RT 560 RT 820 - Wacker Neusonproducts.wackerneuson.com/manuals/Repair/0117935_005Rep.pdf · RT 560...

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Roller

RT 560RT 820

REPAIR MANUAL

0117935 005

0206 en

0 1 1 7 9 3 5

Foreword

Operating / Parts InformationYou must be familiar with the operation of this machine before youattempt to troubleshoot or repair it. Basic operating and maintenanceprocedures are described in the Operator’s Manual supplied with themachine. Keep a copy of the Operator’s Manual with the machine at alltimes. Use the separate Parts Book supplied with the machine to orderreplacement parts. If you are missing either of the documents, pleasecontact Wacker Corporation to order a replacement.

Damage caused by misuse or neglect of the unit should be brought tothe attention of the operator to prevent similar occurrences fromhappening in the future.

This manual provides information and procedures to safely repair andmaintain the above Wacker model(s). For your own safety andprotection from injury, carefully read, understand, and observe allinstructions described in this manual. THE INFORMATIONCONTAINED IN THIS MANUAL IS BASED ON MACHINESMANUFACTURED UP TO THE TIME OF PUBLICATION. WACKERCORPORATION RESERVES THE RIGHT TO CHANGE ANYPORTION OF THIS INFORMATION WITHOUT NOTICE.

This manual covers machines with Item Number:

0009000, 0009001, 0009002, 0009003

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Foreword

CALIFORNIA

Proposition 65 Warning:

Engine exhaust, some of its constituents, and certain vehiclecomponents, contain or emit chemicals known to the State ofCalifornia to cause cancer and birth defects or other reproductiveharm.

Laws Pertaining to Spark Arresters

Notice: State Health Safety Codes and Public Resources Codesspecify that in certain locations spark arresters be used on internalcombustion engines that use hydrocarbon fuels. A spark arrester is adevice designed to prevent accidental discharge of sparks or flamesfrom the engine exhaust. Spark arresters are qualified and rated bythe United States Forest Service for this purpose.

In order to comply with local laws regarding spark arresters, consultthe engine distributor or the local Health and Safety Administrator.

All rights, especially copying and distribution rights, are reserved.

Copyright 2006 by Wacker Corporation

No part of this publication may be reproduced in any form or by anymeans, electronic or mechanical, including photocopying, withoutexpress written permission from Wacker Corporation.

Any type of reproduction or distribution not authorized by WackerCorporation represents an infringement of valid copyrights, andviolators will be prosecuted. We expressly reserve the right to maketechnical modifications, even without due notice, which aim atimproving our machines or their safety standards.

WARNING

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RT 560 / RT 820 Repair Table of Contents

1. Safety Information 6

1.1 Operating Safety .................................................................................. 61.2 Operator Safety while using Internal Combustion Engines .................. 91.3 Service Safety ...................................................................................... 91.4 Label Locations .................................................................................. 111.5 Warning and Informational Labels ...................................................... 13

2. Technical Data 17

2.1 Revision Levels—Older Machines ..................................................... 172.2 Engine—Older Machines ................................................................... 172.3 Roller—Older Machines .................................................................... 182.4 Lubrication—Older Machines ............................................................. 182.5 Revision Levels—Newer Machines .................................................... 192.6 Engine—Newer Machines .................................................................. 192.7 Roller—Newer Machines .................................................................... 202.8 Lubrication—Newer Machines ........................................................... 202.9 Sound and Vibration Measurements .................................................. 21

3. Maintenance 22

3.1 Periodic Maintenance Schedule ......................................................... 223.2 Transporting Machine ......................................................................... 233.3 Lifting Machine ................................................................................... 233.4 Battery ................................................................................................ 243.5 Air Cleaner ......................................................................................... 263.6 Engine Oil System .............................................................................. 273.7 Engine Oil ........................................................................................... 283.8 Valve Clearances ............................................................................... 283.9 Engine Fuel Delivery System Maintenance ........................................ 293.10 Fuel Filter ........................................................................................... 293.11 Priming the Fuel System .................................................................... 303.12 Articulated Steering Joint & Steering Cylinder ................................... 303.13 Drive Gearcase .................................................................................. 313.14 Exciter Lubrication .............................................................................. 323.15 Cleaning Engine Cooling Fins ............................................................ 333.16 Scrapers ............................................................................................. 343.17 Shockmounts ...................................................................................... 34

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Table of Contents RT 560 / RT 820 Repair
3.18 Cleaning CombiControl Transmitter ....................................................353.19 Hydraulic Oil Requirements .................................................................363.20 Hydraulic Fluid Level ...........................................................................363.21 Changing Hydraulic Oil & Filter ...........................................................373.22 Changing Drums .................................................................................383.23 Storage ................................................................................................393.24 Jobsite Storage ...................................................................................393.25 Hydrauic Schematic ............................................................................403.26 Hydraulic Schematic Components ......................................................413.27 Hydraulic Diagram ...............................................................................423.28 Hydraulic Diagram Components .........................................................433.29 Electrical Schematic (Main) .................................................................443.30 Electrical Schematic (Main) Components ...........................................443.31 Electrical Diagram (Main) ....................................................................463.32 Electrical Diagram (Main) Components ...............................................473.33 Electrical Schematic (Engine) .............................................................483.34 Electrical Schematic (Engine) .............................................................493.35 Electrical Diagram (Engine) .................................................................503.36 Electrical Diagram (Engine) .................................................................513.37 Troubleshooting ...................................................................................52
4. Hydraulic System 54

4.1 Hydraulic Flow Diagram—Older Machines .........................................544.2 Flow Diagram Components—Older Machines ....................................554.3 Flow Diagram—Newer Machines .......................................................564.4 Flow Diagram Components—Newer Machines ..................................574.5 Hydraulic System ................................................................................584.6 Hydraulic Hose Connections—Older Machines ..................................604.7 Hydraulic Hose Connection Components—Older Machines ...............614.8 Control Valve Block .............................................................................644.9 Control Valve Block Components .......................................................654.10 High-Speed Travel Circuit Description ................................................674.11 High-Speed Travel Circuit ...................................................................684.12 High-Speed Travel Circuit Components ..............................................694.13 Low-Speed Travel Circuit ....................................................................704.14 Low-Speed Travel Circuit Components ...............................................714.15 Low-Speed Travel Circuit Description .................................................724.16 Exciter Circuit Description ...................................................................734.17 Exciter Circuit ......................................................................................744.18 Exciter Circuit Components .................................................................75


4.19 Steering Circuit Description ................................................................ 764.20 Steering Circuit ................................................................................... 774.21 Hydraulic System Cleanliness ............................................................ 784.22 Hydraulic Oil Requirements ................................................................ 784.23 Checking Hydraulic Pressures ........................................................... 794.24 Checking Drive Circuit ........................................................................ 804.25 Checking Steering Circuit ................................................................... 814.26 Checking Vibration Circuit .................................................................. 824.27 Testing Drive & Exciter Circuit Relief Valves ...................................... 824.28 System Pressures .............................................................................. 834.29 Troubleshooting Hydraulic System ..................................................... 84
5. Disassembly/Reassembly—Older Machines 85

5.1 Tools ................................................................................................... 855.2 Ordering Parts .................................................................................... 855.3 Reference Numbers ( ) ....................................................................... 855.4 Weight Block ...................................................................................... 855.5 Drum Assembly Exploded View ......................................................... 865.6 Drum Assembly Components ............................................................. 875.7 Drums ................................................................................................. 885.8 Drum Support Cover .......................................................................... 905.9 Drive Bearings and Seals ................................................................... 925.10 Drive Housing ..................................................................................... 945.11 Changing Oil ....................................................................................... 965.12 Drive Housing Assembly ................................................................. 985.13 Drive Housing Components ............................................................... 995.14 Brake ................................................................................................ 1005.15 Servicing Brake ................................................................................ 1025.16 Drive Motor ....................................................................................... 1045.17 Drive Housing Components ............................................................. 1065.18 Exciter Assembly Exploded View ..................................................... 1105.19 Exciter Assembly Components ........................................................ 1115.20 Introduction ....................................................................................... 1125.21 Oil Requirements .............................................................................. 1125.22 Exciter .............................................................................................. 1135.23 Exciter Exploded View ...................................................................... 1145.24 Exciter Disassembly ......................................................................... 1155.25 Exciter Assembly .............................................................................. 1175.26 Exciter Motor, Coupling, & Pinion Gear ............................................ 1205.27 Exciter Motor, Coupling, & Pinion Gear Removal ............................ 121


Table of Contents RT 560 / RT 820 Repair
5.28 Exciter Motor, Coupling, & Pinion Gear Installation ..........................1225.29 Exciter Motor .....................................................................................1245.30 Shockmounts .....................................................................................1245.31 Shockmount Assembly .................................................................... 1255.32 Replacing Outer Shockmounts ..........................................................1265.33 Replacing Inner Shockmounts ..........................................................1285.34 Hydraulic Hose Clamps .....................................................................1305.35 Hydraulic Hose Clamp Components .................................................1315.36 Drum Supports ..................................................................................1315.37 Drum Support Exploded View ...........................................................1325.38 Replacing Drum Supports .................................................................1335.39 Articulated Joint and Steering Cylinder Exploded View ....................1345.40 Articulated Joint and Steering Cylinder Components ........................1355.41 Replacing Articulated Joint ................................................................1365.42 Steering Cylinder ...............................................................................1385.43 Drive Pump and Coupling Assembly Exploded View ........................1405.44 Drive Pump and Coupling Assembly Components ...........................1415.45 Replacing Drive Pump and Coupling ................................................1425.46 Removing Engine Cover ...................................................................1445.47 Removing Engine ..............................................................................1465.48 Installing Engine ................................................................................1485.49 Replacing Muffler ..............................................................................1505.50 Replacing Engine Air Cleaner ...........................................................1505.51 Engine Relays ...................................................................................1515.52 Miscellaneous Engine Components ..................................................1525.53 Engine Wiring ....................................................................................154
6. Disassembly/Reassembly—Newer Machines 157

6.1 Tools ..................................................................................................1576.2 Ordering Parts ...................................................................................1576.3 Reference Numbers ( ) ......................................................................1576.4 Weight Block .....................................................................................1576.5 Drum Support Exploded View ...........................................................1586.6 Drum Support Components ...............................................................1596.7 Identifying Drum Supports .................................................................1606.8 Removing Drums ...............................................................................1616.9 Installing Drums .................................................................................1626.10 Opening Drum ...................................................................................1626.11 Closing Drum .....................................................................................1636.12 Disassembling Drive Hub ..................................................................164


6.13 Reassembling Drive Hub .................................................................. 1666.14 Disassembling Slave Hub ................................................................ 1686.15 Reassembling Slave Hub ................................................................. 1706.16 Rebuilding Brake .............................................................................. 1726.17 Exciter Exploded View ...................................................................... 1746.18 Exciter Parts List .............................................................................. 1756.19 Disassembling Exciter ...................................................................... 1766.20 Reassembling Exciter ....................................................................... 1786.21 Removing Drum Support .................................................................. 1806.22 Installing Drum Support .................................................................... 182
7. CombiControl/Electrical System 184

7.1 CombiControl Features .................................................................... 1847.2 CombiControl Operation ................................................................... 1847.3 Decoder Module ............................................................................... 1867.4 Setting Control Channels ................................................................. 1867.5 CombiControl Control Cable ............................................................ 1887.6 CombiControl Receiving Eye Module ............................................... 1907.7 CombiControl Wiring ........................................................................ 1927.8 CombiControl Transmitter Module ................................................... 1937.9 Wiring Schematic—Decoder Module, Control Panel & Engine ........ 194


Safety Information RT 560 / RT 820

1. Safety Information

This manual contains DANGER, WARNING, CAUTION, and NOTEcallouts which must be followed to reduce the possibility of personalinjury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potentialpersonal injury hazards. Obey all safety messages that follow thissymbol to avoid possible injury or death.

