Service Book DD70

7/25/2019 Service Book DD70

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VOLVOCONSTRUCTION

EQUIPMENT

SERVICE

MANUAL

MORECARE.BUILTIN.

D

D70/DD70HF


2/134

CAL

IFORNIA

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Proposition65Warning

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posts,

termi

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accessories

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compo

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ashhandsafterhandling.


3/134

TA

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CONTENTS

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CONTE

NTS

EFF. w/ initialproduction

A1A1

Table of Contents..............................................A1Features of This Manual...................................B1Safety Information ............................................C1Illustrated Hose Schematic ..............................D1

HYDRAULICPropulsion

Vibration

Schematics.....................................................

Component Teardown & Rebuild

Schematics


E1Overview ..................................................E2Neutral/Brakes Applied.............................E3Forward/Brakes Released........................E4Reverse/Brakes Released .......................E5

Propulsion Pump......................................E6Drum Drive Motor.....................................E7

....................................................F1Overview ..................................................F2No Vibration..............................................F3Both Drums CW Vibration ........................F4Both Drums CCW Vibration......................F5Front Vibration only CW ...........................F6Front Vibration only CCW.........................F7

Rear Vibration only CW ............................F8Rear Vibration only CCW .........................F9

Vibration Pump .......................................F10Vibration Motor .......................................F11Vibration Control Valve ...........................F12

DD-70/70HF


4/134

A2A2

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Steering

ELECTRICAL

Schematics ....................................................


Schematics ....................................................

Component Teardown & Repair

G1Overview..................................................G2Neutral .....................................................G3Steer to Right ...........................................G4Steer to Left .............................................G5

Steering Pump .........................................G6Steering Valve..........................................G7Steering Cylinder .....................................G8

H1Start Circuit...............................................H2Ignition Circuit ..........................................H4Brake System, Test Position ....................H6

Brake System, Brakes Released .............H8Ignition/Shutdown Circuit .......................H10Water Circuit #1 .....................................H12Water Circuit #2 .....................................H14Water Circuit #1, Auto Position ..............H16

Alarm Circuit ..........................................H18Lights/Horn/Fuel Gauge.........................H20Vibration Circuit, Vib. Off........................H22

Vibration Circuit, CW, Front Drum..........H24Vibration Circuit, CCW, Rear Drum........H26Vibration Circuit, Auto., Both ..................H28

Water Pump ...........................................H29

November 2002

DD-70/70HF


5/134


TA

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CONTENTS

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A3A3

MACHINE

TROUBLESHOOTING

Hydraulic Symbol Quick Reference Chart ......L1Electrical Schematic Wire Color Code

Reference Chart......................................L2Hydraulic Full Schematic..................................L3Electrical Full Schematic..................................L5Electrical Full Schematic..................................L6

Component Teardown & RepairROPS/FOPS Replacement.......................J1Standard Swivel Bearing...........................J2Off-Set Swivel Bearing..............................J3Drum and Drum Drive...............................J4Eccentric Shaft Assembly..........................J5

Carrier and Spindle Assembly...................J6

Hydraulic ..................................................K1Engine & Water System ...........................K2Electrical System......................................K3

DD-70/70HF


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F6F6

FRONT VIBRATION ONLY CW

VIBRATION VALVE

VIBRATION PUMP

HYDRAULIC TANK

FROM PROPULSION CHARGE CIRCUIT

VIBRATION MOTOR (FRONT)

VIBRATION MOTOR ( REAR )

RETURN MANIFOLD

COOLER

R

R

R

R

a

PILOT

3B

C

P

Y

Y

R

C

Return

Suction

harge

dashed linesindicatelow pressure

L E G E N D

HighPressureigh

Pressure

DD-70

VIBRATION SYSTEM

October 1999

FEATURESOFTHISMAN

UAL

FEATURESOFTHISMAN

UAL

B1B1

ELECTRICALEFF. w/ S/N 141755

HYDRAULICEFF. w/ S/N 141620

PROPULSION PUMP......................................................................E6.4

A

B

Highpressure

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VIBRATIONPUMP

CASE

SUCTION

Schematics &

Trouble

shoo

tingS

chematics &

Trouble

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VIBRATIONPUMP

CASE

SUCTION

Each page is specific toone functional

subsystem.

Colors are standardthroughout manual.

Operational status isidentified by color.

Standard symbols areused.

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.

Comp

onentR

epair

Proc

eduresINSPECTION

ASSEMBLY

PROPULSION PUMP

DISASSEMBLY


7/134

SAFETYINF

ORMAT

ION

SAFETYINF

ORMAT

ION

Before performing any maintenance or service procedures onyour DD-70, refer to the DD-70 operation and maintenance

manual and the AEM Safety Manual for Safety Instructions.

C1C1


DD-70/70HF


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ILLUSTRATEDHOSESCHEMATIC

ILLUSTRATEDHOSESCHEMATIC

D1D1


DD-70/70HF


9/134

E1E1

PROP

U

LSION

PROP

U

LSION

Table of Contents

Overview ....................................E2Neutral/Brakes Applied.............E3Forward/Brakes Released ........E4Reverse/Brakes Released ........E5

EFF. W/ initialproduction

HYDRAULICTANK

DRUMDRIVE MOTOR

(REAR)

DRUMDRIVE MOTOR

(FRONT)

BRAKEDESTOKE

VALVE

RETURNMANIFOLD

PROPULSIONPUMP

DD-70/70HFSettings and Specifications-Propulsion*

Engine RPM (Hi/Low) 2650/1000Flow at Input Speed 88.7 l/m

23.4 g/mSystem Relief Pressure (psi/bar) 6090/420Charge Pressure Relief (psi/bar) 350/24


10/134

E2E2

OVERVIEW

DESTROKE / BRAKE VALVE

FRONT

REAR

DRUM DRIVE MOTOR

DRUM DRIVE MOTOR

HYDRAULIC TANK

RETURN MANIFOLD

PROPULSION PUMP

M4

M5

M3 L2

M1

M2

A

BL1S

L R

A

S1 B!

B2

TPS2

12

24 bar

420 bar

420 bar

20 bar

12 bar fully released


FLOW

R

M6

BRAKE

BRAKE

SUCTION STRAINER

DD-70/70HF

PROPULSION SYSTEM


11/134

E3E3


FRONT

REAR

HYDRAULIC TANK

RETURN MANIFOLD

PROPULSION PUMP

M4

M5

M3 L2

M1

M2

A

BL1S

L R

A

S1 B1

B2

TPS2

12

24 bar

420 bar

420 bar

20 bar



FLOW

R

M6

BRAKE

BRAKE

SUCTION STRAINER

Return

Suction

harge


L E G E N D

NEUTRAL/BRAKES APPLIED

DRUM DRIVE MOTOR

DRUM DRIVE MOTOR

DD-70/70HF

PROPULSION SYSTEM


12/134

E4E4


FRONT

REAR

HYDRAULIC TANK

RETURN MANIFOLD

PROPULSION PUMP

M4

M5

M3 L2

M1

M2

A

BL1S

L R

A

S1 B!

