Ingersoll Rand DD90 Air Cooled Vibratory Asphalt Compactor Operations Maintenance and Parts Manual 70827373-IBPL (2005)

Description

Ingersoll Rand DD90 Air Cooled Vibratory Asphalt Compactor Operations Maintenance and Parts Manual 70827373-IBPL (2005)

This download is the combined operations, maintenance, and parts book issued for the Ingersoll Rand DD90 air-cooled vibratory asphalt compactor. The cover identifies CPN 70827373-IBPL and the November 2005 date. The ordering page applies the book from serial number 05 200 06 967 onwards and lists Ingersoll-Rand (India) Limited, Phase I, Peenya Industrial Area, Bangalore. Operators, shop technicians, and parts buyers use the same volume to start and stop the machine, set vibration, service fluids and filters, and identify replacement items by commercial number.

File Details

• Manual type: Operations, Maintenance and Parts Manual
• Brand / model: Ingersoll Rand DD90 (Air Cooled) vibratory asphalt compactor
• Language: English
• Page count: 275
• File format: PDF
• Document number: CPN 70827373-IBPL
• Date: November, 2005
• Serial application: 05 200 06 967 onwards

What the DD90 Manual Covers on the Machine

The introduction describes a smooth-drum tandem of about 9,500 kg with eight amplitude settings on each drum and vibration frequency selectable from 1500 to 2500 vpm (25 to 42 Hz). Vibration starts automatically when travel reaches 0.8 kmph and drops out below that speed so a stopped drum does not mark the mat; a manual override is provided. Eccentric rotation can follow travel direction or be chosen by the operator. Front only, rear only, or both drums may be selected. Hydrostatic propulsion feeds parallel circuits to both drums through motors with torque hubs, giving infinite travel control independent of engine speed and dynamic braking, with travel listed as 0–12 km/h in the specification tables and up to 12.9 kmph in the introduction.

A 150 litre hydraulic reservoir supplies the system through a 10-micron filter. Emergency and parking braking uses spring-applied, hydraulically released multiple-disc brakes on both drums; they apply automatically if hydraulic power is lost and can also be applied from the console. Center-point articulation is ±40° with ±10° oscillation. Each drum has its own water system with epoxy-lined tank, plastic pipes, brass nozzles, and plated strainers. The seat and control console rotate 180 degrees and lock in any of five positions. Optional cabin, canopy, hand pump, cutter edge, and certified ROPS with seat belt are referenced where the text or parts lists call them out.

Published machine data from the specification pages

• Standard operating weight: 9500 kg; static weight 4750 kg at each drum
• Overall length: 5330 mm, overall width 1790 mm, height to steering wheel 2210 mm, height to cabin 3000 mm
• Drum base: 3200 mm, drum diameter 1120 mm, drum width 1675 mm, shell thickness 19 mm nominal
• Curb clearance: 432 mm, side clearance 70 mm, outside turning radius 5180 mm (to drum edge)
• Centrifugal force per drum: 2660 kg at minimum amplitude, 11830 kg at maximum amplitude
• Nominal amplitude: 0.41 mm minimum to 1.02 mm maximum (eight positions)
• Engine: KOEL HA694, rated power 106 at 2300 rpm, 12 V negative-ground electrical system
• Fuel: 170 litres, hydraulic oil 150 litres (151 litres / 40 gal on the capacity chart), water 830 litres in the spec table and 832 litres / 220 gal on the lubrication chart
• Theoretical gradeability: 30% based on optimum tractive conditions

Approximate subassembly weights are also printed for lifting and transport planning: drum assembly 2050 kg, engine 725 kg, front frame 279 kg, rear frame 733 kg, torque hub 140 kg, swivel frame 265 kg, water tank 265 kg, hydraulic tank 285 kg, triple output gearbox 105 kg, eccentric shaft assembly 85 kg, vibration-side shock mount 125 kg, drive-side shock mount 275 kg.

