Service DD90

VOLVO CONSTRUCTION EQUIPMENT

SERVICE MANUAL

SERIAL NO. 158533-

DD90/DD90HF/DD110/DD110hf

MORE CARE. BUILT IN.

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

CALIFORNIA Proposition 65 Warning Battery posts, terminals and other related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and other reproductive harm. Wash hands after handling.

DD-110/110HF & DD-90/90HF

A1

HYDRAULIC Propulsion/Braking...................................................E1 Schematics Overview..............................................................E2 Neutral-Brakes Applied......................................E3 Forward-Brakes Released.................................E4 Reverse-Brakes Released.................................E5 Component Teardown and Rebuild Drum Drive Motor...............................................E6 Propulsion Pump...............................................E7 Triple Pump Drive..............................................E8

TABLE OF CONTENTS

Table of Contents..................................................A1 Features of This Manual.......................................B1 Safety Information................................................C1 Illustrated Hose Schematic..................................D1

August 2002

DD-110/110HF & DD-90/90HF

TABLE OF CONTENTS

A2

Vibration...............................................................F1 Schematics Overview...........................................................F2 Neutral-No Vibration......................................F3 Clockwise Rotation........................................F4 Counterclockwise Rotation............................F5 Component Teardown and Rebuild Vibration Motor.............................................F6 Vibration Pump............................................F7 Steering.................................................................G1 Schematics Overview..........................................................G2 Neutral..........................................................G3 Steer to Left...................................................G4 Steer to Right................................................G5 Component Teardown and Rebuild Steering Cylinder..........................................G6 Steering Pump (DD-110/110HF)...................G7 Steering Pump (DD-90/90HF)......................G7 Steering Valve..............................................G8

August 2002

DD-110/110HF & DD-90/90HF

Hydraulic Symbol Quick Reference Chart............L1 Electrical Schematic Wire Color Code Reference Chart..........................................L2

TABLE OF CONTENTS

A3

ELECTRICAL Schematics Machine Electrical Schematic.......................H1 Component Teardown & Rebuild Water Pump..................................................H5 MACHINE Component Teardown & Rebuild ROPS/FOPS Replacement............................J1 Console Assembly.........................................J2 Console Bearing Pack Assembly....................J3 Deck Plates....................................................J4 Swivel Bearing Replacement.........................J5 Drum and Drum Drive.....................................J6 Eccentric Shaft Assembly...............................J7 Carrier and Spindle Assembly........................J8 TROUBLESHOOTING Hydraulic.......................................................K1 Electrical/Engine/Water System....................K2

EFF. w/ all S/N August 2002

air p Re t en ures n po ced m Co Pro IO N

L

Disassembly....................................................................E6.4 Inspection........................................................................E6.4 Assembly..........................................................................E6.4

DISASSEMBLY

VIB RA TIO N

INSPECTION

E

PU MP

CA SE

ASSEMBLY

SU CT IO N

A

B

A

VIBRATION MOTOR

- Hose routing diagram w/ components labeled. - Hydraulic symbol quick reference chart. - Wire color code reference chart. - Settings and specifications.

B1

- Troubleshooting chart w/ symptoms & prioritized possible causes.

DD-110/110HF VIBRATION SYSTEM HYDRAULIC TANK

L

E

G

E

N

dashed lines indicate low pressure

Return Suction Charge

VIBRATION PUMP

- Colors are standard throughout manual.

VIBRATION MOTOR

F3 A

FRONT VIBRATION PUMP

VIBRATION FILTER PROPULSION PUMP

- Operational status is identified by color.

A

FRONT DRUM MOTOR

STEERING VALVE

STEERING PUMP

D

High pressure

VIBRATION FILTER

- Each page is specific to one functional subsystem.

RETURN FILTER

B

B

CASE SUCTION

®

- Standard symbols are used.

FRONT VIBRATION MOTOR

LOOP FLUSHING VALVE

NEUTRAL-NO VIBRATION October 1999

REAR VIBRATION PUMP

BRAKE VALVE

SUCTION FILTER

FEATURES OF THIS MANUAL

Hig E Re h p G re Su turn ssu re Ch ction arg e

VIBRATION MOTOR.......................................................................E6.4

HYDRAULIC TANK REAR DRUM MOTOR

STEERING CYLINDER REAR VIBRATION MOTOR

OIL COOLER

August 2002

DD-110/110HF & DD-90/90HF

C1

SAFETY INFORMATION

Before performing any maintenance or service procedures on your DD-110/110HF or DD-90/90HF refer to the DD-110/110HF & DD-90/90HF operation and maintenance manual and the AEM Safety Manual for Safety Instructions.

August 2002

FRONT VIBRATION PUMP STEERING VALVE

STEERING PUMP

FRONT DRUM MOTOR

VIBRATION FILTER PROPULSION PUMP

D1 RETURN FILTER FRONT VIBRATION MOTOR

LOOP FLUSHING VALVE

BRAKE VALVE

SUCTION FILTER REAR VIBRATION PUMP HYDRAULIC TANK REAR DRUM MOTOR

STEERING CYLINDER REAR VIBRATION MOTOR

OIL COOLER

ILLUSTRATED HOSE SCHEMATIC

DD-110/110HF & DD-90/90HF

August 2002

DD-110/110HF & DD-90/90HF PRESSURE GAUGE

Overview............................................................E2 Neutral - Brakes Applied................................E3 Forward - Brakes Released...........................E4 Reverse - Brakes Released...........................E5

BRAKE VALVE PRESSURE SWITCH

DUMP VALVE

OIL COOLER HYDRAULIC TANK

DRUM MOTOR (FRONT) SUCTION FILTER PROPULSION PUMP DRUM MOTOR (REAR)

E1

Settings and Specifications-Propulsion* Engine RPM (Hi/Low) 2457/950 Flow at Input Speed 264.8 l/m 69.6 g/m System Relief Pressure (psi/bar) 5075/350 Charge Pressure Relief (psi/bar) 290/20 * For specific application settings, contact your authorized service personnel.

Settings and Specifications-Propulsion* DD-110

DD-110HF

x x x x

x x x x

DD-90 Engine RPM (Hi/Low) Flow at Input Speed

2420/950 2400/950 195.8 l/m 51.7 g/m 224.2 l/m 59.2 g/m 5075/350 290/20

System Relief Pressure (psi/bar) Charge Pressure Relief (psi/bar) * For specific application settings, contact your authorized

DD-90HF

x x x x x

PROPULSION / BRAKING

Table of Contents

x x x x x

service personnel.

August 2002

DD-110/110HF & DD-90/90HF PROPULSION/BRAKE SYSTEM HYDRAULIC TANK

SUCTION FILTER R

DRUM MOTOR L B N A

PROPULSION PUMP

LOOP FLUSHING VALVE A

OIL COOLER

E2 B

R

DRUM MOTOR BRAKE VALVE

B C

A

PUSHED FOR NORMAL OPERATION

L

PRESSURE SWITCH

OVERVIEW August 2002

DD-110/110HF & DD-90/90HF PROPULSION/BRAKE SYSTEM

HYDRAULIC TANK

SUCTION FILTER R

DRUM MOTOR L

PROPULSION PUMP

B N A

LOOP FLUSHING VALVE A

OIL COOLER

E3 B

L R

DRUM MOTOR BRAKE VALVE

B C

A

PUSHED FOR NORMAL OPERATION

PRESSURE SWITCH

L

E

G

E

N

D

Return Suction Charge Control High pressure dashed lines indicate low pressure

NEUTRAL-BRAKES APPLIED August 2002

DD-110/110HF & DD-90/90HF PROPULSION/BRAKE SYSTEM HYDRAULIC TANK

SUCTION FILTER

DRUM MOTOR

R

L

PROPULSION PUMP

B N A

LOOP FLUSHING VALVE A

OIL COOLER

E4 B

R

DRUM MOTOR BRAKE VALVE

B C

A

PUSHED FOR NORMAL OPERATION

PRESSURE SWITCH

L L

E

G

E

N

D

Return Suction Charge Control High pressure dashed lines indicate low pressure

FORWARD-BRAKES RELEASED August 2002

DD-110/110HF & DD-90/90HF PROPULSION/BRAKE SYSTEM

HYDRAULIC TANK

SUCTION FILTER R

DRUM MOTOR L

PROPULSION PUMP

B N A

A

OIL COOLER

E5 B

LOOP FLUSHING VALVE

R

L

DRUM MOTOR BRAKE VALVE

B C

A

PUSHED FOR NORMAL OPERATION

L

E

G

E

N

D

Return Suction Charge Control High pressure

PRESSURE SWITCH

dashed lines indicate low pressure

REVERSE-BRAKES RELEASED August 2002

DD-110/110HF & DD-90/90HF DRUM DRIVE MOTOR TABLE OF CONTENTS ............................................ E6.1

E6.1

DISTRIBUTION VALVE ............................................. E6.2 Disassembly......................................................... E6.2 Inspection............................................................. E6.2 Assembly ............................................................. E6.3 CYLINDER BLOCK AND CAM ................................. E6.4 Disassembly......................................................... E6.4 Assembly ............................................................. E6.5 CYLINDER BLOCK ................................................... E6.6 Disassembly......................................................... E6.6 Inspection............................................................. E6.6 Assembly ............................................................. E6.7 BEARING HOUSING ................................................ E6.8 Disassembly......................................................... E6.8 Inspection............................................................. E6.8 Assembly ............................................................. E6.9 BRAKE DISC........................................................... E6.10 Disassembly....................................................... E6.10 Inspection........................................................... E6.10 Assembly ........................................................... E6.11

TABLE OF CONTENTS August 2002

DD-110/110HF & DD-90/90HF DRUM DRIVE MOTOR NOTICE: Prior to performing repairs on this component, contact an authorized service representative concerning issues of warranty.

DISASSEMBLY

E6.2

1. Place the drive motor on the bench area. Remove the screws (21) that secure the brake disc (19) to the valving cover (10). 2. Remove the brake disc (19) from the valving cover assembly (10). Set the brake disc aside. 3. Remove and discard the O-ring (12) from the distribution cover (11). 4. Mark the position of the distribution cover (11) in relation to the cam (5) and the bearing support (1). 5. Remove the screws (13 and 15) from the distribution cover (11). 6. Remove the bearing support (1) from the distribution cover (11). 7. Remove the cam (5) and cylinder block (7) from the distribution cover (11). Remove and discard the O-rings (6) from the bearing support (1) and distribution cover (11). 8. Mark the position of the valving (16) in relation to the distribution cover (11). 9. Remove the valving (16) from the distribution cover (11). 10. Remove the springs (18) from the valving (16), then remove the O-rings and back-up rings (17) from the valving (16).

INSPECTION 1. Check the condition of the valving surface on its faces in contact with the cylinder block and the seal facings.

Figure 1-1

DISTRIBUTION VALVE August 2002

DD-110/110HF & DD-90/90HF DRUM DRIVE MOTOR ASSEMBLY

E6.3

1. Apply a light coat of petroleum jelly or grease to the O-rings and back-up rings (17), refer to Figure 1-1. 2. Install the O-rings and back-up rings (17) onto the valving (16). 3. Apply grease into the spring (18) housings. 4. Install the springs (18) into the valving (16). 5. Apply a light coat of petroleum jelly or grease to the faces of the O-rings and back-up rings (17). 6. Install the valving (16) into the distribution cover (11). 7. Apply a light coat of petroleum jelly or grease to the contact surfaces of the cylinder block (7) and the valving (16). 8. Apply a light coat of petroleum jelly or grease to the O-rings (6). 9. Install the new O-rings (6) on the bearing support (1) and distribution cover (11). 10. Install the bearing support (1), cam (5) and cylinder block (7) onto the distribution cover (11). 11. Align the marks on the bearing support (1), cam (5), and distribution cover (11). 12. Install the screws (15 and 14) into the distribution cover (11). 13. Torque the screws (15 and 14) to 350 N·m (258 lb-ft). 14. Apply a light coat of petroleum jelly or grease to the new Oring (12). 15. Install the new O-ring (12) on the distribution cover (11).

Figure 1-1

DISTRIBUTION VALVE August 2002

DD-110/110HF & DD-90/90HF DRUM DRIVE MOTOR DISASSEMBLY

E6.4

1. Mark the position of the bearing support (1) in relation to the cam (5) and the distribution cover (11), refer to Figure 1-1. 2. Remove the screws (15 and 14) from the distribution cover (11). 3. Remove the bearing support (1) from the distribution cover (11). 4. Remove the cam (5) and cylinder block (7) from the distribution cover (11). 5. Remove and discard the O-rings (6) from the bearing support (1) and distribution cover (11). 6. If the valving (16) remains attached to the cylinder block (7), mark the position of the valving (16) in relation to the distribution cover (11). 7. Remove the valving (16) from the cylinder block (7). 8. Remove the springs (18) from the valving (16). 9. If the valving (16) remains in the distribution cover (11), removal of the valving (16) and springs (18) is not necessary.

Figure 1-1

CYLINDER BLOCK AND CAM August 2002

DD-110/110HF & DD-90/90HF DRUM DRIVE MOTOR ASSEMBLY

E6.5

1. Apply grease into the spring (18) housings, refer to Figure 11. 2. Install the springs (18) into the valving (16). 3. Apply a light coat of petroleum jelly or grease to the faces of the O-rings and back-up rings (17). 4. Install the valving (16) into the distribution cover (11). 5. Apply a light coat of petroleum jelly or grease to the contact surfaces of the cylinder block (7) and the valving (16). 6. Apply a light coat of petroleum jelly or grease to the O-rings (6). 7. Install the O-rings (6) on the distribution cover (11) and bearing support (1). 8. Install the bearing support (1), cam (5) and cylinder block (7) onto the distribution cover (11). 9. Install the screws (15 and 14) into the distribution cover (1). 10. Torque the screws (15 and 14) to 350 N·m (258 lb-ft).

Figure 1-1

CYLINDER BLOCK AND CAM August 2002

DD-110/110HF & DD-90/90HF DRUM DRIVE MOTOR DISASSEMBLY

E6.6

1. Mark the position of the bearing support (1) in relation to the cam (5) and the distribution cover (11), refer to Figure 1-1. 2. Remove the screws (15 and 14) from the distribution cover (11). 3. Remove the bearing support (1) from the distribution cover (11). 4. Remove the cam (5) and cylinder block (7) from the distribution cover (11). 5. Remove and discard the O-rings (6) from the bearing support (1) and distribution cover (11). 6. If the valving (16) remains attached to the cylinder block (7), mark the position of the valving (16) in relation to the distribution cover (11). 7. Remove the valving (16) from the cylinder block (7). 8. Remove the springs (18) from the valving (16). 9. If the valving (16) remains in the distribution cover (11), removal of the valving (16) and springs (18) is not necessary. 10. Remove the clips (9) from the cylinder block (7). 11. Remove the pistons (8) from the cylinder block (7).

INSPECTION 1. Inspect the surface condition of the bores in the cylinder block (7) for seizing or abnormal wear.

Figure 1-1

CYLINDER BLOCK August 2002

DD-110/110HF & DD-90/90HF DRUM DRIVE MOTOR ASSEMBLY

E6.7

1. Apply a light coat of petroleum jelly or grease to the pistons (8), refer to Figure 1-1. 2. Install the pistons (8) into the cylinder block (7). 3. Install the clips (9) into the cylinder block (7). 4. Apply grease into the spring (18) housings. 5. Install the springs (18) into the valving (16). 6. Apply a light coat of petroleum jelly or grease to the faces of the O-rings and back-up rings (17). 7. Install the valving (16) into the distribution cover (11). 8. Apply a light coat of petroleum jelly or grease to the contact surfaces of the cylinder block (7) and the valving (16). 9. Apply a light coat of petroleum jelly or grease to the O-rings (6). 10. Install the O-rings (6) on the distribution cover (11) and bearing support (1). 11. Install the bearing support (1), cam (5) and cylinder block onto the distribution cover (11). 12. Install the screws (15 and 14) into the distribution cover (11). 13. Torque the screws (15 and 14) to 350 N·m (258 lb-ft).

Figure 1-1

CYLINDER BLOCK August 2002

DD-110/110HF & DD-90/90HF DRUM DRIVE MOTOR DISASSEMBLY

E6.8

1. Mark the position of the bearing support (1) in relation to the cam (5) and the distribution cover (11), refer to Figure 1-1. 2. Remove the screws (15 and 14) from the distribution cover (11). 3. Remove the bearing support (1) from the distribution cover (11). 4. Remove the cam (5) and cylinder block (7) from the distribution cover (11). 5. Remove and discard the O-rings (6) from the bearing support (1) and distribution block (11). 6. If the valving (16) remains attached to the cylinder block (7), mark the position of the valving (16) in relation to the distribution cover (11). 7. Remove the valving (16) from the cylinder block (7). 8. Remove the springs (18) from the valving (16). 9. If the valving (16) remains in the distribution cover (11), removal of the valving (16) and springs (18) are not necessary.

INSPECTION 1. Inspect the condition of the valving seal face surfaces for smoothness and wear.

Figure 1-1

BEARING HOUSING August 2002

DD-110/110HF & DD-90/90HF DRUM DRIVE MOTOR ASSEMBLY

E6.9

1. Apply a light coat of petroleum jelly or grease to the O-rings and back-up rings (17), refer to Figure 1-1. 2. Install the O-rings and back-up rings (17) onto the valving (16). 3. Apply grease into the spring (18) housings. 4. Install the springs (18) into the valving (16). 5. Apply a light coat of petroleum jelly or grease to the faces of the O-rings and back-up rings (17). 6. Install the valving (16) into the distribution cover (11). 7. Apply a light coat of petroleum jelly or grease to the contact surfaces of the cylinder block (7) and the valving (16). 8. Apply a light coat of petroleum jelly or grease to the O-rings (6). 9. Install the O-rings (6) on the distribution cover (11) and bearing support (1). 10. Install the bearing support (1), cam (5) and cylinder block onto the distribution cover (11). 11. Align the marks on the bearing support (1), cam (5), and distribution cover (11). 12. Install the screws (15 and 14) into the distribution cover (11). 13. Torque the screws (15 and 14) to 350 N·m (258 lb-ft).

Figure 1-1

BEARING HOUSING August 2002

DD-110/110HF & DD-90/90HF DRUM DRIVE MOTOR DISASSEMBLY 1. Remove the plug (32) from the cover (31), refer to Figure 11. 2. Remove the cover (31) from the brake body (20). 3. Compress the spring washer (24) and remove the snap ring. 4. Remove the spring washer (24), piston (23), and brake disc (19) from the brake body. 5. Remove and discard the O-Ring (22) from the brake body (20). 6. Remove and discard the O-Ring (33) from the cover (20).

INSPECTION

E6.10

1. Inspect the condition on the shaft (26) splines and brake body (20) splines. 2. All traces of rust, mud and water must be removed from all the disassembled parts.

Figure 1-1

BRAKE DISC August 2002

DD-110/110HF & DD-90/90HF DRUM DRIVE MOTOR ASSEMBLY

E6.11

1. Lubricate the discs (30) and install alternately one smooth disc then one friction disc, refer to Figure 1-1. 2. Apply an anti-oxidanting grease to the top of the brake piston (23), spring wahsers (24), snap ring (25), and piston contact surface in the brake body (23). 3. Apply a light coating of petroleum jelly or grease to a new Oring (22). 4. Install the new O-ring (22) onto the brake piston (23). 5. Install the brake piston (23) onto the brake body (20). 6. Install the spring washer (24) onto the brake piston (23). 7. Compress the spring washer (24) using a press. 8. Install the snap ring (25) into the brake body (20). 9. Install a new new O-ring (33) onto the cover (31) 10. Install the cover (31) on the brake body (20) 11. Install the plug (32) onto the cover (31).