DANGER indicates an imminently hazardous situation which, if notavoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if notavoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if notavoided, may result in minor or moderate injury.

CAUTION: Used without the safety alert symbol, CAUTION indicatesa potentially hazardous situation which, if not avoided, may result inproperty damage.

Note: Contains additional information important to a procedure.

1.1 Operating Safety

Familiarity and proper training are required for the safe operation ofequipment. Equipment operated improperly or by untrained personnelcan be dangerous. Read the operating instructions contained in boththis manual and the engine manual and familiarize yourself with thelocation and proper use of all controls. Inexperienced operators shouldreceive instruction from someone familiar with the equipment beforebeing allowed to operate the machine.

DANGER

WARNING

CAUTION

WARNING

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RT 560 / RT 820 Safety Information
1.1.1 ALWAYS operate machine with all safety devices and guards in place
and in working order. DO NOT modify or defeat safety devices. DONOT operate machine if any safety devices or guards are missing orinoperative.

1.1.2 ALWAYS disengage and stow the locking bar for the articulatedsteering joint before operating the machine. The machine cannot besteered when the locking bar is engaged.

1.1.3 ALWAYS check that all controls are functioning properly immediatelyafter start-up! DO NOT operate machine unless all controls operatecorrectly.

1.1.4 ALWAYS remain aware of changing positions and the movement ofother equipment and personnel on the job site.

1.1.5 ALWAYS remain in visual contact with machine at all times whileoperating controls.

1.1.6 ALWAYS remain aware of changing surface conditions and use extracare when operating over uneven ground, on hills, or over soft orcoarse material. The machine could shift or slide unexpectedly.

1.1.7 ALWAYS use caution when operating near the edges of pits, trenchesor platforms. Check to be sure that the ground surface is stable enoughto support the weight of the machine with the operator and that thereis no danger of the roller sliding, falling, or tipping.

1.1.8 ALWAYS position yourself safely when operating machine in reverseor on hills. Leave enough space between yourself and the machine soyou will not be placed in a hazardous position should the machine slideor tip.

1.1.9 ALWAYS use the neck strap for the SmartControl™ Transmitter(control box) provided by WACKER. This neck strap is designed tobreak away so that the operator will not be injured should the machineslide, tip, or fall.

1.1.10 ALWAYS wear protective clothing appropriate to the job site whenoperating equipment.

1.1.11 ALWAYS remain aware of moving parts and keep hands, feet, andloose clothing away from the moving parts of the equipment.

1.1.12 ALWAYS read, understand, and follow procedures in the Operator’sManual before attempting to operate the equipment.

1.1.13 ALWAYS store the equipment properly when it is not being used.Equipment should be stored in a clean, dry location out of the reach ofchildren.

1.1.14 NEVER allow anyone to operate this equipment without propertraining. People operating this equipment must be familiar with therisks and hazards associated with it.

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1.1.15 NEVER touch the engine or muffler while the engine is on or
immediately after it has been turned off. These areas get hot and maycause burns.

1.1.16 NEVER use accessories or attachments that are not recommended byWacker. Damage to equipment and injury to the user may result.

1.1.17 NEVER leave machine running unattended.

1.1.18 NEVER start a defective unit in need of service or repair.

1.1.19 NEVER operate the machine with the fuel cap loose or missing.

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1.2 Operator Safety while using Internal Combustion Engines

Internal combustion engines present special hazards during operationand fueling. Read and follow the warning instructions in the engineowner’s manual and the safety guidelines below. Failure to follow thewarnings and safety guidelines could result in severe injury or death.

1.2.1 DO NOT run the machine indoors or in an enclosed area such as adeep trench unless adequate ventilation, through such items asexhaust fans or hoses, is provided. Exhaust gas from the enginecontains poisonous carbon monoxide gas; exposure to carbonmonoxide can cause loss of consciousness and may lead to death.

1.2.2 DO NOT smoke while operating the machine.

1.2.3 DO NOT smoke when refueling the engine.

1.2.4 DO NOT refuel a hot or running engine.

1.2.5 DO NOT refuel the engine near an open flame.

1.2.6 DO NOT spill fuel when refueling the engine.

1.2.7 DO NOT run the engine near open flames.

1.2.8 ALWAYS refill the fuel tank in a well-ventilated area.

1.2.9 ALWAYS replace the fuel tank cap after refueling.

1.2.10 ALWAYS check the fuel lines and the fuel tank for leaks and cracksbefore starting the engine. Do not run the machine if fuel leaks arepresent or the fuel lines are loose.

1.2.11 ALWAYS keep the area around a hot exhaust pipe free of debris toreduce the chance of an accidental fire.

1.3 Service Safety

Poorly maintained equipment can become a safety hazard! In orderfor the equipment to operate safely and properly over a long period oftime, periodic maintenance and occasional repairs are necessary.

1.3.1 Some service procedures require that the machine’s battery bedisconnected. To reduce the risk of personal injury, read andunderstand the service procedures before performing any service tothe machine.

1.3.2 ALWAYS replace the safety devices and guards after repairs andmaintenance.

1.3.3 ALWAYS turn engine off before performing maintenance or makingrepairs.

DANGER

WARNING

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1.3.4 ALWAYS secure the articulated steering joint using the locking bar
before lifting, jacking, and servicing the machine. Machine halvescould swing together unexpectedly and cause a serious injury.

1.3.5 ALWAYS replace missing and hard-to-read labels. See Parts Manualfor ordering information.

1.3.6 ALWAYS make sure slings, chains, hooks, ramps, jacks and othertypes of lifting devices are attached securely and have enough weight-bearing capacity to lift or hold the machine safely. Always remainaware of the location of other people around when lifting the machine.

1.3.7 ALWAYS keep the area around the muffler free of debris such asleaves, paper, cartons, etc. A hot muffler could ignite the debris andstart a fire.

1.3.8 ALWAYS replace worn or damaged components with spare partsdesigned and recommended by Wacker Corporation.

1.3.9 ALWAYS keep the machine clean and labels legible. Replace allmissing and hard-to-read labels. Labels provide important operatinginstructions and warn of dangers and hazards.

1.3.10 DO NOT open hydraulic lines or loosen hydraulic connections whileengine is running! Hydraulic fluid under pressure can penetrate theskin, cause burns, blind, or create other potentially dangeroushazards. Set all controls in neutral and turn engine off before looseninghydraulic lines.

1.3.11 DO NOT attempt to clean or service the machine while it is running.Rotating parts can cause severe injury.

1.3.12 DO NOT use gasoline or other types of fuels or flammable solvents toclean parts, especially in enclosed areas. Fumes from fuels andsolvents can become explosive.

1.3.13 DO NOT modify the equipment without the express written approval ofthe manufacturer.

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1.4 Label Locations

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1.5 Warning and Informational Labels

Wacker machines use international pictorial labels where needed.These labels are described below:

Label Meaning

DANGER!Engines emit carbon monoxide; operate only in well-ventilated area. Read the Operator’s Manual.No sparks, flames, or burning objects near the machine. Shut off the engine before refueling.

WARNING! Hot surface!

WARNING! Hot surface!

WARNING! To prevent hearing loss, wear hearing protec-tion when operating this machine.

WARNING! Pinch point

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Hydraulic oil reservoir fill tube

CAUTION! Use only clean, filtered diesel fuel.

WARNING!Read and understand the supplied Operator’s Manual before operating this machine. Failure to do so increases the risk of injury to yourself or others.

CAUTION! Engine oil may enter the cylinders if machine tips over, causing possible engine damage.

WARNING! Machine may receive stray signals if operated near solid objects.

CAUTION! Use only breakaway neck strap provided by Wacker to avoid possible operator injury.

Label Meaning

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Operator’s Manual must be stored on machine. Replacement Operator’s Manual can be ordered through your local Wacker distribu-tor.

CAUTION! Engine oil pressure is low! Stop the engine and check the oil level.CAUTION! Low voltage! Stop the engine and check the charging system.

Control with cableControl with infraredCharge infrared battery

Glow plug. Press to pre-heat intake manifold before starting in cold weather.

Tie-down point

CAUTION! Lifting point

Label Meaning

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Torque battery hold-down nuts to 3.5 Nm (2.5 ft.lbs.) max.

A nameplate listing the model number, item number, revision number, and serial number is attached to each unit. Please record the infor-mation found on this plate so it will be available should the nameplate become lost or dam-aged. When ordering parts or requesting ser-vice information, you will always be asked to specify the model number, item number, revi-sion number, and serial number of the unit.

This machine may be covered by one or more patents.

Guaranteed sound power level in dB(A)

Label Meaning

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RT 560 / RT 820 Technical Data

2. Technical Data

2.1 Revision Levels—Older Machines

2.2 Engine—Older Machines

Item Number Revision

9000 120 & lower

9001 122 & lower

9002 123 & lower

9003 124 & lower

Item No. RT56000090000009001

RT82000090020009003

Engine

Engine Type 2 cylinder, 4 cycle, air cooled, diesel engine

Engine Make Lombardini

Engine Model 12LD475-2

Rated Power kW (Hp) 15.6 (20.9)

Alternator Amp / V 12 / 16.5 @ 2600 rpm

Engine Speed - full load rpm 2600 ± 100

Valve Clearance (cold) intake / exhaust: mm (in.) 0.20 (0.008)

Air Cleaner type Dry pleated paper elements

Battery V / size 12V - Sealed - 800 cold starting amps

Fuel type No. 2 Diesel

Fuel Tank Capacity l (gal.) 21 (5.6)

Fuel Consumption l (gal.)/hr. 4.2 (1.1)

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Technical Data RT 560 / RT 820

2.3 Roller—Older Machines

2.4 Lubrication—Older Machines

Item No: RT56000090000009001

RT82000090020009003

Roller

Overall Dimensions mm(in.)

2030 x 560 x 1220(80 x 22 x 48)

2030 x 820 x 1220(80 x 32 x 48)

Operating Weight kg (lb.) 1283 (2830) 1345 (2960)

Area Capacity m² (ft²) / hr. 690 (7500) 1016 (10900)

Inside Turning Radius m (in.) 1.6 (63) 1.5 (58)

Low Speed m (ft.)/min. 21 (68)

High Speed m (ft.)/min. 136 (41)

Vibration Frequency Hz (vpm) 40 (2400)

Gradeability with Vibration

% 50

Gradeability without Vibration

% 55

Item No: RT56000090000009001

RT82000090020009003

Lubrication

Engine Crankcase typel (qt.)

SAE 10W30 Class CD rated2.5 (2.5)

Hydraulic System typel (gal)

Premium grade, Anti-wear hydraulic fluid SAE 10W3040 (10.5)

Exciter typeml (oz.)

SAE 10W30950 (32)

Drum Drive Gearcase typeml (oz.)

SAE 10W30240 (8.0)

Articulated Joint typeqty.

Shell Alvania No. 2 GreaseAs Required

Steering Cylinder typeqty.