B2

TPS2

24 bar

420 bar

420 bar



1

FLOW

R

M6

20 bar

2 BRAKE

BRAKE

SUCTION STRAINER

Return

Suction

harge


L E G E N D

High

Pressure

igh

Pressure

FORWARD BRAKES RELEASED

DRUM DRIVE MOTOR

DRUM DRIVE MOTOR

DD-70/70HF

PROPULSION SYSTEM


13/134

E5E5


FRONT

REAR

HYDRAULIC TANK

RETURN MANIFOLD

PROPULSION PUMP

M4

M5

M3 L2

M1

M2

A

BL1S

L R

A

S1 B!

B2

TPS2

24 bar

420 bar

420 bar



FLOW

R

M6

20 bar

2 1 BRAKE

BRAKE

SUCTION STRAINER

Return

Suction

harge


L E G E N D

High

Pressure

igh

Pressure

REVERSE/BRAKES RELEASED

DRUM DRIVE MOTOR

DRUM DRIVE MOTOR

DD-70/70HF

PROPULSION SYSTEM


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1

TABLE OF CONTENTS

E6.1

DD-70 / PROPULSION PUMP

TABLE OF CONTENTS .....................................................................E6.1

LIP SEAL AND SHAFT .......................................................................E6.2Disassembly ..........................................................................E6.2Inspection ..............................................................................E6.2

Assembly ...............................................................................E6.3MULTI FUNCTION VALVE CARTRIDGES ..........................................E6.4

Disassembly ..........................................................................E6.4

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

CHARGE RELIEF VALVE ...................................................................E6.5

Disassembly ..........................................................................E6.5Inspection ..............................................................................E6.5Assembly ...............................................................................E6.5

CHARGE PUMP................................................................................. E6.6

Disassembly ..........................................................................E6.6


REMOTE CHARGE PRESSURE FILTRATION ..................................E6.7

Disassembly ..........................................................................E6.7Inspection ..............................................................................E6.7Assembly ...............................................................................E6.7

MANUAL DISPLACEMENT CONTROL ...................................................E6.8Disassembly ..........................................................................E6.8

Assembly..................................................................................E6.8

PROPULSION

PUMP


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E6.2


SM99A007

NOTICE:Prior to performing repairs on this component, contact the manufacturers

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 and discard 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).

WARNING:Safety glasses must be worn when removing the retaining ring (7).

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) 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 bearingassembly (8) as required.

Figure 1-1.

LIP SEAL AND SHAFT


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E6.3


Figure 1-1.

LIP SEAL AND SHAFT

ASSEMBLY

1. If necessary, install the original bearing assembly (8) or a new bearing

assembly (8) on the shaft (9), refer to Figure 1-1.

WARNING:Safety glasses must be worn when installing the retaining ring (7).

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).

9. Install the retainer plate (2) onto the housing (4) and secure it with the

screws (1).

10. Torque the screws (1) to 16 Nm (12 lb-ft).

SM99A007


17/134

E6.4


SM99A008A

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 cartridge for damage to parts.

ASSEMBLY

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

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

2. Install the new 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


18/134

E6.5


DISASSEMBLY

NOTE:To maintain original adjustment, mark the plug (7), the locknut (8), and thehousing (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 Nm (38 lb-ft).

4. Check and adjust the charge pressure as required.

CHARGE RELIEF VALVE

SM99A008B

Figure 1-3.


19/134

E6.6


DISASSEMBLY

1. Remove the screws (1) and retaining plate (2) from the housing (10),


2. Remove the charge pump cover (3), bushing (4), and O-ring (5). Discard

the O-ring (5). Note the orientation of the gerotor.

3. Remove the charge pump shaft (6) and key (7).

4. Remove the charge pump gerotor assembly (8) and alignment pin (9).

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.

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 gerotorassembly (8) inside diameter and outside diameter.

2. Install the charge pump gerotor assembly (8) and alignment pin (9).

3. Install the charge pump shaft (6) and key (7). The internally splined end

of the shaft must engage the main pump shaft.

4. Install the bushing (4), a new O-ring (5) and charge pump cover (3).

5. Install the retaining plate (2) and secure the retaining plate (2) with

screws (1).

6. Torque the screws (1) to 13.5 Nm (10 lb-ft).

Figure 1-4.

CHARGE PUMP

SM99A028


20/134

E6.7


Figure 1-5.

INTEGRAL CHARGE PRESSURE FILTRATION

DISASSEMBLY

1. Remove the filter canister (11) from the filter head (12), refer to Figure

1-5.

2. Loosen the swivel locknut (13).

3. Remove the filter head (12) from the end cap (10).

4. Remove and discard the O-ring (14) from the filter head (12).

INSPECTION

1. Inspect the filter head (12) and tube (15) for blockage or foreign material.

ASSEMBLY

1. Install a new O-ring (14) onto the filter head (12).

2. Rotate the filter head (12) so the threads engage with the threads in the

end cap (10) and continue to rotate clockwise 6 or 7 turns.

3. Face filter head (12) 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 allowoil to bypass the filter and enter the charge system.

4. Torque the swivel locknut (13) to 122 Nm (90 lb-ft).

5. Install a new filter canister (11) per manufacturers instructions.

SM99A028


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E6.8


Figure 1-6.

MANUAL DISPLACEMENT CONTROL

DISASSEMBLY

1. Clean external surfaces prior to removal.

2. Remove the screws (1) securing the manual displacement control (2) to

the housing (8), refer to Figure 1-6.

3. Remove the manual displacement control (2), orifice check valve (3),

spring (4), spring retainer (5), and gasket (6) from the housing (8).

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

ASSEMBLY

1. Install a new gasket (6) on the housing (8).

2. Install the orifice check valve (3), spring (4), and spring retainer (5) into

the manual displacement control (2).

3. All at once, install the manual displacement control (2) 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 (7) off center creating center torque. If there is a lack of

centering torque, repeat step 3.

5. Align the gasket (6) and install the screws (1), torque the screws (1), to

16 Nm (12 lb-ft).

SM99A029


22/134

1

TABLE OF CONTENTS

E7.1

DD-70 / DRUM DRIVE MOTOR

TABLE OF CONTENTS .....................................................................E7.1

DISTRIBUTION VALVE.......................................................................E7.2Disassembly ..........................................................................E7.2Inspection ..............................................................................E7.2

Assembly ...............................................................................E7.3CYLINDER BLOCK AND CAM ...........................................................E7.4

Disassembly ..........................................................................E7.4

Assembly ...............................................................................E7.5CYLINDER BLOCK ............................................................................E7.6

Disassembly ..........................................................................E7.6


BEARING HOUSING..........................................................................E7.8

Disassembly ..........................................................................E7.8

Inspection ..............................................................................E7.9Assembly ............................................................................. E7.10

BRAKE DISC ....................................................................................E7.12

Disassembly ........................................................................E7.12Inspection ............................................................................E7.12Assembly ............................................................................. E7.13

DRUMDRIVE

MOTOR

DRUMDRIVE

MOTOR


23/134

E7.2


SM99C016A



DISASSEMBLY

1. Mark the position of the distribution block (1) in relation to the cam (2)

and the bearing support (3), refer to Figure 1-1.

2. Remove the screws (4) from the distribution block (1).

3. Remove the distribution block (1) from the cam (2).

4. Mark the position of the valving (5) in relation to the distribution block(1).

5. Remove the valving (5) from the distribution block (1).

6. Remove the springs (7) from the valving (5).

7. Remove and discard the O-rings and backup rings (6) from the valving

(5).