Figure 1-1

BRAKE DISC August 2002

DD-110/110HF & DD-90/90HF / PROPULSION PUMP TABLE OF CONTENTS........................................................E7.1

1E7.1

LIP SEAL AND SHAFT..........................................................E7.2 Disassembly...........................................................E7.2 Inspection................................................................E7.2 Assembly.................................................................E7.3 MULTI FUNCTION VALVE CARTRIDGES.........................E7.4 Disassembly...........................................................E7.4 Inspection................................................................E7.4 Assembly.................................................................E7.4 CHARGE RELIEF VALVE....................................................E7.5 Disassembly ............................................................E7.5 Inspection................................................................E7.5 Assembly.................................................................E7.5 CHARGE PUMP.....................................................................E7.6 Disassembly...........................................................E7.6 Inspection................................................................E7.6 Assembly.................................................................E7.7 INTEGRAL CHARGE PRESSURE FILTRATION..............E7.8 Disassembly...........................................................E7.8 Inspection................................................................E7.8 Assembly.................................................................E7.8 MANUAL DISPLACEMENT CONTROL (MDC) AND SOLENOID OVERRIDE VALVE..........................................E7.9 Disassembly...........................................................E7.9 Assembly..............................................................E7.10

PROPULSION PUMP

TABLE OF CONTENTS August 2002

DD-110/110HF & DD-90/90HF / PROPULSION PUMP NOTICE: Prior to performing repairs on this component, contact an authorized service representative concerning issues of warranty.

E7.2

DISASSEMBLY 1. Position the motor with the shaft end facing up. 2. Remove screws (1) securing the retainer plate (2), refer to Figure 1-1. 3. Remove the retainer plate (2) and seal carrier (3) from the housing (4). 4. Remove the O-ring (5) from seal carrier (3). 5. Press out the lip seal (6) from the seal carrier (3). 6. If necessary, remove the shaft (9) and bearing assembly (8) from the housing (4). 7. Remove the retaining ring (7) that secures the bearing assembly (8) on the shaft (9). 8. Remove the bearing assembly (8) from the shaft (9). INSPECTION 1. Inspect the seal carrier (3), new lip seal (6) and Oring (5) for any damage or nicks. 2. Inspect the sealing area on the shaft (9) for rust, wear, or contamination. Polish the sealing area on the shaft (9) as necessary. 3. Inspect the bearing assembly (8) for damage. Use a new bearing assembly (8) as required. Figure 1-1.

LIP SEAL AND SHAFT August 2002

DD-110/110HF & DD-90/90HF / PROPULSION PUMP ASSEMBLY 1. If necessary, install the original bearing assembly (8) or a new bearing assembly (8) the new shaft (9), refer to Figure 1-1. 2. Secure the bearing assembly (8) on the shaft (9) with the retaining ring (7). 3. Install the shaft (9) and bearing assembly (8) into the housing (4). 4. Lightly lubricate the outside diameter of the new lip seal (6) with Loctite High Performance Sealant #59231. 5. Press the new lip seal (6) into the seal carrier (3). 6. Install a new O-ring (5) on the outside diameter of the seal carrier (3).

E7.3

CAUTION: To prevent damage to the lip seal (6), wrap the spline or key end of the shaft (9) with thin plastic. 7. Lubricate the O-ring (5) and the inside diameter of the lip seal (6) with clean petroleum jelly. 8. Install the seal carrier (3) into the housing (4) bore and secure it with screws (1). 9. Torque the screws (1) to 16 N·m (12 lb-ft).

Figure 1-1.

LIP SEAL AND SHAFT August 2002

DD-110/110HF & DD-90/90HF / PROPULSION PUMP DISASSEMBLY 1. Remove the multi function valve cartridges (1) from the end cap (2), refer to Figure 1-2. 2. Remove and discard the O-rings (3) from the multi function valve cartridges (1). INSPECTION 1. Inspect the multi function valve cartridges (1) for damage to parts. ASSEMBLY

E7.4

CAUTION: If the pressure limiter housing is disassembled for cleaning, the pressure setting must be readjusted after reassembly. 1. Lightly lubricate the O-rings (3) with clean petroleum jelly. 2. Install the O-rings (3) onto the multi function valve cartridges (1). 3. Install the multi function valve cartridges (1) in the end cap (2). 4. Torque the multi function valve cartridges (1) to 89 N·m (66 lb-ft).

Figure 1-2.

MULTI FUNCTION VALVE CARTRIDGES August 2002

DD-110/110HF & DD-90/90HF / PROPULSION PUMP DISASSEMBLY NOTE: To maintain original adjustment, mark the plug (7), the locknut (8), and the housing (2). 1. Loosen the locknut (8) and remove the plug (7) by unscrewing the plug (7) from the housing (2), refer to Figure 1-3. 2. Remove and discard the O-ring (6) from the plug (7). 3. Remove the spring (5) and charge relief valve (4) from the plug (7). INSPECTION 1. Inspect the charge relief valve (4) and mating seat in the end cap for damage or foreign material.

E7.5

ASSEMBLY CAUTION: Do not interchange parts with another valve. 1. Install the charge relief valve (4) and spring (5) onto the plug (7). 2. Install a new O-ring (6) onto plug (7). 3. Install the plug (7) with its locknut (8) aligning the marks made at disassembly and torque the locknut (8) to 52 N·m (38 lb-ft). 4. Check and adjust the charge pressure as required.

Figure 1-3.

CHARGE RELIEF VALVE August 2002

DD-110/110HF & DD-90/90HF / PROPULSION PUMP DISASSEMBLY 1. Remove the screws (1), flange cover (2) and O-ring (3) from the flange adapter (6). Discard the O-ring (3), refer to Figure 1-4. 2. Remove the screws (4), washers (5), and flange adapter (6) from the end cap (22).

E7.6

CAUTION: Do not allow the force of the cylinder block spring and swashplate leveler springs to separate the flange adapter from the charge pump housing. 3. Remove the screws (7), retaining plate (8) and O-ring (9). Discard the O-ring (9). 4. Remove the charge pump cover (10), bushing (11), and coupling (12). Note the orientation of the gerotor assembly (15) 5. Remove the charge pump shaft (13) and key (14). 6. Remove the charge pump gerotor assembly (15) and alignment pin (16). INSPECTION 1. Surfaces need to be clean and free of any foreign material or paint prior to assembly. 2. Inspect for abnormal wear or damage.

Figure 1-4.

CHARGE PUMP August 2002

DD-110/110HF & DD-90/90HF / PROPULSION PUMP ASSEMBLY NOTE: Be sure to install the charge pump in the proper orientation. 1. Apply a small amount of petroleum jelly to the charge pump gerotor assembly (15) inside diameter and outside diameter, refer to Figure 1-4. 2. Install the charge pump gerotor assembly (15) and alignment pin (16). 3. Install the charge pump shaft (13) and key (14). The internally splined end of the shaft must engage the main pump shaft. 4. Install the coupling (12), bushing (11), and charge pump cover (10).

E7.7

CAUTION: In order to avoid loss of charge pressure, always install the charge pump cover with the drain hole located on the same side of the end cap as the charge inlet port. 5. Install the retaining plate (8) and secure the retaining plate (8) with screws (7). 6. Torque the screws (7) to 13.5 N·m (10 lb-ft). 7. Install a new O-ring (9) around the charge pump cover (10). 8. Install the flange adapter (6), washers (5), and screws (4) onto the end cap (22). 9. Torque the screws (4) to 256 N·m (189 lb-ft). 10.If necessary, install a new O-ring (3), flange cover (2), and screws (1) onto the flange adapter (6).

Figure 1-4.

CHARGE PUMP August 2002

DD-110/110HF & DD-90/90HF / PROPULSION PUMP DISASSEMBLY 1. Remove the filter canister (21) from the filter head (17), refer to Figure 1-5. 2. Loosen the swivel locknut (19). 3. Remove the filter head (17) from the end cap (22). 4. Remove and discard the O-ring (20) from the filter head (17). INSPECTION 1. Inspect the filter head (17) and tube (18) for blockage or foreign material.

E7.8

ASSEMBLY 1. Install a new O-ring (20) onto the filter head (17). 2. Rotate the filter head (17) so the threads engage with the threads in the end cap (22), continue to rotate clockwise 6 or 7 turns. 3. Face filter head (17) in desired position. CAUTION: Failure to install the filter manifold to a sufficient depth in the housing will result in insufficient engagement of the tube in the housing. This may allow oil to bypass the filter and enter the charge system. 4. Torque the swivel locknut (19) to 122 N·m (90 lb-ft). 5. Install a new filter canister (21) per manufacturer’s instructions. Figure 1-5.

INTEGRAL CHARGE PRESSURE FILTRATION August 2002

DD-110/110HF & DD-90/90HF / PROPULSION PUMP DISASSEMBLY 1. Clean external surfaces prior to removal. 2. Remove the solenoid manifold screws (1), refer to Figure 1-6. 3. Remove the solenoid manifold (2) and gasket (3) from the manual displacement control (4). Discard the gasket (3). 4. Remove the screws (5) securing the manual displacement control (4) to the housing (11). 5. Remove the manual displacement control (4), orifice check valve (6), spring (7), spring retainer (8), and gasket (9) from the housing (11).

E7.9

CAUTION: Protect exposed surfaces and cavities from damage and foreign material.

Figure 1-6. MANUAL DISPLACEMENT CONTROL (MDC) AND SOLENOID OVERRIDE VALVE August 2002

DD-110/110HF & DD-90/90HF / PROPULSION PUMP

E7.10

ASSEMBLY 1. Install a new gasket (9) on the housing (11), refer to Figure 1-6. 2. Install the orifice check valve (6), spring (7), and spring retainer (8) into the manual displacement control (4). 3. All at once, install the manual displacement control (4) and engage the pin on the control linkage into the mating hole in the link attached to the swashplate. 4. Check for proper engagement of the control linkage pin by moving the control handle (10) off center creating center torque. If there is a lack of centering torque, repeat step 3. 5. Align the gasket (9) and install the screws (5). 6. Torque the screws (5) to 16 N·m (12 lb-ft). 7. If installing a new solenoid valve (12) into the solenoid manifold (2), torque the solenoid valve (12) to 18.6 N·m (13.8 lb-ft). 8. Install a new gasket (3), solenoid manifold (2) and screws (1). 9. Torque the screws (1) to 13.5 N·m (10 lb-ft).

Figure 1-6. MANUAL DISPLACEMENT CONTROL (MDC) AND SOLENOID OVERRIDE VALVE August 2002

DD-110/110HF & DD-90/90HF / TRIPLE PUMP DRIVE TABLE OF CONTENTS........................................................E8.1 TRIPLE PUMP DRIVE...........................................................E8.2 Disassembly...........................................................E8.2 Inspection................................................................E8.3 Assembly.................................................................E8.3

1E8.1

TRIPLE PUMP DRIVE

TABLE OF CONTENTS August 2002

DD-110/110HF & DD-90/90HF / TRIPLE PUMP DRIVE

E8.2

NOTICE: Prior to performing repairs on this component, contact an authorized service representative concerning issues of warranty. DISASSEMBLY 1. Remove the plug (1) from the pump housing (2), refer to Figure 1-1. 2. Drain the oil from the pump housing (2). 3. Remove the drive plate (3) from the pump housing (2). 4. Remove the drive shaft (4) from the pump housing (2). 5. Remove and discard screws (5) from the pump adapters (6). 6. Remove the pump adapters (6) from the pump housing (2). 7. Remove the gears (8) and the bearings (7) from the pump housing (2). 8. Turn the pump housing (2) over. 9. Remove and discard bolts (9) from the flywheel cover (10). 10.Remove the flywheel cover (10) from the pump housing (2). 11.Remove and discard the plastic strip gasket (11). 12.Remove the gear (12) and the bearings (13) from the pump housing (2). 13.Remove and discard the oil seal (14) from the flywheel cover (10). 14.Remove the bearings (7 and 13) from the gears (8 and 12) using an arbor press.

Figure 1-1.

TRIPLE PUMP DRIVE August 2002

DD-110/110HF & DD-90/90HF / TRIPLE PUMP DRIVE INSPECTION 1. Inspects parts for damage and wear, replace if necessary. 2. Inspect bolt holes for foreign material, clean as necessary.

E8.3

ASSEMBLY 1. Press the bearings (7 and 13) onto the gears (8 and 12), refer to Figure 1-1. 2. Press a new oil seal (14) into the flywheel cover (10). 3. Install the gear (12) and bearing (13) into the pump housing (2). 4. Install a new plastic strip gasket (11) onto the pump housing (2). 5. Install the flywheel cover (10) onto the pump housing(2). 6. Apply Loctite 262 to the new bolts (9). 7. Install the new bolts (9) into the flywheel housing (2). 8. Torque the bolts (9) to 271 N·m (200 lb-ft). 9. Turn the pump housing (2) over. 10.Install the gears (8) and bearings (7) into the pump housing (2). 11.Install the pump adapters (6) onto the pump housing (2). 12.Apply Loctite 262 to the new bolts (5). 13.Install the new bolts (5) into the pump housing (2). 14.Torque the bolts (5) to 271 N·m (200 lb-ft). 15.Install the drive shaft (4) into the pump housing (2). 16.Install the drive plate (3) onto the pump housing (2). 17.Install the plug (1) into the pump housing (2).

Figure 1-1.

TRIPLE PUMP DRIVE August 2002

DD-110/110HF & DD-90/90HF / HAND PUMP TABLE OF CONTENTS........................................................E9.1 SEAL KIT.................................................................................E9.2 Disassembly...........................................................E9.2 Assembly.................................................................E9.3 DD-90 EFF. S/N 160549 AND PRIOR DD-110 EFF. S/N 160582 AND PRIOR

1E9.1

HAND PUMP

TABLE OF CONTENTS August 2002

DD-110/110HF & DD-90/90HF / HAND PUMP

E9.2

NOTICE: Prior to performing repairs on this component, contact an authorized service representative concerning issues of warranty. DISASSEMBLY 1. Remove and discard the cotter pins (1) from the clevis pins (2), refer to Figure 1-1. 2. Remove and discard the washer (3) from the clevis pins (2). 3. Remove and discard the clevis pins (2) securing the link (4) to the beam (5) and body (6). 4. Remove and discard the link (4) from the beam (5) and body (6). 5. Remove and discard the cotter pin (7) from the clevis pin (8). 6. Remove and discard the washer (9) from the clevis pin (8). 7. Remove and discard the clevis pin (8) securing the beam (5) to the plunger (10). 8. Remove and discard the beam (5) from the plunger (10). 9. Remove the plunger (10) from the body (6). 10.Remove and discard the wiper (11), back-up washer (12), and the O-ring (13) from the plunger (10). 11.Remove and discard the setscrew (14), spring (15), and the ball (16) from the bore in the body (6). 12.Remove and discard the plug (17), spring (18), and the ball (19) from the bottom of the body (6). 13.Remove the release valve (20) from the front of the body (6). 14.Remove and discard the pin (21) and O-ring (22) from the release valve (20).

Figure 1-1. DD-90 EFF. S/N 160549 AND PRIOR DD-110 EFF. S/N 160582 AND PRIOR

SEAL KIT August 2002

DD-110/110HF & DD-90/90HF / HAND PUMP

E9.3

ASSEMBLY 1. Install a new O-ring (22) on the new release valve (20). 2. Install a new pin (21) into the release valve (20). 3. Install the release valve (20) into the front of the body (6). 4. Install a new ball (19), a new spring (18), and a new plug (17) into the bottom of the body (6). 5. Install a new ball (16), a new spring (15), and a new setscrew (14) into the bore of the body (6). 6. Install a new O-ring (13) followed by a new back-up washer (12), and a new wiper (11) onto a new plunger (10). 7. Install the plunger (10) into the bore of the body (6). 8. Install a new beam (5) onto the plunger (10) and secure the beam (5) with a new clevis pin (8). 9. Secure the clevis pin (8) with a new washer (9) and a new cotter pin (7). 10.Install the link (4) onto the body (6) and secure the link (4) with a new clevis pin (2). 11.Secure the clevis pin (2) with a new washer (3) and a new cotter pin (1). 12.Attach the link (4) to the beam (5) and secure the link (4) with a new clevis pin (2). 13.Secure the clevis pin (2) with a new washer (3) and a new cotter pin (1). Figure 1-1. DD-90 EFF. S/N 160549 AND PRIOR DD-110 EFF. S/N 160582 AND PRIOR

SEAL KIT August 2002

DD-110/110HF & DD-90/90HF Table of Contents

REAR VIBRATION PUMP

Overview.............................................................F2 Neutral.....................................................F3 Clockwise Rotation..................................F4 Counterclockwise Rotation......................F5

VIBRATION FILTER

FRONT VIBRATION PUMP

HYDRAULIC TANK

F1

REAR VIBRATION MOTOR

NOTE: Schematic shows quantity of one vibration motor & pump. Machine contains two of each (see Illustrated Hose Schematic page D1). Settings and Specifications-Vibration*

Settings and Specifications-Vibration*

DD-90 DD-90HF

DD-110 DD-110HF Engine RPM (Hi/Low) 2457/950 Flow at Input Speed 119.1 l/m 31.4 l/m **System Relief Pressure (psi/bar) 4350/300 ***System Relief Pressure (psi/bar) 3625/250 Charge Pressure Relief (psi/bar) 230/15.9 *For specific application settings, contact your authorized service personnel. **Effective with S/N 150303/157478 ***Effective with S/N 157479

VIBRATION

FRONT VIBRATION MOTOR

x x x x x

x x x x x

Engine RPM (Hi/Low) Flow at Input Speed

2420/950 117.3 l/m 31.0 l/m 134.3 l/m 35.5 l/m **System Relief Pressure (psi/bar) 4350/300 ***System Relief Pressure (psi/bar) 3625/250 **Charge Pressure Relief (psi/bar) 230/15.9 ***Charge Pressure Relief (psi/bar) 300/20.7 *For specific application settings, contact your authorized

x x x x x x

x x x x x x

service personnel. **Effective with S/N 150303/157478 ***Effective with S/N 157479

August 2002

DD-110/110HF & DD-90/90HF VIBRATION SYSTEM

OIL COOLER

HYDRAULIC TANK

REAR VIBRATION MOTOR TO A PORT ON 2ND VIBRAITON PUMP

A

F2

SUCTION FILTER

TO B PORT ON 2ND VIBRATION PUMP

B

VIBRATION PUMP

A

A

B

B

CASE

SUCTION

FRONT VIBRATION MOTOR TO SECOND VIBRATION PUMP SUCTION

OVERVIEW August 2002

DD-110/110HF & DD-90/90HF VIBRATION SYSTEM L

E

G

E

High pressure Return Suction Charge

HYDRAULIC TANK

N

D dashed lines indicate low pressure

OIL COOLER REAR VIBRATION MOTOR TO A PORT ON 2ND VIBRAITON PUMP

A

F3

SUCTION FILTER

B

TO B PORT ON 2ND VIBRATION PUMP

VIBRATION PUMP

A

A

B

B

CASE

SUCTION

FRONT VIBRATION MOTOR TO SECOND VIBRATION PUMP SUCTION

NEUTRAL-NO VIBRATION August 2002

DD-110/110HF & DD-90/90HF VIBRATION SYSTEM L

E

G

High pressure Return Suction Charge

E

N

D dashed lines indicate low pressure

HYDRAULIC TANK OIL COOLER REAR VIBRATION MOTOR TO A PORT ON 2ND VIBRAITON PUMP

A

F4

SUCTION FILTER

B

TO B PORT ON 2ND VIBRATION PUMP

VIBRATION PUMP

A

A

B B

CASE

SUCTION

FRONT VIBRATION MOTOR TO SECOND VIBRATION PUMP SUCTION

CLOCKWISE ROTATION August 2002

DD-110/110HF & DD-90/90HF VIBRATION SYSTEM L

E

G

E

High pressure Return Suction Charge HYDRAULIC TANK

N

D dashed lines indicate low pressure

OIL COOLER REAR VIBRATION MOTOR

TO A PORT ON 2ND VIBRAITON PUMP

A

F5

TO B PORT ON 2ND VIBRATION PUMP

B

SUCTION FILTER

VIBRATION PUMP

A

A

B

B

CASE

SUCTION

FRONT VIBRATION MOTOR TO SECOND VIBRATION PUMP SUCTION

COUNTERCLOCKWISE ROTATION August 2002

DD-110/110HF & DD-90/90HF / VIBRATION MOTOR TABLE OF CONTENTS.........................................................F6.1 SEAL KIT..................................................................................F6.2 Disassembly...........................................................F6.2 Inspection................................................................F6.2 Assembly.................................................................F6.3

1F6.1

VIBRATION MOTOR

VIBRATION MOTOR

TABLE OF CONTENTS August 2002

DD-110/110HF & DD-90/90HF / VIBRATION MOTOR

F6.2

NOTICE: Prior to performing repairs on this component, contact an authorized service representative concerning issues of warranty. DISASSEMBLY 1. Remove the retaining ring (1) from the housing (2), refer to Figure 1-1. 2. Carefully remove the lip seal (3) from the housing (2) bore. A slide type hammer may be used to remove the lip seal (3). 3. Remove the retaining ring (1) from the lip seal (3). 4. Remove the o-rings (3), and bearing ball (4) from the housing. Discard o-rings. 5. Position the motor with the shaft end facing down. 6. Loosen the screws that connect the motor end cap (9) to the motor housing (8). 7. Remove the motor end cap (9) from the motor housing (8) . Remove the gasket (7) and the needle bearing (6). 8 Discard the gasket (7). INSPECTION 1. Inspect the sealing area on the shaft (4) for rust, wear, or contamination. Polish the sealing area on the shaft (4) as necessary. 2. Inspect the shaft for rust, wear, or contamination. Polish the the shaft if necessary. Figure 1-1.

