Service DD90

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VO

LVO C

ONS

TRUC

TION E

QUIPMENT

SERVICE MANUAL

MORE C

ARE. BUIL

T IN.

DD9

0/DD9

0HF

/DD110

/DD110hf

SERIAL NO. 15

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8533-CALIFORNIA Propositi on 65 W arnin g Dies el en gine exh aus t and some of it s c onst itue n ts ar e k nown t o th e S tat e o f Califor nia t o ca use can cer , b irt h de fec ts, and o the r repr oduc tive ha rm. CALIFORNIA Propositi on 65 W arnin g Ba tt ery p ost s, t e rmina ls and o the r relat e d ac cess ories cont ain le ad a nd lea d comp ounds , chemica ls known to the S ta te of Ca lif ornia t o cau se ca nc er an d oth e r rep roduc tive h a rm. W ash ha nds af te r h a nd ling.

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T

ABLE

OF

A1

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

Table of Contents...A1 Features of This Manual...B1 Safety Information...C1 Illustrated Hose Schematic...D1 HYDRAULIC Propulsion/Braking...E1 Schematics Overview...E2 Neutral-Brakes Applied...E3 Forward-Brakes Released...E4 Reverse-Brakes Released...E5 Drum Drive Motor...E6 Propulsion Pump...E7 Triple Pump Drive...E8

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T

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OF

A2

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

Component Teardown and Rebuild

Steering....

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A3

EFF. w/ all S/N

ELECTRICAL

MACHINE

TROUBLESHOOTING

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

Reference Chart...L2

Schematics

Component Teardown & Rebuild

Machine Electrical Schematic...H1

Water Pump...H5

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

Hydraulic...K1 Electrical/Engine/Water System...K2

T

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

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A A B High pressure High pressure Return Suction Charge L E G E VIBRA TION PUMP CASE SUCTION ION

-Each page is specific to one functional subsystem. Colors are standard throughout manual. Operational status is identified by color. Standard symbols are used.

-Hose routing diagram w/ components labeled. Hydraulic symbol quick reference chart. Wire color code reference chart. Settings and specifications. Troubleshooting chart w/ symptoms & prioritized possible causes.

Component

Repair

Procedures

Component

Repair

Procedures

High pressure High pressure Return Suction dashed lines indicate low pressure Charge LE GE N D F3 F3 HYDRAULIC TANK VIBRATION PUMP A A B B CASE SUCTION VIBRATION MOTOR ® NEUTRAL-NO VIBRATION DD-110/110HF VIBRATION SYSTEM VIBRATION FILTER October 1999 VIBRATION MOTOR...E6.4 Disassembly...E6.4 Inspection...E6.4 Assembly...E6.4 INSPECTION ASSEMBLY VIBRATION MOTOR DISASSEMBLY

FEA

TURES

OF

THIS

MANUAL

B1

REAR DRUM MOTOR REAR VIBRATION MOTOR FRONT VIBRATION MOTOR STEERING CYLINDER PROPULSION PUMP LOOP FLUSHING VALVE SUCTION FILTER OIL COOLER REAR VIBRATION PUMP FRONT DRUM MOTOR HYDRAULIC TANK RETURN FILTER VIBRATION FILTER FRONT VIBRATION PUMP STEERING VALVE BRAKE VALVE STEERING PUMP

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SAFETY

INFORMA

TION

C1

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.

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ILLUSTRA

TED

HOSE

SCHEMA

TIC

D1

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

REAR DRUM MOTOR REAR VIBRATION MOTOR FRONT VIBRATION MOTOR STEERING CYLINDER PROPULSION PUMP LOOP FLUSHING VALVE SUCTION FILTER OIL COOLER REAR VIBRATION PUMP FRONT DRUM MOTOR HYDRAULIC TANK RETURN FILTER VIBRATION FILTER FRONT VIBRATION PUMP STEERING VALVE BRAKE VALVE STEERING PUMP