8. Remove and discard O-rings (8) from the distribution block (1) andbearing support (3).

INSPECTION

1. Inspect the condition of the valving mating surfaces where it meets the

cylinder block and at the seal contact surfaces.

Figure 1-1.

DISTRIBUTION VALVE


24/134

E7.3


ASSEMBLY

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

rings (6) grooves in the distr ibution block (1), refer to Figure 1-1.

2. Install the O-rings and backup rings (6) into the distribution block (1).

3. Apply grease into the springs (7) housings.

4. Install the springs (7) into the valving (5).

6. Install the valving (5) into the distribution block (1).

7. Apply a light coat of petroleum jelly or grease to the contact surfaces of

the distribution block (1) and the valving (5).

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

9. Install the new O-rings (8) on the distribution block (1) and bearing support

(3).

10. Install the distribution block (1) onto the cam (2). Align marks made

during the disassembly.

13. Install the screws (4) into the distribution block (1).14. Torque the screws (4) to 300 Nm (221 lb-ft).

Figure 1-1.

DISTRIBUTION VALVE

SM99C016A


25/134

E7.4


SM99C016B

DISASSEMBLY

1. Mark the position of the distribution block (1) in relation to the cam (2)

and the bearing support (3), refer to Figure 1-2.

2. Remove the screws (4) from the distribution block (1).

3. Remove the distribution block (1) from the cam (2).

4. If the valving (5) remains in the distribution block (1), removal of the

valving (5) and springs (7) are not necessary.

5. If the valving (5) remains attached to the cylinder block (9), mark the

position of the valving (5) in relation to the distribution block (1).

6. Remove the valving (5) from the distribution block (1).


8. Remove and discard the O-rings and backup rings (6) from the valving

(5).

9. Remove and discard O-rings (8) from the distribution block (1) and

bearing support (3).

Figure 1-2.

CYLINDER BLOCK AND CAM


26/134

E7.5


ASSEMBLY

1. Apply a light coat of petroleum jelly or grease into the O-rings and backup

ring (6) grooves in the distr ibution block (1), refer to Figure 1-2.

2. Install the O-rings and backup rings (6) into the distribution block (1).

3. Apply grease into the spring (7) housings.


5. Install the valving (5) into the distribution block (1).


the distribution block (1) and the valving (5).

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

8. Install the new O-rings (8) on the distribution block (1) and bearing support

(3).

9. Install the cam (2) onto the bearing support (3). Align marks made during

the disassembly.

10. Install the cylinder block (9) into the cam (2).11. Install the distribution block (1) onto the cam (2).

12. Install the screws (4) into the distribution block (1).


Figure 1-2.

CYLINDER BLOCK AND CAM

SM99C016B

DD 70 / DRUM DRIVE MOTOR


27/134

E7.6


Figure 1-3.

CYLINDER BLOCK

DISASSEMBLY

1. Mark the position of the bearing support (3) in relation to the cam (2)

and the distribution cover (1), refer to Figure 1-3.

2. Remove the screws (4) from the distribution cover (1).

3. Remove the bearing support (3) from the distribution cover (1).

4. Remove the cam (2) from the distribution cover (1).

5. Remove and discard the O-rings (8) from the cam (2).


position of the valving (5) in relation to the distribution cover (1).

7. Remove the valving (5) from the cylinder block (9).


9. If the valving (5) remains in the distribution cover (1), removal of the

valving (5) and springs (7) is not necessary.

10. Remove the clips (10) from the cylinder block (9).

11. Remove the pistons (11) from the cylinder block (9).

INSPECTION

1. Inspect the surface condition of the bores in the cylinder block (9) for

seizing or abnormal wear.

SM99C016C



28/134

E7.7


ASSEMBLY

1. Apply a light coat of petroleum jelly or grease to the pistons (11), refer to

Figure 1-3.

2. Install the pistons (11) into the cylinder block (9).

3. Install the clips (10) into the cylinder block (9).



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

and backup rings (6).

7. Install the valving (5) into the distribution cover (1).


the cylinder block (9) and the valving (5).

9. Install the cylinder block (9) into the cam (2).

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

11. Install the O-rings (8) on the distribution cover (1) and bearing support(3).

12. Install the bearing support (3) and cam (2) onto the distribution cover

(1).

13. Install the screws (4) into the distribution cover (1).


Figure 1-3.

CYLINDER BLOCK

SM99C016C



29/134

E7.8


SM99C016D

DISASSEMBLY

1. Mark the position of the bearing support (3) in relation to the cam (2)

and the distribution cover (1), refer to Figure 1-4.

2. Remove the screws (4) from the distribution cover (1).

3. Remove the bearing support (3) from the distribution cover (1).

4. Remove the cam (2) from the distribution cover (1).

5. Remove and discard the O-rings (8) from the cam (2).


position of the valving (5) in relation to the distribution cover (1).

7. Remove the valving (5) from the cylinder block (9).


9. If the valving (5) remains in the distribution cover (1), removal of the

valving (5) and springs (7) are not necessary.

10. Using a press, compress the bearings in the bearing support (3).

WARNING:Safety glasses must be worn when removing the snap rings.

11. Remove the snap ring (13) from the shaft (14).

12. Remove and discard the thrust ring (15) from the bearing support (3).

13. Remove the shims (16) from the bearing support (3).

14. Press out the shaft (14) from the bearing support (3).

15. Remove the sealing ring (17) from the shaft (14).

Figure 1-4.

BEARING HOUSING

6



30/134

E7.9


16. Remove and discard the cage bearing (18) and sealing ring (17) from

the bearing support (3), refer to Figure 1-4.

17. Remove the cage bearing (19) from the bearing support (3).

18. Remove the sealing ring (20) from the bearing support (3).

INSPECTION

1. Inspect the surface of the sealing ring (20) on the shaft (14).

2. Inspect the condition of the splines on the shaft (14).

3. Inspect the contact surfaces of the sealing ring (17) on the bearing

support (3).

4. Inspect the condition of the contact surfaces for their level and wear.

Figure 1-4.

BEARING HOUSING

SM99C016D

6



31/134

E7.10


ASSEMBLY

1. Install the sealing ring (20) into the bearing support (3), refer to Figure

1-4.

2. Install the cage bearing (18 and 19) outer races into the bearing support

(3).

3. Coat the cage bearing (18) with LG EP2 grease.

4. Install the cage bearing (18) inner race into the outer race of the cage

bearing (18).

5. Degrease the sealing ring (17).6. Install the sealing ring (17) onto the shaft (14).

7. Install the shaft (14) into the bearing support (3).

8. Install the inner race of the cage bearing (19) into the bearing support

(3).

9. Install the thrust ring (15) into the bearing support (3).

10. Install the snap ring (13) on to the shaft (14).11. The size of shims (16) to use is determined by adding the distance

between the snap ring (13) and the cage bearing (19) then adding 12

mm.

12. Remove the snap ring (13) and thrust ring (15) from the shaft (14).

13. Install the shims (16) onto the shaft (14).

14. Compress the bearings using a press and install the snap ring (13) onto

the shaft (14).

15. Check the shaft (14) rotation torque.

16. Apply a light coat of petroleum jelly or grease to the O-rings and backup

rings (6).

Figure 1-4.

BEARING HOUSING

SM99C016D

6



32/134

E7.11


17. Install the O-rings and backup rings (6) into the grooves in the distribution

block (1), refer to Figure 1-4.