SEAL KIT August 2002

DD-110/110HF & DD-90/90HF / VIBRATION MOTOR

F6.3

ASSEMBLY 1. Place a new gasket (7) on the motor end cap (9), refer to Figure 1-1. Make sure that the end cap and the gasket line up. 2. Place the needle bearing in the center hole of the end cap gasket (9). 3. Using the bolt provided fasten the motor end cap (7) to the motor housing (8) until firmly secure. 4. Place the new O-Ring (3) and the Roller bearing (4) on the shaft (5) inside the motor housing. 5. Place the retainer ring (1) on the shaft (5) inside the motor housing (8). 6. Lightly lubricate the outside diameter of the new lip seal (3) with Loctite High Performance Sealant #59231. CAUTION: To prevent damage to the lip seal (3), wrap the spline or key end of the shaft (4) with thin plastic. 7. Slide the new lip seal (3) over the shaft (4) and press it into the housing (2) bore. 8. Install the retaining ring (1).

Figure 1-1.

SEAL KIT August 2002

DD-110/110HF & DD-90/90HF / VIBRATION PUMP TABLE OF CONTENTS.........................................................F7.1

1F7.1

LIP SEAL .................................................................................F7.2 Disassembly...........................................................F7.2 Inspection................................................................F7.2 Assembly.................................................................F7.2 BYPASS VALVE....................................................................F7.3 Disassembly...........................................................F7.3 Inspection................................................................F7.3 Assembly.................................................................F7.3 CHARGE CHECK AND HIGH PRESSURE RELIEF VALVE......................................................................F7.4 Disassembly ............................................................F7.4 Inspection................................................................F7.4 Assembly.................................................................F7.4 CHARGE RELIEF VALVE....................................................F7.5 Disassembly...........................................................F7.5 Inspection................................................................F7.5 Assembly.................................................................F7.5 FILTER ADAPTER.................................................................F7.6 Disassembly...........................................................F7.6 Assembly.................................................................F7.6 ELECTRICAL DISPLACEMENT CONTROL.....................F7.7 Disassembly...........................................................F7.7 Inspection................................................................F7.7 Assembly.................................................................F7.8

VIBRATION PUMP REAR

VIBRATION PUMP FRONT

TABLE OF CONTENTS August 2002

DD-110/110HF & DD-90/90HF / VIBRATION PUMP

F7.2

NOTICE Prior to performing repairs on this component, contact an authorized service representative concerning issues of warranty. DISASSEMBLY 1. Remove the retaining ring (1) from the housing (2), refer to Figure 1-1. 2. Carefully remove the lip seal (3) from the housing (2). A slide type hammer may be used to remove the lip seal (3). INSPECTION 1. Inspect the sealing area on the shaft (4) for rust, wear, or contamination. Polish the sealing area on the shaft (4) as necessary. ASSEMBLY 1. Lightly lubricate the outside diameter of the new lip seal (3) with Loctite High Performance Sealant #59231. CAUTION: To prevent damage to the lip seal (3), wrap the spline or key end of the shaft (4) with thin plastic. 2. Slide the new lip seal (3) over the shaft (4) and press it into the housing (2) bore. 3. Install the retaining ring (1).

Figure 1-1.

LIP SEAL August 2002

DD-110/110HF & DD-90/90HF / VIBRATION PUMP

F7.3

DISASSEMBLY 1. Remove the bypass valve (5) from the housing (2), refer to Figure 1-2. 2. Remove and discard the O-ring (6) and backup ring (7) from the bypass valve (5). INSPECTION 1. Inspect the bypass valve (5) and mating seat for damage or foreign material. Use new parts as required. ASSEMBLY 1. Install a new backup ring (7) and O-ring (6) onto the bypass valve (5). 2. Lubricate the O-ring (6) with clean hydraulic fluid and install the bypass valve (5) into the housing. 3. Torque the bypass valve (5) to 9.5 to 13.6 N·m (7 to 10 lb-ft).

Figure 1-2.

BYPASS VALVE August 2002

DD-110/110HF & DD-90/90HF / VIBRATION PUMP

F7.4

DISASSEMBLY 1. Remove the charge check and high pressure relief valve plugs (8), refer to Figure 1-3. 2. Remove and discard the O-rings (9) from the charge check and high pressure relief valve plugs (8). 3. Remove the springs (10) and poppet or valve cartridges (11) from the housing (2). INSPECTION 1. Inspect the poppet or valve cartridges (11) and mating seat in the housing (2) for damage or foreign material. If the seat in the housing (2) is damaged, a new vibration pump must be used and the original must be returned to the manufacturer for warranty repair or replacement. NOTE: Always replace ball type check valves with the poppet type. ASSEMBLY 1. Install a new O-rings (9) on the charge check and high pressure relief valve plugs (8). 2. Install new poppet or valve cartridges (11), new springs (10), and charge check and high pressure relief valve plugs (8) into the housing (2). 3. Torque the charge check and high pressure relief valve plugs (8) to 41 to 95 N·m (30 to 70 lb-ft). CAUTION: The high pressure relief valves are factory set and should not be tampered with except for replacing the entire poppet or valve cartridge. Disassembly may change the setting and cause system malfunctions or premature failure.

Figure 1-3.

CHARGE CHECK AND HIGH PRESSURE RELIEF VALVE August 2002

DD-110/110HF & DD-90/90HF / VIBRATION PUMP

F7.5

DISASSEMBLY 1. Remove the charge relief valve plug (12) from the housing (2), refer to Figure 1-4. 2. Remove and discard the O-ring (13) from the charge relief valve plug (12). 3. Remove the shims (14) from the charge relief valve plug (12). 4. Remove the spring (15) and poppet (16) from the housing (2). INSPECTION 1. Inspect the poppet and mating seat in the end cap for damage or foreign material. Use new parts as required. ASSEMBLY 1. Install a new O-ring (13) on the charge relief valve plug (12). 2. Install new shims (14) in the inside diameter of the charge relief valve plug (12). 3. Install a new poppet (16), new spring (15), and charge relief valve plug (12) with shims (14) into the housing (2). 4. Torque the charge relief valve plug (12) to 41 to 95 N·m (30 to 70 lb-ft).

Figure 1-4.

CHARGE RELIEF VALVE August 2002

DD-110/110HF & DD-90/90HF / VIBRATION PUMP DISASSEMBLY 1. Remove the screws (1), refer to Figure 1-5. 2. Remove the filter adapter (2) and gasket (3) from the housing (19). ASSEMBLY 1. Install a new gasket (3) and filter adapter (2) onto the housing (19). 2. Install the screws (1) to secure the filter adapter (2) onto the housing (19). 3. Torque the screws (1) to 22 to 28 N·m (16 to 21 lb-ft).

F7.6

Figure 1-5.

FILTER ADAPTER August 2002

DD-110/110HF & DD-90/90HF / VIBRATION PUMP CAUTION: The removal of any portion of the electronic displacement control mechanism may result in the loss of neutral, which will require readjustment.

F7.7

DISASSEMBLY 1. Remove the screws (4 and 5), refer to Figure 1-6. 2. Carefully lift the electrical displacement control (6) off the housing (19). 3. Remove the control inlet screen plug (10) from inlet passage. 4. Remove the screws (14) from each side of the housing (19). 5. Remove the servo piston covers (15 and 17) from the housing (19). 6. Remove and discard the gaskets (16). 7. Remove the control orifice plugs (18) from control passages. INSPECTION 1. Clean all parts in a suitable solvent and allow to air dry. 2. Inspect all orifice passages for blockage or foreign material. 3. Inspect the control drain orifice found in the control sleeve (7) for blockage or foreign material. 4. Inspect all machined surface for burrs and sharp edges. Remove any burrs or sharp edges as required. Figure 1-6.

ELECTRICAL DISPLACEMENT CONTROL August 2002

DD-110/110HF & DD-90/90HF / VIBRATION PUMP

F7.8

ASSEMBLY 1. Install the control orifice plugs (18) into the control passages found on each side of the housing (19), refer to Figure 1-6. 2. Install a new gasket (16) for each servo piston cover (15 and 17). 3. Install the servo piston covers (15 and 17) and secure each with screws (14). 4. Torque the screws (14) to 8 to 11 N·m (10.8 to 14.9 lb-ft). 5. Install the control inlet screen plug (10) in the inlet passage of the housing (19). 6. Torque the control inlet screen plug (10) to 2.2 to 3.4 N·m(20 to 30 lb-in). 7. Install O-rings (11, 12, and 13) on the electrical displacement control (6) mounting surface on the housing (19). 8. Carefully align the control spool and the control sleeve and install the electrical displacement control (6) on the housing (19). 9. Install the screws (4 and 5), torque the screws (4 and 5) to 13 to 14 N·m(10 to 11 lb-ft). 10.Perform pump neutral adjustment in accordance to the Service Manual. WARNING: After installing the servo piston cover (15), the pump neutral adjustment MUST be performed before the machine is put back into service. CAUTION: Performance of the pump neutral adjustment may adjust the position of the displacement limiter.

Figure 1-6.

ELECTRICAL DISPLACEMENT CONTROL August 2002

DD-110/110HF & DD-90/90HF STEERING VALVE

Table of Contents Overview...........................................................G2 Neutral.........................................................G3 Steer to Left.................................................G4 Steer to Right..........................................G5

RETURN FILTER

STEERING PUMP

G1

Settings and Specifications-Steering* Engine RPM (Hi/Low) 2457/950 Flow at Input Speed 30.3 l/m 8.0 g/m System Relief Pressure (psi/bar) 2500/172 * For specific application settings, contact your authorized service personnel.

HYDRAULIC TANK

SUCTION STRAINER

STEERING

STEERING CYLINDER

Settings and Specifications-Steering* DD-110

DD-110HF

x x x

x x x

Engine RPM (Hi/Low) Flow at Input Speed

2420/950 35.1 l/m 9.3 g/m 34.8 l/m 9.2 g/m 2500/172

System Relief Pressure (psi/bar) * For specific application settings, contact your authorized

DD-90

DD-90HF

x x

x

x

x x

service personnel.

August 2002

DD-110/110HF & DD-90/90HF STEERING SYSTEM HYDRAULIC TANK

SUCTION STRAINER

S

RETURN FILTER

STEERING PUMP

P

G2 T R

STEERING CYLINDER

P

L

STEERING VALVE

OVERVIEW January 2000

DD-110/110HF & DD-90/90HF STEERING SYSTEM L

E

G

E

N

D

HYDRAULIC TANK

Return

dashed lines indicate low pressure

Suction

SUCTION STRAINER

High Pressure S

RETURN FILTER

STEERING PUMP P

G3 T R

STEERING CYLINDER

P

L

STEERING VALVE

NEUTRAL January 2000

DD-110/110HF & DD-90/90HF STEERING SYSTEM HYDRAULIC TANK

L

E

G

Return SUCTION STRAINER

N

D dashed lines indicate low pressure

Suction High Pressure

S

RETURN FILTER

E

STEERING PUMP P

G4 R

STEERING CYLINDER

L

STEERING VALVE

STEER TO LEFT January 2000

DD-110/110HF & DD-90/90HF STEERING SYSTEM

HYDRAULIC TANK

L

G

E

Return Suction High Pressure

SUCTION STRAINER

S

RETURN FILTER

E

N

D dashed lines indicate low pressure

STEERING PUMP P

G5 R

STEERING CYLINDER L

STEERING VALVE

STEER TO RIGHT January 2000

DD-110/110HF & DD-90/90HF / STEERING CYLINDER TABLE OF CONTENTS........................................................G6.1 SEAL KIT.................................................................................G6.2 Disassembly...........................................................G6.2 Inspection................................................................G6.3 Assembly................................................................G6.4

1G6.1

STEERING CYLINDER

TABLE OF CONTENTS January 2000

DD-110/110HF & DD-90/90HF / STEERING CYLINDER

G6.2

NOTICE: Prior to performing repairs on this component, contact an authorized service representative concerning issues of warranty. DISASSEMBLY 1. Clean the outside of the cylinder. If the hoses were removed with the cylinder, remove the hoses from the cylinder. 2. Fasten the tube (1) in an acceptable repair stand or other holding equipment, refer to Figure 1-1. Be careful not to damage the tube (1). 3. Extend the piston rod (2) until the piston (3) bottoms out on the head (4). 4. Loosen and remove the set screw (5) and nylon plug (16) from the headcap (6). 5. Insert a spanner wrench into the holes provided. Remove the headcap (6) from the tube (1) by turning the headcap (6) counterclockwise. If the headcap (6) is stuck or moves erratically, tap the headcap (6) with a brass or plastic mallet while turning it. 6. Wrap the headcap (6) with a soft cloth to prevent the inside diameter of the headcap (6) from touching the piston rod (2). 7. Gently tap the piston (3) against the head (4) to drive the piston rod (2) assembly from the tube (1). 8. Place the piston rod (2) assembly on a suitable work surface that will not damage the piston rod (2). Figure 1-1.

SEAL KIT March 1999

DD-110/110HF & DD-90/90HF / STEERING CYLINDER

G6.4

ASSEMBLY 1. Install a new lip seal (10) in the middle groove in the inside diameter of the head (4), refer to Figure 1-1. 2. Install a new wiper (9) in the front groove in the inside diameter of the head (4). 3. Install new wear rings (11) in the back groove in the inside diameter of the head (4). 4. Install a new backup ring (13) in the groove on the outside diameter of the head (4) closest to the headcap (6). 5. Install a new O-ring (12) in the groove on the outside diameter of the head (4) next to the backup ring (13). 6. Install a new glyd-ring (15) and wear ring (14) in the grooves on the outside diameter of the piston (3). 7. Lubricate the inside and outside diameters of both the piston (3) and head (4) with clean hydraulic oil. 8. Place the piston rod (2) on a clean work surface. 9. Wrap the headcap (6) with a soft cloth to prevent the inside diameter of the headcap (6) from touching the piston rod (2). 10.Install the headcap (6) onto the piston rod (2). 11.Install the head (4) followed by the piston (3) onto the piston rod (2) noting the proper orientation of each component. 12.Secure the piston (3) onto the piston rod (2) with the locknut (7). 13.Torque the locknut (7) to 1084 to 1355 N·m (800 to 1000 lb-ft).

SEAL KIT March 1999

DD-110/110HF & DD-90/90HF / STEERING CYLINDER 14.Install the piston rod (2) assembly into the tube (1) until the headcap (6) engages the threads of the tube (1). Turn the headcap (6) counterclockwise until the first thread just passes the engagement point, then turn the headcap (6) clockwise until it is hand-tight or fully seated. Refer to Figure 1-1. 15.Use a spanner wrench to tighten the headcap (6) 1/8 to 1/4 turn past fully seated. 16.Install the nylon plug (16) and set screw (5) into the headcap (6).

G6.5

Figure 1-1.

SEAL KIT March 1999

DD-110/110HF & DD-90/90HF / STEERING PUMP TABLE OF CONTENTS........................................................G7.1 SEAL KIT DD-110/110HF....................................................G7.2 Disassembly...........................................................G7.2 Inspection................................................................G7.2 Assembly................................................................G7.3 SEAL KIT DD-90/90HF........................................................G7.4 Disassembly...........................................................G7.4 Inspection................................................................G7.4 Assembly................................................................G7.5

STEERING PUMP

1G7.1

TABLE OF CONTENTS February 1999

DD-110/110HF / STEERING PUMP

G7.2

NOTICE: Prior to performing repairs on this component, contact an authorized service representative concerning issues of warranty. DISASSEMBLY 1. Place the pump in a vise from the flange side. Be careful not to damage the pump housing (1) or flange (2). 2. Loosen and remove the screws (3) from the pump housing (1) and flange (2), refer to Figure 1-1. 3. Place the pump on a table with the shaft end facing up. 4. Remove the flange (2) and dowel pins (4) from the pump housing (1). 5. Clean up any oil left on the work surface after removing the flange (2). 6. Carefully remove and discard the anti-extrusion ring (5) then the seal (6) from the flange (2). 7. Place the flange (2) down on the work surface with a shop towel beneath the flange. Remove the retaining ring (7) and shaft seal (8) from the flange (2). 8. Remove the cover (9) and dowel pins (10) from the pump housing (1). 9. Clean up any oil left on the work surface after removing the cover (9). 10.Carefully remove and discard the anti-extrusion ring (5) then the seal (6) from the cover (9). 11.Carefully remove and discard the O-ring seal (11) from both ends of the pump housing (1). INSPECTION 1. Carefully clean and dry all machined surfaces thoroughly. 2. Inspect all machined surfaces for burrs and sharp edges. Remove burrs and sharp edges as required.

Figure 1-1.

