
bypassed when jump starting directly to the starter or starter solenoid.

! CAUTION
These batteries are connected in parallel for a higher current capacity.
Use only a 12-volt jumper system. You can damage a 12-volt starting
motor and ignition system beyond repair by connecting it to a 24-volt
power supply.

Avoid equipment damage by making sure that the machine being jumped does not come in
contact with the machine supplying the jump.
Never jump start a frozen battery, it will explode.
Be aware that lead acid batteries generate explosive gases while charging. Keep sparks,
flames, and lighted smoking materials away from batteries.
Always wear eye protection when working on or near batteries.
Follow these procedures when jump starting the machine.

1. Connect the positive (+) terminal of the booster battery to the positive (+)
terminal of the discharged battery.
2. Connect the negative (–) terminal of the booster battery to the best ground point
on the machine, away from the battery.
3. Follow all recommended engine starting procedures.
4. Remove the jumper cables in the reverse order of their connection as soon as
the engine has started.

DD90/DD90HF 4-35
 SECTION 4 OPERATING INSTRUCTIONS

4-36 DD90/DD90HF
 SECTION 5 - MAINTENANCE
INSTRUCTIONS

DD90/DD90HF 5-1
 SECTION 5 MAINTENANCE INSTRUCTIONS

MAINTENANCE INSTRUCTIONS
This section describes preventive maintenance procedures recommended for the DD90/
DD90HF series double-drum vibratory roller compactors, and the frequency at which they
should be performed.

General Maintenance Information

NOTE: A selection of hand tools should be stored on the machine to allow for
minor maintenance procedures to be carried out in the field.

This section outlines a preventive maintenance program for the machine. It is organized into
several time periods when specific tasks should be performed. Following the procedures
described in this section will help you get the most production out of your machine, and will
help validate your warranty.
The Preventive Maintenance Schedule lists all the recommended maintenance routines, the
frequency at which they should be performed, and the page number that describes that
procedure. Separate schedules are provided for each time period. Perform the procedures
specified for the number of hours the machine has run since the last maintenance, or the time
period, whichever comes first. Some maintenance may be required more frequently, such as
for cleanup and washdown, and may not fit into the normal time period. In such cases the
reader will still be referred to the correct page number for that procedure.
Reduce machine downtime by ensuring correct maintenance intervals. Coordinate the
Lubrication and Service Chart found in Section 8, FUEL AND LUBE SPECIFICATIONS, and
the Preventive Maintenance Schedule with the machine hourmeter.
Specific procedures can be found by checking the Table of Contents at the front of this
manual, or as listed in the Preventive Maintenance Schedule.

5-2 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

Warnings
Throughout this section of the Operation and Maintenance Manual you will find many
WARNINGS, CAUTIONS, and NOTICES. They relate to specific hazards and safety
concerns. All are designed to help you work safely and protect your machine from damage. All
must be obeyed.
General WARNINGS, CAUTIONS, and NOTICES are shown below. More specific
WARNINGS, CAUTIONS and NOTICES are shown with individual procedures.

! WARNING
Personal Injury Hazard

Allow no one to operate or maintain this machine unless they have read
and understand this Operation and Maintenance Manual, especially
Section 1, SAFETY, and have been authorized, and trained in the proper
operation and maintenance of this machine.

Failure to obey this Warning could result in serious personal injury, or

death.

! WARNING
Personal Injury Hazard

Before attempting to service, attach or remove any part or assembly on

the machine, do the following:

1. Place all controls and switches in the OFF or CENTERED position.

2. Shut down the engine unless the procedure states otherwise.

3. Mount and dismount the machine using walkway steps and handrails
provided, and maintain a three-point contact.

Failure to obey this Warning could result in serious personal injury, or

death.

DD90/DD90HF 5-3
 SECTION 5 MAINTENANCE INSTRUCTIONS

! WARNING
Fire Hazard

Never refuel the machine while the engine is running. Never allow sparks,
open flames, or smoking within 15 m (50 feet) of the machine when
refueling.

Failure to obey this Warning could result in a fire, causing serious

personal injury, or death.

! WARNING
Explosion Hazard

Wet storage batteries produce explosive gases. Keep sparks and open
flames away from batteries. If a battery needs recharging, avoid sparks
by turning off the charger before making connections or disconnections.

Failure to obey this Warning could result in an explosion causing serious

personal injury, or death.

! WARNING
Personal Injury Hazard

Hydraulic fluid, under pressure, can penetrate the skin and flesh causing
serious injury requiring medical attention.

Relieve hydraulic pressure before servicing hydraulic systems, and

particularly before removing any filters, hoses or connections.

Before pressurizing a hydraulic system, make sure all connections are

tight and that all lines and hoses are not damaged.

Check for pin hole leaks in the hydraulic system using a piece of
cardboard, not your hands.

Failure to obey this Warning could result in serious personal injury, or

death.

5-4 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

! WARNING
Burn Hazard

Hot engine coolant escaping from the expansion tank pressure cap can
cause serious burns.

Do not open the expansion tank pressure cap while the engine is hot.

Failure to obey this Warning could result in serious burns, to the body,
hands, face and eyes.

! WARNING
Chemical Hazard

Sulfuric acid in wet storage batteries is both toxic and caustic. Contact
with the flesh can cause serious chemical burns.

Avoid all contact with the skin, eyes, and clothing. When working around
batteries, wear work gloves and both eye and face protection.

Failure to obey this Warning could result in serious chemical burns to the
hands, face and eyes.

! WARNING
Toxic Gas Hazard

Engine exhaust is toxic and potentially fatal. Before starting the engine,
be sure there is adequate ventilation. If it is necessary to operate the
machine inside an enclosed service area, make sure exhaust fumes are
well ventilated.

Failure to obey this Warning could result in serious illness, or death.

! WARNING
Personal Injury Hazard

Verify that all personnel are outside of the danger zone and clear of the

DD90/DD90HF 5-5
 SECTION 5 MAINTENANCE INSTRUCTIONS

machine before starting the engine so they cannot be struck by or caught

in moving parts.

Failure to obey this Warning could result in serious personal injury, or

death.

! WARNING
Personal Injury Hazard

Unexpected machine motion or moving parts can cut or crush.

Apply the parking brake, shut down the engine, and install the
articulation locking bar/locking pin before working on the machine.

Failure to obey this Warning could result in serious personal injury, or

death.

! WARNING
Improper maintenance can be hazardous.

Read and understand Section 1, SAFETY before you perform any

maintenance, service or repairs.

NOTICE
Failure to follow the recommended maintenance schedule could void the
machine warranty.

5-6 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

PREVENTIVE MAINTENANCE GUIDELINES

Preparations Before Service

Before performing preventive maintenance, secure the machine as follows:

1. Park the machine on firm level ground.

2. Shut down the engine and allow it to cool; relieve hydraulic oil pressures before
performing any service on the hydraulic system.

NOTE: During towing preparation and operations, brake release valve/pump

and hosing will retain pressurized oil when brake is being held in the released
position.

3. Chock the drums.

4. Disconnect battery power or remove the ground terminal(s) and cover exposed
terminals before working on the machine's electrical system. Certain
troubleshooting procedures require that battery terminals not be removed.

5. Wash all fittings, caps, and plugs with a nonflammable, nontoxic cleaning
solution before reusing them.

6. Inspect all removed parts. Replace any that are damaged or badly worn.

Fluids and Oil, Fuel Filters

• Provide a container that will hold more than the quantity of fluid to be drained
(such as engine or hydraulic oil, or engine coolant) before draining the liquid.
Refer to Section 8, FUEL AND LUBE SPECIFICATIONS for capacities.
• Dispose of used oil and coolant in an environmentally safe manner. Follow local
guidelines and regulations.
• Clean up any spilled oil or grease immediately.
• Store oily waste, such as rags or shop cloths, in an enclosed metal container.
Dispose of them in an environmentally safe manner following local guidelines
and regulations.

DD90/DD90HF 5-7
 SECTION 5 MAINTENANCE INSTRUCTIONS

Lubrication

NOTE: Most bearings on this machine are sealed, require no lubrication, and
have no grease fittings.

! CAUTION
Use only manual (hand-pump) grease guns when greasing this machine.
Power grease guns may damage bearing seals.

• Lubricate the machine while it is still warm.

• Store lubricants in covered containers.
• Keep lubricants clean.
• Clean funnels and measuring utensils before and after use.
• Clean grease fittings before applying grease.
• Clean around drain, check level, and fill plugs before removing them.
• Clean drain, check level, and fill plugs before replacing them.
To prevent problems, other services or checks are recommended at the time of lubrication.

• Wash fill plugs with a non-flammable, non-toxic, cleaning solution before

servicing, to prevent dirt from entering while performing the service.
• Ensure that lubricants are at operating temperature before draining.
• Visually check components while lubricating them. Make sure that capscrews,
nuts, and pins are secured properly. If any are loose, tighten them all to
specifications and check the overall condition of the component.
• Stop the machine if any function does not operate or operates incorrectly. Report
the problem to your supervisor or site management. Do not continue operations
until the problem is corrected. If necessary, contact the manufacturer’s local
authorized dealer or distributor for results.

5-8 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

INITIAL BREAK-IN MAINTENANCE

New equipment requires the following initial one time break-in maintenance after 50 to 100
hours of operation. After this initial phase, the regular intervals listed in the maintenance
schedule, on the previous page, should be followed.

After 30 Minutes of Operation

1. Check tension of engine V-belts. Refer to Check Engine Belts and Tensioner,
5-58 for details.

The following Maintenance must be Carried out after 50 - 100 Hours

1. Change the engine oil and filter, refer to Change Engine Oil and Filter, 5-41, for
procedure.

2. Change the oil in the eccentrics, refer to Change Drum Eccentric and Carrier
Housing Oil, 5-48, for procedure.

3. Change the oil in the pump drive, refer to Change Pump Drive Oil, 5-50, for
procedure.

4. Change the oil in the drum carrier, refer to Change Drum Eccentric and Carrier
Housing Oil, 5-48, for procedure.

5. Torque the articulation pin nuts to 678 Nm (500 lbf ft).

6. Torque the oscillation swivel nut to 1355 Nm (1000 lbf ft).

DD90/DD90HF 5-9
 SECTION 5 MAINTENANCE INSTRUCTIONS

Maintenance for Machine Storage

Short Term Machine Storage

Perform this maintenance when the machine will be shut down for a short term (2 weeks or
less) parking or storage, or an extended period, such as for the off-season.