20. Install the valving (5) into the distribution cover (1).


the cylinder block (9) and the valving (5).

22. Install the cylinder block (9) into the cam (2).

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

24. Install the O-rings (8) on the distribution cover (1) and bearing support

(3).

25. Install the bearing support (3) and cam (2) onto the distribution cover

(1).

26. Align the marks on the bearing support (3), cam (2), and distribution

cover (1).

27. Install the screws (4) into the distribution cover (1).


Figure 1-4.

BEARING HOUSING

SM99C016D

6



33/134

E7.12


SM99C016E

DISASSEMBLY

1. Remove the plug (21) from the cover (22), refer to Figure 1-5.

2. Remove the cover (22) from the brake body (23).

3. Compress the spring washer (24) and remove the snap ring (25).

3. Remove the spring washer (24), piston (26) and brake disc (27) from

the brake body (23).

4. Remove the shims (28) from the brake body (23).

5. Remove and discard the O-ring (29) from the brake body (23).

6. Remove and discard the O-ring (30) from the cover (22).

INSPECTION

1. Inspect the condition of the shaft (12) splines and brake body (23).

2. All traces of rust, mud, and water must be removed from all the

disassembled parts.

Figure 1-5.

BRAKE DISC


34/134


35/134

VIBRA

TION

VIBRA

TIONTable of Contents

Overview ....................................F2No Vibration ...............................F3Both Drums CW Vibration ........F4Both Drums CCW Vibration......F5Front Vibration only CW ...........F6Front Vibration only CCW.........F7Rear Vibration only CW ............F8Rear Vibration only CCW ..........F9

F1F1 VIBRATION

MOTOR(FRONT)

VIBRATIONVALVE

RETURNMANIFOLD

VIBRATIONMOTOR(REAR)

HYDRAULICTANK

OILCOOLER

VIBRATIONPUMP


DD-70/70HF

Settings and Specifications-Vibration*


23.4 g/mSystem Relief Pressure (psi/bar) 3000/207


36/134

F2F2

VIBRATION VALVE

VIBRATION PUMP

HYDRAULIC TANK



VIBRATION MOTOR ( REAR )RETURN MANIFOLD

COOLER

103 BAR

103 BAR

103 BAR

227 BAR

5a

5b

M7

M5 M4

B

A

M6 PILOT

3A

3B

3C

2

P

Y

Y

4A

4B

S3

S4

1.7 BAR

C

T

DD-70/70HF

VIBRATION SYSTEM

OVERVIEW


37/134

DD 70/70HF


38/134

F4F4

VIBRATION VALVE

VIBRATION PUMP

HYDRAULIC TANK




COOLER

103 BAR

103 BAR

103 BAR

227 BAR

5a

5b

M7

M5 M4

B

A

M6 PILOT

3A

3B

3C

2

P

Y

Y

4A

4B

1.7 BAR

C

T

S3

S4

Return

Suction

harge


L E G E N D

High

Pressure

igh

Pressure

BOTH DRUMS CW VIBRATION

DD-70/70HF

VIBRATION SYSTEM

L E G E N D DD 70/70HF


39/134

F5F5

VIBRATION VALVE

VIBRATION PUMP

HYDRAULIC TANK




COOLER

103 BAR

103 BAR

103 BAR

227 BAR

5a

5b

M7

M5 M4

B

A

M6 PILOT

3A

3B

3C

2

P

Y

Y

4A

4B

1.7 BAR

C

T

S3

S4

Return

Suction

harge


L E G E N D

High

Pressure

igh

Pressure

BOTH DRUMS CCW VIBRATION

DD-70/70HF

VIBRATION SYSTEM


40/134


41/134


42/134

L E G E N D

DD-70/70HF


43/134

F9F9

REAR VIBRATION ONLY CCW

Return

Suction

harge


High

Pressure

igh

Pressure

VIBRATION VALVE

VIBRATION PUMP

HYDRAULIC TANK




COOLER

103 BAR

103 BAR

103 BAR

227 BAR

5a

5b

M7

M5 M4

B

A

M6 PILOT

3A

3B

3C

2

P

Y

Y

4A

4B

1.7 BAR

C

T

S3

S4

DD-70/70HF

VIBRATION SYSTEM

DD-70 / VIBRATION PUMP


44/134

1

TABLE OF CONTENTS

F10.1

TABLE OF CONTENTS ................................................................... F10.1

SEAL KIT ..........................................................................................F10.2

Disassembly ........................................................................ F10.2Inspection ............................................................................F10.3

Assembly .............................................................................F10.3

VIBRATIONPUMP


45/134

DD-70 / VIBRATION PUMP


46/134

F10.3

SEAL KIT

INSPECTION



2. Inspect the pump housing sections (1,2 and 3) for wear or damage.

ASSEMBLY

1. Lightly lubricate the new O-ring (11) with clean petroleum jelly, then

install the new O-ring (11) into the rear housing section (3) of the pump.

2. Install the middle housing section (2) of the pump onto the rear housing

section (3), ensuring that the dowel pins (14) are in place.

3. Lightly lubricate the new O-rings (7,9 and 10) and backup rings (8)

with clean petroleum jelly, then install the new O-rings (7,9 and 10)

and backup rings (8) into the front housing section (1) of the pump.

4. Install the front housing section (1) of the pump onto the middle housing

section (2), ensuring that the dowel pins (14) are in place.

5. Install the eight nuts (12) on the studs (13) and tighten the nuts (12)

securely.

6. Lightly lubricate the outside diameter of the new shaft seal (6) with

Loctite High Performance Sealant #59231.

CAUTION:To prevent damage to the shaft (4) or shaft seal (6), wrap the spline end ofthe shaft (4) with thin plastic.

2. Slide the new shaft seal (6) over the shaft (4) and use a hollow tube to

press the seal to the bottom of the front housing section (1) bore.3. Install the retaining ring (5).

5

4

1

6

78

92

3

11101213

14

DD-70 / VIBRATION MOTOR


47/134

1

TABLE OF CONTENTS

F11.1


SEAL KIT ..........................................................................................F11.2

Disassembly ........................................................................ F11.2Inspection ............................................................................F11.2

Assembly .............................................................................F11.2

VIBRATION

MOTOR

VIBRATIONMOTOR



48/134

F11.2



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.

Figure 1-1.

SEAL KIT



49/134

F11.3

Figure 1-1.

ASSEMBLY

1. Place a new gasket (7) on the motor end cap (9), refer to Figure 1-1.

Make sure that the end cap and the gasket line up.2. Place the needle bearing in the center hole of the end cap gasket (9).

3. Using the bolt provided fasten the motor end cap (7) to the motor housing

(8) until firmly secure.

4. Place the new O-Ring (3) and the Roller bearing (4) on the shaft (5)

inside the motor housing.

5. Place the retainer ring (1) on the shaft (5) inside the motor housing (8).

6. Lightly lubricate the outside diameter of the new lip seal (3) with Loctite

High Performance Sealant #59231.

CAUTION:To prevent damage to the lip seal (3), wrap the spline or key end of theshaft (4) with thin plastic.

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

(2) bore.8. Install the retaining ring (1).