Operating Controls, Instruments, and Electronic Vibration Control

The Ingersoll Rand DD90 Air Cooled Vibratory Asphalt Compactor Operations Maintenance and Parts Manual 70827373-IBPL (2005) numbers every console item for both open-deck and cabin machines. Gauges include a tachometer (0–35 × 100 rpm), hourmeter, engine oil pressure (0–10 bar), engine oil temperature (0–200°C), and an ammeter (−50 to +50 A). Warning lamps cover a broken blower V-belt and no-charge. The main circuit breaker is a 30 A unit. The ignition switch is OFF / RUN / START; starter cranking is limited to 30 seconds with a 2–3 minute cool-down between attempts.

Travel is set with the propulsion lever at the right of the seat: Forward, Neutral, and Reverse with variable speed, plus hydrostatic braking when returned to Neutral. An interlock allows starting only in Neutral. Parking brake is pull-to-apply / push-to-release, with a red applied lamp. The articulation lock bar stores on the right rear frame and must be installed for transport and parking. Throttle is a two-position cable (Idle and Operating rpm) that locks in the operating position and must be shifted sideways to return to idle. Engine stop is a pull cable that cuts fuel. Water flow, main water switch, lights, and (on cabin machines) wipers, turn indicators, working lamps, cabin lamp, fan, fog lamps, and an optional flame-heater button are documented with their switch logic.

Amplitude is set independently on each drum with a detent wheel on the left side of the drum; pull the wheel out, turn to the red indicator, and release. The Electronic Vibration Control (EVC) is a 12 V microprocessor box with a waterproof membrane. After the breaker is switched on, all LEDs light for about five seconds while the unit self-checks. A green button powers the controller (do not hold it more than five seconds or frequency settings can be disturbed). Yellow buttons select front and/or rear drums and Manual clockwise, Manual anti-clockwise, or Auto mode. Auto mode starts vibration near 0.8 kmph and matches eccentric rotation to travel direction. Nine white buttons set 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2300, or 2500 vpm. Clockwise-to-anti-clockwise changes wait about five seconds. Short-circuit on the pump outputs flashes all LEDs and cuts output until the breaker is cycled after the fault is cleared. Factory settings can be restored by a documented 20-second hold sequence. Vibration work requires full specified engine throttle.

Safe Operation, Transport, and Towing

Best-practice and safety chapters walk through pre-start inspection, three-point mounting, Neutral-and-brake start conditions, seated operation with no passengers, slope and side-hill limits, articulation-area crush hazard, and parking off the mat on level ground with chocks and the lock bar installed. Travel speed is not to be controlled with the throttle; the engine stays at Operating rpm. Jump starting is not recommended. Transport instructions cover ramps, chocks, lock-bar use, and chain or cable tie-down centered on the trailer.

Towing is limited to moving the unit off the job, onto or off a transporter, or into the shop. The procedure opens the propulsion-pump bypass cartridges three turns counterclockwise (1-1/16 in and 1-1/4 in wrenches), moves the travel lever full Forward or Reverse, then pressurizes the brake line to 20 bar with an external 0–35 bar hand pump after disconnecting the brake hose. Tow only at walking speed. After the move, reconnect the hose and torque the bypass hex about three turns clockwise to 30 ft-lb. The lock bar must stay locked whenever the machine is transported.

Lubrication Schedule and Fluid Capacities

Lubrication is treated as the core of preventive maintenance. Levels are checked on level ground with cold oil unless noted. Daily / 10-hour work covers engine oil (SAE 20W40 to the dipstick full mark), air-cleaner indicator, diesel #2 fuel, water tank and strainer, and fuel-filter water drain. Weekly / 50-hour work covers hydraulic oil (IR Power Compact at the sight glass), steer-cylinder pins (3 shots MPG EP grease each), articulation and oscillation joints (5 shots each), eccentric oil and torque-hub oil (IR Power Drive to the level hole), pump-drive oil (to the level mark), and battery water.

Monthly / 100-hour work changes the engine oil filter and 12.4 L of SAE 20W40, greases the console bushing, and cleans the pump-drive gearbox. Quarterly / 300-hour work changes the fuel strainer, three hydraulic filters, and one fuel filter, and cleans the pump-drive breather and carrier relief valve. Annual / 1000-hour work flushes 0.5 L of carrier oil, drains and fills 20.8 L eccentric oil, 1.5 L torque-hub oil, and 2.8 L pump-drive oil, torques the horizontal swivel nut to 1000 ft-lb and the vertical articulation nut to 500 ft-lb, cleans the suction strainer, and services the hydraulic tank (151 L / 40 gal) and water tanks (832 L / 220 gal). New machines also require all lubricating and engine oils changed after the first 50 hours. Safety data sheets for Castrol IR Power Compact hydraulic oil, gear oil, and the battery are printed in the lubrication section.