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2.5 Revision Levels—Newer Machines

2.6 Engine—Newer Machines

Item Number Revision

9000 121 & higher

9001 123 & higher

9002 124 & higher

9003 121 & higher

Item No. RT56000090000009001

RT82000090020009003

Engine

Engine Type 2 cylinder, 4 cycle, air cooled, diesel engine

Engine Make Lombardini

Engine Model 12LD475-2

Rated Power kW (Hp) 15.6 (20.9)

Alternator Amp / V 12 / 16.5 @ 2600 rpm

Engine Speed - full load rpm 2600 ± 100

Valve Clearance (cold) intake / exhaust: mm (in.) 0.20 (0.008)

Air Cleaner type Dry pleated paper elements

Battery V / size 12V - Sealed - 800 cold starting amps

Fuel type No. 2 Diesel

Fuel Tank Capacity l (gal.) 21 (5.6)

Fuel Consumption l (gal.)/hr. 4.2 (1.1)

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Technical Data RT 560 / RT 820

2.7 Roller—Newer Machines

2.8 Lubrication—Newer Machines

Item No: RT56000090000009001

RT82000090020009003

Roller

Overall Dimensions mm(in.)

2030 x 560 x 1220(80 x 22 x 48)

2030 x 820 x 1220(80 x 32 x 48)

Operating Weight kg (lb.) 1346 (2976) 1408 (3106)

Area Capacity m² (ft²) / hr. 690 (7500) 1016 (10900)

Inside Turning Radius m (in.) 1.6 (63) 1.5 (58)

Low Speed m (ft.)/min. 21 (68)

High Speed m (ft.)/min. 136 (41)

Vibration Frequency Hz (vpm) 40 (2400)

Gradeability with Vibration

% 50

Gradeability without Vibration

% 55

Item No: RT56000090000009001

RT82000090020009003

Lubrication

Engine crankcase typel (qt.)

SAE 10W30 Class CD rated2.5 (2.5)

Hydraulic system typel (gal)

Premium grade, Anti-wear hydraulic fluid SAE 10W3040 (10.5)

Exciter typeml (oz.)

SAE 10W30950 (32)

Drum drive gearcase typeml (oz.)

SAE 10W30370 (12.5)

Articulated joint typeqty.


Steering cylinder typeqty.


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2.9 Sound and Vibration Measurements

According to Appendix 1, paragraph 1.7.4.f of the EG-MachineRegulation, the requested noise levels are:

The sound pressure level at operator's location (LpA) = 83 dB(A).

The guaranteed sound power level (LWA) = 109 dB(A).

These noise values were obtained at the operator's location accordingto ISO 3744 for the sound power level (LWA) and ISO 6081 for thesound pressure level (LpA).

Noise levels were measured while running the machine at full speed,on crushed gravel, with vibration on.

Because this machine is operated using remote control the operator isnot exposed to vibration.

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Maintenance RT 560 / RT 820

3. Maintenance

3.1 Periodic Maintenance Schedule

The chart below lists basic engine maintenance. Refer to the enginemanufacturer’s Operation Manual for additional information on enginemaintenance.

Lombardini Engine Dailybefore

starting

Every100hrs.

Every250hrs.

Every300hrs.

Every500 hrs.

Check engine oil. Fill to correct level. •

Replace air filter if indicator light is on. •

Check condition and tension on fan belt. •

Clean engine head and cylinder fins. •

Change oil in engine crankcase. •

Replace engine oil filter. •

Check and adjust fan belt. •

Replace fuel filter cartridge. •

Clean injectors and check injector pres-sure.

•

Replace fan belt. •

Check valve clearance. •

Roller Dailybefore

starting

Every100hrs.

Every500hrs.

Once A

Year

Every2

Years

Check hydraulic oil. Fill to correct level.

•

Clean control box / transmitter. •

Grease articulated joint. •

Grease steering cylinder. •

Grease hood hinges. •

Change oil in drive gearcase. •

Change hydraulic system return line filter.

•

Change hydraulic fluid. •

Change exciter oil. •

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RT 560 / RT 820 Maintenance

3.2 Transporting Machine

See Graphic: wc_gr000484

When transporting the machine, place blocks in front of and behindeach drum and use the tie down lugs (a) provided to securely fastenthe machine to the trailer.

Make sure that the joint locking bar (b) is engaged.

3.3 Lifting Machine


Lock front and rear machine halves together using the joint locking bar(b) at the articulated steering joint on the machine. Use a lifting devicewith sufficient weight-bearing capacity. Lift machine from lifting eye (c).

ALWAYS lock the articulated steering joint before lifting the machine.

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3.4 Battery

Before servicing this machine, make sure the engine start switch is inthe off “O” position and that the battery is disconnected. Attach a “DONOT START” sign to the machine. This will notify other personnel thatthe unit is being serviced and will reduce the chance of someoneinadvertently trying to start the unit.

Explosion hazard. Batteries can emit explosive hydrogen gas. Keep allsparks and flames away from the battery. Do not short-circuit batteryposts. Do not touch the machine frame or the negative terminal of thebattery when working on the positive terminal.

Battery fluid is poisonous and corrosive. In the event of ingestion orcontact with skin or eyes seek medical attention immediately.

Dispose of dead batteries in accordance with local environmentalregulations.

To disconnect the battery:

3.4.1 Stop the machine and shut down the engine.

3.4.2 Place all electrical switches in the OFF position.

3.4.3 Disconnect the negative battery cable from the battery.

3.4.4 Disconnect the positive battery cable from the battery.

To connect the battery:

3.4.5 Connect the positive battery cable to the battery.

3.4.6 Connect the negative battery cable to the battery.

WARNING

WARNING

1 2 3 4

wc_gr002565

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The battery supplied on this machine is constructed to resist vibrationand provide long service life.
DO NOT use automotive-type batteries on this machine. Automotive-type batteries are not designed to withstand the heavy vibrationproduced by this machine. The case on automotive-type batteriescould fail, causing battery acid to leak.

Inspect battery periodically. Keep battery terminals clean andconnections tight.

When necessary, tighten the cables and grease the cable clamps withpetroleum jelly.

Maintain the battery at full charge to improve cold weather starting. Dispose of dead batteries in accordance with local environmentalregulations.

CAUTION: Observe the following to prevent serious damage to themachine’s electrical system:

• Never disconnect the battery with the machine running.

• Never attempt to run the machine without a battery.

• Never attempt to jump-start a machine.

• In the event that the machine has a dead battery, either replace the battery with a fully charged battery or charge the battery using an appropriate battery charger.

CAUTION

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3.5 Air Cleaner


Filter Indicator

The air intake system is equipped with a filter indicator (a). Theindicator is mounted to the air intake tube on the filter cannister andcan be viewed by opening the front hood. Replace filter element whenthe indicator appears in or near the red line (b). Push in black rubberbutton (c) on top of indicator to reset it after replacing filter element.

Check condition of air cleaner daily, before starting machine, andreplace element when needed.

Replacing Air Cleaner

Lift front hood and open access door on right side of machine. Removewing nut holding bottom cover (h) and remove cover. Screw off wingnut (f) to remove filter element.

Clean inside of air cleaner cannister to remove dirt and dust, especiallyin area where rubber gasket on filter (d) seals against air intake tube.

Inspect rubber washers (e) and O-ring (g). Replace if damaged. Installnew filter. Tighten wing nut snugly to ensure that both the top andbottom of the filter is sealed.