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PROPULSION

/

BRAKING

E1

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

Settings and Specifications-Propulsion*

DD-110 DD-110HF

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

service personnel. DRUM MOTOR (FRONT) DRUM MOTOR (REAR) PROPULSION PUMP SUCTION FILTER DUMP VALVE PRESSURE

GAUGE BRAKE_VALVE

PRESSURE SWITCH OIL COOLER HYDRAULIC TANK

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OVERVIEW

E2

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

HYDRAULIC TANK SUCTION FILTER OIL COOLER BRAKE VALVE PRESSURE SWITCH B A C PUSHED FOR NORMAL OPERATION A B B N A PROPULSION PUMP DRUM MOTOR R L R L LOOP FLUSHING VALVE DRUM MOTOR

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NEUTRAL-BRAKES APPLIED

E3

HYDRAULIC TANK SUCTION FILTER OIL COOLER BRAKE VALVE PRESSURE SWITCH B A C PUSHED FOR NORMAL OPERATION A B B N A PROPULSION PUMP DRUM MOTOR R L R L LOOP FLUSHING VALVE High pressure High pressure Return Suction Charge Control dashed lines indicate low pressure L E G E N D DRUM MOTOR

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FORWARD-BRAKES RELEASED

E4

HYDRAULIC TANK SUCTION FILTER OIL COOLER BRAKE VALVE PRESSURE SWITCH B A C PUSHED FOR NORMAL OPERATION A B B N A PROPULSION PUMP DRUM MOTOR R L R L LOOP FLUSHING VALVE High pressure High pressure Return Suction Charge Control dashed lines indicate low pressure L E G E N D DRUM MOTOR

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REVERSE-BRAKES RELEASED

E5

HYDRAULIC TANK SUCTION FILTER OIL COOLER BRAKE VALVE PRESSURE SWITCH B A C PUSHED FOR NORMAL OPERATION A B B N A PROPULSION PUMP DRUM MOTOR R L R L LOOP FLUSHING VALVE High pressure High pressure Return Suction Charge Control dashed lines indicate low pressure L E G E N D DRUM MOTOR

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August 2002

TABLE OF CONTENTS ... 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

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

E6.1

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August 2002

NOTICE:

Prior to performing repairs on this component, contact an authorized service representative concerning issues of warranty. DISASSEMBLY

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

E6.2

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August 2002

ASSEMBLY

1. Apply a light coat of petroleum jelly or grease to the O-rings and back-up rings (17), refer to Figure 1-1.

2. Install the O-rings and back-up rings (17) onto the valving (16).

3. Apply grease into the spring (18) housings. 4. Install the springs (18) into the valving (16).

5. Apply a light coat of petroleum jelly or grease to the faces of the O-rings and back-up rings (17).

6. Install the valving (16) into the distribution cover (11).

7. Apply a light coat of petroleum jelly or grease to the contact surfaces of the cylinder block (7) and the valving (16). 8. Apply a light coat of petroleum jelly or grease to the O-rings

(6).

9. Install the new O-rings (6) on the bearing support (1) and distribution cover (11).

10. Install the bearing support (1), cam (5) and cylinder block (7) onto the distribution cover (11).

11. Align the marks on the bearing support (1), cam (5), and distribution cover (11).

12. Install the screws (15 and 14) into the distribution cover (11). 13. Torque the screws (15 and 14) to 350 N·m (258 lb-ft).

14. Apply a light coat of petroleum jelly or grease to the new O-ring (12).

15. Install the new O-ring (12) on the distribution cover (11).

Figure 1-1

DISTRIBUTION VALVE

E6.3

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August 2002

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August 2002

ASSEMBLY

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).

7. Apply a light coat of petroleum jelly or grease to the contact surfaces of the cylinder block (7) and the valving (16).

8. Apply a light coat of petroleum jelly or grease to the O-rings (6).

10. Install the bearing support (1), cam (5) and cylinder block onto the distribution cover (11).

11. Align the marks on the bearing support (1), cam (5), and distribution cover (11).

Figure 1-1

BEARING HOUSING

E6.9

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August 2002

DISASSEMBLY

1. Remove the plug (32) from the cover (31), refer to Figure 1-1.

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

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

E6.10

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August 2002

ASSEMBLY

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 O-ring (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

E6.11

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1

August 2002

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

TABLE OF CONTENTS...E7.1 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

E7.1

PROPULSION

PUMP

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

August 2002

Figure 1-1.