1. Position the machine on level ground.

2. Apply the parking brake.
3. Lower all components positioned by hydraulic cylinders.
4. Place all switches and controls in the OFF or STOP position.
5. Shut down the engine and remove the key.
6. Remove all valuable items that can be easily stolen from the machine.
7. Close and lock all doors and accessible areas.

Long Term Machine Storage

Perform this maintenance when the machine will be shut down for a long term (more than
2 weeks) parking or storage for an extended period, such as for the off-season. The sequence
of the steps may change dependent upon storage location.

1. Lubricate the machine.

2. Fill the fuel tank and hydraulic tank to the maximum level.
3. Check engine coolant concentration to prepare engine cooling system for
freezing temperatures.
4. Wash the machine and allow it to dry.
5. Touch up the paint finish to avoid rusting.
6. Position the machine on level ground.
7. Apply the parking brake.
8. Lower all components positioned by hydraulic cylinders.
9. Place all switches and controls in the OFF or neutral position.
10. Shut down the engine and remove the key.
11. Remove all valuable items that can be easily stolen from the machine.
12. Close and lock all doors and accessible areas.
13. Treat exposed parts with anti-rust agent which can be easily removed at a later
date.

5-10 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

NOTE: Follow all safety instructions for application and removal of the anti-rust
agent provided by the agent manufacturer.

14. Protect all exposed rubber components against direct sunlight.

15. Plug exhaust pipe.

Prepare Machine for Use Following Storage

Perform this maintenance before bringing the machine back into service following storage.

1. Inspect machine for any damage or missing components. Correct as required.

2. Remove plug from exhaust pipe.
3. Remove all rubber protective covers.
4. Remove anti-rust material.

NOTE: Follow all safety instructions for application and removal of the anti-rust
agent provided by the agent manufacturer.

5. Check all fluid levels and add as necessary.

6. Check belt tension and correct if necessary.
7. Check air cleaner for missing elements. Correct as required.

DD90/DD90HF 5-11
 SECTION 5 MAINTENANCE INSTRUCTIONS

PREVENTIVE MAINTENANCE SCHEDULE

The maintenance chart in this section shows those items requiring regular service and the
interval at which they 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.
In the event of extremely severe, dusty, or wet operating condition, more frequent
maintenance than specified may be necessary.
Table 5-1: Preventive Maintenance Schedule

FUNCTION SPECIFICATIONS PAGE REF.

AS REQUIRED
Check air cleaner connections and ducts for leaks page 5-15
Clean/replace air cleaner elements. Check air cleaner page 5-15
restriction indicator
Cleaning the machine page 5-21
Torque up any loose bolted connections page 5-23
Check/replace shock mounts torn or severely cracked page 5-23
EVERY 10 HOURS
Check air cleaner connections and ducts for leaks page 5-15
Check engine oil level dipstick marks page 5-24
Check engine coolant, clean radiator/oil cooler bottle/radiator page 5-25
Check air cleaner restriction indicator indicator page 5-27
Check fuel level level gauge page 5-27
Check water tank level fill page 5-29
Clean water strainers clean page 5-30
Test parking brake page 5-33
Check condition of drum and scraper page 5-34
Check seat belt page 5-34
EVERY 50 HOURS
Check batteries and cables, clean and grease terminals clean and grease page 5-35
Grease articulation and oscillation pin bearings high pressure grease page 5-36
Grease steering cylinder pin bearings high pressure grease page 5-36
Check eccentric oil level level to bottom port page 5-37
Check pump drive oil level check dipstick page 5-38
Check hydraulic oil level level gauge page 5-39
Check air cleaner system integrity page 5-40

5-12 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

FUNCTION SPECIFICATIONS PAGE REF.

EVERY 250 HOURS

Change engine oil Refer to Section 8 page 5-41
Refer engine instruc-
Change engine oil filter page 5-41
tion manual
Change fuel filter and water separator page 5-43
Clean pump drive breather page 5-44
Change hydraulic oil filters page 5-45
Clean drum carrier relief valve page 5-46
Grease console bearing page 5-47
Grease console lever page 5-47
EVERY 1000 HOURS
Change drum carrier and eccentric oil Refer to Section 8 page 5-48
Change pump drive oil Refer to Section 8 page 5-50
Change hydraulic oil/clean hydraulic oil tank/strainer Refer to Section 8 page 5-51
Drain and flush water tank/spray bars Refer to Section 8 page 5-54
Drain, flush, and replace engine coolant Refer engine manual page 5-55
Torque oscillation swivel pin nut 1355 Nm (1000 lbf ft) page 5-57
Torque articulation swivel pin nuts 678 Nm (500 lbf ft page 5-57
Refer engine instruc-
Check engine valve clearance page 5-58
tion manua
Refer engine
Check belt page 5-58
instruction manua

DD90/DD90HF 5-13
 SECTION 5 MAINTENANCE INSTRUCTIONS

ACCESS TO ENGINE
To access the engine, it is necessary to open the hood.

1. Pull down the two draw latches (1, Figure 5-1) on both sides of the machine.

Figure 5-1

2. To open the hood, pull up the handles (2, Figure 5-1).

3. To close the hood, push the handle until the hood is down.
4. Pull up the two draw latches (1, Figure 5-1) on both sides of the machine.

5-14 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

ROUTINE MAINTENANCE - AS REQUIRED

Check Air Cleaner Connections and Ducts for Leaks

Ensure all connections between the air cleaner and engine are tight and sealed.

Checking and Removing the Air Cleaner Primary Element

Maintenance of the air cleaner is due when the air cleaner restriction indicator (1, Figure 5-2)
shows red. This indicates that the air cleaner is plugged and needs to be checked.

Figure 5-2

NOTE: Dust that gets by the air cleaner system can often be detected by
looking for dust streaks on the air transfer tubing or just inside the intake
manifold inlet.

The air cleaner is the dry-type with two elements; a primary element that is replaceable, or can
be cleaned, and a safety element that should only be replaced, and never cleaned. The safety
element should be replaced after every third primary element cleaning or change.

DD90/DD90HF 5-15
 SECTION 5 MAINTENANCE INSTRUCTIONS

! CAUTION
Engine damage.

Raw, unfiltered air can cause engine damage.

Never service the air cleaner while the engine is running.

1. Loosen the clip (1, Figure 5-3) and remove the dust cover (2) to access the
filter elements. Perform a quick check to see that the evacuator valve (3) is not
inverted, damaged, or plugged.

Figure 5-3

2. Gently remove the primary filter element (1, Figure 5-4).

Figure 5-4

5-16 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

! 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.

! CAUTION
Excessive air pressure can damage the air cleaner elements.

Air pressure should not exceed 6.89 bar (100 psi) from a 3 mm (1/8 in)
diameter nozzle located 50 mm (2 in) away from the filter.

3. Ensure that safety element (1, Figure 5-5) is secure and clean the inside of the
dust cover (2) with a clean, damp cloth and the inside of the housing with
compressed air to remove any dirt accumulation.

NOTE: The safety element does not require cleaning. For maximum engine
protection, replace the safety element every third primary element change or
annually.

Figure 5-5

DD90/DD90HF 5-17
 SECTION 5 MAINTENANCE INSTRUCTIONS

Cleaning the Primary Air Cleaner 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.

! CAUTION
Excessive air pressure can damage the primary air element.

Air pressure should not exceed 6.89 bar (100 psi) from a 3 mm (1/8 in)
diameter nozzle located 50 mm (2 in) away from the filter.

Excessive water pressure can damage the primary air element.

Pressure should not exceed 2.75 bar (40 psi) from a water hose. Do not
use a nozzle.

NOTE: No attempt should be made to clean the safety element. For maximum
engine protection, replace the safety element every third primary element
change or annually.

Cleaning Air Cleaner Element - Dry Method

1. Carefully direct the compressed air, not to exceed 6.89 bar (100 psi), at an
angle onto the inside surface of the primary air cleaner element, Figure 5-4.

Figure 5-4

2. Move air jet up and down pleats until no more dust is being removed. Be careful
not to rupture the element pleats with the air nozzle.

5-18 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

3. 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 cleaner elements.

Cleaning Air Cleaner Element - Wet Method

! WARNING
Personal Injury Hazard.

Never use gasoline or solvents to clean the air cleaner elements.

Gasoline and solvents are extremely flammable.

1. Remove loose dirt from the primary filter element using a water hose.

2. Soak the primary filter element in a non-sudsing detergent solution for at least
15 minutes but not more than 24 hours, (Figure 5-5).

Figure 5-5

3. Swish the primary filter element around in the solution to loosen dirt particles
and put them into suspension in the solution.

4. Rinse the primary filter element from the “clean” side to the “dirty” side with a
gentle stream of water. Rinse from both sides if necessary.

5. Dry the primary filter element before reusing. Circulate warm air at less than
71 °C (160 °F). Do not use a light bulb to dry the primary filter element.

6. 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.

7. Protect the filter from dust/damage while drying.

DD90/DD90HF 5-19
 SECTION 5 MAINTENANCE INSTRUCTIONS

Install the Air Cleaner Elements

1. Clean the inside of the air cleaner (2, Figure 5-6).

Figure 5-6

2. Pull the safety element (1, Figure 5-6) out of the housing.

3. Examine the safety element and replace if:

• Examination of the removed primary element reveals torn or perforated element.

• Records indicate that the primary element has been replaced three times or one
year duration has passed since the last replacement.

4. Examine the new or cleaned primary air cleaner element (1, Figure 5-7) for torn
or damaged pleats, liners, or gaskets or bent covers. Discard if damaged and
replace.

Figure 5-7

5-20 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

5. Carefully install the replacement safety element (1, Figure 5-6) and secure by
pushing it straight into housing (2, Figure 5-6).