SEAL KIT

DD-70 / VIBRATION CONTROL VALVE


50/134

1

TABLE OF CONTENTS

F12.1


SEAL KIT ..........................................................................................F12.2

Disassembly ........................................................................ F12.2Assembly .............................................................................F12.3

VIBRATIONCONTROL

VALVE


51/134

DD 70/70HF


52/134

STEER

ING

STEER

ING

Table of Contents

Overview....................................G2Neutral .......................................G3Steer to Right ............................G4Steer to Left...............................G5

G1G1


HYDRAULICRESERVOIR

STEERINGPUMP

STEERINGVALVE

STEERINGCYLINDER

RETURNFILTER

RETURNMANIFOLD

DD-70/70HF

Settings and Specifications-Steering*


27.8 g/mSystem Relief Pressure (psi/bar) 2550/176


53/134


54/134

Return

L E G E N D

High

Pressure

igh

DD-70/70HF

STEERING SYSTEM


55/134

G4G4

RETURNMANIFOLD

FLOW

P

T

235 bar

235 bar

L

R

138bar

RETURNFILTER

HYDRAULIC TANK

3.4 bar

SUCTION STRAINER

STEERING PUMP

STEERING CYLINDER

STEERING VALVE

STEER TO RIGHT

Suction

harge


PressurePressure STEERING SYSTEM

Return

L E G E N D

High

Pressure

igh

DD-70/70HF

STEERING SYSTEM


56/134

G5G5

FLOW

P

T

235 bar

235 bar

L

R

138bar

RETURNMANIFOLD

RETURNFILTER

HYDRAULIC TANK

3.4 bar

STEERING VALVE

STEERING CYLINDER

STEERING PUMP

SUCTION FILTER

Suction

harge


PressurePressure

STEER TO LEFT

STEERING SYSTEM


57/134


58/134

DD-70 / STEERING PUMP

ASSEMBLY


59/134

G6.3

GM99B011

Figure 1-1.

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),


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 installingthe 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.

DD-70 / STEERING VALVE

TABLE OF CONTENTS .................................................................... G7.1


60/134

1

TABLE OF CONTENTS

G7.1

STEERING VALVE ............................................................................ G7.2

Disassembly ......................................................................... G7.2Inspection ............................................................................. G7.4

Assembly .............................................................................. G7.5

STEERINGVALVE


61/134


62/134


22. Remove the manual steering check valve assembly from the housing


63/134

G7.4

SM99B032

(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 ballretainer (29).

23. Remove the set screw (24).

24. Screw 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 sear

(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.

TORQUE PATTERN

Figure 1-1.

STEERING VALVE


ASSEMBLY


64/134

G7.5

SM99B032

1. Install the manual steering check valve assembly in the housing (9),


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 ballretainer (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).

TORQUE PATTERN

Figure 1-1.

STEERING VALVE


13. Position the centering springs (22) on the bench so that the extended

d i d d th h d t ti i t th f t Fi


65/134

G7.6

SM99B032

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 spring slots.

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).

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).

TORQUE PATTERN

Figure 1-1.

STEERING VALVE


66/134

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



67/134

G7.8

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.

SM99B032

TORQUE PATTERN

Figure 1-1.

STEERING VALVE

DD-70 / STEERING CYLINDER

TABLE OF CONTENTS .................................................................... G8.1


68/134

1

TABLE OF CONTENTS

G8.1

SEAL KIT ........................................................................................... G8.2

Disassembly ......................................................................... G8.2Inspection ............................................................................. G8.3

Assembly .............................................................................. G8.4

STEERINGCYLINDER


NOTICE:Prior to performing repairs on this component contact the manufacturers


69/134

G8.2

SM99C010

Prior to performing repairs on this component, contact the manufacturer s


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 theheadcap (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 struck 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


9. Loosen and remove the locknut (7) from the piston rod (2), refer to Figure

1-1.


70/134

G8.3

SM99C010

10. Remove the piston (3), head (4), and headcap (6) from the piston rod

(2).

11. Remove and discard the O-ring (8) from the piston rod (2).

12. Remove and discard the wiper (9), lip seal (10), and wear rings (11)

from the inside diameter of the head (4).

13. Remove and discard the O-ring (12) and backup ring (13) from the outside

diameter of the head (4).

14. Remove and discard the wear ring (14) and glyd-ring (15) from the piston(3).

INSPECTION

1. Clean all parts in cleaning solvent. Use only lint free cloths for cleaning

and drying.

2. If the piston rod (2), piston (3), head (4), or the tube (1) are damaged in

any way, a new cylinder assembly must be used.

Figure 1-1.

SEAL KIT


71/134


72/134

DD-70


73/134

H1H1

ELECTR

ICAL

ELECTR

ICAL

Table ofContents

Start Circuit...................H2


STARTCIRCUIT

POWER

RELAY

THROTTLE

SOLENOID

STARTER

RELAY

ALTERNATOR

DISCHARGE

HYDRAULIC

OIL TEMP.

ENGINE

COOLANTENGINEOIL PRESSUREALTERNATOR

START

CIRCUIT

IGNITION

SWITCH

NEUTRAL

START

DIODE ASSY.

FUEL

SOLENOID

STARTER

PARK BRAKE

SWITCH

FUSE

BLOCK

EMERGENCY

STOP SWITCHHI/LO

RPM

SWITCHNEUTRAL

START

SWITCH

F

DD-70

ELECTRICAL SYSTEMHARNESS

CONNECTION


74/134

H2H2

8 1152

1 64 7

9 1012

TEST

BRAK

E

ON

BRAK

E

OF

M

STARTER

B+

ALTERNATOR

87A

87 30

8685

STARTER RELAY

C

GROUND ON

ELEC. BRACKET

F1

FUSE

15 AMP

IGNITION SWITCH

OFF

ON

START

B PR

GNDSACCI

DBE

RD

DBE

FUEL SOLENOIDBK

OE/WE OE/WE

GY/WE

WE/BN

OE

GY/BK

RD

RD

BK

BK/RD

DGN/BK

OE/RD

EMERGENCY STOP

1B

2B

1A

2A

HI/LO RPM

SWITCH6 4

5

3 1

2

LO HI

POWER RELAY30

87 85

86

N

HARNESS CONNECTION

LBE

LBE

BK

RD/WE

F8FUSE

30 AMP

D

HARNESS

CONNECTION

DGN

TO HI/LO SWITCH

BN/WE

THROTTLE

SOLENOIDABC

DGN

BK

RD

NEUTRAL START

DIODE ASSY.

ABCDWE/BN

NEUTRAL START

SWITCH

P HARNESS

CONNECTION

BK

HARNESS CONNECTION

A

B

C

RD/WE

RD

FUSE

LINKS

BRAKES APPLIED POSITION

PARK BRAKE SWITCH

1.0

5.03.0

L

.8

3

B+

START CIRCUIT

CONNECTION

BK


75/134

DD-70

ELECTRICAL SYSTEM

HARNESS


76/134

H4H4

RHARNESS

CONNECTION

HI/LO RPM

SWITCH

POWER RELAY

EMERGENCY STOP

1B 2B

1A 2A

PARK BRAKE SWITCH

IGNITION SWITCH

OFF

ON

ST

ART

B PR

GNDSACCI

SHUT-DOWN

TIMER RELAY

INPUT

INIT

COM

N/C N/O

B

A

SEAT SWITCH

N HARNESSCONNECTION

1

2

3 4

5

6

ALARM

+

_

85 86

3087

STARTER B+

LHARNESS

CONNECTION

F1

15A

FUSE

TO HI/LO SWITCH

BN/WE

THROTTLE

SOLENOIDAB

C

DGN

BK

ABC

D

HARNESS

CONNECTION

HARNESS

CONNECTION

F8

30 A

FUSE

C

TO

LIGHT

RELAY

TO

AUXILIARY

WATER PUMPS

TO

AUTO VIB.