LIP SEAL AND SHAFT

E7.2

NOTICE:

Prior to performing repairs on this component, contact an authorized service representative concerning issues of warranty.

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 O-ring (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.

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

August 2002

Figure 1-1.

E7.3

LIP SEAL AND SHAFT

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).

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).

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

August 2002

Figure 1-2.

MULTI FUNCTION VALVE CARTRIDGES

E7.4

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 CAUTION:

If the pressure limiter housing is disassembled for cleaning, the pressure setting must be readjusted after reassembly.

1. Lightly lubricate the O-rings (3) with clean petroleum jelly.

2. Install the O-rings (3) onto the multi function valve cartridges (1).

3. Install the multi function valve cartridges (1) in the end cap (2).

4. Torque the multi function valve cartridges (1) to 89 N·m (66 lb-ft).

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

August 2002

Figure 1-3.

CHARGE RELIEF VALVE

E7.5

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.

ASSEMBLY CAUTION:

Do not interchange parts with another valve.

1. Install the charge relief valve (4) and spring (5) onto the plug (7).

2. Install a new O-ring (6) onto plug (7).

3. Install the plug (7) with its locknut (8) aligning the marks made at disassembly and torque the locknut (8) to 52 N·m (38 lb-ft).

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

August 2002 Figure 1-4.

CHARGE PUMP

E7.6

DISASSEMBLY

1. Remove the screws (1), flange cover (2) and O-ring (3) from the flange adapter (6). Discard the O-ring (3), refer to Figure 1-4.

2. Remove the screws (4), washers (5), and flange adapter (6) from the end cap (22).

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.

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

August 2002

Figure 1-4. 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).

CAUTION:

In order to avoid loss of charge pressure, always install the charge pump cover with the drain hole located on the same side of the end cap as the charge inlet port.

5. Install the retaining plate (8) and secure the retaining plate (8) with screws (7).

6. Torque the screws (7) to 13.5 N·m (10 lb-ft). 7. Install a new O-ring (9) around the charge pump

cover (10).

8. Install the flange adapter (6), washers (5), and screws (4) onto the end cap (22).

9. Torque the screws (4) to 256 N·m (189 lb-ft).

10.If necessary, install a new O-ring (3), flange cover (2), and screws (1) onto the flange adapter (6).

CHARGE PUMP

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

August 2002

Figure 1-5.

INTEGRAL CHARGE PRESSURE FILTRATION

E7.8

DISASSEMBLY

1. Remove the filter canister (21) from the filter head (17), refer to Figure 1-5.

2. Loosen the swivel locknut (19).

3. Remove the filter head (17) from the end cap (22). 4. Remove and discard the O-ring (20) from the filter

head (17).

INSPECTION

1. Inspect the filter head (17) and tube (18) for blockage or foreign material.

ASSEMBLY

1. Install a new O-ring (20) onto the filter head (17). 2. Rotate the filter head (17) so the threads engage with

the threads in the end cap (22), continue to rotate clockwise 6 or 7 turns.

3. Face filter head (17) in desired position.

CAUTION:

Failure to install the filter manifold to a sufficient depth in the housing will result in insufficient engagement of the tube in the housing. This may allow oil to bypass the filter and enter the charge system.

4. Torque the swivel locknut (19) to 122 N·m (90 lb-ft). 5. Install a new filter canister (21) per manufacturer’s

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

August 2002

Figure 1-6.

MANUAL DISPLACEMENT CONTROL (MDC) AND SOLENOID OVERRIDE VALVE

E7.9

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).

CAUTION:

Protect exposed surfaces and cavities from damage and foreign material.

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

August 2002

MANUAL DISPLACEMENT CONTROL (MDC) AND SOLENOID OVERRIDE VALVE

Figure 1-6.