SEAL KIT February 1999

DD-110/110HF / STEERING PUMP

G7.3

ASSEMBLY 1. Lightly lubricate the new O-ring seals (11) and seals (6) with petroleum jelly. 2. Install the new O-ring seals (11) on both ends of the pump housing (1), refer to Figure 1-1. 3. Install a new seal (6) in the cover (9). 4. Secure the seal (6) in the cover (9) by installing a new anti-extrusion ring (5) to the outside diameter of the seal (6). 5. Install the dowel pins (10) and cover (9) onto the pump housing (1). 6. Press a new shaft seal (8) into the flange (2) and secure shaft seal (8) with the retaining ring (7). 7. Install a new seal (6) in the flange (2). 8. Secure the seal (6) in the flange (2) by installing a new anti-extrusion ring (5) to the outside diameter of the seal (6). 9. Install the dowel pins (4) in the pump housing (1). CAUTION: Be careful not to damage the shaft seal (8) on the splined shaft when installing the flange (2). 10.Carefully install the flange (2) over the shaft and down onto the pump housing (1). 11.Place the pump in a vise from the flange side. Be careful not to damage the pump housing (1) or flange (2). 12.Install the screws (3) to secure the cover (9), pump housing (1) to the flange (2). 13.Torque the screws (3) to 50 to 55 N·m (36.9 to 40.5 lb-ft), refer to the torque pattern in Figure 1-1.

Figure 1-1.

SEAL KIT February 1999

DD-90/90HF / STEERING PUMP

G7.4

NOTICE: Prior to performing repairs on this component, contact an authorized service representative concerning issues of warranty. DISASSEMBLY 1. Place the pump in a vise with the input shaft end facing down. 2. Loosen and remove the capsrews (1) and washer (2) from the body (3), refer to Figure 1-1. 3. Place the pump on a table with the input shaft end facing up. 4. Tap the end of the drive gear (4) with a plastic mallet to loosen the cover (5). 5. Remove the cover (5) from the body (3). 6. Remove the dowel pins (6) from the body (3). 7. Remove and discard the seal ring (7) and thrust plate (8) from the cover (5). 8. Remove the driven gear (9), drive gear (4) and the wear plate (10) from the body (3). 9. Remove and discard the pressure loading seal (11) from the wear plate (10). 10.Place the body (3) down on the work surface with a shop towel beneath the body (3). Remove and discard the shaft seal (12) from the body (3). INSPECTION 1. Carefully clean and dry all machined surfces thoroughly. 2. Inspect all machined surfaces for burrs and sharp edges. Remove burrs and sharp edges as required.

SEAL KIT May 1999

DD-90/90HF / STEERING PUMP

G7.5

ASSEMBLY 1. Lightly lubricate the new seal ring (7) and pressure loading seal (11) with petroleum jelly. 2. Lightly lubricate the inside of the shaft seal (12). 3. Press the new shaft seal (12) in the body (3), refer to Figure 1-1. 4. Install a new pressure loading seal (11) in the wear plate (10). 5. Lubricate and install the wear plate (10) in the bore of the body (3). 6. Install the drive gear (4) in the body (3). 7. Install the driven gear (9) in the body (3). Make sure the long journal of the driven gear (9) is facing in the same direction as the long journal of the drive gear (4). 8. Lubricate the rear faces of the drive gear (4) and the driven gear (9) with SAE-10 oil. 9. Install the thrust plate (8) into the cover (5). 10.Apply a small amount of grease to the rear cover (2) groove. 11.Install a new seal ring (7) into the cover (5). 12.Install the dowel pin (6) into the body (3). 13.Position the body (3) with the gear bores up in a vertical position before installing the cover (5). 14.Install the cover (5) on the body (3). 15.Install the capscrews (1) and washers (2) to secure the cover (5) to the body (3). 16.Torque the capscrews (1) to 46 to 52 N×m (34 to 38 lb-ft).

Figure 1-1.

SEAL KIT May 1999

DD-110/110HF & DD-90/90HF / STEERING VALVE TABLE OF CONTENTS........................................................G8.1 STEERING VALVE................................................................G8.2 Disassembly...........................................................G8.2 Inspection................................................................G8.4 Assembly................................................................G8.5

STEERING VALVE

1G8.1

TABLE OF CONTENTS February 1999

DD-110/110HF & DD-90/90HF / STEERING VALVE

G8.2

NOTICE: Prior to performing repairs on this component, contact an authorized service representative concerning issues of warranty. DISASSEMBLY 1. Clean the exterior of the steering valve thoroughly. 2. Fasten the edges of the port face sides in a vise. Use protective material on the vise jaws to prevent damage to the housing (9), refer to Figure 1-1. 3. Loosen and remove the cap screws (1) from the housing (9). 4. Remove the end cap (2). 5. Remove and discard the seal (3) from the end cap (2). 6. Carefully remove the gerotor assembly (4) from the spacer plate (8). 7. Remove and discard the seal (5) from the gerotor assembly (4). 8. Remove the drive spacer (6), drive (7), and spacer plate (8) from the housing (9). 9. Remove and discard the seal (5) from the housing (9). 10.Remove the housing (9) from the vise. 11.Remove the anti-cavitation valves from the housing (9). NOTE: Each anti-cavitation valve consists of a spring (10), retainer plug (11), and a check ball (12). 12.Carefully remove the springs (10), retainer plugs (11), and check balls (12) from the bolt holes by tipping the housing (9).

26

TORQUE PATTERN

Figure 1-1.

STEERING VALVE February 1999

DD-110/110HF & DD-90/90HF / STEERING VALVE

G8.3

WARNING: Safety glasses must be worn when removing the retaining ring (13). 13.Pry the retaining ring (13) from the housing (9), refer to Figure 1-1. 14.Lift the spool (14) and the sleeve (15) assembly up just far enough to free the seal gland bushing (16). 15.Remove and discard the quad ring seal (17) from the seal gland bushing (16). 16.Pry the dust seal (18) from the seal gland bushing (16). Be careful not to damage the seal gland bushing (16). 17.Remove the bearing races (19) and needle thrust bearing (20) from the spool (14) and sleeve (15) assembly. CAUTION: Do not bind the spool (14) and sleeve (15) assembly in the housing (9). Rotate the spool (14) and sleeve (15) assembly slowly when removing it from the housing (9). 18.Place the housing (9) onto the port face. Remove the spool (14) and sleeve (15) assembly from the gerotor end of the housing (9). 19.Push the pin (21) from the spool (14) and sleeve (15) assembly. 20.Push the spool (14) partially from the control end of the sleeve (15), then carefully remove the centering springs (22) from the spool (14) using only your hands. 21.Remove and discard the seal (23) from the housing (9).

26

TORQUE PATTERN

Figure 1-1.

STEERING VALVE February 1999

DD-110/110HF & DD-90/90HF / STEERING VALVE

G8.4

22.Remove the manual steering check valve assembly from the housing (9), refer to Figure 1-1. NOTE: The manual steering check valve assembly consists of a set screw (24), check ball seat (25), seals (26 and 27), check ball (28), and a check ball retainer (29). 23.Remove the set screw (24). 24.Install a #10-24 machine screw into the end of the check ball seat (25). Then lift the check ball seat (25) out of the housing (9) by pulling on the screw with pliers. 25.Remove and discard the seals (26 and 27) from the check ball seat (25). 26.Tip the housing (9) to remove the check ball (28) and check ball retainer (29). CAUTION: Do not remove any valves other than the manual steering check valve and the anti-cavitation valves. All other valves are factory preset and are non-serviceable. INSPECTION 1. Inspect all mating surfaces for burrs and sharp edges. Replace parts as required. Do not use grit paper or file or grid these parts. 2. Clean all metal parts in a cleaning solvent. Blow dry all metal parts. Do not wipe dry with cloth or paper towel.

26

TORQUE PATTERN

STEERING VALVE February 1999

DD-110/110HF & DD-90/90HF / STEERING VALVE

G8.5

DISASSEMBLY 1. Install the manual steering check valve assembly in the housing (9), refer to Figure 1-1. NOTE: The manual steering check valve assembly consists of a set screw (24), check ball seat (25), seals (26 and 27), check ball (28), and a check ball retainer (29). 2. Install the check ball retainer (29) into the check valve hole in the housing (9) using needle nose pliers. Make sure the check ball retainer (29) is straight, not tilted on edge. 3. Install the check ball (28) in the housing (9). 4. Lightly lubricate the new seals (26 and 27) with clean petroleum jelly. 5. Install the new seals (26 and 27) on the check ball seat (25). 6. Lubricate the check ball seat (25) and seals (26 and 27) thoroughly with clean petroleum jelly. 7. Install the check ball seat (25) in the housing (9), inserting the open end of the check ball seat (25) first. 8. Install the set screw (24) to secure the check ball seat (25) in the housing (9). 9. Torque the set screw (24) to 11 N·m (8.3 lb-ft). 10.Assemble the spool (14) and sleeve (15) carefully so that the spring slots line up at the same end. 11. Test for free rotation. The spool (14) should rotate smoothly in the sleeve (15) with fingertip force applied at the splined end. 12.Insert the spring installation tool through the spring slots of the spool (14) and sleeve (15).

26

TORQUE PATTERN

Figure 1-1.

STEERING VALVE February 1999

DD-110/110HF & DD-90/90HF / STEERING VALVE

G8.6

13.Position the centering springs (22) on the bench so that the extended edge is down and the arched center section is together, refer to Figure 1-1. 14.Next, with the spring notches facing the sleeve (15), insert one end of the entire spring set into the spring installation tool. 15. Compress the extended end of the centering springs (22) and push the centering springs (22) into the spool (14) and sleeve (15) assembly until the centering springs (22) are centered within the springslots. 16.Insert the pin (21) through the spool (14) and sleeve (15) assembly until the pin is flush on both sides of the sleeve (15). 17.Install the spool (14) and sleeve (15) assembly splined end in the gerotor end of the housing (9). Make sure the parts do not tilt out of position. 18.Push the spool (14) and sleeve (15) assembly gently into place with slight rotating action, keeping the pin (21) nearly horizontal. 19.The spool (14) and sleeve (15) assembly is in position when the back end is flush with the gerotor end of the housing (9). This will prevent the pin (21) from dropping into the discharge groove of the housing (9). 20.Test for free rotation by turning the spool (14) and sleeve (15) assembly with fingertip force at the splined end. 21.Place the housing (9) on a clean, lint free cloth. 22.Lightly lubricate the new seal (23) with clean petroleum jelly and install the seal (23) in the housing (9).

26

TORQUE PATTERN

STEERING VALVE February 1999

DD-110/110HF & DD-90/90HF / STEERING VALVE

G8.7

23.Install the bearing races (19) and the needle thrust bearing (20) on the splined end of the spool (14). 24.Install a new dust seal (18) in the seal gland bushing (16) with the smooth side of the dust seal (18) facing down towards the seal gland bushing (16). 25.Lightly lubricate the new quad ring seal (17) with clean petroleum jelly, refer to Figure 1-1. 26.Install the quad ring seal (17) on the splined end of the spool (14). 27.Install seal gland bushing (16) over the spool (14) end with a twisting motion. Tap the seal gland bushing (16) in place with a rubber hammer. Make sure the seal gland bushing (16) is flush against bearing race (19). WARNING: Safety glasses must be worn when installing the retaining ring (13). 28.Install the retaining ring (13) in the housing (9) to secure the seal gland bushing (16). After installing the retaining ring (13), pry around the retaining ring (13) circumference with a screwdriver to properly seat the retaining ring (13) in the groove. 29.Fasten the edges of the port face sides in a vise. Use protective material on the vise jaws to prevent damage to the housing (9). 30.Lightly lubricate a new seal (5) with clean petroleum jelly and install the seal (5) in the housing (9). 31.Install the anti-cavitation valves in the housing (9). NOTE: Each anti-cavitation valve consists of a spring (10), retainer plug (11), and a check ball (12).

26

TORQUE PATTERN

STEERING VALVE February 1999

DD-110/110HF & DD-90/90HF / STEERING VALVE

G8.8

32.Install the check balls (12), retainer plugs (11), and springs (10) in the two bolt holes furthest from the port face in the housing (9). 33.Align the bolt holes in the spacer plate (8) with the bolt holes in the housing (9) and install the spacer plate (8) on the housing (9). 34.Rotate the spool (14) and sleeve (15) assembly until the pin (21) is parallel with the port face of the housing (9), refer to Figure 1-1. 35.Install the drive (7), making sure the drive (7) is engaged with the pin (21). 36.Lightly lubricate a new seal (5) with clean petroleum jelly and install the seal (5) in the gerotor assembly (4). 37.Align the splines of the gerotor assembly (4) with those of the drive (7) and install the gerotor assembly (4) on the spacer plate (8). 38.Align the bolt holes in the gerotor assembly (4) with the bolt holes in the spacer plate (8) without disengaging the gerotor assembly (4) from the drive (7). 39.Install the drive spacer (6) in the gerotor assembly (4). 40.Lightly lubricate the new seal (3) with clean petroleum jelly and install the seal (3) in the end cap (2). 41.Install end cap (2) on the gerotor assembly (4), aligning the bolt holes. 42.Install the cap screws (1) in the end cap (2). Pretighten each cap screw to 17 N·m (12.5 lb-ft). 43.Torque the cap screws (1) to 25 to 30 N·m (18.7 to 22.9 lb-ft), refer to the torque pattern in Figure 1-1.

26

TORQUE PATTERN

STEERING VALVE February 1999

DD-110/110HF & DD-90/90HF IGNITION SWITCH RELAY

EMERGENCY STOP SWITCH NEUTRAL START SWITCH

KEY SWITCH

Table of Contents Machine Electrical Schematic...................................................H2-H4

TACHOMETER

HARNESS CONNECTION CIRCUIT BREAKER

SEAT SWITCH

STARTER

H1

STARTER SOLENOID RELAY

FUSES ALTERNATOR

ELECTRICAL

BATTERIES

August 2002

DD-110/110HF & DD-90/90HF ELECTRICAL

H2

MACHINE ELECTRICAL SCHEMATIC January 2002

DD-110/110HF & DD-90/90HF ELECTRICAL

H3

MACHINE ELECTRICAL SCHEMATIC January 2002

DD-110/110HF & DD-90/90HF ELECTRICAL

H4

MACHINE ELECTRICAL SCHEMATIC January 2002

DD-110/110HF & DD-90/90HF / WATER PUMP TABLE OF CONTENTS........................................................H5.1 BYPASS VALVE ASSEMBLY..............................................H5.2 Disassembly...........................................................H5.2 Assembly.................................................................H5.2 DIAPHRAGM AND DRIVE ASSEMBLY.............................H5.3 Disassembly...........................................................H5.3 Assembly.................................................................H5.3

WATER PUMPS

1H5.1

WATER PUMPS

TABLE OF CONTENTS August 2002

DD-110/110HF & DD-90/90HF / WATER PUMP NOTICE: Prior to performing repairs on this component, contact an authorized service representative concerning issues of warranty. DISASSEMBLY 1. Loosen and remove screws (1) that secure the pump head assembly (2) to the motor (3), refer to Figure 1-1. 2. Remove the screws (4) from the pump head assembly (2). 3. Separate the pump head cover (5) from the pump head base (6).

H5.2

4. Carefully remove the bypass valve assembly (7) from the pump head cover (5). ASSEMBLY 1. Install a new bypass valve assembly (7) in the pump head cover (5). 2. Assemble the pump head cover (5) and pump head base (6) together. 3. Install the screws (4) to secure the pump head cover (5) to the pump head base (6). 4. Place the pump assembly (2) on the motor (3). 5. Install the screws (1) to secure the pump head assembly (2) to the motor (3). Figure 1-1.

BYPASS VALVE ASSEMBLY August 2002

DD-110/110HF & DD-90/90HF / WATER PUMP DISASSEMBLY 1. Loosen and remove screws (1) that secure the pump head assembly (2) to the motor (3), refer to Figure 1-1. 2. Remove the screws (4) from the pump head assembly (2). 3. Separate the pump head cover (5) from the pump head base (6). 4. If necessary, remove the bypass valve assembly (7) from the pump head cover (5). 5. Carefully remove the diaphragm assembly (8) from the top side pump head base (6). 6. Carefully remove the drive assembly (9) from the under side of the pump head base (6).

H5.3

ASSEMBLY 1. Install a new drive assembly (9) in the under side of the pump head base (6). 2. Install a new diaphragm assembly (8) on the top side of the pump head base (6). 3. If necessary, install a new bypass valve assembly (7) in the pump head cover (5). 4. Assemble the pump head cover (5) and pump head base (6) together. 5. Install the screws (4) to secure the pump head cover (5) to the pump head base (6). 6. Place the pump assembly (2) on the motor (3).

Figure 1-1.

7. Install the screws (1) to secure the pump head assembly (2) to the motor (3).

DIAPHRAGM AND DRIVE ASSEMBLY August 2002

DD-110/110HF & DD-90/90HF / ROPS/FOPS REPLACEMENT TABLE OF CONTENTS ................................................... J1.1 ROPS/FOPS ................................................................... J1.2 Tools Required ..................................................... J1.2 Safety ................................................................... J1.2 Removal ............................................................... J1.3 Inspection ............................................................. J1.4 Installation ............................................................ J1.4

ROPS/FOPS

J1.1

TABLE OF CONTENTS October 2002

DD-110/110HF & DD-90/90HF / ROPS/FOPS REPLACEMENT TOOLS REQUIRED: • Safety glasses • Torque multiplier • Loctite number 271 • Sockets and wrenches for these models • Lifting device with straps and chains, and sufficient capacity for lifting weight specified on ID tag located on the ROPS/ FOPS

NOTE: This illustration shows the model DD-110 ROPS/FOPS. The DD-90 ROPS/FOPS installation is identical.

SAFETY Appropriate safety practices should be observed at all times. Refer to the AEM Safety Manual for safety instructions.

J1.2

These safety practices include the use of safety glasses and adherence to common safety procedures, which should J1.2 include safety practices pertaining to your specific location and situation. WARNING: Lifting equipment should be in perfect condition and have sufficient capacity for lifting the weight specified on the ID tag located on the rollover protective structure (ROPS)/falling object protective structure (FOPS). Take note of the lifting height to ensure that the ROPS/FOPS will clear the unit, and check for overhead power lines or other obstructions. When attaching chains or straps, examine them closely to ensure they are free from defects. Figure 1-1.

ROLLOVER PROTECTIVE STRUCTURE (ROPS) October 2002

DD-110/110HF & DD-90/90HF / ROPS/FOPS REPLACEMENT REMOVAL NOTE To ensure the safe removal and installation of your ROPS/ FOPS, refer to and view the service video which is available from your authorized distributor.

NOTE: This illustration shows the model DD-110 ROPS/FOPS. The DD-90 ROPS/FOPS installation is identical.

1. If work lights and strobe light are installed, disconnect electrical cables by removing the cable tie at the work lights. Disconnect and remove the cables from the back of the deck plates. 2. Attach the straps or chains of the suitable lifting device to the ROPS/FOPS (1).

J1.3

3. Once the lifting device is attached, take out the slack so the straps or chains are fully supporting the ROPS/FOPS J1.3 (1). 4. Loosen and remove the hex head bolts (2), hex nuts (3), and flatwashers (4), refer to Figure 1-1. WARNING: All assisting personnel should stay clear of pinch points and avoid standing under the suspended ROPS/FOPS at all times. 5. Check above the unit for obstructions. Lift the ROPS/FOPS (1) clear of the frame with the suitable lifting device and move to desired location. Figure 1-1.

