SD 110 Step 1 Training

Volvo Single Drum Compactor SD110

Machine Weight (w / ROPS and inside scraper kg

11125

Static weight @ drum

kg

6100

Static weight @ Tires

kg

5025

Shipping weight

kg

10876

Operating Weight (CECE)

Engine Make

Volvo D5DA3

Model

Turbocharged and liquid cooled 4- cylinder

Rated power at 2200 speed

99 KW Hydrostatic, motor on planetary axle w /.No spin differential and 2 –speed axle drive motor

Propulsion Type

Travel speed

2 – speed motor into planetary High 0 – 11. Low 0 - 6

Km/h

Drums Width

VOLVO SINGLE DRUM COMPACTORS

mm

2134 1500

Diameter

mm

Shell thickness

mm

25

Gradeability

%

28%

WALK AROUND SD110

Vibration Frequency

Hz

Amplitude

mm

Low 1.29 & High 1.92

30

Centrifugal force

KN

Low 224 & High 309

Brake system Service brake

Dynamic hydrostatic through propulsion system Spring Applied Hydraulically Released (SAHR) on axle

Parking / Secondary - brake

Miscellaneous 1.

Articul Articulati ation on Angle( Angle(plu pluss / minus) minus)

O

2.

Oscillat Oscillation ion Angle Angle (plus (plus / minus) minus)

3.

Inside Inside Turnin Turning g Radius Radius (to drum drum edge) edge)

mm

4.

F ue ue l c ap apa ci ci ty ty

l

270

5.

Hydra Hydraul ulic ic oil oil capac capacit ity y

l

125

O

Volvo Construction Equipment

40

17

This information is current at the time of publication. Volvo India Private Limited reserves the right to make product improvements without notice

3652

Construction Equipment

Volvo Single Drum Compactor SD110 With optional drum drive Operating Weight (CECE)

kg

11212


kg

6240


kg

4972

kg

10963

Shipping weight Engine Make

Volvo D5DA3

Model



99 KW Hydrostatic, single speed motor on planetary axle w /.No spin differential and 2 – speed drum drive motor

Propulsion Type

Km/h


Width

mm

2134

Diameter

mm

1500

Shell thickness

mm

Gradeability

%

Travel speed


Drums

WALK AROUND SD110

25 52%

Vibration Frequency

Hz

30

Amplitude

mm

Low 1.29 & High 1.92

Centrifugal force

KN

Low 220 & High 300


Dynamic hydrostatic through propulsion system Spring Applied Hydraulically Released (SAHR) on axle and drum drive motor


Miscellaneous 1.


O

40O

2.


O

17

3.


mm

3652

4.


l

270

5. 6.

Hydra Hydraul ulic ic oil oil capac capacit ity y Tire size

l

125 587 x 660 (23.1 x 26) – 8 PR R3




Volvo Single Drum Compactor SD110 P kg

11932


kg

6960


kg

4972

Shipping weight

kg

11683

Operating Weight (CECE)

Engine Make

Volvo D5DA3

Model



99 KW Hydrostatic, single speed motor on planetary axle w /.No spin differential and 2 – speed drum drive motor

Propulsion Type Drum Drive Travel speed


Km/h


Drums Width

mm

2134

Diameter

mm

1500

Shell thickness

mm

25

Gradeability

%

48%

WALK AROUND SD110

Vibration Frequency

Hz

Amplitude

mm

Low 1.06 & High 1.59

30

Centrifugal force

KN

Low 234 & High 314


Dynamic hydrostatic through propulsion system Spring Applied Hydraulically Released (SAHR) on axle and drum drive motor


Miscellaneous 1.


O

40O

2.


O

17

3.


mm

3652

4.


l

270

5. 6.

Hydra Hydraul ulic ic oil oil capac capacit ity y Tire size

l



125 587 x 660 (23.1 x 26) – 8 PR R3


WALK-AROUND GUIDE 10 ROPS / FOPS safety Provides peace of mind and safety by protecting the operator In the event of machine roll over and / or overhead falling objects

1 – Drive system Closed loop hydrostatic ,single speed motor on planetary axle with ,No spin differential and 2 speed drum drive motor long life. High tractive power. Maintenance requirements are minimal.

11 - Reliability Unprecedented, thorough lab and field testing over thousands of hours has proven quality and reliability of design.

8 - Hydraulics Volvo's closed loop and open loop system, hydraulic system powered by variable displacement axial piston pumps and gear pumps provides excellent compactor performance while conserving fuel.

2- Selectable Two amplitudes Easy-to-use operator adjustments allow for frequent change as soil application conditions vary, improving versatility.

3 - Frame Rugged frames, designed and made of heavy gauge steel for long service life, durability and maximum strength.,

Operator Comfort


9- Excellent Operator Environment Isolated operator „s platform. , Trend setting operator comfort offers optimum operator comfort and safety, excellent all-round vision and a wide spectrum of options to please the most discriminating operator. Serviceability is unmatched.

4 - Access Panels Diesel engine and all hydraulic components are easily accessible from all side, Test points incorporated in hydraulic circuit - makes service and maintenance easier than ever before. 5 – Volvo Engine Volvo engine D5DA3 Turbo charged & Liquid cooled Tier 3 Powerful ,environment friendly diesel engine of 133 HP emission compliant, matched to the powertrain optimum performance and fuel efficiency.

Serviceability Serviceabil ity

Productivity

7 – Serviceability – best in class The swing up engine hood design enables fast removal and replacement of major components with a minimum of special tools. Maintenance intervals keep costs to a minimum while increasing machine availability.

6 – Systems Correctly matched -designed components, specifically developed for compactor applications. Drive system, vibration system ,steering system, and brake system design,, for excellent operator control, and long service life.

Safety

Value

SD 110 Compactor Key features 



Design provides easy, complete

Dealer support comes standard service and parts support

access to engine and hydraulic components.