E7.10

ASSEMBLY

1. Install a new gasket (9) on the housing (11), refer to Figure 1-6.

2. Install the orifice check valve (6), spring (7), and spring retainer (8) into the manual displacement control (4).

3. All at once, install the manual displacement control (4) and engage the pin on the control linkage into the mating hole in the link attached to the swashplate. 4. Check for proper engagement of the control linkage

pin by moving the control handle (10) off center creating center torque. If there is a lack of centering torque, repeat step 3.

5. Align the gasket (9) and install the screws (5). 6. Torque the screws (5) to 16 N·m (12 lb-ft).

7. If installing a new solenoid valve (12) into the solenoid manifold (2), torque the solenoid valve (12) to 18.6 N·m (13.8 lb-ft).

8. Install a new gasket (3), solenoid manifold (2) and screws (1).

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1

August 2002

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

TABLE OF CONTENTS...E8.1 TRIPLE PUMP DRIVE...E8.2 Disassembly...E8.2 Inspection...E8.3 Assembly...E8.3

E8.1

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

August 2002

Figure 1-1.

TRIPLE PUMP DRIVE

E8.2

NOTICE:

Prior to performing repairs on this component, contact an authorized service representative concerning issues of warranty.

DISASSEMBLY

1. Remove the plug (1) from the pump housing (2), refer to Figure 1-1.

2. Drain the oil from the pump housing (2).

3. Remove the drive plate (3) from the pump housing (2). 4. Remove the drive shaft (4) from the pump housing (2). 5. Remove and discard screws (5) from the pump

adapters (6).

6. Remove the pump adapters (6) from the pump housing (2).

7. Remove the gears (8) and the bearings (7) from the pump housing (2).

8. Turn the pump housing (2) over.

9. Remove and discard bolts (9) from the flywheel cover (10).

10.Remove the flywheel cover (10) from the pump housing (2).

11.Remove and discard the plastic strip gasket (11). 12.Remove the gear (12) and the bearings (13) from the

pump housing (2).

13.Remove and discard the oil seal (14) from the flywheel cover (10).

14.Remove the bearings (7 and 13) from the gears (8 and 12) using an arbor press.

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

August 2002

Figure 1-1.

E8.3

TRIPLE PUMP DRIVE

INSPECTION

1. Inspects parts for damage and wear, replace if necessary.

2. Inspect bolt holes for foreign material, clean as necessary.

ASSEMBLY

1. Press the bearings (7 and 13) onto the gears (8 and 12), refer to Figure 1-1.

2. Press a new oil seal (14) into the flywheel cover (10). 3. Install the gear (12) and bearing (13) into the pump

housing (2).

4. Install a new plastic strip gasket (11) onto the pump housing (2).

5. Install the flywheel cover (10) onto the pump housing(2). 6. Apply Loctite 262 to the new bolts (9).

7. Install the new bolts (9) into the flywheel housing (2). 8. Torque the bolts (9) to 271 N·m (200 lb-ft).

9. Turn the pump housing (2) over.

10.Install the gears (8) and bearings (7) into the pump housing (2).

11.Install the pump adapters (6) onto the pump housing (2).

12.Apply Loctite 262 to the new bolts (5).

13.Install the new bolts (5) into the pump housing (2). 14.Torque the bolts (5) to 271 N·m (200 lb-ft).

15.Install the drive shaft (4) into the pump housing (2). 16.Install the drive plate (3) onto the pump housing (2). 17.Install the plug (1) into the pump housing (2).

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1

August 2002

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

TABLE OF CONTENTS...E9.1 SEAL KIT...E9.2 Disassembly...E9.2 Assembly...E9.3

E9.1

HAND

PUMP

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

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

SEAL KIT

E9.2

NOTICE:

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).

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

E9.3

SEAL KIT

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).

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VIBRA

TION

F1

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

FRONT VIBRATION PUMP HYDRAULIC TANK REAR VIBRATION PUMP REAR VIBRATION MOTOR FRONT VIBRATION MOTOR VIBRATION FILTER

NOTE: Schematic shows quantity of one vibration motor & pump. Machine contains two of each (see Illustrated Hose Schematic page D1).