6. Carefully install the cleaned or new primary element (1, Figure 5-7).

7. Install air cleaner cover (2, Figure 5-8) and secure with clip (1).

Figure 5-8

8. Inspect all air intake piping and joints between air cleaner and engine air inlet
to ensure no dusty air can enter.

Cleaning the Machine

Anytime a machine or component is washed down with a hose or high pressure wash system,
there is the possibility that water or other contaminants can be forced into bearings, seals, or
other components.
Ensure that after cleaning, the machine is completely lubricated immediately, especially in the
areas that water 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
LUBE SPECIFICATIONS for complete lubrication information.
The complete machine must be given a weekly cleaning. Daily cleaning will be required if
material is adhering to the drums.

! CAUTION
High pressure wash equipment can damage sensitive electrical panels,
electrical components, and other non-electrical components such as
seals and bearings. Protect or avoid directly spraying these components
in the engine compartment or elsewhere on the machine.

DD90/DD90HF 5-21
 SECTION 5 MAINTENANCE INSTRUCTIONS

! CAUTION
Protect all electrical components and control panels against entry of
water or steam when using high pressure cleaning methods.

Do not use harsh cleaners which may damage painted surfaces.

After washing, run the engine until it is warm. This will help to dry out
engine components and electrical connections.

Lubricate all grease fittings immediately following the cleaning of the

machine.

Before Cleaning the Machine

1. Remove any material jammed between the drum and its scraper.

2. Clean the evacuator valve (1, Figure 5-6) on the air cleaner and inspect the
rubber for cracks. Replace as required.

Figure 5-6

After Cleaning the Machine

1. Remove all material added for protection from water entry.

2. Lubricate all grease fittings.

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.

5-22 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

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.

Tighten Loose Bolted Connections

1. Properly tighten all loose nuts or bolts found during the daily inspections.

2. Replace self locking nuts if they have been loosened.

Check all Shock Mounts

1. Check all shock mounts (1, Figure 5-7) periodically for looseness or
deterioration.

Figure 5-7

2. Tighten all capscrews and nuts as necessary, and replace shock mounts (one
at a time) that have torn or excessively cracked rubber.

DD90/DD90HF 5-23
 SECTION 5 MAINTENANCE INSTRUCTIONS

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 5-8) and wipe it clean with a lint-free, dry cloth. Push
dipstick back into engine.

Figure 5-8

3. Pull out the dipstick again. The oil level must be between the FULL - top mark
and LOW mark.

4. If oil level is low, add oil through the fill area (2, Figure 5-8) as specified in
Section 8, FUEL AND LUBE SPECIFICATIONS.

5. Check oil level again after engine has run for about 1 minute. Add oil if necessary.

5-24 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

Check Engine Coolant Level, Clean Radiator and Oil Cooler

! 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 it to cool down before removing
the radiator cap. Remove cap slowly to relieve pressure. Avoid contact
with steam or escaping fluid.

1. To check engine coolant level, carefully remove the coolant bottle cap
(1, Figure 5-9) and view the coolant level. The coolant level must be maintained
within 1 inch from the bottom of the cap.

NOTE: If coolant level is not within view, call for service to investigate cause of
coolant loss.

Figure 5-9

2. If necessary, add coolant and use a reliable brand of permanent antifreeze in

a 50 - 50 mixture. Refer to Section 8, FUEL AND LUBE SPECIFICATIONS for
more details on coolant.

NOTE: If the machine has suffered leaks of oil or fuel, dirt will tend to adhere to
the cooling fins of the radiator and hydraulic oil cooler. This accumulation of dirt
will reduce the cooling efficiency. Therefore, any leaks of oil or fuel should be
immediately repaired and cooling surfaces given a thorough cleaning.

3. Remove bolted-on cover to gain access to radiator and oil cooler surfaces.

DD90/DD90HF 5-25
 SECTION 5 MAINTENANCE INSTRUCTIONS

4. Check for signs of clogging of exposed cooling fins on the radiator and oil
cooler (1, Figure 5-10).

Figure 5-10

! 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.

5. If clogging is dried on dirt, use a suitable brush to remove from cooling fins. If
dry dust is present, use compressed air to clean.

6. In case of severe clogging due to fluid leaks, apply diesel fuel or a commercial
cleaning detergent; let it soak in, and then wash off with a water jet.

5-26 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

Check Air Cleaner Restriction Indicator

1. Check the air cleaner restriction indicator (1, Figure 5-11).

2. If indicator lights red, the air cleaner element(s) are plugged and need to be
replaced or cleaned.

Figure 5-11

Check Fuel Level

1. Check fuel level in fuel tank.

2. Never allow tank to completely empty, otherwise, the entire fuel system will
require bleeding.

! WARNING
Fuel is flammable. May cause severe injury or death.

Never refuel the machine while the engine is running. Never allow sparks,
open flames, or smoking within 15 m (50 feet) of the machine when
refueling.

Shut down the engine and extinguish all open flames while checking or
refueling the machine. Always wipe up any spilled fuel in accordance with
environmental guidelines.

DD90/DD90HF 5-27
 SECTION 5 MAINTENANCE INSTRUCTIONS

3. If required, add fuel by first removing fuel cap (1, Figure 5-12).

Figure 5-12

4. Fill tank with correct grade of fuel. Refer to Section 8, FUEL AND LUBE
SPECIFICATIONS for fuel information.

5. If fuel tank must be drained, use the drain plug (1, Figure 5-13) at the bottom
of the tank.

Figure 5-13

5-28 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

Check Water Tank Level

The water supply for the water spray system is held in tanks (1, Figure 5-14) located at the
front and rear of the machine.

Figure 5-14

1. Maintain a full tank of clean water at all times. Never allow the tank to become
empty for any reason other than for cleaning.

2. If water level is low, remove the fill cap (1, Figure 5-15) located on the tank, and
add clean water to the full level.

Figure 5-15

DD90/DD90HF 5-29
 SECTION 5 MAINTENANCE INSTRUCTIONS

Check Water Strainers

There is a water tank fill strainer basket (1, Figure 5-16), located inside each tank, just under
the fill caps (1, Figure 5-15). These first stage water tank strainers filter water before it enters
the tanks and spray bars.

Figure 5-16

1. Remove water tank fill cap.

2. Lift out the strainer from the fill neck of the tank.

3. Check strainer for any impurities that may build up.

4. If necessary, clean the strainer with a stiff fiber brush and install. Obtain
replacement strainer, if needed.

5. Install strainer back into fill neck of tank.

6. Replace water tank fill cap.

5-30 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

The second stage water tank strainer is a screen located in a sediment bowl at the input to the
water pump located on right hand side below the front and rear water tanks on the machine.

1. Open the water pump access door (1, Figure 5-17).

Figure 5-17

2. Locate sediment bowl (1, Figure 5-18) at input to the water pump.

3. Turn water supply valve (2, Figure 5-18) to OFF.

Figure 5-18

4. Unscrew sediment bowl (1, Figure 5-18). Carefully remove strainer if it does not
come off with sediment bowl.

5. Clean the strainer with clear water and a brush if impurities do not come off with
water. Obtain replacement strainer if damaged or cannot be cleaned. Install
strainer.

DD90/DD90HF 5-31
 SECTION 5 MAINTENANCE INSTRUCTIONS

6. Clean sediment bowl with water and a soft cloth. Install sediment bowl.

7. Turn water supply valve (2, Figure 5-18) to ON.

8. Close the water pump access door (1, Figure 5-17).

The third stage water tank strainer is located within each spray nozzle (1, Figure 5-19)
mounted on the spray bars.

Figure 5-19

1. Access the strainer by twisting the cap (1, Figure 5-20) counterclockwise.

Figure 5-20

2. Remove strainer (3) to check for any impurities that may build up.

3. If necessary, clean strainer with a stiff fiber brush and install. Make sure the
small gasket (2) is properly installed when reassembling.

5-32 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

Test Parking Brake

The parking brake test switch (1, Figure 5-21) must be used to verify the parking brake is
capable of holding the machine from moving with the parking brake applied, engine running,
propulsion control lever (FSR) release pushbutton depressed, and the propulsion control lever
moved forward or reverse. This must be done with the parking brake switch (2) applied and
the light illuminated.

Figure 5-21

1. Start the machine and position it in an area clear of personnel and obstructions.

2. Press the parking brake switch (2, Figure 5-21). The parking brake light will
illuminate.

3. Press and hold the parking brake test switch (1, Figure 5-21). While holding the
parking brake test switch, perform Step 4.

4. Move the propulsion control lever (1, Figure 5-22) toward you, out of the
detent, then move the propulsion control lever towards F (forward) or R
(reverse). The machine should NOT move. If the machine does move, shut
down the machine and have fault corrected before continuing operation.

Figure 5-22

DD90/DD90HF 5-33
 SECTION 5 MAINTENANCE INSTRUCTIONS

5. Move the propulsion control lever to STOP.

6. Release the parking brake test switch (1, Figure 5-21).

7. Shut down the engine and apply parking brake.

If the parking brake is working correctly the machine will not move. If the parking brake is not
working correctly and movement is observed, contact service personnel immediately and do
not use machine until corrected.

Check Condition of Drums and Scrapers

1. Perform a visual inspection of the drums (1, Figure 5-23) and remove any
material adhering to them.

Figure 5-23

2. Check the drum scrapers (2, Figure 5-23) to ensure they are not damaged
Replace any damaged drum scrapers that require attention.

3. Check drum scraper to be sure it is adjusted correctly. Adjustment is made with

the hardware and shims located on the scraper bar assembly. Do not allow the
scraper drum clearance to be less than 20 mm (0.79 inch) or more than 25 mm
(0.98 inch).

Check Seat Belt

Check the seat belt regularly for wear or damage. Inspect belt hardware and fabric. Replace
if hardware is damaged or if strap is nicked, frayed or loose sticking is found. Seat belt
assemblies should be replaced every 3 years regardless of appearance. Seat belt strength
degrades over time and use due to exposure to weather, ultraviolet radiation (UV), and
abrasives (dirt). Ensure mounting hardware is tight.

5-34 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

50 HOUR OR WEEKLY ROUTINE MAINTENANCE

Check Batteries, Clean and Grease Terminals

! WARNING
Batteries contain an acid and can cause injury.

Battery fumes can ignite and explode. Skin and eye contact with the
battery fluid can cause injury.

