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
Vibration Motor.............................................F6
Vibration Pump............................................F7
Steering.................................................................G1
Schematics
Overview..........................................................G2
Neutral..........................................................G3
Steer to Left...................................................G4
Steer to Right................................................G5
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
Disassembly....................................................................E6.4
Inspection........................................................................E6.4
Assembly..........................................................................E6.4
DISASSEMBLY
VIB
RA
TIO
N
INSPECTION
PU
MP
CA
SE
ASSEMBLY
SU
CT
IO
N
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
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.
FRONT
DRUM
MOTOR
STEERING
VALVE
STEERING
PUMP
High pressure
VIBRATION
FILTER
- Each page is specific to

one functional
subsystem.
RETURN
FILTER
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

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
DRUM MOTOR
BRAKE
VALVE
B
C
PUSHED FOR
NORMAL
OPERATION
PRESSURE SWITCH
OVERVIEW
August 2002
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
PUSHED FOR
NORMAL
OPERATION
PRESSURE SWITCH
Return
Suction
Charge
Control
High pressure
dashed lines
indicate
low pressure
NEUTRAL-BRAKES APPLIED
August 2002

HYDRAULIC TANK
SUCTION
FILTER
DRUM MOTOR
PROPULSION PUMP
B N A
LOOP FLUSHING
VALVE
A
OIL COOLER
E4
B
DRUM MOTOR
BRAKE
VALVE
B
C
PUSHED FOR
NORMAL
OPERATION
PRESSURE SWITCH
L
L
Return
Suction
Charge
Control
High pressure
dashed lines
indicate
low pressure
FORWARD-BRAKES RELEASED
August 2002
HYDRAULIC TANK
SUCTION
FILTER
R
DRUM MOTOR
L
PROPULSION PUMP
B N A
OIL COOLER
E5
B
LOOP
FLUSHING VALVE
DRUM MOTOR
BRAKE
VALVE
B
C
PUSHED FOR
NORMAL
OPERATION
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

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

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).
(6).
9. Install the new O-rings (6) on the bearing support (1) and
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
12. Install the screws (15 and 14) into the distribution cover (11).
13. Torque the screws (15 and 14) to 350 Nm (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

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.
(11).
(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
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

ASSEMBLY
E6.5
1. Apply grease into the spring (18) housings, refer to Figure 11.
(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)
Figure 1-1
CYLINDER BLOCK AND CAM

August 2002

DISASSEMBLY
E6.6

(11).
(11).
support (1) and 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

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).
(6).
11. Install the bearing support (1), cam (5) and cylinder block
Figure 1-1
CYLINDER BLOCK
August 2002

DISASSEMBLY
E6.8

(11).
(11).
support (1) and distribution block (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

ASSEMBLY
E6.9

and back-up rings (17), refer to Figure 1-1.
2. Install the O-rings and back-up rings (17) onto the valving
(16).
(6).
10. Install the bearing support (1), cam (5) and cylinder block
11. Align the marks on the bearing support (1), cam (5), and
Figure 1-1
BEARING HOUSING
August 2002

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

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

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

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 Nm (12 lb-ft).
Figure 1-1.
LIP SEAL AND SHAFT

August 2002

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
Nm (66 lb-ft).
Figure 1-2.
MULTI FUNCTION VALVE CARTRIDGES

August 2002

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 Nm (38 lb-ft).
4. Check and adjust the charge pressure as required.
Figure 1-3.
CHARGE RELIEF VALVE

August 2002

DISASSEMBLY
1. Remove the screws (1), flange cover (2) and O-ring
(3) from the flange adapter (6). Discard the O-ring
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

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 Nm (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).
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

DISASSEMBLY
1. Remove the filter canister (21) from the filter head
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 Nm (90 lb-ft).
5. Install a new filter canister (21) per manufacturers
instructions.
Figure 1-5.
INTEGRAL CHARGE PRESSURE FILTRATION

August 2002

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
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).
7. If installing a new solenoid valve (12) into the solenoid
manifold (2), torque the solenoid valve (12) to 18.6
Nm (13.8 lb-ft).
8. Install a new gasket (3), solenoid manifold (2) and
screws (1).
9. Torque the screws (1) to 13.5 Nm (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