(42)

OVERVIEW

F2

HYDRAULIC TANK VIBRATION PUMP A B CASE SUCTION A B SUCTION FILTER

TO SECOND VIBRATION PUMP SUCTION

A

B

FRONT VIBRATION MOTOR REAR VIBRATION MOTOR

OIL COOLER

TO A PORT ON 2ND VIBRAITON PUMP

TO B PORT ON 2ND VIBRATION PUMP

(43)

F3

NEUTRAL-NO VIBRATION

HYDRAULIC TANK VIBRATION PUMP A B CASE SUCTION A B SUCTION FILTER

A

B

High pressure High pressure Return Suction dashed lines indicate low pressure Charge L E G E N D OIL COOLER TO A PORT ON 2ND VIBRAITON PUMP TO B PORT ON 2ND VIBRATION PUMP

(44)

CLOCKWISE ROTATION

F4

A B CASE SUCTION A B A B High pressure High pressure Return Suction dashed lines indicate low pressure Charge L E G E N D HYDRAULIC TANK VIBRATION PUMP SUCTION FILTER

OIL COOLER

(45)

COUNTERCLOCKWISE ROTATION

F5

A B A B A B High pressure High pressure Return Suction dashed lines indicate low pressure Charge L E G E N D CASE SUCTION HYDRAULIC TANK VIBRATION PUMP SUCTION FILTER

OIL COOLER

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1

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

F6.1

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

SEAL KIT

F6.2

NOTICE:

DISASSEMBLY

1. Remove the retaining ring (1) from the housing (2), refer to Figure 1-1.

2. Carefully remove the lip seal (3) from the housing (2) bore. A slide type hammer may be used to remove the lip seal (3).

3. Remove the retaining ring (1) from the lip seal (3). 4. Remove the o-rings (3), and bearing ball (4) from the

housing. Discard o-rings.

5. Position the motor with the shaft end facing down. 6. Loosen the screws that connect the motor end cap (9)

to the motor housing (8).

7. Remove the motor end cap (9) from the motor housing (8) . Remove the gasket (7) and the needle bearing (6).

8 Discard the gasket (7).

INSPECTION

2. Inspect the shaft for rust, wear, or contamination. Polish the the shaft if necessary.

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

F6.3

SEAL KIT

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).

CAUTION:

7. Slide the new lip seal (3) over the shaft (4) and press it into the housing (2) bore.

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1

August 2002

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

TABLE OF CONTENTS...F7.1 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

F7.1

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

LIP SEAL

F7.2

NOTICE

DISASSEMBLY

1. Remove the retaining ring (1) from the housing (2), refer to Figure 1-1.

2. Carefully remove the lip seal (3) from the housing (2). A slide type hammer may be used to remove the lip seal (3).

INSPECTION

ASSEMBLY

CAUTION:

2. Slide the new lip seal (3) over the shaft (4) and press it into the housing (2) bore.

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

F7.3

BYPASS VALVE

DISASSEMBLY

1. Remove the bypass valve (5) from the housing (2), refer to Figure 1-2.

2. Remove and discard the O-ring (6) and backup ring (7) from the bypass valve (5).

INSPECTION

1. Inspect the bypass valve (5) and mating seat for damage or foreign material. Use new parts as required.

ASSEMBLY

1. Install a new backup ring (7) and O-ring (6) onto the bypass valve (5).

2. Lubricate the O-ring (6) with clean hydraulic fluid and install the bypass valve (5) into the housing.

3. Torque the bypass valve (5) to 9.5 to 13.6 N·m (7 to 10 lb-ft).

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

August 2002

Figure 1-3.

CHARGE CHECK AND HIGH PRESSURE

RELIEF VALVE

F7.4

DISASSEMBLY

1. Remove the charge check and high pressure relief valve plugs (8), refer to Figure 1-3.

2. Remove and discard the O-rings (9) from the charge check and high pressure relief valve plugs (8).

3. Remove the springs (10) and poppet or valve cartridges (11) from the housing (2).

INSPECTION

1. Inspect the poppet or valve cartridges (11) and mating seat in the housing (2) for damage or foreign material. If the seat in the housing (2) is damaged, a new vibration pump must be used and the original must be returned to the manufacturer for warranty repair or replacement.