ROPS / FOPS FOPS safety safety Isolated operator’s platform Powerful efficient Volvo Engine Tier 3 , D5DA3 133 hp hp @ 2200 rpm

All – All – round visibility

Heavy duty, no – no –spin spin differential axles

Two speed transmission

High and low amplitude Stable maneuver maneuvering ing

Back up alarm

Balanced weight Variable frequencies frequencies


SD110

Product features & benefits

Top product features 

Engine and drive system



Amplitude and frequency



Visibility and safety



Serviceability



Versatility


Product features and benefits –SD110

Two-speed transmission



Balanced weight Performance

6075 kg 55%


4950 kg 45%


Dual amplitudes applications



Infinitely Variable Frequency



Work site visibility Safety



Articulated steering Performance


Safety


Ground level serviceability Serviceability



ROPS (w/sunshade) Safety



SD110 Walk-Around Station 3 Drum drive or axle drive

Station 4 SD110 center joint for articulated steering and frame oscillation

Station 2 SD110 drum vibration system and performance specs

Station 6 SD110 Volvo engine and other components under rear hood

Station 1 drum isolation and vibration


Station 5 SD110 drive system, rear axle, tires for gradeability and traction

Station 8 SD110 operator platform, seating and controls; safety features


Station 7 SD110 ground level access for maintenance and service

SD110 Walk-Around Station 3 Drum drive or axle drive

Station 4 SD110 center joint for articulated steering and frame oscillation

Station 2 SD110 drum vibration system and performance specs

Station 5 SD110 drive system, rear axle, tires for grade ability and traction Station 6 SD110 Volvo engine and other components under rear hood

Station 1 drum isolation and vibration


Station 8 SD110 operator platform, seating and controls; safety features Product features and benefits –SD110

Station 7 SD110 ground level access for maintenance and service



SD110 Tier III

Technical Specification

Machine Service Specification

Machine Model SD 110 Tier 3


Machine Service specification –SD 110

Machine weights 1.

Weight

SD110

SD110 D

SD110P

11125 Kg

11212Kg

11932Kg

Static weight @ drum:

6100 Kg

6240Kg

6960Kg

Static weight@ Tyres:

5025 Kg

4972Kg

4972Kg

Shipped weight

10876 Kg

10963Kg

11683Kg

Fuel Consumption:

12.3Lts / hr.

12.3 Lts/hr.

12.3 Lts/hr.

Operating weight:



Machine weights 2.

Weight

SD110 Drum drive

Operating weight:

11212 Kg


6240 Kg


4972 Kg

Shipped weight

10963 Kg

Fuel Consumption:

12.3Lts / hr.



Machine weights 3.

Weight

SD110 P

Operating weight:

11932 Kg


6960 Kg


4972 Kg

Shipped weight

11683 Kg

Fuel Consumption:

12.3Lts / hr.



Drum 4.

Drum

SD110

SD110D

SD110P

Width

:

2134mm

2134 mm

2134 mm

Diameter

:

1500mm

1500 mm

1500 mm

25mm

25

25 mm

Shell thickness:

mm

Diameter over Pad feet

1702 mm

Pad feet Number of: Pad Height Pad Tip Area

120 No‟s 102 mm 125 Cm2



Engine 5.

Engine:

Standard

Make:

Volvo

Model:

AG D5DA3

RPM Hi/Low:

2300 / 1000 rpm

Power:

133 hp / 99 kw @ 2200 rpm

Fuel Consumption:

3.2 gph / 12.3 lph @ 67% D.C



Cooling package 6.


COC

:

Radiator:

AKG

Oil cooler:

AKG

Fan:

24 inc plastic 12 blades


Pump Drive

7.


Pump Drive:

None – Direct drive

Make:

Centa – k, CK -125 SAE 10

Ratio:

1


Hydraulic Pumps –Traction – SD110 8.

Hydraulic Pumps: Make: Type: Displacement:

Traction Sauer Series 90 Piston 3.35 cir / 54.9 ccr

System Relief:

5510 psi / 380 bar

Efficiency (Vol):

96% M & 98% Vol

Flow @ op. speed:

30.7 gpm / 116.1 lpm

Charge Pump Disp / psi.:

0.86 cir / 290 psi

Charge Relief: Flow Controls: Input speed Flange & spline

290 psi / 20 bar MDC- 0.032 dia Orifice 2250 rpm SAE-C 21T, 16/32 DP



Hydraulic Pumps –Traction – SD110D & P 8.

Hydraulic Pumps: Make: Type: Displacement:

Traction Sauer Series 90 Piston 6.10 cir / 100.0 ccr

System Relief:

6525 psi / 450 bar

Efficiency (Vol):

91% Mech & 94% Vol

Flow @ op. speed:

55.9 gpm / 211.4. lpm

Charge Pump Disp / psi.:

1.22 cir / 350 psi

Charge Relief: Flow Controls: Input speed Flange & spline

350 psi / 24 bar MDC- 0.032 in dia Orifice 2250 rpm SAE-C 23T, 16/32 DP



Hydraulic Pump – Vibration SD110, D, & P 9.

Hydraulic Pumps: Make: Type:

Vibration Sauer 42 Piston

Displacement:

2.4 cir / 39.3 ccr

System Relief:

4060 psi / 280 bar

Efficiency (Vol):

92 % Mech & 94% Vol

Flow @ op. speed:

22.0 gpm / 83.2 lpm

Charge Pump Disp /psi:

0.85 cir / 285 psi

Input speed Flow Controls: Flange & spline

2250 rpm Manual Displacement control SAE-B 13T, 16/32 DP



Hydraulic Pump – Steering SD110, D, & P 10. Hydraulic Pumps:

Steering

Make: Type:

Sauer - Sundstrand SNP2 /11DSC 06 Gear

Displacement:

0.67 cir / 11 ccr

System Relief:

2500 psi / 172 bar

Efficiency (Vol):

90 % M & 96% Vol

Flow @ op. speed:

6.3 gpm / 23.7 lpm

Charge Pump Disp /psi:

N/a

Input speed Flange & spline

2225 rpm SAE-A 9T, 16/32 DP



Hydraulic Motors SD110 11. Hydraulic Motors:

Axle

Make:

(1) Sauer Sundstrand

Model:

Series 40, M46

Displacement:

2.80 cir

45.9cc/rev

Maximum rated pressure

5000 psi

345 bar

Efficiency (Vol):

91% M

Output speed Low / High

2353rpm

Flow controls

External 2 Speed shift valve

Flange & spline

SAE-A 15T, 16/32 DP



93% Vol 4823rpm

Hydraulic Motors SD110D & P 11. Hydraulic Motors:

Axle

Make:


Model:

Series 90, M75

Displacement: High/ Low

4.58 cir

75.1cc/rev


7000 psi

483 bar

Efficiency (Vol):

91% M


1272rpm

Flow controls

External 2 Speed shift valve

Flange & spline

SAE-A 15T, 16/32 DP



93% Vol 1837rpm

Hydraulic Motors – SD110 12. Hydraulic Motors:

Vibration

Make:


Model:

Series 40, M44

Displacement:

2.65 cir

43.4 cc/rev


5000 psi

345 bar

Efficiency (Vol):

92% M


1720 rpm

Flange & spline

SAE-A 15T, 16/32 DP



97% Vol

Hydraulic Motors – SD110D & P 12. Hydraulic Motors:

Vibration

Make:


Model:

Series 40, M44

Displacement:

2.65 cir

43.4 cc/rev


5000 psi

345 bar

Efficiency (Vol):

91% M


1780 rpm

Flange & spline

SAE-A 15T, 16/32 DP



93% Vol

Gear reducers 13. Axle SD110 Make:

Hurth 193 /93

Efficiency:

91%

Ratio:

113.11 low

Vibration:

None – Direct

Drum Drive:

No Gears



55.19 high

Gear reducers

13. Axle SD110D & P Make:

Hurth 192 /79

Efficiency:

90% Mech

Ratio: Hi / Lo

43.71 Low

Drum Drive: Efficiency Ratio Hi / Lo

MKE 35 – direct 100% Mech 1.00 Low 1.00 High



43.71 High

Brakes

14. Brakes: Service:

Hydrostatic

Secondary/Parking:

Spring Applied, Hydraulic Release common with secondary

Make:

Integral, Multiple wet disc, 218 psi / full release



Propulsion 15. Drive System

SD110

SD110D

Axle Drive

2 Speed Motor with planetary gear box and no spin Differential

Single Speed Motor with no spin differential

Drum Drive

Dummy Hub

Two speed motor with torque Hub



SD110P

Vibration 16. Vibration

SD110

SD110 D

SD110P

Frequency

0-30 Hz 0- 1800VPM

0-30 Hz 0-1800VPM

0-30 Hz 0-1800VPM

Centrifugal force High Centrifugal force Low

309KN 224 KN

300KN 220KN

314KN 234KN

Nominal Amplitude High Nominal Amplitude Low

1.92 mm 1.29 mm

1.92 mm 1.29 mm

1.59 mm 1.06 mm

Note: Bolt on Pad foot amplitude:


1.38 MM High & 0.92 mm Low


Drive Tyres 17. Size


23.1 x 26 R3, 8PR TL

Pressure

16 PSI or 1 bar

Ballast per tyre

387 Kg

Rim Size

DW 20 -26

Over all Dia. (Max)

1514 mm


Electrical 18. Electrical :

12VDC, negative ground

Battery

(1) BCI Group size L537 xW212xH247mm; 1000 CCA; 300 min reserve (@80 0F), 150 Ah

Alternator:

Make ISKRA, 01183181 KZ, 14 volts, 95 A

Starter:

Make ISKRA – 4 KW 00281774



Travel speed

19. Travel Speed:

SD110

SD110D

SD110P

High (Km.h)

0 -11

0 -13

0 -13

Low (Km.h)

0-6

0-9

0-9



Miscellaneous

20. Others

:

SD110

Articulation angle (+/-) Oscillation angle (+/-)

0

0

SD110D

SD110P

40

40

40

17

17

17

3652

3652

Inside Turning Radius mm 3652



Miscellaneous

21. Others

:

SD110

SD110D

SD110P

Fuel Capacity(Total) Fuel Capacity (Useable)

280 l 270 l

280l 270 l

280 l 270 l

Hydraulic Oil Capacity(Total) Hydraulic Oil Capacity (Useable)

160 l 125 l

160 l 125 l

160 l 125 l

Gradeabilty

28%

52%

48 %





Compactor SD110 Tier 3

Major components Major components identification

Major components SD110


Major components components identification identification SD110 – Tier 3

Engine






Volvo D5D GA E3 - Tier 3 Power 133HP or 99 KW @ 2200 rpm



Low Idle 1000 rpm



High idle 2300 rpm

Major components SD110 – Tier 3

Engine cooling package



Cooling package AKG



Fan 24 in plastic 12 blades



CAC



Radiator




Hydraulic oil cooler


Engine Air filter 


Engine air filter



Dry type cleaner with safety cartridge



Primary & secondary filter



Filtration efficiency 99.9 %



Air cleaner end cap



Rubber ejector valve


Love joy coupling 



Drive sleeve (Metal sleeve)



21 T – splines SD110




Love joy coupling

23 T – splines SD110 drum drive




Drive sleeve coupling



Drive sleeve coupling



Drive sleeve (Metal sleeve)



Two grub screws




Allen key 6 mm (socket type)


Love joy coupling 


Plate


Love joy coupling 

Drive sleeve assembled to propulsion pump

 


Torque grub screw 52 Ft lbs. Gap from pump spigot 63.3 +/- 1


Pump drive




Direct drive



Centa-k, CK-125 SAE10



Ratio 1



Pump mounting plate


Hydraulic Propulsion pump












Propulsion pump Axial piston pump Sauer Series 90 Displacement 3.35 in 3 / rev or 54.9 cc/ rev System relief pressure 5510 psi or 380 bar Flow 30.7 GPM or 116.1 l/ m


Hydraulic Vibration pump












Vibration pump Axial piston pump Sauer Series 42 Displacement 2.4 in 3 / rev or 39.3 cc/ rev System relief pressure 4060 psi or 280 bar Flow 22.0 GPM or 83.2 l/ m


Hydraulic Steering pump



Steering pump Gear pump



Sauer SNP2/11 DSC 06








Displacement 0.67 in 3 / rev or 11 cc/ rev System relief pressure 2500 psi or 172 bar Flow 6.3 GPM or 23.7 l/ m


Hydraulic axle motor

Axle motor










Sauer Series 40, M46 Displacement 2.80 in 3 / rev or 45.9 cc/ rev Maximum rated pressure 5000 psi or 345 bar



Output speed Low 2353 rpm



Output speed High 4823 rpm


Hydraulic Vibration motor 

Vibration motor



Sauer Series 40, M44








Displacement 2.65 in 3 / rev or 43.4 cc/ rev Maximum rated pressure 5000 psi or 345 bar Output speed 1780 rpm


SD 110 Tier 3 – Main frame structure



Rear frame + Front frame



Connected by swivel frame



Two articulation pins



One oscillation pin



Hydraulic tank & Diesel tank are mounted



Gear Reducer - Regular Axle




Transmission



Hurth axle 193/93



Efficiency 91 %



Ratio low 113.11 (Low)



Ratio high 55.19 (high)


Hydraulic Steering valve & system

Steering valve

Steering column



Hydraulic Steering cylinders




Steering cylinder



Bore 3.0 in or 76.2 mm



Rod



Stroke 10.0 in or 254 mm


1.5 in or 38.1 mm

Torque Hub 

Torque Hub



General Purpose:

The torque hub is used to provide support for the drum on the drive motor side of the drum, and to rotate the drum for propulsion.