ROLLOVER PROTECTIVE STRUCTURE (ROPS) October 2002

DD-110/110HF & DD-90/90HF / ROPS/FOPS REPLACEMENT INSPECTION 1. Check the ROPS/FOPS (1) for signs of fatigue or cracks. If cracks are found, the machine should be placed out of service and the ROPS/FOPS and all mounting hardware replaced.

NOTE: This illustration shows the model DD-110 ROPS/FOPS. The DD-90 ROPS/FOPS installation is identical.

2. Check all mounting hardware for damage and wear. Replace as necessary. INSTALLATION 1. Attach a suitable lifting device with straps or chains to the ROPS/FOPS.

J1.4

WARNING: All assisting personnel should stay clear of pinch points and avoid standing under the suspended ROPS/FOPS J1.4 at all times. 2. Check overhead for obstructions and lift the ROPS/FOPS (1) slowly over the unit and lower into position. 3. Apply Loctite #271 to the bolts (2). 4. Install the bolts (2), nuts (3), and flatwashers (4) and attach the ROPS/FOPS (1) to the frame. 5. Torque the bolts 2841 N•m (2095 ft-lbs). 6. Remove the lifting device from the ROPS/FOPS (1).

Figure 1-1.

ROLLOVER PROTECTIVE STRUCTURE (ROPS) October 2002

DD-110/110HF & DD-90/90HF / CONSOLE ASSEMBLY TABLE OF CONTENTS ................................................... J2.1 CONSOLE ASSEMBLY ................................................... J2.2 Tools Required ..................................................... J2.2 Safety ................................................................... J2.2 Removal and Disassembly ................................... J2.3 Cleaning and Inspection ....................................... J2.5 Assembly and Installation ..................................... J2.5

CONSOLE ASSEMBLY

J2.1

TABLE OF CONTENTS August 2002

DD-110/110HF & DD-90/90HF / CONSOLE ASSEMBLY TOOLS REQUIRED: • Safety glasses • Basic sockets and wrenches • Torque wrench • Loctite number 271 • Non-residue type solvent • Grease • Lifting device, such as a 3,000 lb. Auto-Crane that is in perfect condition

NOTE: Item 17 shown removed for clarity only; (Do not remove).

SAFETY Accidents are caused by failure to follow simple, fundamental safety rules and precautions. Refer to the AEM Safety Manual for safety instructions. Most accidents can be avoided by paying attention, using common sense, and following the instructions.

J2.2

NOTE Clean the machine, especially connections, of any traces of oil, fuel, or preservatives before carrying out maintenance or repair. Never use aggressive detergents. Use lint free cleaning rags. WARNING: When draining fluids, ensure that adequate sealable containers are available and that every care is taken to prevent spillage. Always ensure waste fluids are disposed of in an environmentally safe manner.

Figure 1-1.

CONSOLE August 2002

DD-110/110HF & DD-90/90HF / CONSOLE ASSEMBLY REMOVAL AND DISASSEMBLY 1. Remove the ROPS/FOPS from the machine, refer to the ROPS/FOPS Installation and Removal information for this model.

NOTE: Item 17 shown removed for clarity only; (Do not remove).

2. Remove the lock bolts (14) from the back plate (36), refer to Figure 1-1. 3. Remove the backplate (36) from the back of console assembly (1).

J2.3

WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance. 4. Tag and disconnect the four hydraulic lines on steering valve (17). Cap or plug all the lines and openings. 5. Tag and disconnect the horn wire from steering column. 6. Remove the control cable from the F-STOP-R control assembly (21). 7. Remove the throttle control cable from the control head. 8. Tag and disconnect any other wires and hoses necessary for removal of the console assembly.

Figure 1-1.

CONSOLE August 2002

DD-110/110HF & DD-90/90HF / CONSOLE ASSEMBLY WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions.

NOTE: Item 17 shown removed for clarity only; (Do not remove).

9. Attach a lifting device to support the console assembly (1). WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance.

J2.4

10. Remove the hoses (9 and 48) from the bearing pack assembly (39). 11. Remove the capscrews (41) and flat washers (40) from console bearing pack assembly (39). 12. If maintenance of the console bearing pack assembly is required, refer to the Console Bearing Pack Assembly Installation and Removal for this machine. 13. Lift the console away from the compactor. Guide all the wires, hoses, and cables through the bottom of the console assembly to ensure they do not catch on the inside of the console. Figure 1-1.

CONSOLE August 2002

DD-110/110HF & DD-90/90HF / CONSOLE ASSEMBLY CLEANING AND INSPECTION 1. Clean all parts in a non-residue type solvent. 2. Check all mounting hardware for damage and wear. Replace as necessary.

NOTE: Item 17 shown removed for clarity only; (Do not remove).

3. Inspect all threaded holes for debris or foreign material. ASSEMBLY AND INSTALLATION 1. Attach a lifting device to the console assembly (1) and raise it over the platform, refer to Figure 1-1. 2. Guide all the wires, hoses, or cables that are to be routed through the console into position before securing the console assembly (1) to the platform.

J2.5

3. Apply Loctite #271 to capscrews (41). Install the capscrews (41) and flat washers (40) and secure the bearing pack assembly (39) into the console assembly (1). 4. Torque the capscrews (41) to 50 N•m (37 lb-ft). 5. Install the hoses (9 and 48) to the bearing pack assembly (39). 6. Attach the throttle cable to the to the control head. 7. Attach the control cable to the F-STOP-R control assembly (21). 8. Connect the horn wire to the steering column as tagged during removal and disassembly. Figure 1-1.

CONSOLE August 2002

DD-110/110HF & DD-90/90HF / CONSOLE ASSEMBLY 9. Connect all the hydraulic hoses to the steering valve (17) as tagged during removal and disassembly. 10. Connect any other wires and hoses disconnected during removal and disassembly.

NOTE: Item 17 shown removed for clarity only; (Do not remove).

11. Install the backplate (36) to the back of the console assembly (1). 12. Install the lock bolts (14) to the backplate (36). 13. Torque the lock bolts (14) to 12 N•m (9 lb-ft). 14. Install the ROPS/FOPS to the machine, refer to the ROPS/ FOPS Installation and Removal information for this model.

J2.6

15. Grease the console bearing. Refer to the Operation and Maintenance Manual for these models for maintenance instructions.

Figure 1-1.

CONSOLE August 2002

DD-110/110HF/90/90HF / CONSOLE BEARING PACK ASSEMBLY TABLE OF CONTENTS ................................................... J3.1 BEARING PACK.............................................................. J3.2 Tools Required ..................................................... J3.2 Safety ................................................................... J3.2 Removal ............................................................... J3.2 Disassembly ......................................................... J3.2 Cleaning and Inspection ....................................... J3.3 Assembly .............................................................. J3.3 Installation ............................................................ J3.4

J3.1

TABLE OF CONTENTS August 2002

DD-110/110HF/90/90HF / CONSOLE BEARING PACK ASSEMBLY TOOLS REQUIRED: • Safety glasses • Basic sockets and wrenches • Torque wrench • Loctite number 271 • Non-residue type solvent • MPG-EP2 Grease SAFETY Accidents are caused by failure to follow simple, fundamental safety rules and precautions. Refer to the AEM Safety Manual for safety instructions. Most accidents can be avoided by paying attention, using common sense, and following the instructions. REMOVAL

J3.2

1. Remove the ROPS/FOPS from the machine, refer to the ROPS/FOPS Installation and Removal information for this model. 2. Remove the Operator’s Console from the machine, refer to the Operator’s Console Installation and Removal information for this model. 3. Remove the bearing pack assembly from the machine, refer to the Operator’s Console Installation and Removal information for this model. DISASSEMBLY 1. Remove the capscrews (8) from the inner race (3), refer to Figure 1-1.

Figure 1-1.

BEARING PACK August 2002

DD-110/110HF/90/90HF / CONSOLE BEARING PACK ASSEMBLY 2. Remove the inner race (3) from the base plate (1). 3. Remove the top closure ring (6) from the bearing holdown (5). 4. Remove the V-ring seal (7) from the bearing holdown (5). 5. Remove the capscrews (10) and flatwasher (9) from the base plate (1). 6. Remove the bearing holdown (5) from the base plate (1). 7. Remove the inner race-top (2) from the bearing holdown (5). CLEANING AND INSPECTION 1. Clean all parts in a non-residue type solvent.

J3.3

2. Check all mounting hardware for damage and wear. Replace as necessary. 3. Inspect all threaded holes for debris or foreign material. ASSEMBLY 1. Place base plate (1) over bottom inner race (3), refer to Figure 1-1. 2. Install bearing (4) and top inner race (2) onto base plate (1). 3. Install the bearing holdown (5) into the base plate (1).

Figure 1-1.

BEARING PACK August 2002

DD-110/110HF/90/90HF / CONSOLE BEARING PACK ASSEMBLY 4. Apply Loctite #271 to the capscrews (10). 5. Install the capscrews (10) and flatwashers (9) into the base plate (1). 6. Torque the capscrews (10) to 50 N•m (37 lb-ft). 7. Install the V-ring seal (7) and top closure ring (6) onto the top inner race (2). 8. Apply Loctite #271 to the capscrews (8). 9. Install the capscrews (8) into the inner race (3). 10. Torque the capscrews (8) to 12 N•m (9 lb-ft). 11. Fill the base plate (1) cavity with MPG-EP2 grease. INSTALLATION

J3.4

1. Install the bearing pack assembly into machine, refer to the Operator’s Console installation and Removal information for this model. 2. Install the Operator’s Console onto the machine, refer to the Operator’s Console Installation and Removal information for this model. 3. Install the ROPS/FOPS to the machine, refer to the ROPS/ FOPS Installation and Removal information for this model.

Figure 1-1.

BEARING PACK August 2002

DD-110/110HF & DD-90/90HF / DECK PLATES TABLE OF CONTENTS ................................................... J4.1 DECK PLATES ............................................................... J4.2 Tools Required ..................................................... J4.2 Safety ................................................................... J4.2 Removal ............................................................... J4.2 Cleaning and Inspection ....................................... J4.3 Installation ............................................................ J4.4

DECK PLATE HALVES

J4.1

TABLE OF CONTENTS August 2002

DD-110/110HF & DD-90/90HF / DECK PLATES TOOLS REQUIRED: • Safety glasses • Basic sockets and wrenches • Torque wrench • Loctite number 271 • Lifting device, such as a 3,000 lb. Auto-Crane that is in perfect condition SAFETY Accidents are caused by failure to follow simple, fundamental safety rules and precautions. Refer to the AEM Safety Manual for safety instructions. Most accidents can be avoided by paying attention, using common sense, and following the instructions. REMOVAL

J4.2

1. Park the machine on a level surface with ample clearance for working. 2. Remove the ROPS/FOPS from the machine, refer to the ROPS/FOPS Installation and Removal information for this model. 3. Ensure the work lights are disconnected. Remove the cable tie (3) and disconnect the electrical connections (1) at the front worklights (2), refer to Figure 1-2. Disconnect and remove the cables from the back of the deck plates. 4. Support the front railing (4) with an adequate lifting device. 5. Remove the locknuts (5), flatwashers (6), and capscrews (7) from the front railing (4).

Figure 1-1.

WORKLIGHTS AND RAILINGS August 2002

DD-110/110HF & DD-90/90HF / DECK PLATES 6. Remove the front railing (4) from the deck plate (8), refer to Figure 1-1. 7. Remove the operators console from the machine, refer to the Operator’s Console Installation and Removal information for this model. 8. Remove the lock screws (13) and locknuts (11) from the deck plates (4 and 12), refer to Figure 1-2. WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions.

J4.3

9. Attach a lifting device to the left deck plate (4) and remove the left deck plate (4) from the machine. 10. Attach a lifting device to the right deck plate (12) and remove the right deck plate (12) from the machine. CLEANING AND INSPECTION 1. Clean all parts in a non-residue type solvent. 2. Check all mounting hardware for damage and wear. Replace as necessary. 3. Inspect all threaded holes for debris or foreign material.

Figure 1-2.

DECK PLATES August 2002

DD-110/110HF & DD-90/90HF / DECK PLATES INSTALLATION 1. Attach a lifting device to the right deck plate (12) and install the deck plate onto the machine, refer to Figure 1-2. 2. Attach a lifting device to the left deck plate (4) and install the deck plate onto the machine. 3. Install the lock screws (13) and lock nuts (11) into the deck plate (4 and 12). 4. Torque the lock screws (13) to 50 N•m (37 lb-ft). 5. Install the operator console onto the machine, refer to the Operator’s Console Installation and Removal information for this model.

J4.4

6. Support the front railing (4) with an adequate lifting device. 7. Install the front railing (4) onto the deck plate (8). 8. Install the locknuts (5), flatwashers (6), and capscrews (7) onto the railing (4). 9. Torque the cap screws (7) to 122 N•m (90 lb-ft). 10. Connect the front worklights (2) electrical connections (1) and install the cable tie (3) . 11. Install the ROPS/FOPS onto the machine, refer to the ROPS/FOPS Installation and Removal information for this model. Figure 1-2.

DECK PLATES August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT TABLE OF CONTENTS ................................................... J5.1 SWIVEL BEARING .......................................................... J5.2 Tools Required ..................................................... J5.2 Safety ................................................................... J5.2 Removal and Disassembly ................................... J5.4 Inspection ............................................................. J5.8 Assembly and Installation ..................................... J5.8

J5.1

SWIVEL BEARINGS

TABLE OF CONTENTS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT TOOLS REQUIRED: • Safety glasses • Basic sockets and wrenches • Torque wrench • Loctite number 271 • Feeler gauges • Petroleum jelly • Sledge hammer • Heat resistant gloves • Non-residue type solvent • Straps or chains • Anti-seize • Lifting device, such as a 3,000 lb. Auto-Crane that is in perfect condition SAFETY

J5.2

Accidents are caused by failure to follow simple, fundamental safety rules and precautions. Refer to the AEM Safety Manual for safety instructions. Most accidents can be avoided by paying attention, using common sense, and following the instructions. WARNING: Improper maintenance can be hazardous. Study the Operator’s Manual and Service Manual before starting, operating, maintaining, fueling, or servicing the compactor. No unauthorized person should be allowed to operate, service, or maintain this compactor. Read and understand all unit mounted safety labels before starting, maintaining, fueling, or servicing this unit.

Figure 1-1.

TOOLS REQUIRED AND SAFETY August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT WARNING: Unexpected machine motion or moving parts can cut or crush. WARNING: Oil under pressure can cause serious cuts or injury. Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before performing maintenance. When handling oil, grease, or other chemical substances, observe the product related safety regulations.

J5.3

Substances such as oil, grease or fuel could be hazardous to health if used incorrectly. Avoid ingestion, skin contact, and breathing fumes. Keep hands and fingers from between small parts. Wear protective gear such as safety glasses, heavy gloves, and safety shoes. Do not perform any work on the equipment that is unauthorized. Avoid whenever possible servicing, cleaning, or examining the compactor with the engine running.

Figure 1-1.

TOOLS REQUIRED AND SAFETY August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT Before starting any work, check the de-energized parts for the presence of power. Ground or short circuit them in addition to insulating adjacent live parts and elements. NOTE Clean the machine, especially connections, of any traces of oil, fuel, or preservatives before carrying out maintenance or repair. Never use aggressive detergents. Use lint free cleaning rags. WARNING: When draining fluids, ensure that adequate sealable containers are available and that every care is taken to prevent spillage. Always ensure waste fluids are disposed of in an environmentally safe manner.

J5.4

REMOVAL AND DISASSEMBLY 1. Park the machine on a level surface with ample clearance for working. WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance. 2. Tag and disconnect the hydraulic lines and hoses that run between the two frames halves that will interfere with the separation of the two halves. Cap or plug all the lines and openings.

Figure 1-2.

WORKLIGHTS AND RAILINGS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT 3. Tag and disconnect the electrical wires that run between the two frames halves that will interfere with the separation of the two halves. 4. Remove the ROPS/FOPS from the machine, refer to the ROPS/FOPS Installation and Removal information for this model. 5. Ensure the work lights are disconnected. Remove the cable tie (3) and disconnect the electrical connections (1) at the front worklights (2), refer to Figure 1-2. 6. Support the front railing (4) with an adequate lifting device.

J5.5

7. Remove the locknuts (5), flatwashers (6), and capscrews (7) from the front railing (4). 8. Remove the front railing (4) from the deck plate (8). 9. Remove the operators console from the machine, refer to the Operator’s Console Installation and Removal information for this model. 10. Remove the deck plate halves from the machine, refer to the Deck Plate Halves Installation and Removal information for this model.

Figure 1-2.

WORKLIGHTS AND RAILINGS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance. 11. Disconnect the hydraulic hoses from the steering cylinder (8), refer to Figure 1-3. 12. Remove the bottom retaining ring (24) from the pivot pin (23). 13. Remove the pivot pin (23) from the rear frame. 14. Move the steering cylinder (8) away from the rear frame.

J5.6

NOTE: It is recommended that the torque on the horizontal swivel pin be broken before the vertical swivel pins are removed so that the rear frame can lend additional leverage for breaking this torque. 15. If the lockbar (9) is installed between the front frame and rear frame, remove the connecting pin and disconnect it from the front frame half, refer to Figure 1-3. 16. Remove the nut (18) and flatwasher (17) from the horizontal swivel pin (5). 17. Break the torque on the back plate capscrews (15), do not remove. Figure 1-3.

SWIVEL BEARINGS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT 18. Remove the stop nuts (21) and flatwashers (20) that are on two vertical pins (19) at the hinge joint. 19. Remove the vertical pins (19) and thrust bearing (6) from the hinge joint. 20. Roll the rear frame assembly (2) away from the front frame (1). 21. Remove and discard the dust seals (4 and 7), from the rear frame (2). 22. Remove horizontal swivel pin (5) and spacer (22) from the frame swivel (3).

J5.7

23. Remove the capscrews (15) and flatwashers (14) from the back plate (16). 24. Remove the backplate (16) and thrust bearing (11). Ensure that any shims (12 and 13) are placed behind backplate (16) and are marked correctly for reinstallation. 25. Remove and discard the dust seals (10) from the front frame (1). 26. Remove the swivel assembly (3) from the front frame (1).

Figure 1-3.

SWIVEL BEARINGS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT INSPECTION 1. Inspect all components for damage or signs of excessive wear. 2. Inspect all weld joints for cracks or signs of fatigue. 3. Inspect and clean the grease fittings on the swivel and related components. 4. Inspect the swivel pins for unusual wear patterns. This usually indicates improper, or lack of, lubrication. 5. Inspect all bolts for missing or damaged threads. ASSEMBLY AND INSTALLATION

J5.8

1. Place the horizontal swivel pin (5) and spacer (22) through the swivel assembly (3), refer to Figure 1-3. NOTE: Take care not to pinch the dust seals during installation. 2. Remove the protective paper from the back of the dust seals (4 and 7) and install them on top and bottom of both hinge arms of the rear frame (2). 3. Install the thrust bearings (6) into the rear frame (2). 4. Move the front frame half (1) and rear frame half (2) together and align the holes of the swivel with the holes on the rear frame hinge. 5. Install the vertical swivel pins (19) into the frame swivel (3). Install bottom pin first, then install top pin.