CONTROL

DBEDBE

RD/WE

DGN

RD/WE

RD/WERD/WE

RD/WE

RD

RD

RD

LBE

N

LBE

LBE

TN

LBE

LBE

LBE

PE/WE

PE/WE

PE/WE

PE/WE

PE/WEPE/WE

BK/WE

BK/WE

PE/WE

BK/WE

PK/WE

GY/BK

+

_

BACK UP

ALARM

TN


G

HARNESSCONNECTION

TN

HI LOW

+_

.8 FUSE LINK

2.0

2.0

1.0

8 1152

1 64 7 9 10 12

TEST

BRAKE

ON

BRAKE

OFF

FUSE LINKS

3

IGNITION CIRCUIT

BACK UP

ALARM SWITCH

F5

20 A

FUSE

CONNECTION


77/134


78/134

DD-70

POWEREMERGENCY FUSE


79/134

H7H7

BRAKE SYSTEM,BRAKES RELEASED

ELECTR

ICAL

ELECTR

ICAL

Table ofContents

Brake System,Brakes Released...............H8


IGNITION

SWITCH

HORN

HORN

BUTTON

NEUTRAL

START

SWITCH

POWER

RELAY

EMERGENCY

STOP SWITCH

FUSE

BLOCK

PARK

BRAKE

LIGHT

PARK

BRAKESWITCH

BRAKE

DUMP

VALVE

PROPULSION

PUMP

RETURN

TO NEUTRALBRAKE

TESTDIODE

ASSY.

IGNITION

SWITCHRELAY

BRAKE

LATCHING

RELAY

NEUTRAL

STARTDIODE

ASSY.

P BRAKE PRESS.

SWITCH

DD-70

ELECTRICAL SYSTEM


80/134

H8H8

NEUTRAL START

DIODE ASSY.

ABCD

NEUTRAL START

SWITCH

P HARNESS

CONNECTION

BK

85

86

87 87A

30

BRAKE LATCHING

RELAY

BRAKE DUMP VALVE

#7PUMP RETURN

TO NEUTRAL

#8BRAKE TEST

DIODE ASSY.

B A

PARK BRAKE

IND. LIGHT

BK

HARNESS

CONNECTION

RD/BK

FROM

POWER

RELAY

A B

SWITCH

G

RD/BK

B

DPE

F2

15 A

FUSE

DPE

EMERGENCY STOP

1B

2B

1A

2A

PARK BRAKE SWITCH

LBE

IGNITION SWITCH

I. TERM.

2 1 2 1

PE/WE

EHARNESS

CONNECTION

PK/WE

PK/WE

YW

YW

F

OE/RDPK/WE

PK/WE

OE/RDOE/RD

OE/RD

BK

OE/RD

BK

WE/BN

YW

T

EST

BRAKEON

BRAKE

OFF

8 1152

1 64 7 9 10

123

HARNESS

CONNECTION

BRAKE SYSTEM, BRAKES RELEASED


81/134

CBK

HARNESS

CONNECTIONTO

DD-70ELECTRICAL SYSTEM


82/134

H10H10

R

HI/LO RPM

SWITCH

POWER RELAY

EMERGENCY STOP

1B 2B

1A 2A

PARK BRAKE

SWITCH

IGNITION SWITCH

OFF

ON

START

B PR

GNDSACCI

SHUT-DOWN

TIMER RELAY

INPUT

INIT

COM

N/C N/O

B

A

SEAT SWITCH

N HARNESS

CONNECTION

1

2

3 4

5

6

BACK UP

BACK UP

ALARM SWITCH

ALARM+

_

85 86

3087

STARTER B+

LHARNESS

CONNECTION

TO HI/LO SWITCH

BN/WE

THROTTLESOLENOID

AB

C

DGN

BK

ABC

D

F5

20 A

FUSE

C

TOLIGHT

RELAY

TO

AUXILIARY

WATER PUMPS

TOAUTO VIB.CONTROL

+

_

DBE DBE

RD/WE

DGN

RD/WE

RD/WERD/WE

RD/WE

RD

RD

RD

LBE

N

LBE

LBE

GTN

TN

TN

LBE

LBE

LBE

PE/WE

PE/WE

PE/WE

PE/WE

PE/WEPE/WE

BK/WE

BK/WE

PE/WE

BK/WE

PK/WE

GY/BK


BK

FUEL SOLENOID

BK

2 second delay

8 1152

1 64 7

9 10 12

TE

ST

BRAKE

ON

BRAKE

OFF

_ +

RD/GY

2.0

2.0

.8

FUSE LINKS

3

HARNESS

CONNECTION

F8

30 A

FUSE

F1

15 A

FUSE

HARNESS

CONNECTION

HARNESS

CONNECTION

BACK UPALARM

HARNESS

CONNECTION

IGNITION/SHUTDOWN CIRCUIT

DD-70

FUSE


83/134

H11H11

WATERCIRCUIT #1

ELECTR

ICAL

ELECTR

ICAL

Table ofContents

Water Circuit #1...............H12


MAIN WATERPUMPREAR

WATER 1FLOW CONTROL

WATER 1SWITCH

BLOCK

NEUTRAL STARTDIODE ASSY.

MAIN WATERPUMP

FRONT

NEUTRALSTART SWITCH

AUTOWATER RELAY

DD-70

WATER 1HARNESS


84/134

H12H12

WATER CIRCUIT #1

WE/BN


A B C D

WE/BN

NEUTRAL STARTSWITCH

P

HARNESS

CONNECTION

BK

A

B

C

1

3

2

FLOW CONTROL

12

3

4

5

6

WATER 1SWITCH

WP

1

2

WP

1

2

WATER 1

1 2 3

BAT

.-

ARM

-

BAT+

ARM

+

85

86

87A

30

87

AUTOWATER

RELAY

WE/RD

DBE/BK

GY/RD

H

J

K

HARNESSCONNECTIONS

K

OE/BK

R

DGN/WE

M

OE/GN

YW/BK

BK/WE

FRONT

REAR

WE/OE

WE/OE

BK/WE

F420 A

FUSE

RD/WE

FROMPOWERRELAY

TERM. 87

HARNESS CONNECTIONS

GY/GN

OE/BK

DGN/WE

OE/GN

DGN/WE

WE/RD

DBE/BK

GY/RD

2.0

OE/BK

OFF POSITION

DD-70

FUSE


85/134

H13H13

WATERCIRCUIT #2

ELECTR

ICAL

ELECTR

ICAL

Table ofContents

Water Circuit #2................H14


WATER 2SWITCH

AUXILARYWATER PUMP

REAR

BLOCK

AUXILARYWATER PUMP

FRONT

DD-70


86/134

H14H14

WATER 2 SWITCH

2

3

WP

1 2

WP

1 2

C

BK

BK

F

BN

BN

BN

DBE

C

DBE

F520 A

FUSE

DBE

DBE

B

HARNESSCONNECTIONFROM

POWER RELAYTERM. 87

RD/WERD/WE

HARNESSCONNECTION

WATER CIRCUIT #2

DD-70

WATER 1

FUSE

BLOCK


87/134

H15H15

WATER CIRCUIT #1,

AUTO POSITION

ELECTR

ICAL

ELECTR

ICAL

Table of

ContentsWater Circuit #1,Auto Position ...............H16


MAIN WATER

PUMP

REAR

WATER 1

FLOW CONTROL

WATER 1SWITCH

NEUTRAL START

DIODE ASSY.