TRIPLE PUMP DRIVE...........................................................E8.2
Disassembly...........................................................E8.2
Inspection................................................................E8.3
Assembly.................................................................E8.3
1E8.1
TRIPLE
PUMP
DRIVE
TABLE OF CONTENTS
August 2002
E8.2
NOTICE:
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

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 Nm (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 Nm (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

SEAL KIT.................................................................................E9.2
Disassembly...........................................................E9.2
Assembly.................................................................E9.3
DD-90 EFF. S/N 160549 AND PRIOR
1E9.1
HAND
PUMP
TABLE OF CONTENTS
August 2002
E9.2
NOTICE:
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.
SEAL KIT
August 2002
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.
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
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
F2
SUCTION
FILTER
TO B PORT ON
2ND VIBRATION PUMP
VIBRATION PUMP
CASE
SUCTION
FRONT VIBRATION MOTOR

TO SECOND VIBRATION PUMP SUCTION
OVERVIEW
August 2002

L
High pressure
Return
Suction
Charge
HYDRAULIC TANK
D
dashed lines
indicate
low pressure
OIL COOLER
TO A PORT ON
2ND VIBRAITON PUMP
F3
SUCTION
FILTER
TO B PORT ON
2ND VIBRATION PUMP
VIBRATION PUMP
CASE
SUCTION

NEUTRAL-NO VIBRATION
August 2002

L
High pressure
Return
Suction
Charge
D
dashed lines
indicate
low pressure
HYDRAULIC TANK
OIL COOLER
TO A PORT ON
2ND VIBRAITON PUMP
F4
SUCTION
FILTER
TO B PORT ON
2ND VIBRATION PUMP
VIBRATION PUMP
B
B
CASE
SUCTION

CLOCKWISE ROTATION
August 2002

L
High pressure
Return
Suction
Charge
HYDRAULIC TANK
D
dashed lines
indicate
low pressure
OIL COOLER
TO A PORT ON
2ND VIBRAITON PUMP
F5
TO B PORT ON
2ND VIBRATION PUMP
SUCTION
FILTER
VIBRATION PUMP
CASE
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
F6.2
NOTICE:
warranty.
DISASSEMBLY
1. Remove the retaining ring (1) from the housing (2),
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
2. Inspect the shaft for rust, wear, or contamination.
Polish the the shaft if necessary.
Figure 1-1.
SEAL KIT
August 2002
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).
#59231.
CAUTION:
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
F7.2
NOTICE
warranty.
DISASSEMBLY
1. Remove the retaining ring (1) from the housing (2),
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
ASSEMBLY
#59231.
CAUTION:
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
F7.3
DISASSEMBLY
1. Remove the bypass valve (5) from the housing (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 Nm (7 to
10 lb-ft).
Figure 1-2.
BYPASS VALVE
August 2002
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 Nm (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
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
Nm (30 to 70 lb-ft).
Figure 1-4.
CHARGE RELIEF VALVE

August 2002

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 Nm (16 to 21 lb-ft).
F7.6
Figure 1-5.
FILTER ADAPTER
August 2002

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
F7.8
ASSEMBLY
1. Install the control orifice plugs (18) into the control
passages found on each side of the housing (19),
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 Nm (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
Nm(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 Nm(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
2500/172
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

DD-90
DD-90HF
x
x
x
x
service personnel.
August 2002
DD-110/110HF & DD-90/90HF STEERING SYSTEM

HYDRAULIC TANK
SUCTION STRAINER
RETURN
FILTER
STEERING
PUMP
G2
T
R
STEERING
CYLINDER
STEERING
VALVE
OVERVIEW
January 2000

L
HYDRAULIC TANK
Return
dashed lines
indicate
low pressure
Suction
SUCTION STRAINER
High Pressure
S
RETURN
FILTER
STEERING
PUMP
P
G3
T
R
STEERING
CYLINDER
STEERING
VALVE
NEUTRAL
January 2000