Do not smoke when observing battery fluid level. Avoid skin and eye
contact with the battery fluid. If contact occurs, flush area immediately
with water.

The standard batteries (1, Figure 5-24) supplied are the maintenance-free type requiring only
the following maintenance:

• Clean terminals.
• Keep battery connections tight.
• Apply small amount of grease to terminals to prevent corrosion.

Figure 5-24

DD90/DD90HF 5-35
 SECTION 5 MAINTENANCE INSTRUCTIONS

Grease Articulation and Oscillation Pin Bearings

1. Clean the two articulation grease fittings (1, Figure 5-25) and the one oscillation
pin grease fitting (2).

2. Apply three shots of MPG-EP grease to the articulation fittings with a manual
grease gun and five shots to the oscillation fitting.

Figure 5-25

Grease Steering Cylinder Pin Bearings

1. Clean the two grease fittings (1, Figure 5-26) located at the rod end and barrel
end of the cylinder.

Figure 5-26

2. Apply three shots of MPG-EP grease to each fitting with a grease gun.

5-36 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

Check Eccentric Oil Level

1. Make sure machine is positioned on stable, level ground with the drum index
located at the top (1, Figure 5-27), the parking brake applied, and the drums
chocked.

Figure 5-27

2. Allow eccentric housing to cool before proceeding.

3. Remove both fill (2) and level plugs (3), refer Figure 5-28.

Figure 5-28

NOTICE
Do not mix SHC-624, SHC-630 oil and EP-90 gear oil.

4. The oil at the level plug hole (3, Figure 5-28) should be level with bottom of hole.
If required, add oil through the fill port (2, Figure 5-28). Refer to Section 8, FUEL
AND LUBE SPECIFICATIONS for details on oil.

5. Allow oil to stop flowing from the lower or level port.

DD90/DD90HF 5-37
 SECTION 5 MAINTENANCE INSTRUCTIONS

6. Clean, instal, and tighten both plugs.

7. Repeat same procedure for the other eccentric housing.

8. Operate the machine and check for any leaks.

Check Pump Drive Oil Level

Located at the rear of the engine is the pump drive gearbox (1, Figure 5-29). The gearbox
drives the hydrostatic pumps that power the propulsion, vibration, and steering systems. To
check the oil level and add oil if needed, refer to the following:

Figure 5-29

1. Make sure machine is positioned on stable, level ground with the parking brake
applied and the drums chocked.

2. Remove the pump drive dipstick (2, Figure 5-29) to view the oil level.

3. Maintain the oil level to the FULL mark on the dipstick. If necessary, add oil by
first removing the 5 psi relief valve breather (3, Figure 5-29).

4. Add oil by filling through the elbow (4).

5. Once the gearbox is full, replace the breather into the elbow.

6. Remove the dipstick and confirm the level is at FULL mark. If not, add more oil
or contact service personnel.

5-38 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

Check Hydraulic Oil Level

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. Check hydraulic oil level by viewing sight gauge (1, Figure 5-30) located on the
hydraulic tank.

Figure 5-30

2. The hydraulic oil level should be between the full mark and the minimum
mark on the sight gauge.

3. If necessary, add fresh, clean (filtered through 10 micron filter) anti-wear

hydraulic oil through the fill cap area (2, Figure 5-30) to bring level to full. Refer
to Section 8, FUEL AND LUBE SPECIFICATIONS for details on oil.

DD90/DD90HF 5-39
 SECTION 5 MAINTENANCE INSTRUCTIONS

Check Air Cleaner System Integrity

To verify that the air cleaner system is functioning properly, refer to Checking and Removing
the Air Cleaner Primary Element, 5-15 through Install the Air Cleaner Elements, 5-20 for
checks and procedures.

5-40 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

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.

Change Engine Oil and Filter

1. Position machine on stable, level surface and shut off engine.

2. Ensure engine oil is warm by viewing water temperature gauge. Temperature

should not exceed 60 °C (140 °F) on gauge before draining oil.

3. Place container (1, Figure 5-31) with capacity of at least 24 liters (25 quarts)
under the engine drain point and remove the drain plug (2).

Figure 5-31

4. Clean around head of filter and remove used filter (1, Figure 5-32) with a 90 - 95
mm filter wrench. Catch any escaping oil in the container and dispose of oil and
filter in accordance with local regulations.

DD90/DD90HF 5-41
 SECTION 5 MAINTENANCE INSTRUCTIONS

Figure 5-32

5. Wipe the sealing face of the filter head and make sure the used seal is removed
before installing new filter.

6. Fill new filter with clean engine oil before installing. Refer to Section 8, FUEL
AND LUBE SPECIFICATIONS for details on oil.

7. Apply a film of clean oil to the seal of the new filter before installing.

8. Install filter as specified by filter manufacturer. Be careful, mechanical

over-tightening may distort the threads or damage filter element seal.

9. Clean drain plug and install using a new sealing ring. Use a 17 mm wrench and
torque the drain plug to 81 Nm (60 lbf ft).

10. Refill crankcase with engine oil through the fill area (2, Figure 5-33). Fill to the
FULL mark on the dipstick (1). Refer to Section 8, FUEL AND LUBE
SPECIFICATIONS for oil details.

Figure 5-33

5-42 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

11. Start the engine. Check engine oil pressure gauge for normal reading of 172 -
207 kPa (25 - 30 psi) at idle speed. Check the machine for any leaks.

12. If oil pressure is high or leaks are present, notify service personnel.

Change Engine Fuel Filter and Fuel/ Water Separator

The engine has both a fuel filter and a fuel/water separator to filter water, rust particles, dust,
and other particles from the fuel. Use the following procedure to replace the fuel filter (1, Figure
5-34) and the fuel/water separator (2).

Figure 5-34

1. Clean area around fuel filter (1).

2. Place container under fuel filter (1) to collect any escaping fuel.

3. Unscrew used fuel filter using 75 - 80 mm and 90 - 95 mm wrenches. Discard

used filter in an environmentally safe manner and in accordance with local
regulations.

4. Clean sealing surface of filter head.

5. If necessary, replace O-ring on the filter head.

6. Fill replacement filter with clean fuel and lubricate O-ring seal with clean oil.

7. Install replacement filter as specified by manufacturer. Most filters have

instructions printed on the side.

8. Unscrew used fuel/water separator (2). Follow Step 3 through Step 7 to replace
fuel filter.

9. If fuel filters are changed according to these instructions, no manual bleeding

of fuel lines should be required. If necessary, refer to engine instruction manual
for information on bleeding the system.

DD90/DD90HF 5-43
 SECTION 5 MAINTENANCE INSTRUCTIONS

10. Check machine for any leaks.

Clean Pump Drive Breather

NOTICE
Dirt in the area of the breather may contaminate the oil and lead to rapid wear.

Before removing the breather, ensure that the area around the breather is
clean.

The pump drive has a 34 kPa (5 psi) relief valve breather that needs to be cleaned
occasionally. To clean the breather perform the following:

1. Loosen and remove breather (1, Figure 5-35) from elbow.

Figure 5-35

2. Wash breather in solvent and dry thoroughly.

3. Install breather and tighten.

5-44 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

Change Hydraulic Oil Filters

! 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.

! CAUTION
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.

There are three spin-on type, suction and return hydraulic filters located on the DD90 and
DD90HF machines. The filters, located in the engine compartment area, are used for
propulsion and vibration (1, Figure 5-36), and steering (2, Figure 5-36).

Figure 5-36

1. Unscrew used filter and dispose of it in accordance with local environmental

guidelines.

DD90/DD90HF 5-45
 SECTION 5 MAINTENANCE INSTRUCTIONS

2. Fill new replacement filter with clean, hydraulic oil. Refer to Section 8, FUEL
AND LUBE SPECIFICATIONS for oil details.

3. Apply a film of clean oil to the seal of the new filter before installing.

4. Screw new filter into place and tighten one quarter (1/4) turn beyond gasket
contact.

5. Start engine and check for proper operation.

6. Check machine for any leaks.

Clean Drum Carrier Relief Valve

The drum carrier relief valve (1, Figure 5-37) relieves excessive pressure in the drum carrier.

Figure 5-37

1. Remove the valve.

2. Wash in a non-residue type solvent and dry thoroughly.

3. Install valve.

5-46 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

Grease Console Bearing

The lubrication fittings for the console bearing (1, Figure 5-38) are located on the right side of
the console. Apply a few shots of MPG-EP grease to each fitting for lubrication.

Figure 5-38

Grease Console Lever

The lubrication fitting for the console lever (1, Figure 5-39) is located under the operator seat
and behind the console lever. Apply five shots of MPG-EP grease for lubrication.

Figure 5-39

DD90/DD90HF 5-47
 SECTION 5 MAINTENANCE INSTRUCTIONS

1000 HOUR OR ANNUAL ROUTINE MAINTENANCE

Change Drum Eccentric and Carrier Housing Oil

NOTE: The oil is to be at operating temperature for draining. Be careful, hot oil
and components can burn.

Use the following procedure to change oil:

1. Position machine on stable, level surface with the index bar (1, Figure 5-40) at
the top and one of the two carrier plugs at 12 o'clock (2).

Figure 5-40

2. Apply parking brake, shut down engine, and chock the drums.

3. Place container (4, Figure 5-40) with capacity of at least 21 liter (22 quart)
under carrier drain point to collect used oil.

4. Remove both eccentric plugs (2, and 3, Figure 5-40) and allow oil to completely
drain. Dispose of used oil in accordance with local guidelines.

5. Reposition the machine so that the index tab (1, Figure 5-41) is at the 12 o'clock
position. This places fill port (2, Figure 5-41) and drain post (3, Figure 5-41) in
the correct position to be refilled.

6. Add oil through the fill port (2, Figure 5-40) until it flows from level port (3, Figure
5-40). Refer to Section 8, FUEL AND LUBE SPECIFICATIONS for oil details.

7. Clean fill plug (2, Figure 5-40) and install.

5-48 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

Figure 5-41

The oil in the carrier housing must also be drained at this time interval.

8. With the drum index bar still (1, Figure 5-42) at the top, this places one of the
eccentric plugs at an upper position (2) and the other plug (3) at a lower
position.