NOTE:

Always replace ball type check valves with the poppet type.

ASSEMBLY

1. Install a new O-rings (9) on the charge check and high pressure relief valve plugs (8).

2. Install new poppet or valve cartridges (11), new springs (10), and charge check and high pressure relief valve plugs (8) into the housing (2).

3. Torque the charge check and high pressure relief valve plugs (8) to 41 to 95 N·m (30 to 70 lb-ft).

CAUTION:

The high pressure relief valves are factory set and should not be tampered with except for replacing the entire poppet or valve cartridge. Disassembly may change the setting and cause system malfunctions or premature failure.

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

August 2002

Figure 1-4.

CHARGE RELIEF VALVE

F7.5

DISASSEMBLY

1. Remove the charge relief valve plug (12) from the housing (2), refer to Figure 1-4.

2. Remove and discard the O-ring (13) from the charge relief valve plug (12).

3. Remove the shims (14) from the charge relief valve plug (12).

4. Remove the spring (15) and poppet (16) from the housing (2).

INSPECTION

1. Inspect the poppet and mating seat in the end cap for damage or foreign material. Use new parts as

required.

ASSEMBLY

1. Install a new O-ring (13) on the charge relief valve plug (12).

2. Install new shims (14) in the inside diameter of the charge relief valve plug (12).

3. Install a new poppet (16), new spring (15), and charge relief valve plug (12) with shims (14) into the housing (2).

4. Torque the charge relief valve plug (12) to 41 to 95 N·m (30 to 70 lb-ft).

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

FILTER ADAPTER

F7.6

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).

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

August 2002

Figure 1-6.

ELECTRICAL DISPLACEMENT CONTROL

F7.7

CAUTION:

The removal of any portion of the electronic displacement control mechanism may result in the loss of neutral, which will require readjustment.

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.

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

August 2002

Figure 1-6.

ELECTRICAL DISPLACEMENT CONTROL

F7.8

ASSEMBLY

1. Install the control orifice plugs (18) into the control passages found on each side of the housing (19), refer to Figure 1-6.

2. Install a new gasket (16) for each servo piston cover (15 and 17).

3. Install the servo piston covers (15 and 17) and secure each with screws (14).

4. Torque the screws (14) to 8 to 11 N·m (10.8 to 14.9 lb-ft).

5. Install the control inlet screen plug (10) in the inlet passage of the housing (19).

6. Torque the control inlet screen plug (10) to 2.2 to 3.4 N·m(20 to 30 lb-in).

7. Install O-rings (11, 12, and 13) on the electrical displacement control (6) mounting surface on the housing (19).

8. Carefully align the control spool and the control sleeve and install the electrical displacement control (6) on the housing (19).

9. Install the screws (4 and 5), torque the screws (4 and 5) to 13 to 14 N·m(10 to 11 lb-ft).

10.Perform pump neutral adjustment in accordance to the Service Manual.

WARNING:

After installing the servo piston cover (15), the pump neutral adjustment MUST be performed before the machine is put back into service.

CAUTION:

Performance of the pump neutral adjustment may adjust the position of the displacement limiter.

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STEERING

G1

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

STEERING CYLINDER STEERING PUMP STEERING VALVE HYDRAULIC TANK SUCTION STRAINER RETURN FILTER

Settings and Specifications-Steering*

DD-90 DD-90HF

Engine RPM (Hi/Low) 2420/950 x x Flow at Input Speed 35.1 l/m 9.3 g/m

34.8 l/m 9.2 g/m x System Relief Pressure (psi/bar) 2500/172 x x

x

*For specific application settings, contact your authorized service personnel.