` ` ` ` `` `` ` `

````` ` ```

``

```

``

````

a

c

b

wc_gr000473

wc_tx000482gb.fm 26


3.6 Engine Oil System

See Graphic: wc_gr000057 & wc_gr000474

Check the engine oil level daily. Add oil as required.

To check oil:

Place the machine on a level surface, remove the dipstick and checkthat the oil level is at the top mark. Add oil through the oil filler cap (a)on top of engine, checking occasionally with dipstick; DO NOT overfill.

Suggested oil grades:

Use only diesel engine oil API service rating CD or equivalent.

ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATUREAmbient Temperature

(Multi-grade)

-25ºC(-13ºF)

-15ºC(5ºF)

-20ºC(-4ºF)

15ºC(59ºF)

30ºC(86ºF)

0ºC(32ºF)

SAE 10W-30

SAE 15W-40, 20W-40

SAE 5W-20

wc_gr000057

wc_tx000482gb.fm 27


3.7 Engine Oil


Change the oil and oil filter (b) every 250 hours. On new machines,change the oil after the first 50 hours of operation. Drain the oil whilethe engine is still warm.

3.7.1 Remove the oil drain plug (c) to the drain oil.

Note: In the interests of environmental protection, place plasticsheeting and a container under the machine to collect the liquid whichdrains off. Dispose of this liquid properly.

3.7.2 Install the drain plug.

3.7.3 Remove the oil filler cap (a) and fill the engine crankcase with therecommended oil.

Oil Capacity: 2.5 liters (2.5 qts.) SAE15W40, CD rated

3.7.4 Install the oil filler cap.

3.8 Valve Clearances


Check and adjust the valve clearance every 500 hours.

Set the clearance when the engine is cold.

3.8.1 Remove the rocker arm cover and check the gaskets for breakage.

3.8.2 Bring each cylinder piston to top dead center on the compressionstroke and set the clearance.

Valve clearance: 0.20 mm (0.008 in.).

3.8.3 Replace the rocker arm cover and tighten bolts to 19 Nm (14 ft.lbs.).

wc_gr000476

wc_tx000482gb.fm 28


3.9 Engine Fuel Delivery System Maintenance

Maintenance to the engine fuel delivery system should be performedby an experienced mechanic familiar with diesel engines. For detailedmaintenance procedures on the engine fuel system, refer to the enginemanual supplied with the machine at the time of shipment.

3.10 Fuel Filter


Change the engine fuel filter every 300 hours of operation.

3.10.1 Remove the filter (a) from the engine block.

3.10.2 Install a new filter. If necessary, prime the fuel lines as described in thenext section.

wc_tx000482gb.fm 29


3.11 Priming the Fuel System


If the fuel tank has been run completely dry or drained for service, it willbe necessary to manually prime the fuel system.

To prime the fuel system:

3.11.1 Turn both the key switch on the machine, and the on-off switch oncontrol box, on. This will open the fuel valve.

3.11.2 Loosen the bleed screw on the fuel filter and pump the lever on the fuelpump (b) until fuel flows freely from the bleed screw. Tighten the bleedscrew.

3.11.3 Repeat this procedure for the fuel line bleed screw (c).

3.12 Articulated Steering Joint & Steering Cylinder


Lubricate top and bottom bearing blocks (b) and cylinder knuckles (a)every 100 hours using a hand-held grease gun. Cylinder knuckles canbe accessed through holes on side of machine.

Use Shell Alvania No. 2 or an equivalent No. 2 general purposegrease.

wc_tx000482gb.fm 30


3.13 Drive Gearcase


Any disassembly of the drive gearcase should be done on the oppositeside of graphic wc_gr000479.

Change the oil in the drive gearcase once a year or every 500 hours ofoperation.

To change the oil:

3.13.1 Remove drum from drivecase side of machine. On the front drum thiswill be on the left side, on the rear drum it is the right side.

3.13.2 Open fill plug (c) for venting and then remove drain plug (b) frombottom of drum assembly.


3.13.3 Install drain plug and remove level plug (a) from gearcase.

3.13.4 Add SAE 10W30 oil through fill plug opening until oil flows out of levelplug opening, approx. 370 ml (12.5 oz.).

3.13.5 Replace plugs and install drum.

CAUTION

wc_tx000482gb.fm 31


3.14 Exciter Lubrication


The exciter is a sealed unit and under normal conditions should notrequire any periodic maintenance; however, an oil change once everytwo years is recommended to ensure bearing life.

Exciter maintenance should be done on the right front (a) and left rear(b) only.

Changing the exciter oil requires special tools and should beperformed by an experienced mechanic.

CAUTION

wc_tx000482gb.fm 32


3.15 Cleaning Engine Cooling Fins


The engine is air-cooled and depends on the cylinder cooling fins todissipate heat. In dusty conditions the cooling fins may becomeclogged or covered with dust, reducing engine cooling.

Remove the engine cover and inspect the engine cooling fins every100 hours.

Remove dirt build-up using a brush and diesel fuel or kerosene. Drythe engine using compressed air. Replace the inspection cover beforestarting the engine.

wc_tx000482gb.fm 33


3.16 Scrapers


Scrapers are provided on all four drums to prevent dirt from building upon the drum surfaces. These scrapers should be inspected andadjusted as required to remove as much dirt from the drums aspossible.

To adjust scraper, loosen the three screws (a) holding each scraper tothe drum casting. Position the scraper as close to the drum aspossible. Tighten screws and run machine to check that the scraperdoes not rub against the drum surface.

3.17 Shockmounts


Inspect the drum shockmounts (a) every 300 hours for cracking,splitting or tearing. Replace shockmounts as needed.

CAUTION: The shockmounts isolate the upper part of the machinefrom the heavy vibrations produced in the drums. Operating themachine with damaged shockmounts for an extended period of timemay eventually damage other machine parts.

wc_tx000482gb.fm 34


3.18 Cleaning CombiControl Transmitter

The transmitter and switches are completely sealed to keep dust andmoisture out; however, contact with water should be kept to aminimum. Even a small amount of moisture can cause connectionsand contacts to corrode. Avoid immersing transmitter in water and donot clean using a pressure wash.

To clean the transmitter, wash off using a damp cloth and allow to dry.To remove dirt and dust trapped around switches, use compressed air.

Keeping the hydraulic oil clean is a vital factor affecting the service lifeof hydraulic components. Oil in hydraulic systems is used not only totransfer power, but also to lubricate the hydraulic components used inthe system. Keeping the hydraulic system clean will help avoid costlydowntime and repairs.

Major sources of hydraulic system contamination include:

• Particles of dirt introduced when the hydraulic system is opened for maintenance or repair

• Contaminants generated by the mechanical components of the system during operation

• Improper storage and handling of hydraulic oil

• Use of the wrong type of hydraulic oil

• Leakage in lines and fittings

To minimize hydraulic oil contamination:

CLEAN hydraulic connections before opening the lines. When addingoil, clean the hydraulic tank filler cap and surrounding area beforeremoving it.

AVOID opening the pumps, motors, or hose connections unlessabsolutely necessary.

PLUG or cap all open hydraulic connections while servicing thesystem.

CLEAN and cover the containers, funnels, and spouts used to storeand transfer the hydraulic oil.

CHANGE the hydraulic filters and oils at the recommended serviceintervals.

wc_tx000482gb.fm 35


3.19 Hydraulic Oil Requirements

Wacker recommends the use of a good petroleum-based, anti-wearhydraulic oil in the hydraulic system of this equipment. Good anti-wearhydraulic oils contain special additives to reduce oxidation, preventfoaming, and provide for good water separation.

When selecting hydraulic oil for your machine, be sure to specify anti-wear properties. Most hydraulic oil suppliers will provide assistance infinding the correct hydraulic oil for your machine.

Avoid mixing different brands and grades of hydraulic oils.

Most hydraulic oils are available in different viscosities.

The SAE number for an oil is used strictly to identify viscosity—it doesnot indicate the type of oil (engine, hydraulic, gear, etc.).

When selecting a hydraulic oil be sure it matches the specified SAEviscosity rating and is intended to be used as a hydraulic oil. SeeTechnical Data—Lubrication.

3.20 Hydraulic Fluid Level


A hydraulic oil level sight gauge (e) is located on the hydraulic tankinside the rear section of the machine.

Check that the oil level is within 25 mm (one inch) of the top of the sightgauge. Add oil as required through the filter housing on top ofhydraulic tank.

If hydraulic oil continually needs to be added, inspect hoses andconnections for possible leaks. Repair hydraulic leaks immediately toprevent damage to hydraulic components.

wc_tx000482gb.fm 36


3.21 Changing Hydraulic Oil & Filter


3.21.1 Remove drain plug from bottom of frame and allow hydraulic fluid todrain.


3.21.2 Clean filter housing cover. Remove cover from the filter housing andremove the filter element (a).

Be extremely careful to avoid dropping anything into the filter housingwhile cover is off.

3.21.3 Install drain plug.

3.21.4 Fill hydraulic tank through filter housing (b) using clean hydraulic fluid.

3.21.5 Install new filter element (a) as shown in illustration. Replace housingcover.

CAUTION

wc_tx000482gb.fm 37


3.22 Changing Drums


The drums can be changed to adjust the working width of the machine.Drums are available in two standard sizes that provide a working widthof 560 mm (22 in.) or 820 mm (32 in.).

To change drum:

3.22.1 Lock the articulated joint.

3.22.2 Remove scraper bars.

3.22.3 Use a screw jack, hoist or other type of lifting device to lift drums 25–50 mm (1–2 inches) off the ground. Lift only one end of the machine.Keep the other end in contact with the ground for stability.

3.22.4 Use a 22 mm wrench and remove the six screws which hold the drumto the drum support.

3.22.5 Remove the three plugs (a) covering the pusher holes.

3.22.6 Insert three of the mounting screws into the pusher holes and threadthem in evenly to push drum off.

3.22.7 Install new drum and fasten to support. Secure mounting screws witha medium-strength threadlocking adhesive.

3.22.8 Replace pusher hole plugs. Install the correct size scraper bars.

wc_tx000482gb.fm 38


3.23 Storage

If storing unit longer than 30 days the following steps arerecommended:

3.23.1 Change the engine oil.

3.23.2 Clean or change air cleaner elements.

3.23.3 Clean the engine cylinder cooling fins.

3.23.4 Drain any water that may have collected at the bottom of the fuel tank.Replace the fuel filter. Refill the tank with fresh No. 2 diesel fuel.

Note: Diesel fuel is subject to bacterial growth which can contaminatefuel lines. Allowing the tank to sit dry for a long period of time helpspromote such growth. The addition of a biocide to the fuel isrecommended to inhibit bacterial growth and protect the engine fuelsystem.

3.23.5 Store the unit indoors in a clean dry area. If the unit must be storedoutside, cover it.

3.24 Jobsite Storage


Never allow the roller to sit overnight in a ditch, trench or other low-lying area which might fill with water during a heavy rain. Park the rolleron a flat level surface, out of the way of traffic patterns and congestion.If the roller must be parked on an incline, chock the drums to preventany chance of movement.

If leaving the roller on the job site, remember to remove the key andlock the control panel cover and engine hood to prevent tampering.Both the front and rear hoods and access cover are equipped with alocking ring (a) for use with a padlock for this purpose.

If desired, the CombiControl can be removed from the roller and storedseparately.

wc_tx000482gb.fm 39


3.25 Hydrauic Schematic

wc_tx000482gb.fm 40


3.26 Hydraulic Schematic Components


Ref. Description Ref. Description

1 Brake (9001, 9003) 9 Oil cooler

2 Brake valve (9001, 9003) 10 Return filter

3 Drive motor 11 Steering cylinder