Figure 5-42

9. Move container (4, Figure 5-42) from carrier drain point to eccentric drain point.

10. Remove both eccentric plugs (1 and 3, Figure 5-42) and allow oil to drain.
Dispose of used oil in accordance with local guidelines.

11. Clean and install drain plug (3, Figure 5-42).

12. Add oil through fill point. Refer to Section 8, FUEL AND LUBE
SPECIFICATIONS.

13. Clean and install fill plug (1, Figure 5-42).

14. Operate the machine and check for any leaks.

15. Repeat steps 1 through 14 for other eccentric and carrier housing.

DD90/DD90HF 5-49
 SECTION 5 MAINTENANCE INSTRUCTIONS

Change Pump Drive Oil

NOTE: The oil is to be at operating temperature for draining. Be careful, hot oil
and components can burn.

Use the following procedure to change oil:

1. Position machine on stable, level surface.

2. Apply parking brake, shut down engine, and chock the drums.

3. Place container at pump drive drain point to collect used oil.

4. Remove drain plug (1, Figure 5-43) and pump drive breather (2). Access to the
drain plug is through the small access door beneath the gearbox.

Figure 5-43

5. Allow oil to drain and dispose of it in accordance with local environmental

guidelines.

6. After oil has completely drained, clean and install drain plug.

5-50 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

7. Add oil through the elbow (3, Figure 5-43) where the breather was removed.
Refer to Section 8, FUEL AND LUBE SPECIFICATIONS for details on oil.

8. Check oil level by viewing dipstick (4, Figure 5-43). Oil should be at FULL mark
on dipstick.

9. Install breather back into elbow and tighten.

10. Operate machine and check for any leaks.

Change Hydraulic Oil and Suction Strainer

The oil and suction strainer must be changed annually and after any major hydraulic system
repairs.

NOTE: The oil is to be at operating temperature for draining. Be careful, hot oil
and components can burn.

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. Position machine on stable, level surface and apply parking brake, shut down
engine, and chock the drums.

2. Place container with at least capacity of 170 liters (45 US gal) under drain point
to collect used oil.

DD90/DD90HF 5-51
 SECTION 5 MAINTENANCE INSTRUCTIONS

3. Remove drain plug (1, Figure 5-44) at bottom of tank and allow oil to completely
drain.

Figure 5-44

4. Once hydraulic tank (1, Figure 5-45) is completely empty of oil, remove the 12
screws, lock washers, gasket and cover plate (5, Figure 5-45) from the tank.

Figure 5-45

5-52 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

5. Reach inside of the tank and loosen the screw-on suction strainer at the bottom
of the tank.

NOTICE
A partially plugged strainer will lead to cavitation, contamination and a
sluggish operating machine.

Ensure strainer is cleaned or replaced.

6. Clean strainer in a solvent using a stiff fiber brush to remove embedded

impurities. If strainer is damaged or impurities cannot be removed, replace
strainer.

NOTICE
Excessive air pressure can damage the strainer.

Pressure at the air nozzle must not exceed 276 kPa (40 psi).

7. Air-dry the suction strainer from the inside out.

8. Clean out any dirt and contaminants from within the tank.

9. Reach inside the tank and install the cleaned or replacement strainer back into
the tank.

10. Install the drain plug (1, Figure 5-44) back into the bottom of the tank.

11. Install the screws, lock washers, gaskets and cover plates (5, Figure 5-45) back
onto the top of the tank. Use new gaskets if used ones are damaged and worn.

12. Open the hydraulic tank fill cap (2, Figure 5-45) and add clean, hydraulic oil to
the tank by filtering the oil through a 10 micron filter. Refer to Section 8, FUEL
AND LUBE SPECIFICATIONS for oil details.

13. Ensure oil level on sight level gauge (3, Figure 5-45) is at FULL mark.

DD90/DD90HF 5-53
 SECTION 5 MAINTENANCE INSTRUCTIONS

Drain and Flush Water Tank and Spray Bars

1. Remove drain plug (1, Figure 5-46) to drain water from tank.

Figure 5-46

2. Clean and replace tank drain plug.

3. Remove drain cap (1, Figure 5-47) at end of spray bars to flush out any
accumulated sediment.

Figure 5-47

4. Fill water tank with clean water.

NOTE: The water tank should never be allowed to become empty for any
reason other than cleaning or storage.

5-54 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

Drain, Flush, and Replace Engine Coolant

! WARNING
Injury can occur when removing the coolant 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
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 least once a year.
Unless coolant has a corrosion preventive in it, rust and scale will eventually clog up the
system. Any effective, commercial flushing agent should be used at least once or twice a year
to ensure against build-up.

NOTE: Remove the coolant bottle cap (1, Figure 5-48) when draining the
system, to ensure proper draining.

Figure 5-48

1. Place a container capable of holding at least 21 liters (22 quarts) of fluid under
the radiator drain point.

2. Open the drain valve (1, Figure 5-49) at the base of the radiator and loosen
petcock on side of after cooler (2).

DD90/DD90HF 5-55
 SECTION 5 MAINTENANCE INSTRUCTIONS

Figure 5-49

3. Check for damaged hoses and loose or damaged hose clamps. Replace as
required. Check radiator for leaks, damage, and build-up of dirt. Clean and
repair as required.

4. For flushing and cleaning procedure, refer to engine instruction manual.

5. It is recommended to refill radiator with a 50 - 50 ethylene glycol antifreeze and

water mixture. The addition of a separate lubricant and corrosion inhibitor will
guard against internal corrosion and freezing.

6. The system has a maximum fill rate of 14 liters (14 quarts) per minute. Do not
exceed this fill rate.

7. The system must be filled slowly to prevent air locks. During filling, air must be
vented from the engine coolant passages. Be sure to open petcock on
aftercooler.

8. Wait 2 to 3 minutes to allow air to be vented, then add mixture to bring the level
to the top.

9. Install radiator cap and operate engine until it reaches a temperature of 80 °C

(180 °F). Check for any leaks.

10. Check coolant level again to make sure system is full of coolant or that coolant
level has risen to hot level in expansion bottle.

5-56 DD90/DD90HF
MAINTENANCE INSTRUCTIONS SECTION 5

Tighten Oscillation Swivel Pin Nut

1. Tighten the nut (1, Figure 5-50) to 1355 Nm (1000 lbf ft).

Figure 5-50

2. After tightening the nut, the clearance between the drum frame (2, Figure 5-50)
and backing plate (3) should be parallel as viewed from the side.

NOTE: If not parallel, the bearing needs to be replaced or an adjustment made.

Contact appropriate service personnel for action prior to operating the
machine.

Tighten Articulation Swivel Pin Nuts

1. Tighten each swivel pin nut (1, Figure 5-51) to 678 Nm (500 lbf ft).

Figure 5-51

DD90/DD90HF 5-57
 SECTION 5 MAINTENANCE INSTRUCTIONS

Check Engine Valve Clearance

NOTE: Refer to engine instruction manual for maintenance instructions. This

operation requires a trained service engineer.

Check Engine Belts and Tensioner

1. Check engine belts for wear, breaks, cracks, or other damage (Figure 5-52).
Replace belts if necessary.

Figure 5-52

2. Cummins engines have automatic belt tensioning and do not require manual
adjustments.

5-58 DD90/DD90HF
 SECTION 6 - TROUBLESHOOTING

DD90/DD90HF 6-1
 SECTION 6 TROUBLESHOOTING

TROUBLESHOOTING

! WARNING
Allow no one to operate or maintain this machine unless they have read
and understand this Operation and Maintenance Manual, especially
Section 1, SAFETY, and have been authorized, and trained in the proper
operation and maintenance of this machine.

Improper operation and 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 authorized service office.
The troubleshooting chart is limited to machine control operational problems which will guide
the operator to rectifying the cause of the failure.

FUSE BLOCK AND RELAYS

The fuses and relays for the machine are located under the operator console as shown. The
components are identified below.

Figure 6-1

1. Fuse block
2. Electric vibration control forward and reverse relays

6-2 DD90/DD90HF
TROUBLESHOOTING SECTION 6

FUSE IDENTIFICATION
Fuse identification and physical position are shown in Figure 6-2. The fuse ratings and the
circuits for fuses F1 through F18 are shown in Table 1: Fuse Ratings and Circuits.

Figure 6-2

Table 6-1: Fuse Ratings and Circuits

FUSE RATING CIRCUIT

F1 15 AMPS Auxiliary water pump - front

F2 15 AMPS Auxiliary water pump - rear
F3 15 AMPS Main water pump - rear
F4 15 AMPS Main water pump - front
F5 OPEN Open
F6 3 AMPS Water tank fluid level
F7 3 AMPS EVC - control
F8 10 AMPS Backup alarm
F9 5 AMP Engine ECM ignition
F10 15 AMPS Engine circuits seat timer diagnostic
F11 15 AMPS Front lights - option
F12 15 AMPS Rear lights - option

DD90/DD90HF 6-3
 SECTION 6 TROUBLESHOOTING

F13 25 AMPS Relay - light - option

F14 10 AMPS 4-way flasher - option
F15 OPEN Open
F16 10 AMPS Beacon light
F17 5 AMPS Edge cutter
F18 30 AMPS Engine ECM power - engine
compartment

ENGINE WILL NOT START

CAUSE CORRECTION
Starter does not rotate
Fuse defective Check console fuse and replace.
Emergency stop switch requires resetting Check Emergency stop switch and reset if
required.
Propulsion control lever not in STOP position Move to STOP position.
Throttle switch not in LOW RPM and park Press engine throttle switch to LOW RPM
brake switch not on and press park brake switch on
Batteries discharged Check battery, charge if necessary.
Battery cable connections loose or Clean and tighten terminal connections.
disconnected.
In-line fuse to starter fused Call for service to correct fault.
Starter relay fault Call for service to correct fault.
Ignition switch defective Call for service to replace.
Starter solenoid or starter defective Call for service to replace.

CAUSE CORRECTION
Starter does not rotate
Empty fuel tank Fill
Fuel solenoid at fuel pump defective Call for service to test/replace.
Defective wiring Check with test lamp.