Figure 1-3.

SWIVEL BEARINGS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT 6. Install the stop nuts (21) and flatwashers (20) on the vertical swivel pins. When tightening down the nuts ensure that an even spacing is maintained in the gaps where dust seals (4 and 7) are located. This will ensure that rubbing will not occur between the two halves of the swivel hinge. 7. Torque the vertical pin stop nuts (21) 406 to 475 N·m (300 to 350 lb-ft). 8. Remove the protective paper from the back of the dust seals (10) and install them on both sides of front frame around the horizontal swivel pin hole. 9. Install the horizontal pin (5) through the thrust bearings (11) and front frame (1).

J5.9

10. Install the backplate (16) over horizontal pin (5). Align the holes for backplate with capscrews (15) and washers (14). Snug them down, but do not torque the cap screws. 11. Install the nut (18) and flatwasher (17) onto the horizontal pin (5). 12. Torque the nut (18) to 488 N•m (360 lb-ft). 13. Measure the gaps between swivel (3) and backplate (16) along the two sides that the bolts are installed. Select shim set or sets (12 and 13) that will fill this gap. 14. Break the torque on horizontal pin nut (18) and remove backplate capscrews (15). Figure 1-3.

SWIVEL BEARINGS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT 15. Install shims (12 and 13) and backplate capscrews (15) and flatwashers (14), refer to Figure 1-1. 16. Torque the backplate capscrews (15) to 298 N•m (220 lbft). 17. Retighten and torque the horizontal pin nut (18) to 1356 N•m (1000 lb-ft). 18. Ensure that all wiring and fluid lines are properly routed. 19. Install the hydraulic lines on the steering cylinder (8). 20. Attach the steering cylinder (8) to the rear frame. 21. Install the pivot pin (23) into the steering cylinder (8). 22. Install the retaining ring (24) to the pivot pin (23).

J5.10

23. Grease the steer cylinder pin bearing and the articulation and oscillating bearings. Refer to the Operation and Maintenance Manual for these models for maintenance instructions.

Figure 1-3.

SWIVEL BEARINGS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT 24. Install the right and left deck plates, refer to the Deck Plate Halves Installation and Removal information for this model. 25. Install the operator’s console, refer to the Operator’s Console Installation and Removal information for this model. 26. Support the front railing (4) with an adequate lifting device, refer to Figure 1-4. 27. Install the front railing (4) to the deck plate (8). 28. Install the locknuts (5), flatwashers (6), and cap screws (7) from the front railing (4). 29. Torque the capscrews (7) to 122 N•m (90 lb-ft).

J5.11

30. Connect the front worklights (2) electrical connections (1) and install the cable tie (3). 31. Install the ROPS/FOPS, refer to the ROPS/FOPS Installation and Removal information for this model. 32. Reconnect all the electrical connections and hydraulic lines. 33. Reconnect lockbar to the front frame halve.

Figure 1-4.

WORKLIGHTS AND RAILINGS August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE TABLE OF CONTENTS .................................................. J6.1 DRUM AND DRUM DRIVE .............................................. J6.2 Tools Required ..................................................... J6.2 Safety ................................................................... J6.2 Removal and Disassembly ................................... J6.4 Drum Drive Motor Removal and Disassembly ...... J6.7 Eccentric Removal and Disassembly ................... J6.8 Cleaning and Inspection ..................................... J6.12 Eccentric Assembly and Installation ................... J6.12 Drum Drive Motor Assembly and Installation ...... J6.17 Installation .......................................................... J6.18

J6.1

DRUM

TABLE OF CONTENTS August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE TOOLS REQUIRED: • Safety glasses • Torque wrench • Blue Loctite • Sledge hammer • Non-residue type solvent • Straps or chains • Anti-seize • Lifting device, such as a perfect condition

• Basic sockets and wrenches • Loctite number 271 • Feeler gauges • Heat resistant gloves • Acetylene torch • Loctite primer-T • Petroleum jelly 3,000 lb. Auto-Crane that is in

SAFETY

J6.2

Accidents are caused by failure to follow simple, fundamental safety rules and precautions. Refer to the AEM Safety Manual for safety instructions. Most accidents can be avoided by paying attention, using common sense, and following the instructions. WARNING: Improper maintenance can be hazardous. Study the Operator’s Manual and Service Manual before starting, operating, maintaining, fueling, or servicing the compactor. No unauthorized person should be allowed to operate, service, or maintain this compactor. Read and understand all unit mounted safety labels before starting, maintaining, fueling, or servicing this unit.

Figure 1-1.

TOOLS REQUIRED AND SAFETY August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE WARNING: Unexpected machine motion or moving parts can cut or crush. WARNING: Oil under pressure can cause serious cuts or injury. Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before performing maintenance. When handling oil, grease, or other chemical substances, observe the product related safety regulations.

J6.3

Substances such as oil, grease or fuel could be hazardous to health if used incorrectly. Avoid ingestion, skin contact, and breathing fumes. Keep hands and fingers from between small parts. Wear protective gear such as safety glasses, heavy gloves, and safety shoes. Do not perform any work on the equipment that is unauthorized. Avoid whenever possible servicing, cleaning, or examining the compactor with the engine running. Before starting any work, check the de-energized parts for the presence of power. Ground or short circuit them in addition to insulating adjacent live parts and elements.

Figure 1-1.

TOOLS REQUIRED AND SAFETY August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE NOTE Clean the machine, especially connections, of any traces of oil, fuel, or preservatives before carrying out maintenance or repair. Never use aggressive detergents. Use lint free cleaning rags. NOTE Take extra care when working around or on the hydraulic system to ensure its complete cleanliness. WARNING: When draining fluids, ensure that adequate sealable containers are available and that every care is taken to prevent spillage. Always ensure waste fluids are disposed of in an environmentally safe manner.

J6.4

REMOVAL AND DISASSEMBLY 1. Park the machine on a level surface with ample clearance for working. This should include space to allow for rolling the drum assemblies out from the frame of the compactor. 2. Install the articulation lock pin and chock the drum not being worked on to prevent movement when removing the other drum assembly. 3. Block up both outer ends of the frame to provide frame support and prevent movement. Leave room between the blocks to permit the drum to be rolled out of the frame. 4. Position a jack at the center articulation joint to raise the frame, refer to Figure 1-2.

Figure 1-2.

JACK PLACEMENT August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE 5. To allow for easier removal of the drum mounting hardware, measure from the inner drum shell to the top and bottom of the frame rail; positions A and B. Adjust the jack up or down until the measurements are roughly equal. This will relieve any load on the shock mounts, refer to Figure 1-2.

NOTE: Shims shown are for model DD110. Shims for model DD-90 have different shape.

6. Repeat the previous procedure on the other side of the drum. 7. Detach electrical lines from water tank and secure away from drum to avoid damage.

J6.5

WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 8. Attach an adequate lifting/supporting device to the water tank (1) and the tank support (2), refer to Figure 1-3. 9. Remove the capscrews (3), flatwashers (15), and shims (16) securing the water tank to the drum frame (4). 10. Tag and wire the shims together so that they can be reinstalled at the same locations. Use the lifting device to remove the water tank. 11. Place the water tank (1) on blocks in a safe location. NOTICE: Placing the water tank (1) directly on the floor can cause damage to the scraper bar.

Figure 1-3.

DRUM, DRUM FRAME, AND WATER TANK August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE The scraper bar is not designed to support the weight of the water tank (1) and can be bent or damaged if the water tank (1) is not placed on blocks. When removing the water tank (1), support the water tank (1) with blocks under the water tank structure.

NOTE: Shims shown are for model DD110. Shims for model DD-90 have different shape.

WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance.

J6.6

12. Tag and disconnect the hydraulic lines to the vibration motor (5) (right side of the drum). Cap or plug all the lines and openings, refer to Figure 1-3. NOTE: Steps 13, 14 and 15 are normally performed after the drum (12) is removed from the frame (4). 13. Remove the capscrews (6) and flatwashers (7) securing the vibration motor (5). 14. Remove the vibration motor (5) and O-ring (8) from the drum (12). WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance.

Figure 1-3.

DRUM, DRUM FRAME, AND WATER TANK August 2002

DD-110/110HF/90/90HF / CONSOLE BEARING PACK ASSEMBLY 4. Apply Loctite #271 to the capscrews (10). 5. Install the capscrews (10) and flatwashers (9) into the base plate (1). 6. Torque the capscrews (10) to 50 N•m (37 lb-ft). 7. Install the V-ring seal (7) and top closure ring (6) onto the top inner race (2). 8. Apply Loctite #271 to the capscrews (8). 9. Install the capscrews (8) into the inner race (3). 10. Torque the capscrews (8) to 12 N•m (9 lb-ft). 11. Fill the base plate (1) cavity with MPG-EP2 grease. INSTALLATION

J3.4

1. Install the bearing pack assembly into machine, refer to the Operator’s Console installation and Removal information for this model. 2. Install the Operator’s Console onto the machine, refer to the Operator’s Console Installation and Removal information for this model. 3. Install the ROPS/FOPS to the machine, refer to the ROPS/ FOPS Installation and Removal information for this model.

Figure 1-1.

BEARING PACK August 2002

DD-110/110HF & DD-90/90HF / DECK PLATES TABLE OF CONTENTS ................................................... J4.1 DECK PLATES ............................................................... J4.2 Tools Required ..................................................... J4.2 Safety ................................................................... J4.2 Removal ............................................................... J4.2 Cleaning and Inspection ....................................... J4.3 Installation ............................................................ J4.4

DECK PLATE HALVES

J4.1

TABLE OF CONTENTS August 2002

DD-110/110HF & DD-90/90HF / DECK PLATES TOOLS REQUIRED: • Safety glasses • Basic sockets and wrenches • Torque wrench • Loctite number 271 • Lifting device, such as a 3,000 lb. Auto-Crane that is in perfect condition SAFETY Accidents are caused by failure to follow simple, fundamental safety rules and precautions. Refer to the AEM Safety Manual for safety instructions. Most accidents can be avoided by paying attention, using common sense, and following the instructions. REMOVAL

J4.2

1. Park the machine on a level surface with ample clearance for working. 2. Remove the ROPS/FOPS from the machine, refer to the ROPS/FOPS Installation and Removal information for this model. 3. Ensure the work lights are disconnected. Remove the cable tie (3) and disconnect the electrical connections (1) at the front worklights (2), refer to Figure 1-2. Disconnect and remove the cables from the back of the deck plates. 4. Support the front railing (4) with an adequate lifting device. 5. Remove the locknuts (5), flatwashers (6), and capscrews (7) from the front railing (4).

Figure 1-1.

WORKLIGHTS AND RAILINGS August 2002

DD-110/110HF & DD-90/90HF / DECK PLATES 6. Remove the front railing (4) from the deck plate (8), refer to Figure 1-1. 7. Remove the operators console from the machine, refer to the Operator’s Console Installation and Removal information for this model. 8. Remove the lock screws (13) and locknuts (11) from the deck plates (4 and 12), refer to Figure 1-2. WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions.

J4.3

9. Attach a lifting device to the left deck plate (4) and remove the left deck plate (4) from the machine. 10. Attach a lifting device to the right deck plate (12) and remove the right deck plate (12) from the machine. CLEANING AND INSPECTION 1. Clean all parts in a non-residue type solvent. 2. Check all mounting hardware for damage and wear. Replace as necessary. 3. Inspect all threaded holes for debris or foreign material.

Figure 1-2.

DECK PLATES August 2002

DD-110/110HF & DD-90/90HF / DECK PLATES INSTALLATION 1. Attach a lifting device to the right deck plate (12) and install the deck plate onto the machine, refer to Figure 1-2. 2. Attach a lifting device to the left deck plate (4) and install the deck plate onto the machine. 3. Install the lock screws (13) and lock nuts (11) into the deck plate (4 and 12). 4. Torque the lock screws (13) to 50 N•m (37 lb-ft). 5. Install the operator console onto the machine, refer to the Operator’s Console Installation and Removal information for this model.

J4.4

6. Support the front railing (4) with an adequate lifting device. 7. Install the front railing (4) onto the deck plate (8). 8. Install the locknuts (5), flatwashers (6), and capscrews (7) onto the railing (4). 9. Torque the cap screws (7) to 122 N•m (90 lb-ft). 10. Connect the front worklights (2) electrical connections (1) and install the cable tie (3) . 11. Install the ROPS/FOPS onto the machine, refer to the ROPS/FOPS Installation and Removal information for this model. Figure 1-2.

DECK PLATES August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT TABLE OF CONTENTS ................................................... J5.1 SWIVEL BEARING .......................................................... J5.2 Tools Required ..................................................... J5.2 Safety ................................................................... J5.2 Removal and Disassembly ................................... J5.4 Inspection ............................................................. J5.8 Assembly and Installation ..................................... J5.8

J5.1

SWIVEL BEARINGS

TABLE OF CONTENTS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT TOOLS REQUIRED: • Safety glasses • Basic sockets and wrenches • Torque wrench • Loctite number 271 • Feeler gauges • Petroleum jelly • Sledge hammer • Heat resistant gloves • Non-residue type solvent • Straps or chains • Anti-seize • Lifting device, such as a 3,000 lb. Auto-Crane that is in perfect condition SAFETY

J5.2

Accidents are caused by failure to follow simple, fundamental safety rules and precautions. Refer to the AEM Safety Manual for safety instructions. Most accidents can be avoided by paying attention, using common sense, and following the instructions. WARNING: Improper maintenance can be hazardous. Study the Operator’s Manual and Service Manual before starting, operating, maintaining, fueling, or servicing the compactor. No unauthorized person should be allowed to operate, service, or maintain this compactor. Read and understand all unit mounted safety labels before starting, maintaining, fueling, or servicing this unit.

Figure 1-1.

TOOLS REQUIRED AND SAFETY August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT WARNING: Unexpected machine motion or moving parts can cut or crush. WARNING: Oil under pressure can cause serious cuts or injury. Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before performing maintenance. When handling oil, grease, or other chemical substances, observe the product related safety regulations.

J5.3

Substances such as oil, grease or fuel could be hazardous to health if used incorrectly. Avoid ingestion, skin contact, and breathing fumes. Keep hands and fingers from between small parts. Wear protective gear such as safety glasses, heavy gloves, and safety shoes. Do not perform any work on the equipment that is unauthorized. Avoid whenever possible servicing, cleaning, or examining the compactor with the engine running.

Figure 1-1.

TOOLS REQUIRED AND SAFETY August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT Before starting any work, check the de-energized parts for the presence of power. Ground or short circuit them in addition to insulating adjacent live parts and elements. NOTE Clean the machine, especially connections, of any traces of oil, fuel, or preservatives before carrying out maintenance or repair. Never use aggressive detergents. Use lint free cleaning rags. WARNING: When draining fluids, ensure that adequate sealable containers are available and that every care is taken to prevent spillage. Always ensure waste fluids are disposed of in an environmentally safe manner.

J5.4

REMOVAL AND DISASSEMBLY 1. Park the machine on a level surface with ample clearance for working. WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance. 2. Tag and disconnect the hydraulic lines and hoses that run between the two frames halves that will interfere with the separation of the two halves. Cap or plug all the lines and openings.

Figure 1-2.

WORKLIGHTS AND RAILINGS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT 3. Tag and disconnect the electrical wires that run between the two frames halves that will interfere with the separation of the two halves. 4. Remove the ROPS/FOPS from the machine, refer to the ROPS/FOPS Installation and Removal information for this model. 5. Ensure the work lights are disconnected. Remove the cable tie (3) and disconnect the electrical connections (1) at the front worklights (2), refer to Figure 1-2. 6. Support the front railing (4) with an adequate lifting device.

J5.5

7. Remove the locknuts (5), flatwashers (6), and capscrews (7) from the front railing (4). 8. Remove the front railing (4) from the deck plate (8). 9. Remove the operators console from the machine, refer to the Operator’s Console Installation and Removal information for this model. 10. Remove the deck plate halves from the machine, refer to the Deck Plate Halves Installation and Removal information for this model.

Figure 1-2.

WORKLIGHTS AND RAILINGS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance. 11. Disconnect the hydraulic hoses from the steering cylinder (8), refer to Figure 1-3. 12. Remove the bottom retaining ring (24) from the pivot pin (23). 13. Remove the pivot pin (23) from the rear frame. 14. Move the steering cylinder (8) away from the rear frame.

J5.6

NOTE: It is recommended that the torque on the horizontal swivel pin be broken before the vertical swivel pins are removed so that the rear frame can lend additional leverage for breaking this torque. 15. If the lockbar (9) is installed between the front frame and rear frame, remove the connecting pin and disconnect it from the front frame half, refer to Figure 1-3. 16. Remove the nut (18) and flatwasher (17) from the horizontal swivel pin (5). 17. Break the torque on the back plate capscrews (15), do not remove. Figure 1-3.

SWIVEL BEARINGS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT 18. Remove the stop nuts (21) and flatwashers (20) that are on two vertical pins (19) at the hinge joint. 19. Remove the vertical pins (19) and thrust bearing (6) from the hinge joint. 20. Roll the rear frame assembly (2) away from the front frame (1). 21. Remove and discard the dust seals (4 and 7), from the rear frame (2). 22. Remove horizontal swivel pin (5) and spacer (22) from the frame swivel (3).

J5.7

23. Remove the capscrews (15) and flatwashers (14) from the back plate (16). 24. Remove the backplate (16) and thrust bearing (11). Ensure that any shims (12 and 13) are placed behind backplate (16) and are marked correctly for reinstallation. 25. Remove and discard the dust seals (10) from the front frame (1). 26. Remove the swivel assembly (3) from the front frame (1).

Figure 1-3.

SWIVEL BEARINGS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT INSPECTION 1. Inspect all components for damage or signs of excessive wear. 2. Inspect all weld joints for cracks or signs of fatigue. 3. Inspect and clean the grease fittings on the swivel and related components. 4. Inspect the swivel pins for unusual wear patterns. This usually indicates improper, or lack of, lubrication. 5. Inspect all bolts for missing or damaged threads. ASSEMBLY AND INSTALLATION

J5.8

1. Place the horizontal swivel pin (5) and spacer (22) through the swivel assembly (3), refer to Figure 1-3. NOTE: Take care not to pinch the dust seals during installation. 2. Remove the protective paper from the back of the dust seals (4 and 7) and install them on top and bottom of both hinge arms of the rear frame (2). 3. Install the thrust bearings (6) into the rear frame (2). 4. Move the front frame half (1) and rear frame half (2) together and align the holes of the swivel with the holes on the rear frame hinge. 5. Install the vertical swivel pins (19) into the frame swivel (3). Install bottom pin first, then install top pin.

Figure 1-3.

SWIVEL BEARINGS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT 6. Install the stop nuts (21) and flatwashers (20) on the vertical swivel pins. When tightening down the nuts ensure that an even spacing is maintained in the gaps where dust seals (4 and 7) are located. This will ensure that rubbing will not occur between the two halves of the swivel hinge. 7. Torque the vertical pin stop nuts (21) 406 to 475 N·m (300 to 350 lb-ft). 8. Remove the protective paper from the back of the dust seals (10) and install them on both sides of front frame around the horizontal swivel pin hole. 9. Install the horizontal pin (5) through the thrust bearings (11) and front frame (1).