4 Drive pump 12 Steering valve

5 Exciter motor 13 Strainer

6 Exciter pump 14 Travel valve

7 Exciter (vibration) valve 15 Relief valve

8 Manifold

wc_tx000482gb.fm 41


3.27 Hydraulic Diagram

wc_tx000482gb.fm 42


3.28 Hydraulic Diagram Components



1 Brake (9001, 9003) 9 Oil cooler

2 Brake valve (9001, 9003) 10 Return filter

3 Drive motor 11 Steering cylinder

4 Drive pump 12 Steering valve

5 Exciter motor 13 Strainer

6 Exciter pump 14 Travel valve

7 Exciter (vibration) valve 15 Relief valve

8 Manifold

wc_tx000482gb.fm 43


3.29 Electrical Schematic (Main)

3.30 Electrical Schematic (Main) Components


Ref. Description Ref. Descriptiona Engine connector k Glow plug

b Decoder module m Tilt

c Receptacle n Keyswitch

d Infra-red eye module o 82 Ω resistor

e Control cord p Hour meter

wc_tx000482gb.fm 44


f Hydraulic valves q Alternator

g Backup safety r Oil

h Reverse polarity module s Battery 12VDC

j Control t To starter “30”

Note: Decoder has 10 second switchover delay for exciter outputs

b1 Decoder Module Terminal StripRef. Description Ref. Description

1 Negative, ground 3 Not used

2 Signal, I.R. 4 Positive, 12VDC

b2 Decoder Module Terminal StripRef. Description Ref. Description32 Reverse 16 Steering - right

30 Forward 14 High speed

28 Control light 12 Fuel valves

26 Vibration - high 10 Starter

24 Vibration - low 8 Not used

22 Not used 6 12V (positive)

20 Brake (9001, 9003) 4 Ground

18 Steering - left

f Hydraulic ValvesRef. Description Ref. Description32 Reverse 20 Brake

30 Forward 18 Steering - left

26 Vibration - high 16 Steering - right

24 Vibration - low 14 High speed

Wire Colors

B Black R Red Y Yellow Or Orange

G Green T Tan Br Brown Pr Purple

L Blue V Violet Cl Clear Sh Shield

P Pink W White Gr Gray LL Light blue


wc_tx000482gb.fm 45


3.31 Electrical Diagram (Main)

wc_tx000482gb.fm 46


3.32 Electrical Diagram (Main) Components



1. Engine connector 10. Glow plug

2. Decoder module 11. Tilt

3. Receptacle 12. Keyswitch

4. Infra-Red eye module 13. 82 Ω resistor

5. Control cord 14. Hour meter

6. Hydraulic valves 15. Alternator

7. Backup safety 16. Oil

8. Reverse polarity module 17. Battery 12VDC

9. Control 18. Charging cable

Wire Colors





wc_tx000482gb.fm 47


3.33 Electrical Schematic (Engine)

wc_tx000482gb.fm 48


3.34 Electrical Schematic (Engine)



a Engine connector g Engine oil pressure

b From battery h Starter relay

c Starter j Anti-restart module

d Alternator k Glow plug

e Voltage regulator m Glow plug relay

f QSD fuel valve

Wire Colors





wc_tx000482gb.fm 49


3.35 Electrical Diagram (Engine)

wc_tx000482gb.fm 50


3.36 Electrical Diagram (Engine)



1. Engine connector 7. Engine oil pressure

2. From battery 8. Starter relay

3. Starter 9. Anti-restart module

4. Alternator 10. Glow plug

5. Voltage regulator 11. Glow plug relay

6. QSD fuel valve

Wire Colors





wc_tx000482gb.fm 51


3.37 Troubleshooting

Problem / Symptom Reason / Remedy

ENGINE DOES NOT START • Fuel tank empty. Fill with No. 2 diesel fuel and prime fuel lines.

• Wrong type of fuel.

• Old fuel. Drain tank, change fuel filter and fill with fresh fuel.

• Fuel system not primed.

• Fuel filter restricted or plugged. Replace filter.

• Battery connections loose or corroded. Battery dead.

• Engine oil level too low.

• Air cleaner element plugged.

• Starter motor defective.

• Starter button on control box or transmitter defective.

• Fuel valve solenoids on engine inoperative.

• Starter relay inoperative.

• Electrical connections loose or broken.

• Machine out of infrared signal range.

ENGINE STOPS BY ITSELF • Fuel tank empty.

• Fuel filter plugged.

• Fuel lines broken or loose.

• Machine out of infra-red range.

NO VIBRATION • Machine in high speed travel mode.

• Defective switch or poor connection in control box or transmitter.

• Solenoid on vibration valve inoperative.

• Exciter assembly damaged.

• Exciter motor coupling damaged.

• Exciter motor damaged.

• Exciter pump damaged.

wc_tx000482gb.fm 52


NO TRAVEL or TRAVEL ONLY IN ONE DIRECTION

• Defective switch or poor connection in control box or transmitter.

• Solenoid on travel valve inoperative.

• Drive gearcase assembly damaged.

• Loose, broken or corroded wire connections.

• Drive motor damaged.

• Drive pump damaged.

NO HIGH SPEED TRAVEL • Defective switch or poor connection in control box or transmitter.

• Solenoid on manifold inoperative.


• Exciter pump worn or damaged.

• Vibration is turned on.

NO STEERING • Defective switch or poor connection in control box or transmitter.

• Solenoid on steering valve inoperative.


• Steering cylinder damaged.

• Locking bar is engaged.

Problem / Symptom Reason / Remedy

wc_tx000482gb.fm 53

Hydraulic System RT 560 / RT 820

4. Hydraulic System

4.1 Hydraulic Flow Diagram—Older Machines

P1

P2

E

F

Motor Case DrainsHigh Pressure LinesSupply Line

Return Lines

wc_gr002481

Front Rear

a bc

de

fg

h

i

j k

l

m

n

o

p

q

r

wc_tx000472gb.fm 54

RT 560 / RT 820 Hydraulic System

4.2 Flow Diagram Components—Older Machines

Used on models:

0009000 revision 120 and lower




* Used only on machines 9001 & 9003

a Suction strainer g Steering cylinder m Check valve

b Return line filer h Brake valve n Front exciter motor

c Hydraulic tank i Vibration valve o Front drive motor

d Front pump j Main manifold p Brake assembly*

e Rear pump k Travel valve q Rear drive motor

f Oil cooler l Steering valve r Rear exciter motor

wc_tx000472gb.fm 55


4.3 Flow Diagram—Newer Machines

wc_gr002482

P1

P2

E

F

Motor Case DrainsHigh Pressure LinesSupply Line

Return Lines

Front Rear

abc

de

f g

h

i

j k

l

m

n

o

p

q

r

wc_tx000472gb.fm 56


4.4 Flow Diagram Components—Newer Machines

Used on models:

0009000 revision 121 and higher











wc_tx000472gb.fm 57


4.5 Hydraulic System

See Graphic: wc_gr002481 and wc_gr002482

Description:

Pressure in the hydraulic system is generated by two gear pumpsmounted in tandem to the back of the engine. The pumps are drivenby a common shaft which is connected to the engine crankshaftthrough a three-piece coupling. Capacity of the front pump (d) isapproximately 8 gpm (32 l/m) and is used to operate vibration or highspeed travel. Rear pump (e) capacity is approximately 4 gpm (16 l/m)and is used for low speed travel.

A control valve block directs oil flow from the pumps to the motors andsteering cylinder. The control valve block is mounted beneath thecontrol panel at the rear of the machine. It consists of the manifold (j),vibration (i), travel (k) and steering (l) valves. These valves aresolenoid operated. During operation, the solenoids respond to theelectrical signals being transmitted by the operator from the controlbox. Two reliefs, located on the main manifold, limit exciter and drivepressures to 3000 PSI (21 mPa). The steering circuit relief is mountedon the steering valve and is set at 1000 PSI (7 mPa). See sectionControl Valve Block for control valve components.

Oil from the hydraulic tank (c) flows through a suction strainer (a)before it is drawn into the pump suction port. The suction strainer ismounted in the tank and is magnetic for removing metal particles.Hoses connect the output ports of the pumps to the main manifold (j)on the control block. The main manifold directs oil flow into thevibration (i) and travel (k) valves. These valves in turn supply hydraulicpressure to operate the exciter and drive motors.

When operating in low-speed travel, the larger front pump is used tooperate the exciter motors (n, r), the smaller rear pump is used tooperate the drive motors (o, q). When operating in high-speed travel,the main manifold redirects front pump oil flow away from the excitermotors to the drive motors. Flow from the rear pump is directed backto the tank. In high-speed travel the exciter motors do not operate. Seelater sections in this unit for a detailed description of the exciter anddrive circuits.

Return oil from the drive circuit flows to the steering valve (l) whichdirects it to the steering cylinder (g).

The hydraulic system is protected by a return line filter (b). The returnline filter removes particles down to 10 microns and includes a by-passfor cold weather start-up.

wc_tx000472gb.fm 58

Oil Cooler & Brake:
Return flow from the steering valve is directed through a check valve(m) to the oil cooler (f) before returning to the hydraulic tank.

A hydraulic brake (p) is available on machines with item numbers 9001& 9003. The brake is connected to the hydraulic system through themain manifold (j) and brake valve (h). The brake is spring loaded andnormally set when the machine is off. When the hydraulic system ispressurized, the brake is automatically released. The brake can be setmanually by setting the toggle switch on the transmitter module. Thisactivates the solenoid on the brake valve (h) and releases thehydraulic pressure to the brake. This will also shut off the engine.

wc_tx000472gb.fm 59


4.6 Hydraulic Hose Connections—Older Machines

wc_gr002483

4

19

16

12

8

10

9

24

12

1

25

11

14

15

16

22

20

23

18

27

32

25

29

2733

35

5

3132

36

21

34

37

26

18

18

17

7

54

19

27 3318

27

27

6

h

e

d

f

n

o

p

q

r

l

jki

ba

wc_tx000472gb.fm 60


4.7 Hydraulic Hose Connection Components—Older Machines


No Description Part No. No Description Part No.

1 HOSE - Oil Cooler to Check Valve

0086394 18 FITTING - Elbow 90, Hydraulic

0078962

2 FITTING - Sae/orfs, SDE45, 08x08st

0086581 O-RING .364 x .070 2-012 0080736

O-RING .644 x .087 DURO90 3-908

0080732 O-RING .468 x .078 DURO90 3-906

0080731

O-RING .489 x .070 2-014 0080737 19 FITTING - Male Adapter, Straight

0078861

4 FITTING - Hydraulic 0083412 O-RING .364 x .070 2-012 0080736

O-RING .364 x .070 2-012 0080736 O-RING .468 x .078 DURO90 3-906

0080731

O-RING .468 x .078 DURO90 3-906

0080731 20 HOSE - Front Vibration 0117532

5 FITTING - Elbow 90, Hydraulic

0078962 21 HOSE - Rear Vibration 0117534

O-RING .364 x .070 2-012 0080736 22 HOSE - Front Exciter to Tank

0116693

O-RING .468 x .078 DURO90 3-906

0080731 23 HOSE - Front Drive to Tank

0117535

6 FITTING - Hydraulic 0083411 24 HOSE - Brake Valve to Blk-hd Fitng.

0117528

O-RING .364 x .070 2-012 0080736 25 HOSE - Check Valve to Return Filter

0086392

26 HOSE - Manifold to Return Filter

0081842

7 O-RING 0081913 27 FITTING - Elbow 90, Hydraulic

0081340

8 HOSE - Oil Supply 0083446 O-RING .489 x .070 2-014 0080737

9 FITTING #8 0081583 O-RING .755 x .097 DURO90 3-91

0080733

O-RING .468 x .078 DURO90 3-906

0080731 28 FITTING - orfs, Blk-Hd, E90 06 ST.

0086556

wc_tx000472gb.fm 61


wc_tx000472gb.fm 62

wc_gr002483

4

19

16

12

8

10

9

24

12

1

25

11

14

15

16

22

20

23

18

27

32

25

29

2733

35

5

3132

36

21

34

37

26

18

18

17

7

54

19

27 3318

27

27

6

h

e

d

f

n

o

p

q

r

l

jki

ba



O-RING .489 x .070 2-014 0080737 O-RING .364 x .070 2-012 0080736

10 HOSE - Pump to Manifold 0116705 29 HOSE - Bulk-Head Fitting to Brake

0117528

11 HOSE - Pump to Manifold 0116706 30 HOSE - Front Drive to Manifold

0117531

12 HOSE - Brake Valve to Tank

0086578 31 HOSE - Rear Drive to Manifold

0117533

13 FITTING #8 0081583 32 FITTING - Elbow 90, st. thd, Hyd.

0052713

O-RING .644 x .087 DURO90 3-908

0080732 O-RING .351 x .072 DURO90 3-904

0080730

O-RING .489 x .070 2-014 0080737 33 FITTING - str. thd. Con-nector

0079875

14 HOSE - Steering Cyl. to Steering Valve

0117521 O-RING .755 x .097 DURO90 3-91

0080733

15 HOSE - Steering Cyl. to Steering Valve

0117520 O-RING .489 x .070 2-014 0080737

16 FITTING - Hydraulic 0083434 34 HOSE - Rear Exciter to Tank

0117526

O-RING .364 x .070 2-012 0080736 35 HOSE - Front Drive to Rear Drive

0117530

O-RING .468 x .078 DURO90 3-906

0080731 36 HOSE - Front Exciter to Rear Exciter

0117522

17 HOSE - Manifold to Brake Valve

0116707 37 HOSE - Rear Drive to Tank

0117525







wc_tx000472gb.fm 63


4.8 Control Valve Block