HYDRAULIC TANK
Return
SUCTION STRAINER
D
dashed lines
indicate
low pressure
Suction
High Pressure
RETURN
FILTER
STEERING
PUMP
P
G4
R
STEERING
CYLINDER
STEERING
VALVE
STEER TO LEFT
January 2000
HYDRAULIC TANK
Return
Suction
High Pressure
SUCTION STRAINER
RETURN
FILTER
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
G6.2
NOTICE:
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
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 Nm (800 to
1000 lb-ft).
SEAL KIT
March 1999

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

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:
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
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 Nm (36.9 to 40.5
lb-ft), refer to the torque pattern in Figure 1-1.
Figure 1-1.
SEAL KIT
February 1999
G7.4
NOTICE:
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
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 Nm (34 to 38
lb-ft).
Figure 1-1.
SEAL KIT
May 1999
DD-110/110HF & DD-90/90HF / STEERING VALVE

STEERING VALVE................................................................G8.2
Disassembly...........................................................G8.2
Inspection................................................................G8.4
Assembly................................................................G8.5
STEERING
VALVE
1G8.1
TABLE OF CONTENTS
February 1999
G8.2
NOTICE:
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
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
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
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 Nm (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
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
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
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 Nm (12.5 lb-ft).
43.Torque the cap screws (1) to 25 to 30 Nm (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
H3

January 2002
H4

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

NOTICE:
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

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
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
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

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

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.

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.

October 2002

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.

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 Nm (2095 ft-lbs).
6. Remove the lifting device from the ROPS/FOPS (1).
Figure 1-1.

October 2002
DD-110/110HF & DD-90/90HF / CONSOLE ASSEMBLY

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

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

REMOVAL AND DISASSEMBLY
1. Remove the ROPS/FOPS from the machine, refer to the
ROPS/FOPS Installation and Removal information for
this model.

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

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.

9. Attach a lifting device to support the console assembly

(1).
WARNING:
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

CLEANING AND INSPECTION
1. Clean all parts in a non-residue type solvent.

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 Nm (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

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.

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 Nm (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

BEARING PACK.............................................................. J3.2
Tools Required ..................................................... J3.2
Safety ................................................................... J3.2
Removal ............................................................... J3.2
Disassembly ......................................................... J3.2
Assembly .............................................................. J3.3
Installation ............................................................ J3.4
J3.1
TABLE OF CONTENTS
August 2002

TOOLS REQUIRED:
Safety glasses
Torque wrench
Loctite number 271
Non-residue type solvent MPG-EP2 Grease
SAFETY
instructions.
REMOVAL
J3.2

this model.
2. Remove the Operators Console from the machine, refer
to the Operators Console Installation and Removal information for this model.
3. Remove the bearing pack assembly from the machine,
refer to the Operators 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

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).
J3.3
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

4. Apply Loctite #271 to the capscrews (10).
5. Install the capscrews (10) and flatwashers (9) into the base
plate (1).
7. Install the V-ring seal (7) and top closure ring (6) onto the
top inner race (2).
9. Install the capscrews (8) into the inner race (3).
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 Operators Console installation and Removal information for this model.
2. Install the Operators Console onto the machine, refer to
the Operators Console Installation and Removal information for this model.
model.
Figure 1-1.
BEARING PACK
August 2002
DD-110/110HF & DD-90/90HF / DECK PLATES

DECK PLATES ............................................................... J4.2
Tools Required ..................................................... J4.2
Safety ................................................................... J4.2
Removal ............................................................... J4.2
Installation ............................................................ J4.4
DECK PLATE
HALVES
J4.1
TABLE OF CONTENTS
August 2002

TOOLS REQUIRED:
Safety glasses
Torque wrench
Loctite number 271
condition
SAFETY
instructions.
REMOVAL
J4.2
1. Park the machine on a level surface with ample clearance

for working.
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

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
8. Remove the lock screws (13) and locknuts (11) from the
deck plates (4 and 12), refer to Figure 1-2.
WARNING:
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.
Figure 1-2.
DECK PLATES
August 2002

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 Nm (37 lb-ft).
5. Install the operator console onto the machine, refer to the
Operators Console Installation and Removal information for this model.
J4.4