Settings and Specifications-Steering*

DD-110 DD-110HF

Engine RPM (Hi/Low) 2457/950 x x Flow at Input Speed 30.3 l/m 8.0 g/m x x System Relief Pressure (psi/bar) 2500/172 x x *For specific application settings, contact your authorized

(58)

G2

OVERVIEW

HYDRAULIC TANK SUCTION STRAINER STEERING PUMP STEERING VALVE STEERING CYLINDER RETURN FILTER S P R L T P

(59)

NEUTRAL

G3

Suction High Pressure High Pressure dashed lines indicate low pressure Return L E G E N D HYDRAULIC TANK SUCTION STRAINER STEERING PUMP STEERING VALVE STEERING CYLINDER RETURN FILTER T P R L S P

(60)

STEER TO LEFT

G4

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

Suction High Pressure High Pressure dashed lines indicate low pressure Return L E G E N D HYDRAULIC TANK SUCTION STRAINER STEERING PUMP STEERING VALVE STEERING CYLINDER RETURN FILTER S P R L

(61)

STEER TO RIGHT

G5

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

Suction High Pressure High Pressure dashed lines indicate low pressure Return L E G E N D HYDRAULIC TANK SUCTION STRAINER STEERING PUMP STEERING VALVE STEERING CYLINDER RETURN FILTER S P R L

(62)

1

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

G6.1

STEERING

CYLINDER

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

March 1999 Figure 1-1.

SEAL KIT

G6.2

NOTICE:

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).

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

March 1999 ASSEMBLY

1. Install a new lip seal (10) in the middle groove in the inside diameter of the head (4), refer to Figure 1-1. 2. Install a new wiper (9) in the front groove in the inside

diameter of the head (4).

3. Install new wear rings (11) in the back groove in the inside diameter of the head (4).

4. Install a new backup ring (13) in the groove on the outside diameter of the head (4) closest to the headcap (6).

5. Install a new O-ring (12) in the groove on the outside diameter of the head (4) next to the backup ring (13). 6. Install a new glyd-ring (15) and wear ring (14) in the

grooves on the outside diameter of the piston (3). 7. Lubricate the inside and outside diameters of both the

piston (3) and head (4) with clean hydraulic oil. 8. Place the piston rod (2) on a clean work surface. 9. Wrap the headcap (6) with a soft cloth to prevent the

inside diameter of the headcap (6) from touching the piston rod (2).

10.Install the headcap (6) onto the piston rod (2).

11.Install the head (4) followed by the piston (3) onto the piston rod (2) noting the proper orientation of each component.

12.Secure the piston (3) onto the piston rod (2) with the locknut (7).

13.Torque the locknut (7) to 1084 to 1355 N·m (800 to 1000 lb-ft).

G6.4

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

March 1999 Figure 1-1.

SEAL KIT

G6.5

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).

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1

February 1999

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

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

G7.1

SEAL KIT

G7.2

NOTICE:

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.

February 1999

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Figure 1-1.

G7.3

SEAL KIT

ASSEMBLY

1. Lightly lubricate the new O-ring seals (11) and seals (6) with petroleum jelly.

2. Install the new O-ring seals (11) on both ends of the pump housing (1), refer to Figure 1-1.

3. Install a new seal (6) in the cover (9).

4. Secure the seal (6) in the cover (9) by installing a new anti-extrusion ring (5) to the outside diameter of the seal (6).

5. Install the dowel pins (10) and cover (9) onto the pump housing (1).

6. Press a new shaft seal (8) into the flange (2) and secure shaft seal (8) with the retaining ring (7). 7. Install a new seal (6) in the flange (2).

8. Secure the seal (6) in the flange (2) by installing a new anti-extrusion ring (5) to the outside diameter of the seal (6).

9. Install the dowel pins (4) in the pump housing (1).

CAUTION:

Be careful not to damage the shaft seal (8) on the splined shaft when installing the flange (2).

10.Carefully install the flange (2) over the shaft and down onto the pump housing (1).

11.Place the pump in a vise from the flange side. Be careful not to damage the pump housing (1) or flange (2).

12.Install the screws (3) to secure the cover (9), pump housing (1) to the flange (2).