The solenoids located on the vibration and travel valves are equippedwith manual over-rides. Use of these over-rides for testing machinefunctions is not recommended. Pushing any of the over-ride buttonswhile the engine is running will cause sudden machine movement andcould result in a serious or fatal injury. If testing must be done usingthese over-rides, stand at side of machine and make sure feet areaway from drums before pushing button.

P1

P2

E

F

wc_gr002484

1 23

4

SV

5

TV

15

67

8MN

9

10

11

EV

12

13 14 16

WARNING

wc_tx000472gb.fm 64


4.9 Control Valve Block Components


1 Travel speed solenoid 11 Check valve for high speed travel

2 Reverse travel solenoid 12 Low amplitude vibration solenoid

3 Right steer solenoid 13 Manual over-ride button (4 places)

4 Left steer solenoid 14 Exciter circuit relief valve 3000 PSI (21 MPa)

5 Flow regulating valve for steering 15 Steering circuit relief valve 1000 PSI (7 MPa)

6 Double check valve for drive circuit 16 Drive circuit relief valve

7 Foward travel solenoid SV Steering control valve

8 Vibration / high speed travel control valve

TV Travel valve (forward / reverse)

9 High amplitude vibration solenoid EV Exciter control valve

10 Outlet to brake valve MN Main manifold block

wc_tx000472gb.fm 65

Notes
wc_tx000472gb.fm 66


4.10 High-Speed Travel Circuit Description


Note: The diagram shows the direction of oil flow when operating inforward at high speed travel, vibration switch in OFF position.

High speed travel is obtained by using the full flow from the larger frontpump (g) to operate the drive motors. This is accomplished byswitching flow from the front pump away from the exciter circuit andinto the drive circuit. The pilot-operated directional control valve (h)located in the main manifold valve (k) is used to do the switching.

Oil flows from the rear pump (f) to the travel speed valve (c). When theoperator switches to high speed travel, the travel speed solenoid isenergized, which shifts the valve to the position shown. In this position,oil flows through the valve and returns to the hydraulic tank. Thiscauses pilot oil pressure at the directional control valve (h) to drop, andallows spring force in the valve to shift the spool to the position shown.In this position, oil flow from the front pump is directed to the brake,drive, and steering circuits. There is no flow to the exciter motors.

Relief valve (j) limits hydraulic pressure in the drive circuit to 3000 psi(21 mPa). Check valve (i) prevents front pump oil flow frompressurizing the pilot circuit and shifting the directional control valve.

Machine forward and reverse directions are controlled by the solenoid-operated travel valve (a) which switches the direction of oil flowthrough the valve and drive motors.

When the operator switches to forward, the bottom solenoid on thetravel valve energizes, which shifts the valve spool to the positionshown. In this position, oil flows through the valve, rear drive motor (e),front drive motor (d), and back through the valve to the steering circuit.With the directional controls in neutral, both solenoids are off andsprings in the travel valve (a) return the spool to a neutral position.Operation in reverse will cause oil through the travel valve (a) to flowopposite the direction shown, reversing the direction of the drivemotors.

Note: Top or bottom as described above refers to the location of thesolenoids as installed on the machine.

A double check valve (b) provides a hydraulic lock to prevent the drivemotors from rotating while the machine is in neutral or is turned off.When pressurized, the pilot port in each check valve opens the valveand allows oil flow in both directions.

wc_tx000472gb.fm 67


4.11 High-Speed Travel Circuit


3000 PSI(21 MPa)

P1P2

3000 PSI(21 MPa)

HIGH PRESSURE FLOW

RETURN FLOW

PILOT PRESSURE

INACTIVE LINE (NO PRESSURE)

wc_gr002485

1*

2

3

a

b

d

e

fg

c

h

i

j

4

5

6

7

8

wc_tx000472gb.fm 68


4.12 High-Speed Travel Circuit Components



a Travel valve f Rear pump

b Double check valve g Front pump

c Travel speed valve h Directional control valve

d Front drive motor i Check valve

e Rear drive motor j Drive circuit relief valve

1* To brake valve.

2 Return line to hydraulic tank.

3 To steering valve.

4 Valve (c) opens and directs flow from rear pump (f) into return line.

5 Spring pressure shifts valve (h) and directs flow from front pump (g) into drive circuit.

6 To exciter (vibration valve).

7 From exciter motor case drain.

8 From hydraulic tank.

wc_tx000472gb.fm 69


4.13 Low-Speed Travel Circuit


wc_gr002486

3000 PSI(21 MPa)

P1P2

3000 PSI(21 MPa)

HIGH PRESSURE FLOW

RETURN FLOW

PILOT PRESSURE


1*

2

3

9

i

j

a

b

dc

fg

k

h

e4

5

6

7

8

wc_tx000472gb.fm 70


4.14 Low-Speed Travel Circuit Components



a Travel valve g Front pump

b Double check valve h Directional control valve

c Travel speed valve i Check valve

d Front drive motor j Drive circuit relief valve

e Rear drive motor k Exciter circuit relief valve

f Rear pump

1* To brake valve.


3 To steering valve.

4 Valve (c) closes and directs flow from rear pump (f) through check valve (i) into drive circuit.

5 Pressure from rear pump (f) shifts valve (h) and directs flow from front pump (g) into exciter circuit.

6 To exciter (vibration valve).

7 From exciter motor case drain.


9 Pilot pressure.

wc_tx000472gb.fm 71


4.15 Low-Speed Travel Circuit Description


Note: The diagram shows the direction of oil flow when operating atlow speed travel and going forward, vibration switch in OFF position.

Low speed travel is obtained by using oil flow from the smaller rearpump (f) to operate the drive motors. This is accomplished by thesolenoid-operated travel speed valve (c), which directs flow from therear pump to the drive circuit.

Oil flows from the rear pump to the travel speed valve. When theoperator switches to low speed travel, the travel speed valve solenoid(c) is turned off. This allows spring force in the valve to shift the spoolto the position shown. In this position, flow from the rear pump isdirected through check valve (i) and on to the drive and steeringcircuits. High pressure oil is also directed to the pilot port of thedirectional control valve (h). Spring resistance in the directional controlvalve (h) is overcome by the increased oil pressure which shifts thespool to the position shown. In this position, oil flow from the largerfront pump (g) is directed to the exciter circuit. A flow regulating valvein the steering circuit always provides enough pressure to shift thedirectional control valve even if the travel and steering function are inneutral.

Relief valves (j, k) limit hydraulic pressure in the drive and excitercircuits to 3000 psi (21 mPa).

Machine forward and reverse movements are controlled by thesolenoid-operated travel direction valve (a) which switches thedirection of oil flow through the valve and drive motors.

When the operator switches into forward, the bottom solenoid on thetravel valve energizes, which shifts the valve spool to the positionshown. In this position, oil flows through the valve, rear drive motor (e),front drive motor (d) and back through the valve to the steering circuit.When the operator switches into reverse, oil flow through the valve isopposite the direction shown, reversing the direction of the drivemotors. When the machine is in neutral, both solenoids are off andsprings in the valve return the spool to neutral.


A double check valve (b) provides a hydraulic lock to prevent the drivemotors from rotating while the machine is in neutral or turned off. Whenpressurized, the pilot port in each check valve opens the valve andallows oil flow in both directions.

wc_tx000472gb.fm 72


4.16 Exciter Circuit Description


Note: The diagram shows the direction of oil flow when operating atlow speed travel with the EXCITER switch set to LO.

Operating in low speed travel opens flow from the front pump to theexciter circuit. When operating in high speed travel the exciter circuit isclosed and all flow is directed to the drive motors .

When the operator switches to low speed travel, the travel speed valve(d) is turned off. This allows spring force in the valve to shift the spoolto the position shown. In this position, flow from the rear pump isdirected through check valve (h) and on to the drive and steeringcircuits. High pressure oil is also directed to the pilot port of thedirectional control valve (c). Spring resistance in the directional controlvalve is overcome by the increased oil pressure which shifts the spoolto the position shown. In this position, oil flow from the larger frontpump (g) is directed to the exciter circuit. A flow regulating valve in thesteering circuit always provides enough pressure to shift the directionalcontrol valve even if the travel and steering functions are in neutral.

Low or high amplitude vibration is controlled by the solenoid-operatedexciter valve (l). This valve switches the direction of oil flow throughexciter motors.

With the VIBRATION pushbutton switch set in the low position, the topsolenoid is energized and the valve spool will be at the position shown.In this position, oil flows through the valve, rear exciter motor (i), to thefront exciter motor (j) and back through the valve to the hydraulic tank.When the VIBRATION pushbutton switch is in the high position, the LOsolenoid is turned off and the valve returns to neutral. A timer in theelectrical circuit keeps the valve in neutral for approximately 7 secondsbefore turning on the HI solenoid. This allows the exciter weights tostop rotating before reversing direction. With the exciter switch set atHI, oil flow through the motors is opposite of the direction shown,causing the exciter motors to reverse direction.


Relief valve (e) limits hydraulic pressure in the exciter circuit to 3000psi (21 mPa).

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4.17 Exciter Circuit


wc_gr002487

HIGH PRESSURE FLOW

RETURN FLOW

PILOT PRESSURE


3000 PSI(21 MPa)

P1P2

3000 PSI(21 MPa)

1*2

3

4

l

k

a

c

i

jh

e d

fg

wc_tx000472gb.fm 74


4.18 Exciter Circuit Components



a Drive circuit relief valve g Front pump

b Travel valve h Check valve

c Directional control valve i Rear exciter motor

d Travel speed valve j Front exciter motor

e Exciter circuit relief valve k Exciter valve

f Rear pump l Exciter speed valve

1* To brake valve.


3 To drive and steering valve.


wc_tx000472gb.fm 75


4.19 Steering Circuit Description

See graphic: wc_gr002488

Note: The diagram shows the direction of oil flow when steering left.

The steering circuit consists of a flow regulating valve (c), pressurerelief valve (f), solenoid-operated control valve (g), and steeringcylinder (h).

Return oil from the drive circuit flows into the steering circuit andthrough the flow regulating valve (c) before entering the solenoid-operated steering control valve (g). The flow regulating valvemaintains a constant 1 gpm flow rate in the steering circuit. This isnecessary to provide the same degree of steering control whetheroperating in low or high speed travel. It also creates sufficient backpressure in the system to shift the directional control valve in the mainmanifold. This keeps the exciter circuit open when the steering andtravel valves are in neutral.

When the operator steers left, the top solenoid on the steering valve(g) is energized and the valve spool shifts to the position shown. In thisposition, oil flows out port “E” of the valve, to the rod end of the steeringcylinder (h). At the same time, oil from the head end of the cylinderreturns through port “F” and back to the hydraulic tank. This causes thecylinder rod to retract, turning the machine left. When the operatorsteers right, oil flows in the opposite direction causing the cylinder rodto extend and turn the machine to the right. With steering in neutral,both solenoids are turned off. Springs in the valve return the spool tocenter which allows oil to pass through the valve, out port “T”, and backto tank.