6-4 DD90/DD90HF
TROUBLESHOOTING
ENGINE DIFFICULT TO START AND HAS POOR AND IRREGULAR
PERFORMANCE
CAUSE
Low battery power
Batteries discharged
Battery cable connections loose or
corroded causing starter to turn too slowly.
Low ambient temperature, using too high a
viscosity oil
Fuel line blockage due to: wax separation
in winter
Incorrect valve clearances
Defective fuel injectors
Defect turbo charger
Blocked air cleaner element.
ENGINE MAKING EXCESSIVE FUMES
CAUSE
Engine oil level too high
Blocked air cleaner element.
Low compression due to poor condition of
the valves or incorrect valve clearance
ENGINE OVERHEATS - STOP ENGINE IMMEDIATELY
CAUSE
Excessive dirt on cooling system
Engine belt broken
DD90/DD90HF
SECTION 6
CORRECTION
Check battery.
Charge battery if necessary.
Clean and tighten terminal connections, cover
with acid free grease.
Use appropriate oil grade for the ambient
temperature conditions.
Change fuel filters, bleed fuel system, check
for fuel line leaks and loose connections.
Always use winter grade fuel in winter.
Call for service to adjust.
Call for specialist service.
Call for specialist service.
Clean or replace element.
CORRECTION
Drain engine oil to correct level on the dip
stick.
Clean or replace element.
Call for specialist service.
CORRECTION
Clean the cooling fins.
Call for service to correct fault.
6-5
 SECTION 6 TROUBLESHOOTING

CAUSE CORRECTION
Defective injector nozzles Call for service to correct fault.
Blocked cooling air flow Clear blockage.

LOW ENGINE OIL PRESSURE

CAUSE CORRECTION
Low engine oil level (low engine oil pressure Fill oil level to dipstick mark
gauge)
Leaks from lubrication system Stop engine and check for, and tighten
any loose fittings on the oil lines

VOLTMETER INDICATES LOW OR NEGATIVE VALUE

CAUSE CORRECTION
Speed of alternator too low Check V-belt tension, change belt if
required
Not charging due to defective alternator or Call for service to correct fault.
regulator
Fuse defective Check console fuse and replace.
Defective wiring or parts Call for service to correct fault.

Horn does not sound

Fuse defective Check console fuse and replace.
Defective wiring or parts Call for service to correct fault.

Backup Alarm does not sound

Fuse defective Check console fuse and replace.
Defectivewiring or parts Call for service to correct fault.

6-6 DD90/DD90HF
TROUBLESHOOTING SECTION 6

CAUSE CORRECTION
Vibration controls not functioning
Fuse defective Check console fuse and replace.
Defective wiring or parts Call for service to correct fault.

No power to engine ECM

Fuse defective Check console fuse and replace.
Defective wiring or parts Call for service to correct fault.

Warning indicator lights not functioning

Fuse defective Check console fuse and replace.
Defective wiring or parts Call for service to correct fault.

Brake indicator lights not functioning

Fuse defective Check console fuse and replace.
Defectivewiring or parts Call for service to correct fault.

Gauges not functioning

Fuse defective Check console fuse and replace.
Defective wiring or parts Call for service to correct fault.

Working lights not functioning

Fuse defective Check console fuse and replace.
Defective wiring or parts Call for service to correct fault.

Flashing Beacon not functioning

Fuse defective Check console fuse and replace.
Defective wiring or parts Call for service to correct fault.

DD90/DD90HF 6-7
 SECTION 6 TROUBLESHOOTING

6-8 DD90/DD90HF
 SECTION 7 - TECHNICAL
SPECIFICATIONS

DD90/DD90HF 7-1
 SECTION 7
TECHNICAL SPECIFICATIONS
GENERAL IDENTIFICATION
Name of machine
Type of machine
Serial number and product range
Name and address of manufacturer
Name of machine
Type of machine
Serial number and product range
Name and address of manufacturer
7-2
TECHNICAL SPECIFICATIONS
: DD90
: Double drum vibratory compactor
: Serial number 197375 and above
: Volvo Construction Equipment
312 Volvo Way
Shippensburg, Pennsylvania 17257, USA
: DD90HF
: Double drum vibratory compactor
: Serial number 197375 and above
: Volvo Construction Equipment
312 Volvo Way
Shippensburg, Pennsylvania 17257, USA
DD90/DD90HF
TECHNICAL SPECIFICATIONS SECTION 7

MACHINE DIMENSIONS

DD90 / DD90HF (With ROPS)

Unit A B C D E F G H I J K L M N O

Millimeter 3200 1220 19 430 2210 2845 19.4° 380 1675 1830 5086 1910 1600 3558 5502

Inch 126 48 0.75 17 87 112 19.4° 15 66 72 200 75 63 140 217

DD90/DD90HF 7-3
 SECTION 7 TECHNICAL SPECIFICATIONS

MACHINE WEIGHTS AND FIGURES

WEIGHTS with ROPS/FOPS (DD90)

Operating weight kg (lb) 9895 (21820)
Static weight at front drum kg (lb) 5156 (11370)
Static weight at rear drum kg (lb) 4739 (10450)
Shipping weight kg (lb) 9104 (20076)
Static linear load (front drum) kg/cm (lb/in) 29.5 (165.0)
Static linear load (rear drum) kg/cm (lb/in) 29.5 (165.0)
WEIGHTS with ROPS/FOPS (DD90HF)
Operating weight kg (lb) 9843 (21750)
Static weight at front drum kg (lb) 5115 (11280)
Static weight at rear drum kg (lb) 4728 (10425)
Shipping weight kg (lb) 9104 (20076)
Static linear load (front drum) kg/cm (lb/in) 29.4 (164.0)
Static linear load (rear drum) kg/cm (lb/in) 29.4 (164.0)

Propulsion (Transmission)
Type of system Closed-loop hydrostatic
Drum drive (both) Low speed, high torque motor
Travel speed km/h (mph) 0 - 11.8 (0 - 7.4) - DD90
0 - 14.0 (0 - 8.7) - DD90HF
Gradeability (theoretical) 24.8 - DD90
percent 25.0 - DD90HF

Brakes
Service Hydrostatic through propulsion system
Secondary/parking brake Spring-applied, hydraulically released on each drum

Steering
Design Centerpoint articulation
Type system Hydrostatic
Control system Hydraulic
Articulation angle ± 40°
Drum oscillation angle ± 10°

7-4 DD90/DD90HF
TECHNICAL SPECIFICATIONS SECTION 7

Vibration
Vibrating drums 1/2
Drive system Hydraulic/Fixed
Frequency (standard) Hz (VPM) 30.8 (1850) - DD90
47.5 (2850) - DD90HF
Frequency (optional) Hz (VPM) 41.7 (2500) - DD90
63.3 (3800) - DD90HF

Engine
Standard Cummins QSB 4.5 (Tier 3)
Cylinders 4
Bore mm (in) 102 (4.02)
Stroke mm (in) 120 (4.72)
Torque Nm (lbf ft) 459.6 (339) @ 140 rpm
Capacity L (qt) 10.21 (11.0)
Rated power kW (hp) 97 (130) @ 2200 rpm (DD90 and DD90HF)
Oil filtration Spin-on
Fuel filtration Spin-on
Fuel system type Bosch
Type air cleaner Dry - 2-stage
Starting system 12 Volt
Cooling system Liquid-cooled

VARIABLE AMPLITUDE SETTINGS

DD90 Variable Amplitude

Frequency Hz (VPM) 30.8 (1850) 41.7 (2500)
Amplitude Centrifugal Force Centrifugal Force
Setting
mm in kN lb kN lb
1 0.14 0.016 25.9 5840 47.5 10670
2 0.46 0.018 29.0 6520 52.9 11900
3 0.58 0.023 36.1 8120 65.9 14820
4 0.71 0.028 44.4 9980 81.1 18230
5 0.84 0.033 52.1 11710 95.1 21390
6 0.91 0.036 58.0 13080 106.2 23880
7 0.99 0.039 62.0 13940 113.2 25460
8 1.02 0.04 63.3 14240 115.6 26000

DD90/DD90HF 7-5
 SECTION 7 TECHNICAL SPECIFICATIONS

DD90HF Variable Amplitude

Frequency Hz (VPM) 47.5 (2850) 63.3 (3800)
Amplitude Centrifugal Force Centrifugal Force
Setting
mm in kN lb kN lb
1 0.41 0.0188 71.3 16030 126.8 28500
2 0.46 0.0192 72.3 16350 129.3 29070
3 0.58 0.0202 76.6 17220 136.2 30620
4 0.71 0.0216 81.9 18400 145.5 32720
5 0.84 0.0230 87.3 19630 155.2 34900
6 0.91 0.0242 92.0 20680 163.5 36760
7 0.99 0.0250 95.1 21370 169.0 38000
8 1.02 0.0253 96.1 21610 170.9 38430

7-6 DD90/DD90HF
 SECTION 8 - FUEL AND LUBE
SPECIFICATIONS

DD90/DD90HF 8-1
 SECTION 8 FUEL AND LUBE SPECIFICATIONS

FUEL AND LUBRICATION SPECIFICATIONS

GENERAL INFORMATION
Lubrication is an essential part of preventive maintenance, affecting to a great extent the
useful life of the machine. Periodic lubrication of the moving parts reduces to a minimum the
possibility of mechanical failures.
Different lubricants are needed and some components in the machine require more frequent
lubricant than others. Therefore, it is important that the instructions regarding types of
frequency of the application be explicitly followed.
The Lubrication Chart that follows in this section shows those items requiring regular service
and the interval at which they should be performed. Details concerning fuel, oil, and other
lubricants follow the lubrication chart. A regular service program should be geared to the items
listed 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.
Specific recommendations of brand and grade of lubricants are not made here due to regional
availability, operating conditions, and the continual development of improved products. Where
questions arise, refer to the component manufacturer's manual and a reliable supplier.
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 edge of the check port.
All grease fittings are SAE standard unless otherwise indicated. Grease non-sealed fittings
until grease is seen extruding from the fitting. One pump on a standard 0.45 kg (1 pound)
grease gun equals 28 grams (1 ounce) of EP-MPG.
Over lubrication on non-sealed fittings will not harm the fittings or components, but under
lubrication will definitely lead to a shorter lifetime.
Unless otherwise indicated, items not equipped with grease fittings (linkages, pins, levers,
etc.) should be lubricated with oil once a week. Engine oil, applied sparingly, will provide the
necessary lubrication and help prevent the formation of rust. An anti-seeze compound may be
used if rust has not formed. Otherwise, the component must be cleaned first.
Grease fittings that are worn and will not hold the grease gun, or those that have a stuck check
ball, must be replaced.