13.Torque the screws (3) to 50 to 55 N·m (36.9 to 40.5 lb-ft), refer to the torque pattern in Figure 1-1.

February 1999

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G7.4

SEAL KIT

NOTICE:

Prior to performing repairs on this component, contact an authorized service representative concerning issues of warranty.

DISASSEMBLY

1. Place the pump in a vise with the input shaft end facing down.

2. Loosen and remove the capsrews (1) and washer (2) from the body (3), refer to Figure 1-1.

3. Place the pump on a table with the input shaft end facing up.

4. Tap the end of the drive gear (4) with a plastic mallet to loosen the cover (5).

5. Remove the cover (5) from the body (3). 6. Remove the dowel pins (6) from the body (3).

7. Remove and discard the seal ring (7) and thrust plate (8) from the cover (5).

8. Remove the driven gear (9), drive gear (4) and the wear plate (10) from the body (3).

9. Remove and discard the pressure loading seal (11) from the wear plate (10).

10.Place the body (3) down on the work surface with a shop towel beneath the body (3). Remove and discard the shaft seal (12) from the body (3).

INSPECTION

1. Carefully clean and dry all machined surfces thoroughly.

2. Inspect all machined surfaces for burrs and sharp edges. Remove burrs and sharp edges as required.

May 1999

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Figure 1-1.

SEAL KIT

G7.5

ASSEMBLY

1. Lightly lubricate the new seal ring (7) and pressure loading seal (11) with petroleum jelly.

2. Lightly lubricate the inside of the shaft seal (12). 3. Press the new shaft seal (12) in the body (3), refer to

Figure 1-1.

4. Install a new pressure loading seal (11) in the wear plate (10).

5. Lubricate and install the wear plate (10) in the bore of the body (3).

6. Install the drive gear (4) in the body (3).

7. Install the driven gear (9) in the body (3). Make sure the long journal of the driven gear (9) is facing in the same direction as the long journal of the drive

gear (4).

8. Lubricate the rear faces of the drive gear (4) and the driven gear (9) with SAE-10 oil.

9. Install the thrust plate (8) into the cover (5).

10.Apply a small amount of grease to the rear cover (2) groove.

11.Install a new seal ring (7) into the cover (5). 12.Install the dowel pin (6) into the body (3).

13.Position the body (3) with the gear bores up in a vertical position before installing the cover (5). 14.Install the cover (5) on the body (3).

15.Install the capscrews (1) and washers (2) to secure the cover (5) to the body (3).

16.Torque the capscrews (1) to 46 to 52 N×m (34 to 38 lb-ft).

May 1999

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1

February 1999

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

TABLE OF CONTENTS...G8.1 STEERING VALVE...G8.2 Disassembly...G8.2 Inspection...G8.4 Assembly...G8.5

G8.1

STEERING

VALVE

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

February 1999 26 TORQUE PATTERN

STEERING VALVE

Figure 1-1.

G8.2

NOTICE:

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).

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

STEERING VALVE

Figure 1-1.

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).

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

STEERING VALVE

G8.4

22.Remove the manual steering check valve assembly from the housing (9), refer to Figure 1-1.

NOTE:

The manual steering check valve assembly consists of a set screw (24), check ball seat (25), seals (26 and 27), check ball (28), and a check ball retainer (29).

23.Remove the set screw (24).

24.Install a #10-24 machine screw into the end of the check ball seat (25). Then lift the check ball seat (25) out of the housing (9) by pulling on the screw with pliers.

25.Remove and discard the seals (26 and 27) from the check ball seat (25).

26.Tip the housing (9) to remove the check ball (28) and check ball retainer (29).

CAUTION:

Do not remove any valves other than the manual steering check valve and the anti-cavitation valves. All other valves are factory preset and are non-serviceable.

INSPECTION

1. Inspect all mating surfaces for burrs and sharp edges. Replace parts as required. Do not use grit paper or file or grid these parts.

2. Clean all metal parts in a cleaning solvent. Blow dry all metal parts. Do not wipe dry with cloth or paper towel.