Maintenance Procedures in the Book

Section 6 gives step-by-step service for engine oil and spin-on filter (hand-tight plus 1/4 turn only), precleaner and dry air cleaner (clean main element with compressed air not over 3.5 kg/cm² / 50 psi at 45°, replace main element at 300 hours or 3 months, replace safety element every three main-element changes and never reuse it), battery hydrometer check under the right deck, fuel tank under the left deck, engine belts, hydraulic fill through a 10-micron filter, drum face and scrapers, daily air-pressure engine cleaning plus steam-cleaning of cylinder fins, blower, and oil coolers, swivel and steer-pin greasing, torque-hub and eccentric oil checks using the drum index key at 12 o’clock, shift-linkage oiling, dual fuel-filter bowl service and bleeding, hydraulic tank breather wash, and separate 300-hour spin-on filters for propulsion and for steering-return / vibration. Warnings cover crush hazard, hot oil, battery acid and fumes, and fuel fire risk. The text also points to the engine repair manual for belt adjustment and governor settings that must not be altered.

Chapters Covered

• Safety Precautions and Guidelines — overview, pre-start inspection, stopping, maintenance, transporting and hauling, starting, operating, safety-related decals, hazardous substance precaution, specifications
• Introduction — machine description, serial plate location
• Operating Controls and Instruments — gauges, switches, brake and travel controls, throttle, water and lights, amplitude wheel; Electronic Vibration Control operating instructions
• Operation — best practices for pre-start, starting, operating, stopping, maintenance work, transporting and hauling
• Lubrication — lubrication points and intervals, fluid capacities, hydraulic-oil SDS, gear-oil SDS, battery MSDS
• Maintenance — procedures, prestart safety checks, general practices, towing, engine/air/fuel/hydraulic/drum/eccentric service
• Section A Main Frame Assembly — main frame, deck (open and cabin), steering cylinder, optional hand pump
• Section B Cowling and Hydraulic Tank — cowling, hood (engine and pump sides), hydraulic tank, railing, canopy, optional cabin
• Section C Power Pack — air cleaner/exhaust, engine installation and assembly, propulsion/steering/vibration pumps, triple pump drive
• Section D Control Console — console, bearing pack, propulsion lever, throttle, panel (open and cabin)
• Section E Drum Assembly — front and rear drums, eccentric shaft, drum drives and motors, rotary groups, pistons, drive shafts, backup plates, vibration motors, carrier and spindle, optional cutter edge
• Section F Hydraulic Piping
• Section G Wiring Installation and battery
• Section H Water System — tanks, pumps, cabin-machine tank layouts
• Section I Decals — open and cabin machines
• Section J Service Kits and Tool Kit

Taken together, the front half of the Ingersoll Rand DD90 Air Cooled Vibratory Asphalt Compactor Operations Maintenance and Parts Manual 70827373-IBPL (2005) is the operator and service text a crew needs on the job, while Sections A–J supply exploded drawings and commercial-number parts lists for frames, pumps, drums, piping, electrics, water, decals, and kits. Cabin and open machines are called out as separate assemblies where they differ.

Use This Manual on the Job

With this file a technician can inspect and start a DD90, set EVC frequency and drum selection, adjust amplitude, run the water spray, park and lock the machine for transport, open the propulsion bypass and release the spring brakes for a short tow, follow the 10 / 50 / 100 / 300 / 1000 hour charts, change filters and oils to the printed capacities, and order the correct IR commercial numbers from the exploded views. Using the published intervals, torque figures, and part identities avoids guessed grease shots, over-tightened spin-on filters, and mixed cabin versus open-deck hardware.

The listing is a PDF you receive immediately after payment. Open it on a phone, tablet, or shop computer and print the lubrication chart, towing steps, or a single parts plate as needed. No shipping delay and no extra hardware required.