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 Nm (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
this model.
Figure 1-2.
DECK PLATES
August 2002
DD-110/110HF/90/90HF / SWIVEL BEARING REPLACEMENT

SWIVEL BEARING .......................................................... J5.2
Tools Required ..................................................... J5.2
Safety ................................................................... J5.2
Inspection ............................................................. J5.8
J5.1
SWIVEL
BEARINGS
TABLE OF CONTENTS
August 2002

TOOLS REQUIRED:
Safety glasses
Torque wrench
Loctite number 271
Feeler gauges
Petroleum jelly
Sledge hammer
Heat resistant gloves
Non-residue type solvent Straps or chains
Anti-seize
condition
SAFETY
J5.2

instructions.
WARNING:
Improper maintenance can be hazardous.
Study the Operators 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

WARNING:
Unexpected machine motion or moving parts can cut or
crush.
WARNING:
Oil under pressure can cause serious cuts or injury.
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.

August 2002

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
cleaning rags.
WARNING:
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

for working.
WARNING:
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.

August 2002

3. Tag and disconnect the electrical wires that run between
the two frames halves that will interfere with the separation of the two halves.
this model.
at the front worklights (2), refer to Figure 1-2.
J5.5

8. Remove the front railing (4) from the deck plate (8).
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.

August 2002

WARNING:
11. Disconnect the hydraulic hoses from the steering cylinder
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

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

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.
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

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 Nm (300
to 350 lb-ft).
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 Nm (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

15. Install shims (12 and 13) and backplate capscrews (15)
16. Torque the backplate capscrews (15) to 298 Nm (220 lbft).
17. Retighten and torque the horizontal pin nut (18) to 1356
Nm (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

24. Install the right and left deck plates, refer to the Deck Plate
Halves Installation and Removal information for this
model.
25. Install the operators console, refer to the Operators 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).
J5.11

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.

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
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

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

Loctite number 271
Feeler gauges
Acetylene torch
Loctite primer-T
Petroleum jelly
3,000 lb. Auto-Crane that is in
SAFETY
J6.2

instructions.
WARNING:
compactor.
No unauthorized person should be allowed to operate,
service, or maintain this compactor.
Figure 1-1.

August 2002

WARNING:
crush.
WARNING:
maintenance.
J6.3

safety shoes.
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.

August 2002

NOTE
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:
J6.4

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

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:
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

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

model DD-90 have
different shape.
WARNING:
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:
Figure 1-3.

August 2002

5. Install the capscrews (10) and flatwashers (9) into the base
plate (1).
7. Install the V-ring seal (7) and top closure ring (6) onto the
top inner race (2).
9. Install the capscrews (8) into the inner race (3).
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 Operators Console installation and Removal information for this model.
2. Install the Operators Console onto the machine, refer to
model.
Figure 1-1.
BEARING PACK
August 2002

DECK PLATES ............................................................... J4.2
Tools Required ..................................................... J4.2
Safety ................................................................... J4.2
Removal ............................................................... J4.2
Installation ............................................................ J4.4
DECK PLATE
HALVES
J4.1
TABLE OF CONTENTS
August 2002

TOOLS REQUIRED:
Safety glasses
Torque wrench
Loctite number 271
condition
SAFETY
instructions.
REMOVAL
J4.2

for working.
this model.
at the front worklights (2), refer to Figure 1-2. Disconnect
and remove the cables from the back of the deck plates.
Figure 1-1.

August 2002

6. Remove the front railing (4) from the deck plate (8), refer
to Figure 1-1.
8. Remove the lock screws (13) and locknuts (11) from the
deck plates (4 and 12), refer to Figure 1-2.
WARNING:
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.
Figure 1-2.
DECK PLATES
August 2002

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 Nm (37 lb-ft).
5. Install the operator console onto the machine, refer to the
Operators Console Installation and Removal information for this model.
J4.4

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 Nm (90 lb-ft).
and install the cable tie (3) .
11. Install the ROPS/FOPS onto the machine, refer to the
this model.
Figure 1-2.
DECK PLATES
August 2002

SWIVEL BEARING .......................................................... J5.2
Tools Required ..................................................... J5.2
Safety ................................................................... J5.2
Inspection ............................................................. J5.8
J5.1
SWIVEL
BEARINGS
TABLE OF CONTENTS
August 2002

TOOLS REQUIRED:
Safety glasses
Torque wrench
Loctite number 271
Feeler gauges
Petroleum jelly
Sledge hammer
Anti-seize
condition
SAFETY
J5.2

instructions.
WARNING:
compactor.
No unauthorized person should be allowed to operate, service,
or maintain this compactor.
Figure 1-1.