Carrier



Carrier



General Purpose:

The carrier assembly acts like a wheel bearing and provides the right support for the drum, allowing the drum to turn while being fastened to the frame.



Drum eccentric assembly Hub

Eccentric shaft W= 74. 7 kgs

Bearing

Eccentric shaft Drive sleeve Bearing Hub Low amplitude eccentric W = 138.6 kgs Volvo Construction Equipment


Standard W= 126 kgs

Drum eccentric assembly High & Low Internal Eccentric Stop

Eccentric Rotation

Eccentric Rotation

High Amplitude

Low Amplitude Volvo Construction Equipment

Center Eccentric is Free to Rotate Inside Eccentric Outer Housing. It will Locate Itself Depending on the Rotation of the Eccentric Assembly. Shown in the High Amplitude Position. Major components SD110 – Tier 3

Wheel / Rim 


Rim size DW 20 -26



Air valve



Valve cap



Plug


Drive tyres




Size 23.1 x 26 R3, 8 PR



Pressure 16 psi or 1 bar



3/4th of water



Approx – 500 L


Hydraulic oil Tank






Hydraulic tank



Hydraulic oil:



Volvo super hydraulic oil ISO VG 46



Capacity: 33.02 GAL or 125 L

Hydraulic tank breather with a hole in the plug


Hydraulic tank strainers






Hydraulic tank suction Strainers Two numbers inside tank


Hydraulic filters




Propulsion pump suction filter



Vibration pump suction filter



Filtration 10 microns



No bypass


Brake & De-stroke valve




Brake pressure switch



Brake valve



De – stroke valve


Hydraulic Thermal bypass valve Thermal bypass valve




Temp below 71 0 C (1600 F) directly to tank



Between 710 C (1600 F) and 850 C (1850 F) and higher thermal by pass valve



Directs thru cooler


External 2 Speed shift valve 



Two speed shift valve Low & High speed

Connections on the valve numbers M3 Y L1



P=3 B1=2 T =1

Engine FRP hood




Engine FRP hood



Slopping & lockable


Engine FRP hood



Engine FRP hood



Slopping & lockable






Latches Retractor mechanism & strap


Bent tube ROPS/FOPS (w/sunshade)



ROPS/FOPS (w/sunshade)



Weight: 314 Kgs



Torque: 1860 ft. lbs. or 2522 Nm



ISO 3471 -1 – 2004



No alternation or modification on this structure



Propulsion & Vibration control lever

1. Propulsion lever

2. Vibration control lever

3. Control lever internals



Swivel Frame 

Swivel frame 2 Articulation pin & 1 Oscillation pin clevis)

Rear Frame assembly Front Frame assembly Swivel frame Volvo Construction Equipment


Diesel Fuel Tank



Fuel tank



Capacity 73.96 Gallon or



280 L (Total)



270 L (Useable)

 Diesel


tank breather


Drum Drive motor



Drum Drive



Poclain MKE 35 – 1 No



Displacement High 85.1 Cir



Displacement Low 213.1 Cir



Max rated pressure – 450 bar or 6530 psi



SD110 Drum assembly cut section view



SD110 T3 D - Single Drum

1. Drum 2. Drive plate 3. Motor Drum Drive 4. Shock mount 5. Bracket, Drive motor mounting

2 Speed Radial piston motor Volvo Construction Equipment


SD110 Drum Shim set calculation


Drum shim set calculation

Drum Drive motor








From Brake valve Drum drive motor R to Axle motor B Drum drive motor L to Axle motor A



Motor case drain to Hyd Tank



From 2 speed shift valve


Bolt – on pad foot shell




Bolt on Pad foot Drum shell



Bolt – 8 No‟s



Washer – 16 No‟s



Hexagon nut – 8 no‟s


Bolt – on pad foot shell on drum 1. Shell thickness 25 mm 2. Diameter over pad feet 1702 mm 3. Pad feet number of 120 4. Pad feet tip area cm2 125



Material scraper




Drum material scraper


Material scraper






Pad foot machine Drum scrapper


SD110/ Pad foot shell




Pad foot shell machine in different view


Axle Drum drive

1. Heavy duty Hurth axle (192/79) 2. Ratio low: 1 (Low) 3. Ratio high: 1 (High) 4. Designed for heavy duty cycle 5. Parts are not replaceable with regular axle 193/93



Drive Tyres 






Size 23.1x 26R3,8PR TL Pressure 16 psi Ballast per tyre 854lb or 387 kgs.


Operator seat 


One number ergonomically designed operator seat



Lap type Seat belt



Seat switch


Compact meter

Accelerometer

Compact meter • The Compact meter is simply a measure of soil stiffness.

• It consist off accelerometer (s) mounted inside the drum and it measures “ rebound” and the gauge simply read out in increasing values. • If the material is soft when the drum impacts it, the energy is absorbed, low number value on gauge. If soil is more compacted the drum will impact it and “stop” quicker; which the accelerometer measures. Volvo Construction Equipment


Battery



Electrical 12VDC, negative ground



Battery – one



BCI: L537 x W212 x H247 mm



1000 CCA: 300 min reserve @ 80 deg F)




A.H – 150 ampere hour


Battery cut off switch




Battery cut of switch


Starter




Starter Motor



Iskara – 12 Volts 4 KW


Alternator

Alternator








Iskara – 01183181 KZ 12 Volts (95 Amps)


LH Control panel carling switches 1. Hazard switch 2. Beacon light switch 3. High / Low speed switch 4. Park brake test switch 5. Park brake switch



Warning Indicators on operator console Tell Tales 1. LH & RH turn indicator 2. Seat belt indicator 3. Air filter choke indicator 4. Coolant temperature indicator 5.