8-2 DD90/DD90HF
FUEL AND LUBE SPECIFICATIONS SECTION 8

To prevent minor irregularities from developing into serious conditions several other
services or checks are recommended for the same intervals as the periodic lubrication.

1. Thoroughly wash all fittings, caps, plugs, etc. with non-flammable, non-toxic
cleaning solution before servicing, to prevent dirt from entering while
performing the service.

2. Lubricants must be at operating temperature when draining.

3. During regular lubrication service, visually check the entire machine in regard
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 manufacturer’s local authorized dealer or distributor for assistance.

6. This symbol represents an area where lubrication is required.

Periodic lubrication requirements are listed in the following Lubrication Chart. These
requirements include lubricant checks and greasing designated areas of the machine.

DD90/DD90HF 8-3
 SECTION 8 FUEL AND LUBE SPECIFICATIONS

Symbol Key
These standard symbols, identified in Table 8-1, are used in the Lubrication and Service Chart,
8-5.
Table 8-1Standard Symbols

Engine oil level – Engine oil filter –

Engine oil – 1372
1373 1376

Diesel fuel filter – Diesel fuel level – Fuel filter/water

D 1541 D NA D separator

Hydraulic oil – Hydraulic oil level Hydraulic oil filter –

1411 – 1412 1415

Grease – 0787 s Synthetic oil Pump drive oil

Operation and
Battery condition – Engine coolant –
Maintenance
0247 1377
Manual

Engine air intake Engine air intake Engine coolant

filter – 1170 integrity – 1381 level – 1378

Carrier breather/
Air cleaner system
Lamp pump drive
integrity
breather

Engine valve
Engine belt Water tank
clearance

8-4 DD90/DD90HF
FUEL AND LUBE SPECIFICATIONS SECTION 8

Lubrication and Service Chart

DD90/DD90HF 8-5
 SECTION 8 FUEL AND LUBE SPECIFICATIONS

SERVICE FUNCTIONS:
S - CHECK T - TORQUE CL - CLEAN D - DRAIN
C - CHANGE G - GREASE AR - AS REQUIRED
F - FILL A - ADD FTLH - FILL TO LEVEL HOLE/MARK

SERVICE
REF. NO DESCRIPTION SERVICE PART NO. OR LUBRICANT COMMENTS
INTERVAL
1 ENGINE OIL S, A SAE 15W 40 - SEE NOTE 4 FULL ON DIPSTICK
2 ENGINE COOLANT S, A WATER / ANTI-FREEZE AR

10 HRS. OR 3 AIR CLEANER S CHECK INDICATOR

DAILY 4 FUEL TANK S, A #2 DIESEL FUEL AR
5 WATER TANK S, A WATER AR
6 WATER STRAINER C, L
11 BATTERY & CABLES S
12 SWIVEL & CYL. PINS G MPG-EP GREASE 3 SHOTS EACH
13 CENTER SWIVEL G MPG-EP GREASE 5 SHOTS
ECCENTRIC OIL - Effective DD90 - MOBIL SHC 630
with S/N 197375-275395 DD90HF - MOBIL SHC 624
14 S, A FTLH
ECCENTRIC OIL - Effective DD90 - MOBIL SHC 630
50 HRS. OR
with S/N 275396- DD90HF - MOBIL SHC 630
WEEKLY
PUMP DRIVE OIL - Eff. with DD90 - MOBIL SHC 630
S/N 197375-275395 DD90HF - MOBIL SHC 624
16 S, A FULL ON DIPSTICK
PUMP DRIVE OIL - Eff. with DD90 - MOBIL SHC 630
S/N 275396- DD90HF - MOBIL SHC 630
17 HYDRAULIC OIL S, A MOBIL DTE 13 or equivalent CHECK SIGHT GLASS
18 AIR CL. SYS. INTEGRITY S (3)
31 ENGINE OIL FILTER C (4) 1
32 ENGINE OIL DF SAE 15W 40 - SEE NOTE 4 FULL ON DIPSTICK
33 CONSOLE LEVER G MPG-EP GREASE 5 SHOTS
34 FUEL FILTERS C (3) 2
250 HRS. OR
QUATERLY 35 PUMP DRIVE BREATHER CL
36 HYD. OIL FILTERS C (3) 3 FILTERS
37 CARRIER BREATHER CL
SWIVEL CONSOLE WHILE
38 CONSOLE BEARING G MPG-EP GREASE
GREASING
ECCENTRIC OIL - Effective DD90 - SHC 630
with S/N 197375-275395 DD90HF - SHC 624
61 D, F FTLH
ECCENTRIC OIL - Effective DD90 - SHC 630
with S/N 275396- DD90HF - SHC 630
PUMP DRIVE OIL - Eff. with DD90 - SHC 630
1000 HRS. S/N 197375-275395 DD90HF - SHC 624
OR 63 D, F FULL ON DIPSTICK
ANNUALLY PUMP DRIVE OIL - Eff. with DD90 - SHC 630
S/N 275396- DD90HF - SHC 630
CARRIER OIL - Effective DD90 - SHC 630
with S/N 197375-275395 DD90HF - SHC 624
64 D, F FLUSH, 1 PINT
CARRIER OIL - Effective DD90 - SHC 630
with S/N 275396- DD90HF - SHC 630

8-6 DD90/DD90HF
FUEL AND LUBE SPECIFICATIONS SECTION 8

SERVICE
REF. NO DESCRIPTION SERVICE PART NO. OR LUBRICANT COMMENTS
INTERVAL

1000 HRS. 65 HYD. OIL STRAINER CL

OR 66 HYDRAULIC OIL D, C, F MOBIL DTE 13 or equivalent 151 L/40 US GAL.
ANNUALLY
(Continued) 67 WATER TANK D, CL, F 492 L/130 US GAL
68 ENGINE COOLANT D, F WATER / ANTI-FREEZE FTLH
69 OSCIL. SW. NUT S, T 1355 Nm/1000 lb-ft
70 ARTICULATION NUTS S, T 678 Nm/500 lb-ft
71 ENG. VALVE CLEARANCE S (2)
72 BELT TENSIONER S (2)
73 ENGINE BELTS S (2)

NOTES:
1. SEE ENGINE OPERATION MANUAL FOR
INITIAL ENGINE BREAK-IN MAINTENANCE.
2. SEE OPERATORS MANUAL
3. SEE PARTS MANUAL
4. SEE ENGINE MANUAL

DD90/DD90HF 8-7
 SECTION 8 FUEL AND LUBE SPECIFICATIONS

Fluid Capacities
The following fluid capacities are provided for servicing personnel who must perform machine
maintenance in remote locations where complete shop facilities and resources are not
available. 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 8-2
FLUID/OIL USEABLE CAPACITY
Diesel fuel (#2 ASTMD-975-60T) 170 liter (45 US gallon)
Hydraulic oil (ISO Grade 46) 151 liter (40 US gallon)
Multi-purpose premium engine oil (SAE 15W40) 11 liter (11.6 quart)
Engine coolant 16 liter (17 quart)
Water tank (per tank) 492 liter (130 US gallon)
Effective with S/N 197375-275395
Drum eccentric oil (per drum) - DD90 - Mobil SHC 630 13.2 liter (14 quart)
Drum eccentric oil (per drum) - DD90HF - Mobil SHC 624 18.0 liter (19 quart)
Drum carrier oil (per drum) - DD90 - Mobil SHC 630 0.47 liter (1 pint)
Drum carrier oil (per drum) - DD90HF - Mobil SHC 624 0.47 liter (1 pint)
Pump drive oil - DD90 - Mobil SHC 630 4.2 liter (4.4 quart)
Pump drive oil - DD90HF - Mobil SHC 624 4.2 liter (4.4 quart)
Effective with S/N 275396-
Drum eccentric oil (per drum) - DD90 - Mobil SHC 630 13.2 liter (14 quart)
Drum eccentric oil (per drum) - DD90HF - Mobil SHC 630 18.0 liter (19 quart)
Drum carrier oil (per drum) - DD90 - Mobil SHC 630 0.47 liter (1 pint)
Drum carrier oil (per drum) - DD90HF - Mobil SHC 630 0.47 liter (1 pint)
Pump drive oil - DD90 - Mobil SHC 630 4.2 liter (4.4 quart)
Pump drive oil - DD90HF - Mobil SHC 630 4.2 liter (4.4 quart)

8-8 DD90/DD90HF
FUEL AND LUBE SPECIFICATIONS SECTION 8

HYDRAULIC OIL REQUIREMENTS AND SPECIFICATIONS

The quality of the hydraulic oil is important to the satisfactory performance of any hydraulic
system. The oil serves as the power transmission medium, system coolant, and lubricant.
Selection of the proper oil is essential to ensure proper system performance and life. For the
specifications and requirements that hydraulic oil used in this machine should meet, refer to
information below.
Table 8-3
Viscosity: 60 SUS minimum at operating temperature
7500 SUS maximum at starting temperature
150 to 225 SUS AT 38 °C (100 °F) (generally)
44 to 48 SUS AT 99 °C (210 °F) (generally)
Viscosity Index: 90 minimum
Aniline Point: -175 minimum
API gravity: 28 minimum

Paraffinic oils: 28 or more

Recommended Additives:
Desirable Characteristics:
Mixed base: 24 to 28
Napthanic or asphaltic base: 24 or less
Rust and oxidation inhibitors
Foam depressant
Stability of physical and chemical characteristics
High demulsibility (low emulsibility) for separation of
water, air, and contaminants
Resistance to the formation of gums, sludges, acids, tars,
and varnishes
High lubricity and film strength

NOTE: For temperatures -12 °C (10 °F) and above, use all season premium
hydraulic oil - ISO VG46 VI 104 (min). For temperatures below -12 °C (10 °F),
use ISO VG 32.