J5.9

10. Install the backplate (16) over horizontal pin (5). Align the holes for backplate with capscrews (15) and washers (14). Snug them down, but do not torque the cap screws. 11. Install the nut (18) and flatwasher (17) onto the horizontal pin (5). 12. Torque the nut (18) to 488 N•m (360 lb-ft). 13. Measure the gaps between swivel (3) and backplate (16) along the two sides that the bolts are installed. Select shim set or sets (12 and 13) that will fill this gap. 14. Break the torque on horizontal pin nut (18) and remove backplate capscrews (15). Figure 1-3.

SWIVEL BEARINGS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT 15. Install shims (12 and 13) and backplate capscrews (15) and flatwashers (14), refer to Figure 1-1. 16. Torque the backplate capscrews (15) to 298 N•m (220 lbft). 17. Retighten and torque the horizontal pin nut (18) to 1356 N•m (1000 lb-ft). 18. Ensure that all wiring and fluid lines are properly routed. 19. Install the hydraulic lines on the steering cylinder (8). 20. Attach the steering cylinder (8) to the rear frame. 21. Install the pivot pin (23) into the steering cylinder (8). 22. Install the retaining ring (24) to the pivot pin (23).

J5.10

23. Grease the steer cylinder pin bearing and the articulation and oscillating bearings. Refer to the Operation and Maintenance Manual for these models for maintenance instructions.

Figure 1-3.

SWIVEL BEARINGS August 2002

DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT 24. Install the right and left deck plates, refer to the Deck Plate Halves Installation and Removal information for this model. 25. Install the operator’s console, refer to the Operator’s Console Installation and Removal information for this model. 26. Support the front railing (4) with an adequate lifting device, refer to Figure 1-4. 27. Install the front railing (4) to the deck plate (8). 28. Install the locknuts (5), flatwashers (6), and cap screws (7) from the front railing (4). 29. Torque the capscrews (7) to 122 N•m (90 lb-ft).

J5.11

30. Connect the front worklights (2) electrical connections (1) and install the cable tie (3). 31. Install the ROPS/FOPS, refer to the ROPS/FOPS Installation and Removal information for this model. 32. Reconnect all the electrical connections and hydraulic lines. 33. Reconnect lockbar to the front frame halve.

Figure 1-4.

WORKLIGHTS AND RAILINGS August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE TABLE OF CONTENTS .................................................. J6.1 DRUM AND DRUM DRIVE .............................................. J6.2 Tools Required ..................................................... J6.2 Safety ................................................................... J6.2 Removal and Disassembly ................................... J6.4 Drum Drive Motor Removal and Disassembly ...... J6.7 Eccentric Removal and Disassembly ................... J6.8 Cleaning and Inspection ..................................... J6.12 Eccentric Assembly and Installation ................... J6.12 Drum Drive Motor Assembly and Installation ...... J6.17 Installation .......................................................... J6.18

J6.1

DRUM

TABLE OF CONTENTS August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE TOOLS REQUIRED: • Safety glasses • Torque wrench • Blue Loctite • Sledge hammer • Non-residue type solvent • Straps or chains • Anti-seize • Lifting device, such as a perfect condition

• Basic sockets and wrenches • Loctite number 271 • Feeler gauges • Heat resistant gloves • Acetylene torch • Loctite primer-T • Petroleum jelly 3,000 lb. Auto-Crane that is in

SAFETY

J6.2

Accidents are caused by failure to follow simple, fundamental safety rules and precautions. Refer to the AEM Safety Manual for safety instructions. Most accidents can be avoided by paying attention, using common sense, and following the instructions. WARNING: Improper maintenance can be hazardous. Study the Operator’s Manual and Service Manual before starting, operating, maintaining, fueling, or servicing the compactor. No unauthorized person should be allowed to operate, service, or maintain this compactor. Read and understand all unit mounted safety labels before starting, maintaining, fueling, or servicing this unit.

Figure 1-1.

TOOLS REQUIRED AND SAFETY August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE WARNING: Unexpected machine motion or moving parts can cut or crush. WARNING: Oil under pressure can cause serious cuts or injury. Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before performing maintenance. When handling oil, grease, or other chemical substances, observe the product related safety regulations.

J6.3

Substances such as oil, grease or fuel could be hazardous to health if used incorrectly. Avoid ingestion, skin contact, and breathing fumes. Keep hands and fingers from between small parts. Wear protective gear such as safety glasses, heavy gloves, and safety shoes. Do not perform any work on the equipment that is unauthorized. Avoid whenever possible servicing, cleaning, or examining the compactor with the engine running. Before starting any work, check the de-energized parts for the presence of power. Ground or short circuit them in addition to insulating adjacent live parts and elements.

Figure 1-1.

TOOLS REQUIRED AND SAFETY August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE NOTE Clean the machine, especially connections, of any traces of oil, fuel, or preservatives before carrying out maintenance or repair. Never use aggressive detergents. Use lint free cleaning rags. NOTE Take extra care when working around or on the hydraulic system to ensure its complete cleanliness. WARNING: When draining fluids, ensure that adequate sealable containers are available and that every care is taken to prevent spillage. Always ensure waste fluids are disposed of in an environmentally safe manner.

J6.4

REMOVAL AND DISASSEMBLY 1. Park the machine on a level surface with ample clearance for working. This should include space to allow for rolling the drum assemblies out from the frame of the compactor. 2. Install the articulation lock pin and chock the drum not being worked on to prevent movement when removing the other drum assembly. 3. Block up both outer ends of the frame to provide frame support and prevent movement. Leave room between the blocks to permit the drum to be rolled out of the frame. 4. Position a jack at the center articulation joint to raise the frame, refer to Figure 1-2.

Figure 1-2.

JACK PLACEMENT August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE 5. To allow for easier removal of the drum mounting hardware, measure from the inner drum shell to the top and bottom of the frame rail; positions A and B. Adjust the jack up or down until the measurements are roughly equal. This will relieve any load on the shock mounts, refer to Figure 1-2.

NOTE: Shims shown are for model DD110. Shims for model DD-90 have different shape.

6. Repeat the previous procedure on the other side of the drum. 7. Detach electrical lines from water tank and secure away from drum to avoid damage.

J6.5

WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 8. Attach an adequate lifting/supporting device to the water tank (1) and the tank support (2), refer to Figure 1-3. 9. Remove the capscrews (3), flatwashers (15), and shims (16) securing the water tank to the drum frame (4). 10. Tag and wire the shims together so that they can be reinstalled at the same locations. Use the lifting device to remove the water tank. 11. Place the water tank (1) on blocks in a safe location. NOTICE: Placing the water tank (1) directly on the floor can cause damage to the scraper bar.

Figure 1-3.

DRUM, DRUM FRAME, AND WATER TANK August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE The scraper bar is not designed to support the weight of the water tank (1) and can be bent or damaged if the water tank (1) is not placed on blocks. When removing the water tank (1), support the water tank (1) with blocks under the water tank structure.

NOTE: Shims shown are for model DD110. Shims for model DD-90 have different shape.

WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance.

J6.6

12. Tag and disconnect the hydraulic lines to the vibration motor (5) (right side of the drum). Cap or plug all the lines and openings, refer to Figure 1-3. NOTE: Steps 13, 14 and 15 are normally performed after the drum (12) is removed from the frame (4). 13. Remove the capscrews (6) and flatwashers (7) securing the vibration motor (5). 14. Remove the vibration motor (5) and O-ring (8) from the drum (12). WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance.

Figure 1-3.

DRUM, DRUM FRAME, AND WATER TANK August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE 15. Tag and disconnect the hydraulic lines and the electrical line to the drum drive motor (9), refer to Figure 1-3. Cap or plug all lines and openings. 16. Remove the capscrews (10), nuts (11), and flatwashers (13) securing the drum (12) to drum frame (4), refer to Figure 1-3. 17. Tag and wire the shims (14) together for installation in the same locations and same side of machine during installation. 18. Carefully roll the drum assembly out from the frame and block in position for further maintenance. DRUM DRIVE MOTOR REMOVAL AND DISASSEMBLY

J6.7

1. Use an adequate lifting/supporting device to support drive motor (1) and drive plate (3). 2. Remove the capcrews (51), flatwashers (52 and 55), and nuts (56) from the drum drive plate (54), refer to Figure 15. 3. Remove the drive motor (1), drive plate (3), and flange (2 and 21) from the drum, refer to Figure 1-4 4. Remove the capscrews (8) and flatwashers (9) from the spacer (4), drive plate (3), speed ring (16), and drive motor (1). 5. On the front drive assembly, remove the locknut (20) and flatwasher (21) securing the sensor bracket to the right hand mounting flange.

Item 22 on model DD-110 only Item 23 not on model DD-90 Front Figure 1-4.

DRUM DRIVE August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE 6. Remove the capscrews (5), flatwashers (6), and nuts (7) from the mounting flange (2 and 21) and drive motor (1), refer to Figure 1-4. 7. Separate the drum drive motor (1) from the drive plate (3), speed ring (16), and flange (2 and 21). 8. If maintenance of the drum drive motor (1) is required, refer to the Drum Drive Motor service information for this model. ECCENTRIC REMOVAL AND DISASSEMBLY 1. Refer to the Drum Drive Motor Removal and Disassembly in this section and remove the drum drive motor assembly.

J6.8

2. Support the carrier plate (1) and remove the nuts (2), lockwashers (3), capscrews (4), and lockwashers (5) from the carrier plate (1), refer to Figure 1-5. 3. Remove the carrier plate (1) from the shocks (6). 4. Remove the nuts (9), lockwashers (10), capscrews (7), and lockwashers (8) from the shocks (6). 5. Remove the shocks (6) from carrier mounting plate (15). 6. Remove the fill plug (11), drain plug (61), and relief valve (12) from the carrier mounting plate (15). 7. Remove the capscrews (13) and washers (14) securing the carrier mounting plate (15) to carrier and spindle assembly (18).

Figure 1-5.

DRUM August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE 8. Remove the carrier mounting plate (15) and gasket (16) from the drum shell (30). 9. Remove the nuts (17) from the carrier and spindle assembly (18) and studs (19). 10. Remove the carrier and spindle assembly (18) from drum shell (30), refer to Figure 1-5. 11. Do not remove the studs (19) from the drum unless damaged. When replacing damaged studs, clean stud and hole of rust and dirt. Apply Loctite primer-T and Loctite #271. Insert and tighten stud within five minutes. Tightened stud must protrude 63.5 mm (2.5 inches) from face of drum mounting flange.

J6.9

12. Remove the splined coupling (24) and splined shaft (23) from the eccentric shaft (28). NOTE: Do not remove the pin (25) from splined coupling unless necessary. 13. Remove the nuts (58), lockwashers (59), cap screws (50), and lockwashers (49) from the shock mounts (53). 14. Remove the shock mounts (53) from the drum shell (30). 15. Remove the screws (48) and bushing (47) from the handwheel (46). 16. Remove the handwheel (46) and woodruff key (57) from the drum shell (30).

Figure 1-5.

DRUM August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE 17. Remove the capscrews (45) securing the indicator (44) to eccentric shaft assembly. 18. Remove the indicator (44). 19. Remove and discard the oil seal (43) from the indicator (44), refer to Figure 1-5. 20. Remove the bolts (42) from the bearing cover (40) 21. Remove the bearing cover (40) from the drum shell (30). 22. Remove and discard the oil seal (41) and O-ring (39) from the bearing cover (40). 23. Remove the retaining ring (38) from the eccentric shaft assembly (28).

J6.10

24. Remove the capscrews (36), flatwashers (35), and nuts (34) from the bearing housing (32). 25. Remove the bearing housing (32) from the drum shell (30). 26. Do not remove studs (33) from the drum (30) unless damaged. When replacing damaged studs, clean stud and hole of rust and dirt. Apply Loctite primer-T and Loctite #271. Insert and tighten stud within five minutes. Tightened stud must protrude 31.8 mm (1.25 in.) from face of drum mounting flange. 27. Remove and discard the spherical bearing (37) and Oring (60) from bearing housing (32). Figure 1-5.

DRUM August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE 28. Remove the eccentric drive shaft assembly (28) out of the bearing cover (21) through the drive end of the drum (30), refer to Figure 1-5. 29. If maintenance of the eccentric drive shaft assembly is required, refer to the Eccentric Assembly service information for this model. 30. Remove the capscrews (22) from the bearing cover (21). 31. Remove the bearing cover (21) from the carrier and spindle assembly (18). WARNING: Safety glasses must be worn when removing the retaining rings.

J6.11

32. Remove and discard the O-rings (20 and 26), retaining ring (27), and spherical bearing (31). 33. If maintenance of the carrier and spindle assembly is required, refer to the Carrier and Spindle Assembly service information for this model.

Figure 1-5.

DRUM August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE CLEANING AND INSPECTION 1. Clean all metal parts in a nonresidue type solvent. 2. Check all mounting hardware for damage or wear. Replace as necessary. 3. Inspect all threaded holes. 4. Check the carrier plate for cracks, wear, or other damage. Replace as necessary. 5. Check the bearings for wear, spalling, or other damage. 6. Check shocks for cracks, wear or other damage. Replace as necessary. 7. Clean the inside of the drum.

J6.12

ECCENTRIC ASSEMBLY AND INSTALLATION 1. Locate fill plug (29) on the vibration end of the drum (30). On the opposite end of the drum (30) (drive end), place a mark in line with the fill plug (29), refer to Figure 1-5. a. Under ideal shop conditions, use an adequate lifting/ supporting device, and position the drum assembly (30) on end with the drum drive motor end up. b. Under real-life field conditions, the drum (30) is left on it’s side and maintenance is performed from either side after drum is rolled out from frame. 2. Apply petroleum jelly to the new O-ring (60). Figure 1-5.

DRUM August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE 3. Install the new O-ring (60) onto the bearing housing (32)., refer to Figure 1-5. 4. Locate the end of the drum (30) that contains three studs (33). Position the bearing housing (32) in this end of the drum. Align stud holes in the bearing housing with the three studs (33). 5. Install the six capscrews (36) and washers (35) into the bearing housing (32). 6. Apply Loctite #271 to the capscrews (36). 7. Torque the capscrews (36) to 244 N•m (180 ft-lbs). 8. Install the nuts (34) onto the studs (33).

J6.13

9. Torque the nuts (34) to 136 N•m (100 ft-lbs). 10. Position eccentric assembly (28) inside the drum (30), splined end out, so that opposite end shaft passes through eccentric bearing housing at drive motor end. 11. Apply petroleum jelly to the new O-ring (26). 12. Install the new O-ring (26) onto the bearing cover (21), refer to Figure 1-5. WARNING: Safety glasses must be worn when installing the retaining rings. 13. Install the new spherical bearing (31) into the bearing housing (32) and secure in place with the new retaining ring (27).

Figure 1-5.

DRUM August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE 14. Install the bearing cover (21) onto the drum (30) by guiding the eccentric shaft through the spherical bearing (31), refer to Figure 1-5. 15. Align the bearing cover (21) so that studs (19) pass through the non-chamfered holes. 16. Install the capscrews (22) into the bearing cover (21). 17. Torque the capscrews (22) to 108 N•m (80 ft-lbs). 18. Install the new bearing (37) onto the eccentric shaft assembly (28) and into the bearing housing (32). 19. Install the new retaining ring (38) into the bearing housing (32).

J6.14

20. Apply petroleum jelly to the new O-ring (39). 21. Install the new O-ring (39) and new oil seal (41) onto the bearing cover (40). 22. Install the bearing cover (40) onto the bearing housing (32). 23. Apply Loctite #271 to the bolts (42). 24. Install the bolts (42) into the bearing cover (40). 25. Torque the bolts (42). 26. Install new oil seal (43) into the indicator (44). 27. Install the indicator (44) onto the eccentric shaft assembly (28), refer to Figure 1-5. 28. Install the capscrews (45) into the indicator (44).

Figure 1-5.

DRUM August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE NOTE: The indicator must point toward the fill plug mark, previously made in step 1. 29. Install the woodruff key (57) onto the eccentric shaft, refer to Figure 1-5. 30. Install the handwheel (46) onto the eccentric shaft. 31. Install the bushing (47) onto the eccentric shaft. 32. Install the screws (48) into the bushing (47). 33. Apply Loctite #271 to the cap screws (50). 34. Install the shock mounts (53) onto drum (30).

J6.15

35. Install the capscrews (50), flatwashers (49 and 59), and nuts (58) into the shocks (57). 36. Torque the capscrews (50) to 122 N•m (90 ft-lbs). 37. Apply anti-seize compound to the spline coupling teeth on the end of splined shaft (23) that engages eccentric shaft assembly (28). 38. Apply petroleum jelly to the new O-ring (20). 39. Install the new O-ring (20) onto the bearing cover (21), refer to Figure 1-5. 40. Install the carrier and spindle assembly (18) onto the bearing cover (21). 41. Install the nuts (17) onto the studs (19). 42. Torque the nuts (17) to 278 N•m (205 ft-lbs).

Figure 1-5.

DRUM August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE 43. Install the gasket (16) and carrier mounting plate (15) onto the carrier and spindle assembly (18). 44. Install the capscrews (13) and washers (14) into the carrier mounting plate (15). 45. Install the fill and drain plugs (11 and 61) and relief valve (12) into the carrier mounting plate (15). 46. Apply Loctite #271 to the cap screws (7). 47. Install the shocks (6) onto carrier mounting plate (15). 48. Install the capscrews (7), lockwashers (8 and 10), and nuts (9) into the shocks (6). 49. Torque the capscrews (7) to 122 N•m (90 ft-lbs).

J6.16

50. Apply Loctite #271 to capscrews (4). 51. Install the carrier plate (1) over the shocks (6). 52. Install the capscrews (4), lockwashers (5 and 3), and nuts (2) into the carrier plate (1). 53. Torque the capscrews (4) to 122 N•m (90 ft-lbs). 54. Check the eccentric and carrier housing oil. Refer to the Operation and Maintenance Manual for these models for maintenance instructions.

Figure 1-5.

DRUM August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE DRUM DRIVE MOTOR ASSEMBLY AND INSTALLATION 1. Apply Loctite #271 to capscrews (5), refer to Figure 1-6. 2. Install the flange (2 and 21) to the drive motor (1). 3. Install the capscrews (5), flatwashers (6), and nuts (7) into the flange (2) and (21) and the drive motor (1). 4. Torque the capscrews (5) to 890 N•m (510 ft-lbs). 5. Position the speed ring (16) on the drive plate (3). 6. Using an adequate lifting/supporting device, position the drive motor (1) onto the drive plate (13) and speed ring (16). 7. Install the spacer (4) to the drive plate (3).

J6.17

8. Apply loctite #271 to the capscrews (8). 9. Install the capscrews (8) and flatwashers (9) into spacer (4), drive plate (13), speed ring (16), and drive motor (1). 10. Torque the capscrews (8) to 730 N•m (540 ft-lbs). 11. Using an adequate lifting/supporting device, position the drive plate (3) and the drive motor (1) into the drum. 12. Apply Loctite #271 to the capscrews (51), refer to Figure 15 13. Install the drive plate (54) onto drum shock mounts (53), refer to Figure 1-5.

Item 22 on model DD-110 only Item 23 not on model DD-90 Front

14. Install the capscrews (51), flatwashers (52 and 55), and nuts (56) into the drum drive plate (54), refer to Figure 1-5. 15. Torque the cap screws (51) to 122 N•m (90 ft-lbs).

Figure 1-6.