Pre heat indicator

6. Engine oil pressure indicator 7. No charge indicator 8. High beam indicator Volvo Construction Equipment


RH Control panel carling switches 1. High beam switch 2. Low beam switch 3. Rear work lamp switch 4. Park light switch 5. LH & RH indicator switch 6. Horn push button 7. Fuel gauge 8. Key switch Volvo Construction Equipment


Operator Control panel




Monitoring gauges



Carling Switches



Indicators on panel



Vandalism cover


Electrical relays & fuse location in box 1. 60 Amps fuse 2. Low beam relay 3. Alarm relay 4. Brake latch relay 5. Brake light relay



Electrical distribution box 6. Head light relay 7. Reverse light relay 8. Flasher light relay 9. Position light relay 10. Rear light relay 11. High beam relay



Electrical distribution box

1. Power relay 2. Resistor 68Ω 5 watts 3. Timer relay 4. Fuses



Electrical distribution box



On Frame rear near battery

1. Starter relay 2. Fuse 60 Amps 3. Glow plug relay   

No of Relays No of fuses No of Diodes


= 14 No‟s = 15 No‟s = 15 No‟s Major components SD110 – Tier 3

Beckon light

1. Flashing Beacon Light (Option) 2. Rear work Light



Rear working light

Rear Work Light



Rear combination light LH & RH • Top Amber left & right indicator & Hazard • Red park light on only when park light switch on or when rear light on • White light on while reversing •


Bottom Red brake light


Railings 


New designed railings


Vibratory Compactor

SD110 Service Function

SD110 Vibratory Compactor 

Service Function



S – Check

 A – Add 

G – Grease



T – Torque

 AR – As

Required


Service Function –SD110



Service Function



C – Change



D – Drain



F - Fill



CL – Clean



FTLH – Fill To Level Hole

SD110 Vibratory Compactor







Service Intervals 10 Hours or Daily



Ref No: 1  Description: Engine oil  Recommended Lubricant: VDS-3,CL,SAE 15W40  Service code: SA  Comments: Fill to Dipstick Full Mark







Ref No: 2 Description: Air Cleaner Service code: S Comments: Check indicator Outer element change at clog indication Inner element change at 3 rd change of outer element.

  

1. 2.







Ref No: 3  Description: Fuel filter  Recommended Lubricant: Collected water  Service code: D  Comments:







Ref No: 4  Description: Fuel tank  Recommended Lubricant: Diesel fuel  Service code: SA  Comments: 74 GAL / 280 L







Ref No: 5  Description: Engine coolant  Recommended Lubricant: Volvo VCS coolant – 15.5 liters  Service code: SA  Comments: Change coolant at 6000 hrs. / 4 Years

Tool Required ; 22 & 24 Double end







Ref No: 6  Description: Engine cooling system  Recommended Lubricant: Clean fins  Service code: S  Comments:




Service Intervals 50 Hours or Weekly



Ref No: 7  Description: Battery  Recommended Lubricant: Distilled water  Service code: SA  Comments: As required

Tool required; Open end or Ring spanner 16/17







Ref No: 8  Description: Torque Hub Oil  Recommended Lubricant: SAE 85W -90 LS API GL5  Service code: SA  Comments: Fill to Level Hole

Tool required; Square plug key 3/8”







Ref No: 9  Description: Swivel & Cylinder pins  Recommended Lubricant: MPG –EP2 Grease  Service code: G  Comments: 3 Shots each

Tool required; Grease gun







Ref No: 10  Description: Centre Swivel  Recommended Lubricant: MPG –EP2 Grease  Service code: G  Comments: 5 Shots

Tool required; Grease gun







Ref No: 11  Description: Tyre Pressure  Recommended Lubricant: Compressed Air  Service code: SA Comments: 16 psi

Tool required; Tyre pressure gauge







Ref No: 12  Description: Hydraulic Oil  Recommended Lubricant: Volvo super hydraulic oil ISO VG 46  Service code: SA  Comments: FTLH







Ref No: 13  Description: Wheel nut  Recommended Lubricant: See operator manual  Service code: S T  Comments: 350 FT - LB

Tool required; Tool Hex socket 1. 5/16 ”x3/4 sq drive Torque wrench Volvo Construction Equipment






Ref No: 14  Description: Eccentric Oil  Recommended Lubricant: Mobil SHC 630  Service code: SA  Comments: Fill to Level Hole

Tool required; Allen key 14 mm







Ref No: 16  Description: Air cleaner system integrity  Recommended Lubricant: (3)  Service code: S  Comments: See operators manual




Service Intervals 100 Hours or Monthly



Ref No: 17  Description: Shift Linkage  Recommended Lubricant: Engine oil  Service code: A  Comments: 2 Drops each

Tool required; Lubricating oil can







Ref No: 18  Description: Axle housing Oil  Recommended Lubricant: SAE 85W -90 LS API GL5  Service code: SA  Comments: As required

Tool required; Ring spanner 17 mm







Ref No: 19  Description: Transmission Oil  Recommended Lubricant: SAE 85W -90 LS API GL5  Service code: SA  Comments: As required








Ref No: 20  Description: Wheel End Oil  Recommended Lubricant: SAE 85W -90 LS API GL5  Service code: SA  Comments: Fill to Level Hole

Tool required; Key Allen 12 mm




Service Intervals 250 Hours or Quarterly



Ref No: 21  Description: Engine Oil  Recommended Lubricant: VDS -3 CL -4 SAE 15W - 40  Service code:  Comments: 1.See engine operation manual for initial engine break – in maintenance 4. See engine manual Oil Qty – 15.5 LT MAX

Tool required; Drain valve coupling Volvo Construction Equipment






Ref No: 22  Description: Engine Filter (Lub Oil)  Recommended Lubricant: (1) & (4)  Service code: C  Comments: 1.See engine operation manual for initial engine break – in maintenance 4. See operator manual