Relief valve (e) limits hydraulic pressure in the steering circuit to 1000psi (7 mPa).

wc_tx000472gb.fm 76


4.20 Steering Circuit

T

E F

1000 PSI(7 MPa)

HIGH PRESSURE FLOW

RETURN FLOW

PILOT PRESSURE


wc_gr002488

1

c

f

a

b

d

e

2

h

g

wc_tx000472gb.fm 77


4.21 Hydraulic System Cleanliness

Keeping the hydraulic fluid clean is a vital factor affecting the servicelife of hydraulic components. Oil in hydraulic systems is used not onlyto transfer power, but also to lubricate the hydraulic components usedin the system. Keeping the hydraulic system clean will help avoidcostly downtime and repairs.

Major sources of hydraulic system contamination include:

• Particles of dirt introduced when the hydraulic system is opened for maintenance or repair.

• Contaminants generated by the mechanical components of the system during operation.

• Improper storage and handling of hydraulic fluid.

• Use of the wrong type of hydraulic fluid.

• Leakage in lines and fittings.

To minimize hydraulic fluid contamination:

• Clean hydraulic connections before opening lines. When adding oil, clean hydraulic tank filler cap and surrounding area before remov-ing.

• Avoid opening pumps, motors or hose connections unless abso-lutely necessary.

• Plug or cap all open hydraulic connections while servicing system.

• Change hydraulic filters and fluids at the recommended service intervals.

4.22 Hydraulic Oil Requirements

WACKER recommends the use of a good petroleum-based, anti-wearhydraulic oil in the hydraulic system of this equipment. Good anti-wearhydraulic oils contain special additives to reduce oxidation, preventfoaming and provide for good water separation.

Premium grade, anti-wear hydraulic fluid.

Viscosity: 10W30.

See Technical Data for quantity.

Most hydraulic oils are available in different viscosities. The SAEnumber for an oil is used strictly to identify viscosity—it does notindicate the type of oil (engine, hydraulic, gear, etc.).

wc_tx000472gb.fm 78


4.23 Checking Hydraulic Pressures


Before making pressure checks:

4.23.1 Inspect machine for hydraulic leaks.

4.23.2 Check level of hydraulic fluid in tank.

4.23.3 Check engine operating speed at full throttle. Set at 2600 RPM.

4.23.4 Run machine for 5-10 minutes before testing to allow time for hydraulicsystem to warm up.

A test port is provided on the front (a) and rear (b) pumps for checkingsystem pressures.

Note: Test ports are equipped with quick disconnects and aredesigned for use with WACKER hydraulic test equipment.

Before opening hydraulic connections, shut engine off.

WARNING

wc_gr002489

b a

wc_tx000472gb.fm 79


4.24 Checking Drive Circuit


Operating Pressure (Low Speed)

Check operating pressure with the machine on a level compactiblesurface, such as gravel or dirt.

4.24.1 Install 5000 PSI gauge in rear pump test port (b).

4.24.2 Start engine and run at full throttle (2600 rpm).

4.24.3 Move joystick forward but not fully forward, and read forwardoperating pressure. Record reading.

4.24.4 Move joystick in reverse and read reverse operating pressure. Recordreading.

Note: Operating pressures should be within range as shown in sectionSystem Pressures. If pressure readings are above or below range,refer to section Troubleshooting Hydraulic System.

Operating Pressure (High Speed)

Check operating pressure with the machine on a level compactiblesurface, such as gravel or dirt.

4.24.5 Install 5000 PSI gauge in front pump test port (a).

4.24.6 Start engine and run at full throttle (2600 rpm).

4.24.7 Move joystick fully forward and read forward operating pressure.Record reading.

4.24.8 Move joystick in reverse and read reverse operating pressure. Recordreading.


Relief Pressure

4.24.9 Block in front of and behind both drums to prevent machine frommoving, or deadhead machine against a solid concrete abutment.

Make sure blocks are large enough so machine will not climb overthem during testing.

4.24.10 Install a 5000 PSI gauge in front pump test port (a).

4.24.11 Start engine and run machine at full throttle.

WARNING

wc_tx000472gb.fm 80

4.24.12 Push joystick fully forward until pressure on gauge tops out. This is
the high speed relief valve pressure. Make sure drums do not spin.Record reading.

4.24.13 Stop engine. Install gauge in rear pump test port (b).

4.24.14 Push joystick forward but not fully forward until pressure on gaugetops out. This is the low speed relief valve pressure. Record reading.

Note: Relief valve pressures should be within range as shown insection System Pressures. If pressure readings are above or belowrange, refer to section Troubleshooting Hydraulic System.

4.25 Checking Steering Circuit


4.25.1 Install 2000 PSI gauge in rear pump test port (b).

4.25.2 Start engine and run machine at full throttle (2600 rpm).

4.25.3 Move joystick right or left. Gauge will show operating pressure untilcylinder gets to end of stroke and then show relief pressure. Recordreadings.

Note: Operating and relief pressures should be within range as shownin section System Pressures. If pressure readings are above or belowrange, refer to section Troubleshooting Hydraulic System.

wc_gr002489

b a

wc_tx000472gb.fm 81


4.26 Checking Vibration Circuit


Test vibration with drums on soil or gravel. If testing is done inside,position drum on rubber tire or heavy mat to absorb vibration.

DO NOT run vibration on concrete.

Operating Pressure (High Amplitude)


4.26.2 Start engine and run machine at full throttle (2600 rpm) with joystick inneutral.

4.26.3 Switch vibration to HI. Gauge will show relief pressure momentarily asexciter starts and then fall to normal operating pressure as exciterreaches full speed. Record reading.


Operating Pressure (Low Amplitude)


4.26.5 Start engine and run machine at full throttle (2600 rpm) with joystick inneutral.

4.26.6 Switch vibration to LO. Gauge will show relief pressure momentarily asexciter starts and then fall to normal operating pressure as exciterreaches full speed. Record reading.

Note: Operating pressures should be within range as shown sectionSystem Pressures. If pressure readings are above or below range,refer to section Troubleshooting Hydraulic System.

4.27 Testing Drive & Exciter Circuit Relief Valves


4.27.1 Drive and exciter circuit relief valves are identical and set at the samepressures. They can be tested for correct operation by simplyswapping positions with one another. Swap the one in question withthe other and test for correct pressure. If pressure is correct with thesecond valve installed, the original valve is malfunctioning and willrequire replacement.

CAUTION

wc_tx000472gb.fm 82


4.28 System Pressures

The table below lists normal operating pressures based on themachine running over a level compactible surface. These pressuresare approximate and will vary for different operating conditions.Operating pressure readings for the drive and steering circuits may behigher when operating in extremely loose soils or on an incline.Operating pressure readings will be lower when operating on flat, hardsurfaces where there is less surface resistance.

Normal OperatingPressure @ 2600 RPM

PSI (mPa)

Relief ValvePressurePSI (mPa)

TestPort

Location

Forward orReverse in LOW Speed

180 - 600 (1.2 - 4.2) 3000 (21) Rear Pump

Forward orReverse in HIGH Speed

300 - 800 (2.1 - 5.6) 3000 (21) Front Pump

Exciter in LOW Vibration

1050 - 1250 (7.3 - 8.7) 3000 (21) Front Pump

Exciter in HIGH Vibration

1200 - 1600 (8.4 - 11.2) 3000 (21) Front Pump

Steering 300 - 800 (2.1 - 5.6) 1000 (7) Rear Pump(Low speed travel)

wc_tx000472gb.fm 83


4.29 Troubleshooting Hydraulic System

Problem / Symptom REASON / REMEDY

Drive circuit operating pressures are too LOW

1. Testing surface is too hard or smooth. Check readings while machine is on compactible soil.2. Engine operating below 2600 rpm. Set throttle to deliver 2600 rpm.3. Suction hose or fittings leaking, allowing air into pump inlet. Tighten hose fittings as necessary. 4. Oil level is too low in tank. Make sure oil is at proper level.5. Worn pump coupling. Remove and repair as necessary.6. Malfunctioning relief valve. Test relief valve for proper opera-tion.

Drive circuit operating pressures are too HIGH(ABOVE 800 psi)

1. Wrong weight of oil in drive gearcase (viscosity too high). Drain and fill with proper weight oil for operating conditions. If pressures are still high, continue.2. Engine operating above 2600 rpm. Set throttle to deliver 2600 rpm.3. Drum binding due to dirt build-up between drums and drum supports. Remove dirt build-up.4. Drive assembly binding due to worn or improperly assembled parts. Remove, inspect, repair and properly assemble drive assembly.5. Hoses routed incorrectly. Make sure hoses are routed prop-erly.

Exciter circuit operating pressure is too LOW (Below 800 psi) - Drive circuit pressure ok

1. Sticky spool in exciter or directional control valve, allowing partial pressure loss. Check electrical circuits to make sure sole-noids are functioning properly. If ok, continue. or Remove con-trol valve and repair or replace if necessary.2. Hoses leaking. Tighten fittings.3. Worn exciter motor(s). Replace exciter motor(s). 4. Malfunctioning relief valve. Test relief valve for proper opera-tion.

Exciter circuit operating pressure is too HIGH (Above 1800 psi) - Drive circuit pressures ok

1. Wrong weight of oil in exciter assembly (viscosity too high). Drain and fill with proper weight oil for operating conditions.2. Exciter assembly oil level too high. Remove, inspect, and repair exciter assembly as necessary. Fill with oil to proper level3. Binding in exciter assembly (bearings worn or damaged). Remove, inspect, and replace exciter assembly as necessary.

Relief pressure too LOW

1. Relief valve adjustment wrong. Adjust or replace valve as necessary. 2. Worn pump or motor. Repair as necessary.

wc_tx000472gb.fm 84

RT Repair Disassembly/Reassembly—Older Machines

5. Disassembly/Reassembly—Older Machines

5.1 Tools

Because all possible problems encountered while repairing theequipment cannot be anticipated, it is up to the mechanic to usecommon sense and good judgement in tool selection.

The use of any special tools is recommended only for those operationswhere the use of conventional tools proves inadequate.

Before substituting another tool or procedure, you should be satisfiedthat neither personal injury nor damage to the component will result.

5.2 Ordering Parts

The repair procedures contained in this manual do not include partnumbers. For parts replacement information, refer to the Parts Bookoriginally supplied with the unit.

If the original Parts Book has been lost, a replacement may be orderedfrom Wacker Corporation. When ordering a replacement Parts Book,please list the model number, item number, revision level, and serialnumber of the machine. Parts Books are also available on the WackerCorporation Web site. See www.wackergroup.com. Enter the site as avisitor.

5.3 Reference Numbers ( )

Repair procedures contain reference numbers enclosed inparentheses ( ). These numbers refer to the item numbers shown onthe assembly drawings and other detailed drawings. They are includedto aid the mechanic in identifying parts and assembling components.

5.4 Weight Block


The weight block symbol gives an approximate weight measurementto aid the mechanic when lifting/hoisting larger components.

250 kg(550 lbs.)

wc_gr000843

wc_tx000473gb.fm 85

Disassembly/Reassembly—Older Machines RT Repair

5.5 Drum Assembly Exploded View

wc_gr002501

9 [T2]

12 [L2]

13 [L3]

16

18

1927

23

24

26[L1,T4]

25[L1,T4]

17 [L1,T5]

7 [L1,T1]

13 [L1,T1]

22 [L1,T3]

20 [L1,T3]21

15[L3] 14[L1]

8 [L4]7 [L1,T1]

4 [G1]

1 [L1]

1011

6

5

32

wc_tx000473gb.fm 86


5.6 Drum Assembly Components

See Graphic:wc_gr002501

Ref. Description Qty. Ref. Description Qty.

1 Screw (M8 x 16) 6 14 Screw (M8 x 20) 2

2 Plate-retaining 1 15 Plate-cover 1