August 2002

WARNING:
crush.
WARNING:
maintenance.
J5.3

safety shoes.
Figure 1-1.

August 2002

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
cleaning rags.
WARNING:
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

for working.
WARNING:
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.

August 2002

3. Tag and disconnect the electrical wires that run between
the two frames halves that will interfere with the separation of the two halves.
this model.
at the front worklights (2), refer to Figure 1-2.
J5.5

8. Remove the front railing (4) from the deck plate (8).
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.

August 2002

WARNING:
11. Disconnect the hydraulic hoses from the steering cylinder
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

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
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

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.
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.
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

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 Nm (300
to 350 lb-ft).
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 Nm (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

15. Install shims (12 and 13) and backplate capscrews (15)
16. Torque the backplate capscrews (15) to 298 Nm (220 lbft).
17. Retighten and torque the horizontal pin nut (18) to 1356
Nm (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

24. Install the right and left deck plates, refer to the Deck Plate
Halves Installation and Removal information for this
model.
25. Install the operators console, refer to the Operators 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).
J5.11

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.

August 2002

TABLE OF CONTENTS .................................................. J6.1
DRUM AND DRUM DRIVE .............................................. J6.2
Tools Required ..................................................... J6.2
Safety ................................................................... J6.2
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

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

Loctite number 271
Feeler gauges
Acetylene torch
Loctite primer-T
Petroleum jelly
3,000 lb. Auto-Crane that is in
SAFETY
J6.2

instructions.
WARNING:
compactor.
No unauthorized person should be allowed to operate,
service, or maintain this compactor.
Figure 1-1.

August 2002

WARNING:
crush.
WARNING:
maintenance.
J6.3

safety shoes.
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.

August 2002

NOTE
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:
J6.4

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

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

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:
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.

August 2002

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

model DD-90 have
different shape.
WARNING:
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:
Figure 1-3.

August 2002

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
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

6. Remove the capscrews (5), flatwashers (6), and nuts (7)
from the mounting flange (2 and 21) and drive motor (1),
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

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

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
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

28. Remove the eccentric drive shaft assembly (28) out of the
bearing cover (21) through the drive end of the drum (30),
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

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
its 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

3. Install the new O-ring (60) onto the bearing housing (32).,
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).
7. Torque the capscrews (36) to 244 Nm (180 ft-lbs).
8. Install the nuts (34) onto the studs (33).
J6.13
9. Torque the nuts (34) to 136 Nm (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.
12. Install the new O-ring (26) onto the bearing cover (21),
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

14. Install the bearing cover (21) onto the drum (30) by guiding the eccentric shaft through the spherical bearing (31),
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).
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

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. Install the capscrews (45) into the indicator (44).
Figure 1-5.
DRUM
August 2002

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).
37. Apply anti-seize compound to the spline coupling teeth
on the end of splined shaft (23) that engages eccentric
shaft assembly (28).
39. Install the new O-ring (20) onto the bearing cover (21),
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 Nm (205 ft-lbs).
Figure 1-5.
DRUM
August 2002

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).
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).
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

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).
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).
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 Nm (90 ft-lbs).
Figure 1-6.
DRUM DRIVE
August 2002

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

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

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.
14. Torque the bolts (10) to 895 Nm (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.

August 2002

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

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.