Tool required; Heavy duty filter wrench Volvo Construction Equipment






Ref No: 23  Description: Axle housing Breather  Recommended Lubricant: (2)  Service code: CL  Comments: 2 See operator manual

Tool required; Ring spanner 24 mm & 14 mm







Ref No: 24  Description: Hydraulic filters  Recommended Lubricant: (2) & (3)  Service code: C  Comments: 2 See operator manual 3 See parts manual Qty – 2 No‟s







Ref No: 25  Description: Engine Fuel filters  Recommended Lubricant: (2) & (3)  Service code: C  Comments: 1 See engine operation manual for initial engine break – in maintenance 2 See operator manual 3 See parts manual Qty – 3 filters







Ref No: 26  Description: Carrier Breather  Recommended Lubricant: (2)  Service code: C L  Comments:

Tool required; Ring spanner / DE 22 mm




Service Intervals 500 Hours or Semi Annually



Ref No: 27  Description: ARTL Vertical Nuts  Recommended Lubricant:  Service code: ST  Comments: 500 FT - LB

Tool required; Box spanner 75 mm & Torque wrench







Ref No: 28  Description: Eccentric Oil  Recommended Lubricant: Mobil SHC 630  Service code: DF  Comments: 41 LT – Max (Total) Drain & Fill

Tool required; Allen key 14 mm







Ref No: 29  Description: Axle housing Oil  Recommended Lubricant: SAE 85W -90 LS API GL5  Service code: DF  Comments: 12 LT – Max Drain & Fill








Ref No: 30  Description: Transmission Oil (Drop out put box)  Recommended Lubricant: SAE 85W -90 LS API GL5  Service code: DF  Comments: 1.9 LT – Max Drain & Fill








Ref No: 31  Description: Wheel end Oil  Recommended Lubricant: SAE 85W -90 LS API GL5  Service code: DF  Comments: 1.8 LT – Max (Drain & Fill)

Tool required; Key Allen 12 mm







Ref No: 32  Description: Axle mounting bolts  Recommended Lubricant: (2)  Service code: ST  Comments: 460 FT – LB Torque

Tool required; 30 mm Box spanner & Ring 30 Torque wrench Volvo Construction Equipment






Ref No: 33  Description: Horizontal Swivel Nut  Recommended Lubricant: (2)  Service code: ST  Comments: See operators manual

Tool required; Box spanner 100 mm & Torque wrench Volvo Construction Equipment






Ref No: 34  Description: Torque Hub oil  Recommended Lubricant: SAE 85W -90 LS GL5  Service code: DF  Comments: FTLH (2 LT) Fill to Level Hole

Tool required; 3/8” square drive







Ref No: 35  Description: Carrier Oil  Recommended Lubricant: Mobil SCH 630  Service code: DF  Comments: FTLH (2 LT) Fill to Level Hole

Tool required; 27 & 22 DE 14/15 mm Double end Volvo Construction Equipment






Ref No: 36  Description: Air Filter Element  Recommended Lubricant: (2)  Service code: C  Comments: 1 See engine operation manual for initial engine break – in maintenance

Change at 1000 hrs. or 1 year which ever earlier







Ref No: 37  Description: Poly V - Belt  Recommended Lubricant: (2)  Service code: S  Comments: 1 See engine operation manual for initial engine break – in maintenance

Tool Required: ½ “ square drive T handle




Service Intervals 1000 Hours or Annually



Ref No: 38  Description: Hydraulic Oil  Recommended Lubricant: Volvo super hydraulic oil ISO VG 46  Service code: DF  Comments: 42GAL / 160 L Drain & Fill

Tool required; Open end spanner 24 mm




Service Intervals 1000 Hours or Annually



Ref No: 39  Description: Suction Strainer  Recommended Lubricant: (2)  Service code: CL  Comments: Clean

Tool required;

65 mm Spanner OE for strainer

50 mm Spanner OE for hose Volvo Construction Equipment



SD110 -Tool kit for service functions





Vibratory Compactor SD110

Lubricants information

Lubricants SD110 – Tier 3

SD110 Tier 3

Lubricants

Part No

Description

Quantity

Unit

Drum

70865670

Mobil SCH 630

41

Liter

Drum Torque hub Oil

15188563

Oil Gear SAE 85W 40

1.9

Liter

Carrier Oil

70865670

Mobil SCH 630

0.9

Liter

Eccentric Oil


Lubricants –SD110 Tier 3

Lubricants SD110 – Tier 3 SD110 Tier 3

Lubricants

Part No

Description

Quantity

Unit

Axle Differential & Brake

15188563

Oil Gear, SAE 85W 40

12

Liter

Transmission

15188563


1.9

Liter

15188563


1.8

Liter

(drop out put box) Wheel end oil



Lubricants SD110 – Tier 3 SD110 Tier 3

Lubricants

Part No

Description

Quantity

Unit

Engine Radiator Coolant

11715727

VCS Coolant

22

Liter

Engine Crank Case Oil

11708321

SAE 15W - 40

15.5

Liter

Grease

13923115

MPG-EPGrease

2

Kg



Lubricants SD110 – Tier 3

SD110 Tier 3

Lubricants

Part No

Description

Quantity

Unit

Diesel

70652102

Diesel

280 - Total

Liter

270 - Useable Hydraulic Oil

936903


Hydraulic Oil ISO VG 46


160 (Total) 125 (Useable)

Liter



D5 Engine Training

Road machine

Engine Identification - 010102

Engine identification plate Also on engine cover Engine serial number Volvo Construction Equipment

D5 engine training Road machine

Engine Identification plate - 010103

Engine Type plate: • Engine model • Engine spec No • Engine serial number (8 digits) • Rated engine speed • Injection timing and type of cam shaft • Injection pump code • Piston class Volvo Construction Equipment


Engine view from right

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Crank case breather Lubricating oil filling Injection pump Lubricating oil stick Lube oil cooler Lube oil replacement filter Lubricating oil drain plug Exchangeable fuel filter N/A V-belts Generator


Paver D5 engine

Engine view from left

1. 2. 3. 4. 5. 6.