MAIN WATER

PUMP

FRONT

NEUTRAL

START SWITCHAUTO

WATER RELAY


WATER 1FLOW CONTROL

HARNESS CONNECTIONS


88/134

H16H16

WE/BN


A BC D

WE/BN

NEUTRAL STARTSWITCH

PHARNESSCONNECTION

BK

A

B

C

1

3

2

12

3

4

56

WATER 1

SWITCH

WP1

2

WP1

2

WATER 1

1 2 3

BAT

.-

ARM

-

BAT+

ARM

+

85

86

87A

30

87

AUTOWATERRELAY

WE/RD

DBE/BK

GY/RD

H

J

K

K

OE/BK

R

DGN/WE

M

OE/GN

YW/BK

BK/WE

FRONT

REAR

WE/OE

WE/OE

BK/WE

F420 A

FUSE

RD/WE

FROMPOWERRELAY

HARNESS CONNECTIONS

HARNESS CONNECTIONS

2.0

SHOWN INOUT OF NEUTRAL

POSITION

FUSE LINK

WATER CIRCUIT #1, AUTO POSITION

DD-70

FUSEBLOCK

ENGINE

COOLANTENGINE OIL


89/134

H17H17

ALARMCIRCUIT

ELECTR

ICAL

ELECTR

ICAL

Table of

ContentsAlarm Circuit ................H18


IGNITIONSWITCH

ALTERNATORDIODE

OIL PRESSURESWITCH

HYD. TEMP.SWITCH

COOLANT TEMP.

SWITCH

ALTERNATOR

HYD. OIL

TEMP.

ALARM

FUSEBLOCKCOOLANTENGINE OILPRESSURE

ALTERNATORDISCHARGE


BK/RD

OIL PRESS. SWITCH

PLBE


90/134

H18H18

ALARM CIRCUIT

ALARM+

_

A

B

C

D

E

IGNITION SWITCH

OFF

B PR

GNDSACCI

3

5

4

2

1

6

68 OHM5 WATT

A

B

ALTERNATOR

ALT.DIODE

E

LGN/WE

LGN/WE

T

COOLANT TEMP.SWITCH

LBE/WE D LBE/WE

T

HYD. TEMP. SWITCH

DGN/RD

M DGN/RD

LGN/WE

LBE/WE

DGN/RD

DPE

RD/WE

F215 AFUSE

FROMPOWERRELAY

HARNESSCONNECTION

HARNESS

CONNECTION

HARNESSCONNECTION

YW/BK

LBE/BK

GY/GN

2.0

A

FUSE LINK

DIODE ASSY.

I

START

ON

DD-70

WORK LIGHTSWITCH

IMPACTMETER

FUSEBLOCK


91/134

H19H19

LIGHTS/HORN/FUEL GAUGE

ELECTR

ICAL

ELECTR

ICAL

Table of

ContentsLights/Horn/Fuel Gauge ...................H20


HORNBUTTON

WORK LIGHTSWITCH

FUELGAUGEALTERNATOR

DIODE

HORNLIGHTRELAY

FUEL

SENDER

ALTERNATOR


IALTERNATOR

A

TO ALTERNATOR DIODEGY/GN

GY/GN

HARNESS


92/134

H20H20L

FUEL SENDER

HORN BUTTON

IMPACT METER

WORKLIGHTSWITCH

LIGHTSWITCH

FUEL GAUGE

HORN

85

86

87A

30

87

LIGHTRELAY

FROMPOWER RELAY

TERM. 87

RD/WE

P

WE

F720 A

FUSE

WE

WE

WE

A B C D

LGN PK

BK BK BK

BK

BK BK

LGN

LGN LGNPK PK

BK BK

PK

JPK PK

FROMPOWER RELAY

TERM. 87

K

BHARNESSCONNECTION

DPE

OE OE BK

DPE

DPE

BK

PK

S

H

WE/GN

WE/GN

RD/WE

33 - 240 ohms

+ _

GY/GN

BAND PASS FILTER

CONNECTION

+

FRONTLAMPS

1.0

B

2.0

FUSE LINK

FUSE LINK

HARNESSCONNECTION

HARNESS

CONNECTION

REARLAMPS

HARNESSCONNECTION

F620 A

FUSE

HARNESSCONNECTION

F215 A

FUSE

LIGHTS/HORN/ FUEL GAUGE


93/134

MANUAL VIB.BUTTON BACK UP

BACK UPALARM SWITCH

FROMPOWER RELAY

TERMINAL 87

2.0

FUSE LINK



94/134

H22H22

VIBRATION CIRCUIT, VIB. OFF

2

5

3

1

6

4

ROTATIONALDIRECTION

CONTROL

2

1

3

DRUM

SELECTORSWITCH

FRONT

REAR

BOTH

B A

BUTTON

B C A

SPEEDOMETERSENSOR

2 1 2 1 21 21

#2 FRONT #1 REAR #4 CCW #3 CW

VIBRATION SOLENOID VALVES

AUTOVIBRATION

CONTROL

D

E

A

B

G

H

GROUND ON ELEC. BRACKET

TN +

_

ALARM

G

HARNESSCONNECTION

TN

WE/YW

WE/YW

LGN/BE

F315 A

FUSE

B

RD/WE

RD/WE

C

BN BN

PE/OE PE/OE

F

E

LPE LPE

PE/OE

LPE

H

GY GY

YW/RDYW/RD

J

BK

GND. ONENGINE BLOCK

PK/RD

B

FROMPOWER RELAY

TERMINAL 87

F215 A

FUSE

DPE

RD/WE

DPE

BK

SIMPACT METER

G

PK/RD PK/RD PK/RD

TN

LBE

FROMIGNITION SWITCH

I TERMINAL

HARNESS CONNECTIONS

HARNESS CONNECTIONSCW

CCW

AUTO

1 MPH = 20 HZ2 MPH = 40 HZ

HARNESSCONNECTION

2.0

FUSE LINK

FUSELINK

PRIOR TOS/N 154575

HARNESSCONNECTION

DD-70

IMPACT

METER

FUSE

BLOCK


95/134

H23H23

VIBRATION CIRCUIT,CW, FRONT DRUM

ELECTR

ICAL

ELECTR

ICAL

Table of

ContentsVibration Circuit,CW, Front Drum ...........H24


VIBRATIONSOLENOID

VALVESROTATIONAL

DIRECTIONCONTROL

BACK UPALARM

AUTOVIBRATION

CONTROL

BACK UP

ALARMSWITCH

SPEEDOMETERSENSOR

MANUALVIBRATION

BUTTON

DRUMSELECTOR

SWITCH


MANUAL VIB.