August 2002
DD-110/110HF & DD-90/90HF / ECCENTRIC SHAFT ASSEMBLY

ECCENTRIC SHAFT ASSEMBLY ................................... J7.2
Tools Required ..................................................... J7.2
Safety ................................................................... J7.2
Disassembly ......................................................... J7.2
Assembly .............................................................. J7.4
ECCENTRIC
ASSEMBLY
J7.1
TABLE OF CONTENTS
August 2002

TOOLS REQUIRED:
Saftey glasses
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

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

6. Remove eccentric journal (3) from the eccentric tube (1),
WARNING:
Safety glasses must be worn when removing the retaining
rings.
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).

Figure 1-1.

August 2002


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.

Figure 1-1.

August 2002

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.
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 oclock position on the eccentric journal (3).
13. Torque the capscrews (12) to 80 Nm (59 lb-ft) on models
DD-90/110, or 67 Nm (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).

Figure 1-1.

August 2002

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).
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 Nm (59 lb-ft) on models
DD-90/110, or 67 Nm (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.
Figure 1-1.

August 2002
DD-110/110HF/90/90HF / CARRIER AND SPINDLE ASSEMBLY

CARRIER AND SPINDLE ................................................ J8.2
Tools Required ..................................................... J8.2
Safety ................................................................... J8.2
Disassembly ......................................................... J8.2
Assembly .............................................................. J8.3
CARRIER AND
SPINDLE
ASSEMBLY
J8.1
TABLE OF CONTENTS
August 2002

TOOLS REQUIRED:
Safety glasses
Torque wrench
Loctite number 271
Blue Loctite
Feeler gauges
Sledge hammer
condition
SAFETY
J8.2

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

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).
ASSEMBLY
NOTE:
Bearing cups are to be cooled to 0F (-18C) for 2 to 4 hours
before installation.
Figure 1-1.
CARRIER AND SPINDLE

August 2002

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 225F (107C) 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,
8. Heat the new outboard bearing cone (8) to 225F (107C)
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

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 225F (107C)
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).
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

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).
26. Check the rolling torque required to rotate the spindle (2).
Rolling torque should be 34 to 41 Nm (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).
30. Install the lock plates (12) and capscrews (11) into the bearing retainer (3).
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,
Fixed Displacement,
Bidirectional
Hydraulic Pump
Pressure Relief Valve
Push Button
Cooler
Level
Variable Displacement,
Bidirectional,
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

Control Valve
Solenoid
Hydraulic Lines
Spring
Working Hydraulic
Line
Lines Joining
Open Center, Three

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

Service DD90

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VOLVO CONSTRUCTION EQUIPMENT

SERIAL NO. 158533-

MORE CARE. BUILT IN.

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

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

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

Hydraulic Symbol Quick Reference Chart............L1

EFF. w/ all S/N

- Hose routing diagram w/ components labeled.

- Troubleshooting chart w/ symptoms & prioritized possible causes.

DD-110/110HF VIBRATION SYSTEM

- Colors are standard

- Each page is specific to

- Standard symbols are

FEATURES OF THIS MANUAL

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

Before performing any maintenance or service procedures on

ILLUSTRATED HOSE SCHEMATIC

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

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

Settings and Specifications-Propulsion*

Settings and Specifications-Propulsion*

System Relief Pressure (psi/bar)

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

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

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

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

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

DISTRIBUTION VALVE ............................................. E6.2

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

1. Place the drive motor on the bench area. Remove the

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

1. Apply a light coat of petroleum jelly or grease to the O-rings

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

1. Mark the position of the bearing support (1) in relation to the

CYLINDER BLOCK AND CAM

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

CYLINDER BLOCK AND CAM

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

1. Mark the position of the bearing support (1) in relation to the

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

1. Apply a light coat of petroleum jelly or grease to the pistons

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

1. Mark the position of the bearing support (1) in relation to the

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

1. Apply a light coat of petroleum jelly or grease to the O-rings

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

1. Inspect the condition on the shaft (26) splines and brake

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

1. Lubricate the discs (30) and install alternately one smooth

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

LIP SEAL AND SHAFT..........................................................E7.2

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

LIP SEAL AND SHAFT

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

LIP SEAL AND SHAFT

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

MULTI FUNCTION VALVE CARTRIDGES

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

CHARGE RELIEF VALVE

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

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

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

INTEGRAL CHARGE PRESSURE FILTRATION