Combustion air inlet Coolant out let Coolant inlet Connection charge air cooler Exhaust outlet Starter


Paver D5 engine

Engine Ignition order - 010104 Direction of rotation: Counter clockwise As seen from the fly wheel

Engine Ignition order : 1 – 3 – 4 - 2 Volvo Construction Equipment


Cylinder head valves - 010202

Valves:


•

There are some difference in valve guide

•

The valve springs of D5D / D7D have no special direction of installation and are replaceable

•

D5D / D7D valve guide are seal with „O” rings


Crank mechanism - 010301

•



Crank mechanism

Crank mechanism - 010302

D5D & D7D: Wet liner replaceable



Crank mechanism - 010303 Connecting rod:


•

The connecting rod is made of forged steel and the bearing cap (1) is guided using two guide pin (3)

•

Locating lug (2) are provided in bearing shells

•

Connecting rod and bearing are marked (4)

•

Marking (5) on the piston is to face the fly wheel


Piston - 010304

Max injection pressure 1500 bar

•

The pistons are made of special aluminum alloy. The piston is slightly off – Centre (A) in relation to the piston guide pin

• •

The piston must be installed with fly wheel symbol on the piston top facing the fly wheel There are three piston rings. The top ring has a ring carrier made of cast iron

•

6 hole nozzle Volvo Construction Equipment


Selecting gasket - 010305

Gasket holes 1, 2 & 3

Piston crown clearance: • To obtain the power, fuel consumption and exhaust gas emission specified for engine the piston height above the block face has to me measured and correct thickness for the cylinder head gasket has to be determined • The piston height is measured using a dial gauge (1) fixture (2) and spacer (3) • The procedure is described in service manual Volvo Construction Equipment


Engine Timing gear - 010401

1. 2.

Governor gear Transfer gear

3.

Cam shaft gear

4. Crank shaft gear



Lubricating oil diagram 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Lubricating oil sump Lubricating oil pump Pressure limiting valve TCD2013 Lube oil cooler Check valve TCD 2012 Bypass valve Bypass valve Pressure control valve Lubricating oil filter Main lube oil channel Piston cooling nozzle Rocker arm Internally switched exhaust gas return Turbo charger Air compressor


Paver D5 engine

Lubrication system - 020103 Lubrication system D5D 7. Lube oil filter with integrated by pass valve 2.5 bar 8. By pass valve oil cooler located in oil cooler housing 4.0 bar 9.

Oil pressure valve located in oil cooler housing 10 bar

10. Lube oil pump 90 l/min at 2500 rpm



Oil pump - 020202 1.

Suction

2. Pressure chamber to crank housing


3.

Inner Rotor

4.

Outer Rotor

5.

Driven from crank shaft

6.

Safety valve


Piston Cooling Nozzle - 020301

•

The piston cooling nozzle made of plastic are fitted in the main bearing pedestals



Fuel system - 030101

• • •

Change unit injector pump for cylinder number 3 on D5D with injection timer Read off EP code for cylinder No 3 on the engine identification plate under column EP (1) Read sequence Line 1 = cylinder 1 Line 2 = cylinder 2 and so on……





1.

Injection pump

2.

Delivery pipe

3.

Engine block

4.

Shim

5.

Roller tappet

6.

Cam shaft

7.

Fuel rack

8.

Fuel duct

9.

Injector


Mechanical single injection pump system


Paver D5 engine




Fuel schematic

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Fuel tank Fuel pre-filter Fuel pump Exchangeable fuel filter Fuel supply line to the FCU Control block fuel control unit High pressure pump Rail (Not applicable) Injector Fuel return to fuel tank


Paver D5 engine

Fuel schematic


Paver D5 engine

Fuel block diagram 1.

Diesel Tank

2.

Water separator

Fuel filter

5.

Fuel supply to fuel control unit / Control block

4.

6. U. I High pressure pump

8.

7.

9.

Excess leak return


3.


Feed pump

Injector

Diesel Tank

Coolant diagram (example) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Cooler Cooler inlet Coolant pump Coolant partial flow to the lubricating oil cooler Lube oil cooler Coolant supply for engine cooling Cylinder pipe head cooling Connection possibility for cab heating Heat exchanger Return line Coolant return to thermostat Coolant out let Compensation line Venting pipe


Paver D5 engine

Schematic outlet controlled cooling system

Expansion Tank Water out let Thermostat Water inlet

Water Pump Engine oil cooler


Radiator Paver D5 engine

Coolant block diagram (example) 1.

Oil cooler inlet

2.

Water pump

3.

Engine cooler

4. Engine block / Head / Engine cylinder Head

5.

7.

Thermostat cooler out let

6.

By pass thru special lines

Oil cooler outlet



Working description The coolant pump (“water pump”) draws in the coolant via hose lines directly from the cooler and delivers it first via the engine-integrated lube oil cooler, thereafter enters the engine, flows along the cylinder, upwards into the cylinder head and to the thermostat at the coolant outlet. From there, the coolant is directed via special lines to the cooler inlet. When the engine is still cold the coolant is short circuited through the engine until thermostat response temperature has been reached (starting opening) according to the volume of hot coolant flowing off, the water pump draws in cold coolant from the cooler


Paver D5 engine

Coolant thermostat Checking the thermostat when removed 1.

Measure dimension “a” on thermostat

Note: “a” starts of lift at approx. 83+2 (T1) “b” end of lift at approx. 95+5 (T2)

Lift movement with indicated temp T2, Min. 8 mm



Fuel system cylinder No positions 030113



Internal exhaust gas recirculation 1.

Additional cam for exhaust gas recirculation Inlet valve opens briefly during the outlet cycle and emits an exhaust gas partial flow to the suction system. This partial volume is sucked back in the next suction cycle


Paver D5 engine

Charging

Compressor Turbine

From filter

Turbo charger with charge air cooling Advantages: 

Volumetric efficiency of engine increases  Increase Horse Power  Emission improved  Compact in size

To CAC


Paver D5 engine

Charging piping connection Air filter

Compressor

CAC

Engine Inlet manifold

Engine exhaust Volvo Construction Equipment

Paver D5 engine

Fuel shut off solenoid

Resistance 4.9 ohms

1. Fuel shut off solenoid operates when there is ignition supply – 2nd position 2. Fuel shut off solenoid + excess fuel solenoid in 3 rd start position



Excess fuel solenoid

1.

Excess fuel solenoid

2.