BUTTON

BACK UPALARM SWITCH

FROMPOWER RELAY

TERMINAL 87

RD/WE

2.0FUSE LINK

BACK UPALARM


96/134

H24H24

VIBRATION CIRCUIT, CW, FRONT DRUM

2

5

3

1

6

4

ROTATIONALDIRECTIONCONTROL

21

3DRUMSELECTOR

SWITCH

FRONT

REAR

BOTH

B A

B C A

SPEEDOMETERSENSOR

2 1 2 1 21 21



AUTOVIBRATION

CONTROL

D

E

A

B

G

H


TN +

_

GTN

WE/YW

WE/YW

LGN/BE

F315 A

FUSE

BHARNESS

CONNECTION

RD/WE

RD/WE

CBN BN

PE/OE PE/OE

F

E

LPE LPE

PE/OELPE

H

GY GY

YW/RDYW/RD

J

BK

GND. ONENGINE BLOCK

PK/RD

B

FROMPOWER RELAY

TERMINAL 87

F215 A

FUSE

DPE

RD/WE

DPE

BK

SIMPACT METER

G

PK/RD PK/RD PK/RD

TN

LBE

FROMIGNITION SWITCH

I TERMINAL

HARNESS CONNECTIONS


CCW

AUTO

1 MPH = 20 HZ2 MPH = 40 HZ

HARNESSCONNECTION 2.0

FUSELINK

PRIOR TOS/N 154575

HARNESSCONNECTION


97/134


98/134

DD-70

IMPACT

METER

FUSE

BLOCK


99/134

H27H27

VIBRATION CIRCUIT,AUTO., BOTH

ELECTR

ICAL

ELECTR

ICAL

Table of

ContentsVibration Circuit,Auto., Both ...................H28


VIBRATION

SOLENOID

VALVESROTATIONAL

DIRECTION

CONTROL

BACK UPALARM AUTO VIBRATION

CONTROL

BACK UP

ALARMSWITCH

SPEEDOMETER

SENSOR

MANUAL

VIBRATION

BUTTON

DRUM

SELECTOR

SWITCH

MANUAL VIB.BUTTON BACK UPALARM

BACK UPALARM SWITCH

FROMPOWER RELAY

TERMINAL 87

RD/WE

2.0

FUSE LINK



100/134

H28H28

2

5

3

1

6

4

ROTATIONALDIRECTIONCONTROL

2

1

3DRUM

SELECTORSWITCH

FRONT

REAR

BOTH

B A

B C A

SPEEDOMETERSENSOR

2 1 2 1 21 21



AUTOVIBRATION

CONTROL

D

E

A

B

G

H


TN +

_

ALARM

G

HARNESSCONNECTION

TN

WE/YW

WE/YW

LGN/BE

F315 A

FUSE

BHARNESS

CONNECTION

RD/WE

RD/WE

C

BN BN

PE/OE PE/OE

F

E

LPE LPE

PE/OELPE

H

GY GY

YW/RDYW/RD

J

BK

GND. ONENGINE BLOCK

PK/RD

B

FROMPOWER RELAY

TERMINAL 87

F215 A

FUSE

DPE

RD/WE

DPE

BK

SIMPACT METER

G

PK/RD PK/RD PK/RD

TN

LBE

FROMIGNITION SWITCH

I TERMINAL

HARNESS CONNECTIONS


CCW

AUTO

1 MPH = 20 HZ2 MPH = 40 HZ

HARNESSCONNECTION

2.0

FUSELINK

PRIOR TOS/N 154575

VIBRATION CIRCUIT, AUTO., BOTH

HARNESSCONNECTIONS

DD-70 / WATER PUMP

TABLE OF CONTENTS .................................................................. H29.1

BYPASS VALVE ASSEMBLY ........................................................... H29.2

Disassembly ....................................................................... H29.2

Assembly ............................................................................ H29.2DIAPHRAGM AND DRIVE ASSEMBLY........................................... H29.3


101/134

1

TABLE OF CONTENTS

H29.1

Disassembly ....................................................................... H29.3Assembly ............................................................................ H29.3

WATER

PUMP

WATERPUMP

DD-70 / WATER PUMP



DISASSEMBLY

1 Loosen and removescrews (1) thatsecure the pumphead assembly (2)


102/134

H29.2

SM99C023

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. 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


103/134

DD-70/70HF / ROPS/FOPS REPLACEMENTTABLE OF CONTENTS................................................... J1.1

ROPS/FOPS ................................................................... J1.2

Tools Required ..................................................... J1.2Safety ................................................................... J1.2Removal J1 3


104/134

J1.1

Removal ............................................................... J1.3Inspection ............................................................. J1.4Installation ............................................................ J1.4

ROPS/FOPS

TABLE OF CONTENTS

DD-70/70HF PRO PAC / ROPS/FOPS REPLACEMENTTOOLS REQUIRED:

Safety glasses

Torque multiplier Loctite number 271

Sockets and wrenches for these models

Lifting device with straps and chains, and sufficient capacity for


105/134

J1.2

g p , p y

lifting weight specified on ID tag located on the ROPS/FOPS

SAFETY

Appropriate safety practices should be observed at all times.

Refer to the AEM Safety Manual for safety instructions.

These safety practices include the use of safety glasses and

adherence to common safety procedures, which should 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)


106/134

DD-70/70HF / STANDARD SWIVEL BEARINGTABLE OF CONTENTS................................................... J2.1

SWIVEL BEARINGS........................................................ J2.2

Tools Required ..................................................... J2.2Safety ................................................................... J2.2

Disassembly J2 4


107/134

J2.1

Disassembly ......................................................... J2.4Inspection ............................................................. J2.7Assembly .............................................................. J2.7

TABLE OF CONTENTS


108/134


109/134


110/134

DD-70/70HF / OFF-SET SWIVEL BEARINGWARNING:

Unexpected machine motion or moving parts can cut or

crush.

WARNING:Oil under pressure can cause serious cuts or injury.


111/134

J3.3

Figure 1-2.

SWIVEL BEARINGS

Exercise extreme caution when working around pressurized

hydraulic systems. Do not work on a hydraulic system while

the engine is running or pressure is still in the system. Ensure

all pressure is relieved from the system before performing

maintenance.

When handling oil, grease, or other chemical substances,

observe the product related safety regulations.

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.


112/134


113/134


114/134


115/134

DD-70/70HF / ECCENTRIC SHAFT ASSEMBLYTABLE OF CONTENTS................................................... J5.1

ECCENTRIC SHAFT ASSEMBLY ................................... J5.2

Tool Required ....................................................... J5.2Safety ................................................................... J5.2Disassembly ......................................................... J5.2Cleaning and Inspection....................................... J5.4


116/134

J5.1

Cleaning and Inspection....................................... J5.4Assembly.............................................................. J5.4

ECCENTRIC

ASSEMBLY

TABLE OF CONTENTS


117/134

DD-70/70HF / ECCENTRIC SHAFT ASSEMBLY6. Remove eccentric journal (4) from the eccentric tube (1),


WARNING:

Safety glasses must be worn when removing the retainingrings.

7 Remove and discard the retaining ring (10) and bearing


118/134

J5.3

12. Remove the handwheel shaft (9) from the eccentric shaft

(2).

13. Remove the compression spring (12) from the handwheel

shaft (9).

Figure 1-1.

ECCENTRIC SHAFT ASSEMBLY

7. Remove and discard the retaining ring (10) and bearing

(7) from the ecce

Documents

Service Book DD70