DRUM DRIVE August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE INSTALLATION 1. Carefully roll the drum assembly into position in the drum frame. 2. Measure the distance between the frame sides at positions A and D in Fig. 1-7. Measurement A should be no more than 1.0 in. (25,4 mm) greater than measurement D. 3. Measure the water tank length. The difference between the water tank length and A measurement is the required shim pack thickness for the water tank installation.

J6.18

4. Compare this thickness of the shim pack removed at disassembly. If the thickness of the shim pack equals the thickness required, use the shim pack as is. Add or subtract shims equally to both sides if the determined shim thickness is different than the thickness of the shim pack removed. 5. Using an adequate lifting/supporting device, position water tank (1) in place in drum frame (4), refer to Figure 1-8. 6. Shim both ends of the water tank (1) equally as required. 7. Install and tighten the mounting capscrews (3) temporarily. NOTE: Ensure that the scraper bar on bottom of the water tank (1) does not interfere with installation of water tank (1). The scraper bar should be down and against drum (12) when water tank (1) is installed. Figure 1-7.

CLEARANCE MEASUREMENTS August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE 8. Align the drum (12) to the frame mounting holes by rocking the drum forward and backward until the mounting bolts can be inserted temporarily on each side. Install mounting capscrews (10), flatwashers (13), and nuts (11), refer to Figure 1-8. 9. Take clearance measurements B and C on both ends of the drum. Measure between the edge of the drum shell and the drum frame. Shift the drum until these measurements are equal, refer to Figure 1-7.

NOTE: Shims shown are for model DD110. Shims for model DD-90 have different shape.

10. Measure to determine the shim thickness on each end at the drum mounting location E in Fig. 1-7.

J6.19

11. Compare this to the thickness of the shim packs removed at disassembly. Add or subtract shims equally to both sides as necessary to meet the required thickness. 12. Install required shims (14) at each end of the drum and tighten bolts (10). The shims at each end of the tank are different; install the same configuration of shims as removed at disassembly. It may be necessary to loosen water tank cap screws (3) to slip the shims into place. 13. Apply Loctite #271 to the capscrews (3). 14. Torque the bolts (10) to 895 N•m (660 ft-lbs). 15. Install the vibration motor (5), ensuring that splined shaft of the motor engages with splined coupling (24), inside carrier and spindle assembly, refer to Figure 1-8. Figure 1-8.

DRUM, DRUM FRAME, AND WATER TANK August 2002

DD-110/110HF & DD-90/90HF / DRUM AND DRUM DRIVE 16. Install the hydraulic hoses on the motors as tagged during removal. 17. Install the electrical line on motor as tagged during removal. 18. Secure all lines and hoses in place with ty-wraps.

NOTE: Shims shown are for model DD110. Shims for model DD-90 have different shape.

19. Check the system hydraulic oil. Refer to the Operations and Maintenance Manual for these models for maintenance instructions. 20. Operate the compactor and check for proper operation, and ensure there are no oil leaks.

J6.20

Figure 1-8.

DRUM, DRUM FRAME, AND WATER TANK August 2002

DD-110/110HF & DD-90/90HF / ECCENTRIC SHAFT ASSEMBLY TABLE OF CONTENTS ................................................... J7.1 ECCENTRIC SHAFT ASSEMBLY ................................... J7.2 Tools Required ..................................................... J7.2 Safety ................................................................... J7.2 Disassembly ......................................................... J7.2 Cleaning and Inspection ....................................... J7.4 Assembly .............................................................. J7.4 ECCENTRIC ASSEMBLY

J7.1

TABLE OF CONTENTS August 2002

DD-110/110HF & DD-90/90HF / ECCENTRIC SHAFT ASSEMBLY TOOLS REQUIRED: • Saftey glasses • Basic sockets and wrenches • Torque wrench • Loctite number 271 • Non-residue type solvent • Grease • Hammer • Punch • Lifting device, such as a 3,000 lb. Auto-Crane that is in perfect condition

NOTE: Illustration shown is for models DD90/110. Parts for models DD-90HF/110HF are similar. Written procedures apply to both the DD-90/110 and DD-90HF/110HF.

SAFETY

J7.2

Accidents are caused by failure to follow simple, fundamental safety rules and precautions. Refer to the AEM Safety Manual for safety instructions. Most accidents can be avoided by paying attention, using common sense, and following the instructions. DISASSEMBLY 1. Remove and discard the shear pin (14) from the splined coupling (16), refer to Figure 1-1. 2. Remove the splined coupling (16) from the eccentric journal (3). 3. Remove the capscrews (12), locknuts (7), and washers (17) from the hub eccentric (9). 4. Pull the eccentric tube (1) from the hub eccentric (9). 5. Remove the capscrews (12), locknuts (7), and washers (17) from the eccentric journal (3).

Item 17 applies to models DD-90/110 Only Figure 1-1.

ECCENTRIC SHAFT ASSEMBLY August 2002

DD-110/110HF & DD-90/90HF / ECCENTRIC SHAFT ASSEMBLY 6. Remove eccentric journal (3) from the eccentric tube (1), refer to Figure 1-1. WARNING: Safety glasses must be worn when removing the retaining rings.

NOTE: Illustration shown is for models DD90/110. Parts for models DD-90HF/110HF are similar. Written procedures apply to both the DD-90/110 and DD-90HF/110HF.

7. Remove and discard the retaining ring (6) and bearing (5) from the eccentric journal (3). 8. Remove and discard the retaining ring (6) and bearing (5) from the hub eccentric (9). 9. Remove the splined coupling (10) and woodruff key (11) from the hub eccentric (9).

J7.3

10. Remove and discard the wear sleeve (18) from the hub eccentric (9). 11. Remove the shear-proof pin (13) from the eccentric shaft (2). 12. Remove the handwheel shaft (8) from the eccentric shaft (2). 13. Remove the compression spring (15) from the handwheel shaft (8).

Item 17 applies to models DD-90/110 Only Figure 1-1.

ECCENTRIC SHAFT ASSEMBLY August 2002

DD-110/110HF & DD-90/90HF / ECCENTRIC SHAFT ASSEMBLY CLEANING AND INSPECTION 1. Clean all parts in a non-residue type solvent. 2. Check all mounting hardware for damage and wear. Replace as necessary.

NOTE: Illustration shown is for models DD90/110. Parts for models DD-90HF/110HF are similar. Written procedures apply to both the DD-90/110 and DD-90HF/110HF.

3. Inspect all threaded holes for debris or foreign material. ASSEMBLY 1. Install the eccentric shaft (2) in the eccentric tube (1), disengagement shaft end first with both eccentric weights down, refer to Figure 1-1. 2. Polish the hub journal end of tube. 3. Polish the carrier journal end of tube.

J7.4

4. Install the compression spring (15) on non-key end of handwheel shaft (8). 5. Install the handwheel shaft (8) into eccentric shaft (2) so that the disengagement shaft keyway is opposite eccentric weights. 6. Install the first of the new sheer-proof pins (13) approximately one-half to two-thirds of the way. 7. Rotate the eccentric shaft (2) and insert the second of the new sheer-proof pins completely. Insert first drive pin the rest of the way. Finish pin installation with hammer and punch. Do not mar journal.

Item 17 applies to models DD-90/110 Only Figure 1-1.

ECCENTRIC SHAFT ASSEMBLY August 2002

DD-110/110HF & DD-90/90HF / ECCENTRIC SHAFT ASSEMBLY WARNING: Safety glasses must be worn when installing the retaining rings. 8. Install the new bearing (5) into the eccentric journal (3) and secure with the new retaining ring (6). The eccentric journal (3) is the one without an internal keyway, refer to Figure 1-1.

NOTE: Illustration shown is for models DD90/110. Parts for models DD-90HF/110HF are similar. Written procedures apply to both the DD-90/110 and DD-90HF/110HF.

9. Apply grease to the bearing (5). 10. Install the eccentric journal (3) onto the eccentric tube (1) and align bolt holes. 11. Apply Loctite #271 to two of the capscrews (12) and locknuts (7).

J7.5

12. Install the two capscrews (12), locknuts (7), and washers (17) in the 3 and 9 o’clock position on the eccentric journal (3). 13. Torque the capscrews (12) to 80 N·m (59 lb-ft) on models DD-90/110, or 67 N·m (50 lb-ft) on models DD-90/110HF. 14. Apply Loctite #294 to the wear sleeve (18) and install on the hub eccentric (9). Do not install the wear sleeve past the chamfer on the eccentric. 15. Install the splined coupling (10) with woodruff key (11) into hub eccentric (9).

Item 17 applies to models DD-90/110 Only Figure 1-1.

ECCENTRIC SHAFT ASSEMBLY August 2002

DD-110/110HF & DD-90/90HF / ECCENTRIC SHAFT ASSEMBLY 16. Install the new bearing (5) and new retaining ring (6) into the hub eccentric (9), refer to Figure 1-1. 17. Install the hub eccentric (9) onto eccentric tube (1). 18. Apply Loctite #271 to the capscrews (12) and locknuts (7).

NOTE: Illustration shown is for models DD90/110. Parts for models DD-90HF/110HF are similar. Written procedures apply to both the DD-90/110 and DD-90HF/110HF.

19. Install the capscrews (12), locknuts (7), and washers (17) into the hub eccentric (9).

J7.6

20. Install the handwheel, without bushings or screws, onto handwheel shaft (8). Check the disengaging and amplitude change system. System should disengage with fingertip pressure, rotate freely, and engage itself with slight turning of the handwheel when released. If it does not, check and correct disengagement shaft alignment into the eccentric shaft (2). Alignment can be corrected by tapping the shaft to center. 21. Torque the capscrews (12) to 80 N·m (59 lb-ft) on models DD-90/110, or 67 N·m (50 lb-ft) on models DD-90/110HF. 22. Remove handwheel from the handwheel shaft (8). 23. Refer to the Drum And Drum Drive information for these models, for handwheel assembly and installation procedures. Item 17 applies to models DD-90/110 Only Figure 1-1.

ECCENTRIC SHAFT ASSEMBLY August 2002

DD-110/110HF/90/90HF / CARRIER AND SPINDLE ASSEMBLY TABLE OF CONTENTS ................................................... J8.1 CARRIER AND SPINDLE ................................................ J8.2 Tools Required ..................................................... J8.2 Safety ................................................................... J8.2 Disassembly ......................................................... J8.2 Cleaning and Inspection ....................................... J8.3 Assembly .............................................................. J8.3 CARRIER AND SPINDLE ASSEMBLY

J8.1

TABLE OF CONTENTS August 2002

DD-110/110HF/90/90HF / CARRIER AND SPINDLE ASSEMBLY TOOLS REQUIRED: • Safety glasses • Basic sockets and wrenches • Torque wrench • Loctite number 271 • Blue Loctite • Feeler gauges • Sledge hammer • Heat resistant gloves • Non-residue type solvent • Straps or chains • Lifting device, such as a 3,000 lb. Auto-Crane that is in perfect condition SAFETY

J8.2

Accidents are caused by failure to follow simple, fundamental safety rules and precautions. Refer to the AEM Safety Manual for safety instructions. Most accidents can be avoided by paying attention, using common sense, and following the instructions. DISASSEMBLY 1. Place the carrier assembly on a work bench with the wide flange down, refer to Figure 1-1. 2. Remove the capscrews (11) and locking plates (12) securing the retaining ring (3). 3. Remove the locking plates (12) from the bearing retaining ring (3). 4. Remove the bearing retaining ring (3) from the spindle (1). 5. Remove the shims (4, 5, and 6) from the spindle (1).

Figure 1-1.

CARRIER AND SPINDLE August 2002

DD-110/110HF/90/90HF / CARRIER AND SPINDLE ASSEMBLY 6. Remove and discard the inboard bearing cone (8) from the spindle (1). 7. Turn the carrier housing (2) over and lift the spindle (1) from the carrier housing (2). 8. Remove and discard the dust band (13). 9. Remove and discard the outboard bearing cone (8) from the spindle (1). 10. Remove and discard the oil seals (10) from the carrier housing (2). 11. Remove and discard the bearing cups (7) from both ends of the carrier housing (2).

J8.3

12. Remove and discard the wear sleeves (9) from the spindle (1). CLEANING AND INSPECTION 1. Clean all parts in a non-residue type solvent. 2. Check all mounting hardware for damage and wear. Replace as necessary. 3. Inspect all threaded holes for debris or foreign material. ASSEMBLY NOTE: Bearing cups are to be cooled to 0°F (-18°C) for 2 to 4 hours before installation. Figure 1-1.

CARRIER AND SPINDLE August 2002

DD-110/110HF/90/90HF / CARRIER AND SPINDLE ASSEMBLY 1. Lower the temperature of the new bearing cups (7), refer to Figure 1-1. 2. Using a machine press, install the new cool bearing cups (7) into either end of the carrier housing (2). 3. Place the spindle (1) on a work bench with the wide flange down. 4. Apply blue Loctite to outer edges of the new oil seals (10). NOTE: The inner oil seal should be positioned to hold the oil in, the outer seal should be positioned to keep the dirt out. 5. Install the new oil seals (10) into the carrier housing (2).

J8.4

6. Heat the new wear sleeves (9) to 225°F (107°C) for 15 to 30 minutes. WARNING: Wear protective heat resistant gloves when handling heated parts. Contact with hot wear sleeves will cause severe burns. 7. Install the new wear sleeves (9) onto the spindle (1). Carefully tap into place. Allow the wear sleeves (9) to cool, refer to Figure 1-1. 8. Heat the new outboard bearing cone (8) to 225°F (107°C) for 15 to 30 minutes. WARNING: Wear protective heat resistant gloves when handling heated parts. Contact with hot bearings will cause severe burns.

Figure 1-1.

CARRIER AND SPINDLE August 2002

DD-110/110HF/90/90HF / CARRIER AND SPINDLE ASSEMBLY 9. Install the new outboard bearing cone (8) onto spindle (1). Allow the outboard bearing cone (8) to cool. 10. Install the carrier housing (2) onto the spindle (1). 11. Heat the new inboard bearing cone (8) to 225°F (107°C) for 15 to 30 minutes. 12. Install the new inboard bearing cone (8) onto the spindle (1). Hold the inboard bearing cone (8) into place until cool. 13. Install the retaining ring (3) to the spindle (1). NOTE: The beveled edge of the retaining ring (3) should be facing up.

J8.5

14. Install the capscrews (11) into the retaining ring (3). 15. Torque the capscrews (11) to 20 N·m (15 lb-ft). 16. Turn the carrier housing (2) by hand, 360° six times, then 180° back and forth six times. 17. Ensure that the rollers are fully seated. 18. Recheck the torque of the cap screws (11). 19. With a feeler gauge, measure the clearance between the retaining ring (3) and the spindle (1). There needs to be a clearance of 0.005 in. (0,13 mm) between the retaining ring (3) and the spindle (1), refer to Figure 1-1. 20. Remove the capscrews (11) from the bearing retaining ring (3).

Figure 1-1.

CARRIER AND SPINDLE August 2002

DD-110/110HF/90/90HF / CARRIER AND SPINDLE ASSEMBLY 21. Remove the bearing retaining ring (3) from the spindle (1). 22. Install shims (4, 5, and 6) or the appropriate amount of shims to allow the desired clearance. 23. Install the retaining ring (3) onto the spindle (1). NOTE: The beveled edge of the retaining ring (3) should be facing up. 24. Install the capscrews (11) into the retaining ring (3). 25. Torque the capscrews (11) to 47 N·m (35 lb-ft). 26. Check the rolling torque required to rotate the spindle (2). Rolling torque should be 34 to 41 N·m (25 to 30 lb-ft).

J8.6

27. Add or delete shims (4, 5, and 6) under the bearing retaining ring (3), until the correct rolling torque is obtained. 28. With the appropriate clearance obtained, remove the cap screws (11) from the bearing retainer (3). 29. Apply Loctite #271 to the capscrews (11). 30. Install the lock plates (12) and capscrews (11) into the bearing retainer (3). 31. Torque the capscrews (11) to 47 N·m (35 lb-ft). 32. Bend up the ends of the lock plates (12) to secure the capscrews (11). 33. Install the new dust band (13) onto the spindle (1). Figure 1-1.

CARRIER AND SPINDLE August 2002

K1

August 2002

K2

August 2002

Hydraulic Symbol Quick Reference Chart Operation Methods

Manual

Motors & Cylinders Fixed Displacement, Unidirectional, Rotary Hydraulic Motor

Miscellaneous Symbols Pressure Gauge

Pumps Fixed Displacement, Unidirectional Hydraulic Pump

Valves Check Valve

Manual Shut Off Valve Pedal Or Treadle

Temperature Gauge Fixed Displacement, Bidirectional, Rotary Hydraulic Motor

Fixed Displacement, Bidirectional Hydraulic Pump

Pressure Relief Valve

Push Button Cooler

Level

Variable Displacement, Bidirectional, Rotary Hydraulic Motor

Needle Valve Variable Displacement, Non-Compensating, Bidirectional Hydraulic Pump

Pressure Switch

Closed Center, Three Position Directional Control Valve

L1 Pilot Pressure

Double Acting Cylinder

Filter or Strainer

Component Enclosure Line

Tandem Center, Three Position Directional Control Valve

Solenoid

Hydraulic Lines Spring

Working Hydraulic Line

Lines Joining

Open Center, Three Position Directional Control Valve

Line to Tank (Above Fluid Level)

Pilot Line

Float Center, Three Position Directional Control Valve

Lines Passing

Servo

Line to Tank (Below Fluid Level)

Drain Line

Fixed Restriction

Plug or Plugged Connection

Two Position Multiple Flow Path Valve (Arrows show direction of flow)

August 2002

Electrical Schematic Code Reference Chart Wire Color Codes

L2

Gray/Black

GY/BK

Orange/Black

OE/BK

Black/Yellow

BK/YW

White/Violet

WE/VT

White/Gray

WE/GY

Gray/Yellow

GY/YW

Dr Blue/White

DBE/WE

Yellow/Brown

YW/BN

Black/Orange

BK/OE

Dr Green/Orange

DGN/OE

White/Orange

WE/OE

White/Blue

WE/BE

Dr Blue/Yellow

DBE/YW

Dr Blue/Black

DBE/BK

Lt Green/Black

LGN/BK

White/Green

WE/GN

Dr Green/Red

DGN/RD

Gray/Red

GY/RD

Dr Blue/Red

DBE/RD

Yellow/Red

YW/RD

Purple/Red

PE/RD

Pink/Red

PK/RD

Orange/Red

OE/RD

Brown/Red

BN/RD

White/Red

WE/RD

Black/Red

BK/RD

White/Brown

WE/BN

White/Yellow

WE/YW

Tan/White

TN/WE

Lt Green/White

LGN/WE

Lt Blue/White

LBE/WE

Gray/White

GY/WE

Dr Blue/White

DBE/WE

Yellow/White

YW/WE

Red/White

RD/WE

Purple/White

PE/WE

Pink/White

PK/WE

Orange/White

OE/WE

White/Black

WE/BK

Brown/White

BN/WE

Black/White

BK/WE

Dk Green

DGN

Lt Green

LGN

Lt Blue

LBE

Gray

GY

Dk Blue

DBE

Yellow

YW

Red

RD

Purple

PE

Pink

PK

Orange

OE

White

WE

Brown

BN

Black

BK August 2002

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

Ref. No. VOE21A1004529H CPN 43944347 Printed in USA 2007-12 Volvo, Shippensburg

CST

English