DD90/DD90HF 8-9
 SECTION 8 FUEL AND LUBE SPECIFICATIONS

LUBRICATING OIL/GREASE SPECIFICATIONS (EXCEPT ENGINE)

Synthetic Component Lubricant

Synthetic component lubricant is a synthesized hydrocarbon fluid (SHF) base oil with additives
that enhance oxidization stability and provide protection against rust, corrosion, and wear.
Synthetic component lubricant has a naturally high viscosity index compared to mineral oils,
providing lower viscosity at lower temperatures and higher viscosity at higher temperatures. A
low traction coefficient and high viscosity index combine to reduce power consumption,
resulting in extended service life for both parts and lubricant.

ISO viscosity grade 220

Gravity, API 31.4
Pour point °C (°F) -40 (-40)
Flash point °C (°F) 229.4 (445)
Viscosity
cSt at 40 °C 217
cSt at 100 °C 25.9
SUS at 100 °F 1122
SUS at 210 °F 127
Viscosity index 152

Extreme Pressure Multi-Purpose Grease

This is a lithium soap base grease with a high load carrying capacity. The following properties
are recommended:

Timken OK load 18 kg (40 lb) minimum

Dropping point 177° C (350 °F) minimum
Oil viscosity 75 SUS minimum at 99 °C (210 °F)
Water resistance Excellent

Under normal operating conditions, the following consistency grades are recommended:

NLGI No. 0 for temperatures below -18 °C (0 °F).

NLGI No. 1 or No. 2 for ambient temperatures -18 °C to 38 °C (0°F to 100 °F).
NLGI No. 2 or No. 3 for temperatures over 38 °C (100 °F).

8-10 DD90/DD90HF
FUEL AND LUBE SPECIFICATIONS SECTION 8

ENGINE LUBE OIL SPECIFICATIONS

NOTE: For latest applicable engine lubricating oil specifications, contact engine
manufacturer, engine distributor or the manufacturer’s local authorized dealer
or distributor.

CUMMINS FUEL OIL SPECIFICATIONS

Cummins diesel engines have been developed to take advantage of the high energy content
and generally lower cost of No. 2 diesel fuels. Experience has shown that a Cummins diesel
engine will also operate satisfactorily on No. 1 fuels or other fuels within the specifications
shown in Table 8-4.
Table 8-4

1.3 to 5.8 mm per second at 40 °C

Viscosity (ASTM D-445)
Cetane number (ASTM D-613)
Sulfur content (ASTM D-129 or 1552)
Water and sediment (ASTM D-1796)
Carbon residue (Ramsbottom, ASTM-D-524 Not to exceed 0.25 percent by weight on 10
or Conradson, ASTM D-189)
Flash point (ASTM D-93)
Density (ASTM D-287)
Cloud point (ASTM D-97)
Active sulfur
Ash (ASTM D-482)
Distillation (ASTM D-86)
(1.3 to 5.8 centistokes per second at 104 °F)
40 minimum except in cold weather or in service
with prolonged idle, a higher cetane number is
desirable.
Not to exceed 1 percent by weight.
Not to exceed 0.1 percent by volume.
percent volume residue.
At least 52 °C (125 °F) or legal temperature if
higher than 52 °C (125 °F).
-1 to 6 °C (30 to 42 °F ) API gravity at 16 °C
(60 °F) (0.816 to 0.876 Sp. Gr.).
6 °C (10 °F) below lowest ambient temperature
at which the fuel is expected to operate.
Copper strip corrosion not to exceed No. 2 rating
after 3 hours at 49 °C (122 °F).
Not to exceed 0.02 percent by weight.
The distillation curve must be smooth and
continuous. At least 90 percent of the fuel must
evaporate at less than 360 °C (680 °F). All of the
fuel must evaporate at less than 385 °C (725 °F).

DD90/DD90HF 8-11
 SECTION 8 FUEL AND LUBE SPECIFICATIONS

8-12 DD90/DD90HF
 SUBJECT INDEX
NUMERICS
10 Hour or Daily Routine
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
1000 Hour or Annual Routine
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
250 Hour or Quarterly Routine
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
50 Hour or Weekly Routine
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
A Extreme Pressure Multi-Purpose Grease . . . 8-10
After 30 minutes of operation . . . . . . . . . . . . . . 5-9
Amplitude Adjusting Wheel . . . . . . . . . . . . . . . 4-22
B Four-Way Flasher . . . . . . . . . . . . . . . . . . . . . . . 3-18
Beacon Light Switch . . . . . . . . . . . . . . . . . . . . 3-16
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-12
C Pin Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Change Drum Eccentric and Carrier
Housing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Change Engine Fuel Filter and Water
Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Change Engine Oil and Filter . . . . . . . . . . . . . 5-41
Change Hydraulic Oil and Suction Strainer . 5-51
Change Hydraulic Oil Filters . . . . . . . . . . . . . . 5-45
Change Pump Drive Oil . . . . . . . . . . . . . . . . . 5-50
Check Air Cleaner Connections and Ducts for
Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Check Air Cleaner Restriction Indicator . . . . 5-27
Check Air Cleaner System Integrity . . . . . . . 5-40
Check all Shock Mounts . . . . . . . . . . . . . . . . . 5-23
Check Battery, Clean and Grease
Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Check Condition of Drums and Scrapers . . . 5-34
Check Eccentric Oil Level . . . . . . . . . . . . . . . . 5-37
Check Engine Belts and Tensioner . . . . . . . . 5-58
Check Engine Coolant Level, Clean Radiator and
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Check Engine Oil Level . . . . . . . . . . . . . . . . . . 5-24
Check Engine Valve Clearance . . . . . . . . . . . 5-58
Check Fuel Level . . . . . . . . . . . . . . . . . . . . . . . 5-27
Check Hydraulic Oil Level . . . . . . . . . . . . . . . . 5-39
Check Parking Brake . . . . . . . . . . . . . . . . . . . . 5-33
Check Pump Drive Oil Level . . . . . . . . . . . . . 5-38
Check Water Strainer . . . . . . . . . . . . . . . . . . . 5-30
Check Water Tank Level . . . . . . . . . . . . . . . . . 5-29
Checking and Removing the Air Cleaner Primary
Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Checks and verifications of machine controls 4-7
Checks and Verifications of Overall Machine 4-3
Clean Drum Carrier Relief Valve . . . . . . . . . . 5-46
Clean Pump Drive Breather . . . . . . . . . . . . . . 5-44
DD90/DD90HF
Cleaning the Air Cleaner Element . . . . . . . . . 5-18
Cleaning the Machine . . . . . . . . . . . . . . . . . . . 5-21
D
Drain and Flush Water Tank and
Spray Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Drain, Flush, and Replace Engine Coolant . 5-55
E
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro-11
F
Fluids and Oil, Fuel Filters . . . . . . . . . . . . . . . . 5-7
G
Grease Articulation and Oscillation
Grease Console Bearing . . . . . . . . . . . . . . . . . 5-47
Grease Steering Cylinder Pin Bearings . . . . 5-36
H
Hazardous Substance Precaution . . . . . . . . . 1-16
Hydraulic Oil Temperature Gauge . . . . . . . . . 3-18
I
Identification Data . . . . . . . . . . . . . . . . . . . . . Intro-4
Inspection, Pre Start . . . . . . . . . . . . . . . . . . . . . 1-6
International Symbols . . . . . . . . . . . . . . . . . . . . 2-3
L
Loading the machine by lifting the equipment for
transporting. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Loading the Machine Under its Own Power (Drive
On) for Transporting. . . . . . . . . . . . . . . . . . . 4-26
M
Machine
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
MAINTENANCE INSTRUCTIONS . . . . . . . . . . 5-2
Maintenance, Initial Break-In . . . . . . . . . . . . . . 5-9
Moving the Machine (Propulsion Control) . . . 4-16
O
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Operating Suggestions and Checks while Operat-
ing Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Operator Station . . . . . . . . . . . . . . . . . . . . . Intro-12
Organizational Measures . . . . . . . . . . . . . . . . . 1-4
Overhead Electric Lines . . . . . . . . . . . . . . . . . 1-17
1-1
 SUBJECT INDEX
P
Parking the Machine . . . . . . . . . . . . . . . . . . . . 4-24
Preparations Before Service . . . . . . . . . . . . . . 5-7

R
Replacing the Air Cleaner Elements . . . . . . . 5-20
Roading Machine Safely . . . . . . . . . . . . . . . . . 1-15
Routine Maintenance - As Required . . . . . . . 5-15

S
Safety
Instructions Governing Operation . . . . . . . . . . 1-7
Working Within Dangerous Areas . . . . . . . . . 1-6
Safety Awareness . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Securing the machine to the transporter (Tie-
down). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Selection and Qualification of Personnel . . . . 1-3
Serviceability . . . . . . . . . . . . . . . . . . . . . . . . Intro-12
Setting the Auto Vibration Control Module . . 4-18
Shutting Down the Machine . . . . . . . . . . . . . . 4-25
Special Dangers . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Speed Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Speedometer/Tachometer . . . . . . . . . . . . . . . 3-16
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Starting procedure and checks and verifications
while engine running. . . . . . . . . . . . . . . . . . . 4-11
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Stopping the Machine . . . . . . . . . . . . . . . . . . . 4-24
Symbol Identification . . . . . . . . . . . . . . . . . . . . . 2-2
Symbols, safety . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

T
To Tow the Machine, Maximum 300 Meters, use
the Following Procedure . . . . . . . . . . . . . . . 4-30
Torque Articulation Swivel Pin Nuts . . . . . . . 5-57
Torque Loose Bolted Connections . . . . . . . . 5-23
Torque Oscillation Swivel Pin Nut . . . . . . . . . 5-57
Towing Machine Safely . . . . . . . . . . . . . . . . . . 1-15
Transporting, Towing and Roading . . . . . . . . 1-15
Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . 3-17

U
Using Vibration (Vibration Controls) . . . . . . . 4-18

V
Vibration System . . . . . . . . . . . . . . . . . . . . Intro-12

W
Working Within Dangerous Areas . . . . . . . . . . 1-6

1-2 DD90/DD90HF