Sensor Not applicable

1. Fuel shut off solenoid operates when there is ignition supply – 2nd position 2. Fuel shut off solenoid + excess fuel solenoid in 3 rd start position


Electrical Harness Installation –SD110

Engine oil pressure switch




Engine oil pressure switch


Engine water temperature switch




Engine Water temperature switch


Engine glow plug



Engine Glow plug



Time - 8 seconds




Temperature 950 0 c


Diesel tank fuel sender




Fuel sender


Mechanical governor

Governor adjustment screws

J

G


E

Full load

“G”

Torque maximum

“E”

NA based fuel charge

“J”

Excess fuel start solenoid

Paver D5 engine

Engine V- belt Procedure Change Engine V belt V – belt AVX 11 (Width 11 mm) Belt tensioning – Automatic tensioning Spring – loaded clamping roller



Removing the Starter motor



Installing the Starter motor



EK code - 030114



A measurement - 030115



Dimensions, definitions - 030116



Theoretical shim thickness - 030118



Actual shim thickness - 030119



Reinstallation - 030120



Special tools - 030121



Unit pump installation - 030122



Unit pump installation - 030123



Assembly injection pump



Unit injection pump system



Explanation Lo & EP- code for D5D engines



EP-Code on identification plate



Determination compensation shim



From value TS to SS



F I P installation, step 1



F I P installation, step 2



Example – Lubricating oil consumption (at least 100 operating hours) engine in high load operation Op. h

Fuel Lts

Lube oil

Date

Driver

9

423

2

15.2 12

Paul

12

551

2

16.2.12

13

523

2

17.2.12

11

600

2

18.2.12

13

620

2

19.2.12

14

590

2

20.2.12

10

450

2

21.2.12

11

597

2

22.2.12

12

580

2

23.2.12

13

620

2

24.2.12

118

5554

20


Shashi

Ballal

Ramalu


Example

Example – Lubricating oil consumption (at least 100 operating hours) engine in high load operation Calculation example: 

Fuel consumption = 5554 l  Lubricating oil consumption = 20 l 

Calculation: 5554 l = 100% 20 l

20 L X=

5554 L

= x


= 0.36 %

100 %


Maintenance Job Volvo D5D Engine 

Check oil level in engine



Engine oil change



Cleaning fuel pre filters & fuel filter cartridge



Checking and cleaning air filter



Cleaning cooling system



Maintenance Job Volvo D5D Engine 

Checking V- belt tension



Battery servicing works



Breathing fuel pipes



Checking cooling water level



Thank You & Happy Learning



SD110 – Electrical schematic circuit

India


Hydraulic & Electrical schematic circuit - SD110

SD110 T3 (Export) - Electrical schematic circuit

Drawing No 12780856 Issue No 03 Sheet No 1/4



SD110 T3 (Export - Electrical schematic circuit












5- Axle and motor brake

Manual Release of axle brake Gap 34mm + 0.5 mm between the Axle arm and screw head top Volvo Construction Equipment

Axle & Motor brake - SD110

5- SD110 D axle and motor brake

SD110D axle


SD110 D Drum Drive motor



Brake

Cam Cover Bearing support

Dynamic brake

SD110 D Drum Drive motor Volvo Construction Equipment


5- SD110 Drum drive motor – Pt. no12765132

Speed sensor out let 1. Purpose: Transducer can be connected 2.

Function : Measure the speed Model A302590


SD110 Drum drive motor

5 - Brake / Destroke valve

1.

Brake Pressure switch

2.

Brake dump valve

3.

Pump destroke valve



BDV Coil – Resistance = 7.2 Ω  PDV Coil – Resistance = 7.2 Ω


Brake & Destroke Trouble shooting guide –SD110

5 - Brake / Destroke valve Part No: 59122085 Voltage: 12 volts Max Torque; 4 -6 lb –ft or 5 -8 Nm

P T

B2 B1

Minimum brake release – 14 bar or 203 psi Maximum brake release – 20 bar or 290 psi

S1 S2

B1 = SAHR Brake B2 = SAHR Brake

NO C

NC

P = Pump Charge pump pressure

S1 = To Pump servo control M4 S2 = To Pump servo control M5

T = Hydraulic Tank Volvo Construction Equipment


5 - Brake / Destroke valve Neutral condition without power 1. P T

B2 B1

NO C

S1 & S2 – is connected – B1, B2 & T is connected P – blocked

S1

Energized condition power on

S2

2.

S1 & S2 – blocked – P connected to B1, B2 T – blocked

NC

3. If charge pressure is normal at brakes all that is required to release the brakes P = Pump Charge pump pressure (minimum 203 psi or 14 bar) – It confirms T = Hydraulic Tank the valve is hydraulically okay & the problem could be in the axle brake itself B1 & B2 = SAHR Brake S1 & S2 = To Pump servo control M4 & M5 Volvo Construction Equipment


5 - Brake / Destroke valve Finally to check and conclude the valve is hydraulically okay or not working

P T

B2 B1

S1 S2

NO C

NC

P = Pump Charge pump pressure T = Hydraulic Tank

1. Fix a pressure gauge on B1 & B2 and block the Axle brake port 2. If brake release pressure is obtained minimum 203 psi or 14 bar we can conclude the valve is okay 3. Note: This is when the valve is in energized condition

B1 & B2 = SAHR Brake S1 & S2 = To Pump servo control M4 & M5 Volvo Construction Equipment


5 - Brake / Destroke valve Electrical Block Diagram

Key Switch

Fuse F1 (40 Amps)

Power Relay

Park Brake / Test Switch

Brake dump valve D6 Diode

►

Pump destroke valve Volvo Construction Equipment



SD110 D Axle Motor


SD110 D Two speed shift valve


6-Hydraulic Steering valve & system


Hydraulic steering SD110 – Tier 3

7- Frame Rear frame compatibility for Standard axle & drum drive axle

Front frame

Rear frame

Swivel frame Volvo Construction Equipment

Frame assembly - SD110

8- Cab & ROP’s

Operators console assembly


Operators platform assembly

Console & Rops - SD110

9 - Simple Hydrostatic Circuit Building 

Learning Exercise


Simple Hydrostatic Circuit Building

9 - SD110 – Hydraulic schematic circuit


Hydraulic schematic circuit - SD110

9 – SD110D Hydraulic schematic circuit



9 – SD110D Hydraulic piping circuit









SD 110 Step 1 Training

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