3 Seal-shaft 1 16 Washer-lock (A12) 6

4 Bearing-roller 1 17 Screw (M12 x 25) 6

5 Seal-shaft 1 18 Scraper-bar 2

6 Cover-support 1 19 Key 1

7 Screw (M10 x 20) 24 20 Stud- shockmount 1

8 Seal-shaft 1 21 Drum support 1

9 Nut-hex (1¼-18) 1 22 Screw (M12 x 35) 8

10 Washer (1-1/8") 1 23 Drum 2

11 Hub-drum 1 24 Washer (B17) 6

12 Plug (M26 x 1.5) 1 25 Screw (M16 x 16) 6

Seal-ring 1 26 Screw (M16 x 25) 12

13 Screw (M10 x 16) 6 27 Drivecase 1

[G1] 0066982 Unirex No. 2[L1] 0029311 [L2] 0073287 [L3] 0070735 [L4] Silicone[T1] 36 ft.lbs. (49 Nm) [T2] 450 ft.lbs. (610 Nm) [T3] 88 ft.lbs. (120 Nm) [T4] 155 ft.lbs. (210 Nm)[T5] 63 ft.lbs. (85 Nm)

wc_tx000473gb.fm 87


5.7 Drums

Removal:

5.7.1 Lock articulated joint.

5.7.2 Lift machine by the lifting eye using an appropriate crane or hoist. Alsouse jack stands (a) to support machine from underneath machineframe.

1

3

13

16

17

24

5

15

10

76

8

9

1112

a

wc_gr002502

wc_tx000473gb.fm 88

Only use steel ropes or chains for hoisting. Ropes or chains must havethe suitable specified lifting capacity. Do not use improvised ropes orchains.
Only use blocks or jacks with a suitable load bearing capacity. Do notuse improvised blocks or jacks.

5.7.3 Loosen three M12 screws (1) and washers (2) mounting scraper bar(3) and shim (4) to drum support (5).

5.7.4 Loosen four M8 screws (6), washers (7), and nuts (8) mounting outerscraper (9) to bracket (10). Remove two M12 screws (11) andwashers (12) mounting outer scraper to drum support (5).

5.7.5 Remove six M16 screws (13) holding the drum (14) to the drivehousing (15).

5.7.6 Remove three M16 screws (16) and washers (17) and insert three M16x 55 screws into the holes. Turn screws in to push drum off drivehousing.

Installation:

5.7.7 Mount drum (14) to drive housing (15) using M16 screws (13) . Securescrews with Loctite 243, or an equivalent medium strengththreadlocking compound and torque to 155 ft.lbs. (210 Nm).

5.7.8 Install the three M16 x 16 screws (16) and washers (17) into pusherholes to plug holes and protect threads. Secure screws with Loctite243, or an equivalent medium strength threadlocking compound andtorque to 155 ft.lbs (210 Nm).

5.7.9 Mount scraper bar (3) and shim (4) to drum support (5) using M12screws (1) and washers (2). Secure screws with Loctite 243 or anequivalent medium strength threadlocking compound and torque to 63ft.lbs. (85 Nm).

5.7.10 Mount outer scraper (9) to drum support (5) using M12 screws (11) andwashers (12). Secure screws with Loctite 243 or an equivalentmedium strength threadlocking compound.

5.7.11 Mount outer scraper (9) to bracket (10) using M8 screws (6), washers(7), and nuts (8).

Note: See sealant and torque reference charts in back of book forappropriate threadlocking adhesives and torque values.

Before you start the machine, ensure that all tools have been removedfrom the machine and that replacement parts and adjusters are firmlytightened.

WARNING

WARNING

WARNING

wc_tx000473gb.fm 89


5.8 Drum Support Cover


Removal:

5.8.1 Remove drums and scrapers bars. See section Drums.

5.8.2 Using a large breaker bar remove the 1-1/4" hex nut (1) and washer(2) which holds the drum on the axle.

5.8.3 Insert three M16 x 55 screws (3) into alternating holes on hub in whichdrum was mounted. Turn screws in to push drum hub (4) off supportcover (5).

5.8.4 Remove shaft seal (6) from support cover (5).

5.8.5 Remove the twelve M10 screws (7) holding the support cover (5) to thedrum support (8).

5.8.6 Remove the three M10 screws (9) in the support cover. Into theseholes insert three M10 x 55 screws. Turn screws in to push cover fromdrum support.

Installation:

Drum drive housing must be in place before assembling drum supportcover. See section Drive Housing.

5.8.7 Install support cover (5) on drum support (8) using twelve M10 screws(7). Secure screws with Loctite 243, or an equivalent medium strengththreadlocking compound and torque to 36 ft. lbs. (49 Nm). Install thethree M10 screws (9) back into pusher holes to protect the threads.

5.8.8 Apply a bead of silicone to support cover (5) where shaft seal (6) willseat. This will help hold shaft seal in place and prevent it from spinning.Attach shaft seal to support cover.

5.8.9 Install drum hub (4) into drum support (8) with washer (2) and nut (1).Secure nut by using Loctite 243 on axle shaft threads and torque nutto 450 ft. lbs. (610 Nm).

5.8.10 Install drums and scraper bars. See section Drums.

wc_tx000473gb.fm 90


2

3

46

9

7

5

8

1

wc_gr002503

wc_tx000473gb.fm 91


5.9 Drive Bearings and Seals


Disassembly:

5.9.1 Remove drum support cover. See Section 5.4 Drum Support Cover.

5.9.2 Clean drum hub (1) of all grease. Heat bearing race (2) with propanetorch. Once race is hot, use a chisel to pry race off drum hub farenough to install a puller. It may be necessary to use an oxy-acetylenetorch in order to heat bearing race fast and hot enough for removal.

Always wear safety glasses, gloves, and approprate clothing whendealing with heat and open flames.

CAUTION: If using a torch, extreme care should be used to avoidcutting through race and damaging hub.

Note: Bearing must be replaced once race is removed.

5.9.3 Remove M8 screws (3) holding retaining plate (4) and press retainingplate from support cover (5).

5.9.4 Press shaft seal (6) from the retaining plate (4).

Note: Shaft seal must be replaced once it is removed.

5.9.5 Press roller bearing cage (7) and shaft seal (8) from support cover (5).

Note: Shaft seal must be replaced once it is removed.

Assembly:

5.9.6 Press shaft seal (8) into support cover (5).

5.9.7 Separate roller bearing into race (2) and cage (7). Pack cage portionof bearing (7) with bearing grease and press into support cover (5).

5.9.8 Press shaft seal (6) into retaining plate (4).

5.9.9 Install retaining plate (4) on support cover (5) with M8 screws (3).Secure screws using Loctite 243 or an equivalent medium strengththreadlocking compound.

5.9.10 Press bearing race (2) onto drum hub (1).

Note: Heating race on a hot plate or hot oil bath will make installationeasier.

5.9.11 Install drum support cover. See Section 5.4 Drum Support Cover.



WARNING

WARNING

wc_tx000473gb.fm 92


2

1

5

8

7

64

3

wc_gr002504

wc_tx000473gb.fm 93


5.10 Drive Housing


Removal:

5.10.1 Remove drums and scrapers bars. See Section 5.3 Drums. Removesupport cover. See Section 5.4 Drum Support Cover.

5.10.2 Tag and disconnect hydraulic hoses from drive motor (1). Cap or plugall open connections.

Note: Machines with Item Numbers 9001 & 9003 include a brakeassembly (2) on the front drum. On these machines it will also benecessary to disconnect the hydraulic line that engages the brake.

5.10.3 Remove twelve M10 screws (3) holding the drive housing (4) to thedrum support (5).

Note: Before removing the drive housing, add reference marks to thedrum support and the drive housing. This will help align the two pieceslater on and make installation easier.

5.10.4 Remove three M10 screw plugs (6) in the drive assembly flange andinsert three M10 x 55 screws in their place. Turn screws in to pushdrive housing (4) from drum support (5). Pull complete drive housingfrom the drum support.

Installation:

Both the drive motor (1) and brake assembly (2) must be mounted tothe drive housing (4) before installing it in drum support (5). SeeSections 5.9 & 5.11.

5.10.5 Install drive housing (4) in drum support (5) using twelve M10 screws(3). Secure screws using Loctite 243 or an equivalent mediumstrength threadlocking compound and torque to 36 ft. lbs. (49 Nm).

5.10.6 Install three M10 screws (6) into pusher holes. Secure using Loctite243 or an equivalent medium strength threadlocking compound.

5.10.7 Apply Loctite 545 or an equivalent hydraulic sealant to hydraulic fittingsand connect hydraulic lines to drive motor (1) and brake (2).

5.10.8 Clean inside of drum hub (7) and tapered end of axle. For Installation,see Section 5.4 Drum Support Cover.

5.10.9 Check oil level in drive housing.



WARNING

wc_tx000473gb.fm 94


7

wc_gr002505

5

6

3

4

2

1

wc_tx000473gb.fm 95


5.11 Changing Oil


The drum drive case is lubricated in an oil bath.

To drain oil:

5.11.1 Remove drum from the drive housing side of machine (see sectionDrums). On the front of the machine this will be the right side, and onthe rear of the machine the left side.

5.11.2 Remove fill plug (b) for venting.

5.11.3 Remove drain plug (c) and drain oil from drum.

Note: In the interests of environmental protection, place a plastic sheetand a container under the machine to collect the liquid which drains off,and dispose of properly.

To add oil:

5.11.4 Install drain plug (c).

5.11.5 Remove level plug (a).

5.11.6 Add SAE 10W30 oil at fill plug until oil flows out of level plug opening.Replace plugs.

Total Capacity: 8 oz. (240 ml).

5.11.7 Install fill plug (b).

wc_tx000473gb.fm 96


c

a

b

wc_gr002506

wc_tx000473gb.fm 97


5.12 Drive Housing Assembly

3334

wc_gr002507

111

10

98

4 [L1,T3]5 [L3]

192021

5051

52

18 [L1,T5]

32 [L1,T4]28 [L1,T4]

53

54

29 [L2]23

30

35

31

27

12

23[L1,T1]

13[L1,T2]

1415

161617

6

wc_tx000473gb.fm 98


5.13 Drive Housing Components


1 Brake assembly 1 18 Screw (M8x18) 5

2 Washer 6 19 Seal-shaft 1

3 Screw (M6x90) 6 20 Retaining ring 1

4 Screw (3/8-16x1) 1 21 Gear-drum drive 1

5 Cover-gear 1 22 Retaining ring 1

6 Axle-drive 1 23 Bearing-roller 1

7 Key 1 24 Seal-shaft 1

8 Washer 1 25 Set-plug 3

9 Gear-pinion 1 26 O-Ring 3

10 Motor-hydraulic drive 1 27 Housing-drive 1

11 Fitting-elbow 1 28 Screw (M10x20) 12

12 O-Ring 1 29 Seal-shaft 1

13 Screw (M12x 70) 2 30 Spacer-ring 1

14 O-Ring 2 31 Key 1

15 Fitting 1 32 Screw (M10x16) 3

16 O-Ring 2 33 Screw (M6x15) 6

17 O-Ring 1 34 Cover-brake 1

[L1] 0029311 [L2] Silicone [L3] 0070735 [T1] 7 ft.lbs. (9 Nm) [T2] 90 ft.lbs. (122 Nm) [T3] 43 ft.lbs. (58 Nm) [T4] 36 ft.lbs. (49 Nm)[T5] 18 ft.lbs. (25 Nm)

wc_tx000473gb.fm 99


5.14 Brake


The brake is located on the front drum only and is mounted to the gearcover of the drivecase. To remove the brake the complete drivehousing must be removed from the drum support.

Removal:

5.14.1 Remove drums from roller. See section Drums.

5.14.2 Remove drive housing from drum support. See section Drive Housing.

5.14.3 Remove the six M6 screws (1) and washers (2) holding brakeassembly (3) and remove brake assembly from drive housing.

Installation:

5.14.4 Apply Loctite 515 gasket compound to face of gear cover (4) wherebrake mounts (a).

5.14.5 Mount the brake assembly (3) with six M6 screws (1) and washers (2).Apply Loctite 271 or an equivalent high strength threadlocker toscrews, and torque to 7 ft.lbs. (9 Nm).

5.14.6 Position hydraulic fitting (5) on brake as shown.

5.14.7 Install drive housing to drum support. See section Drive Housing.



WARNING

wc_tx000473gb.fm 100


wc_gr002508

12

3

4

a

5



5.15 Servicing Brake


Disassembly:

5.15.1 Remove fitting (20).

5.15.2 Remove retaining ring (6) and pull gear (7) off shaft.

5.15.3 Remove three M6 screws (21) which hold the brake assemblytogether.

Note: When removing last screw, rear housing may "pop" off fronthousing due to spring tension.

5.15.4 Disassemble interior pieces (12–16).

5.15.5 Remove retaining ring (11) from front housing (8) and press out ballbearing (10).

5.15.6 Remove seal (9).

5.15.7 Remove retaining ring (17) from rear housing (19) and press out ballbearing (18).

Assembly:

5.15.8 Press bearings (10 & 18) into front and rear housings and secure inplace using retaining rings (11 & 17).

5.15.9 Install seal (9) into front housing (8).

5.15.10 Insert ring spacer (12) into front housing.

5.15.11 Set front housing on face and insert spring (13), O-rings (14), shaft (16)and locking plate (15).

5.15.12 Secure rear housing assembly to front housing with three M6 screws(21). Secure screws using Loctite 243 or an equivalent mediumstrength threadlocking compound, and torque to 7 ft.lbs. (9 Nm).

5.15.13 Install fitting (20) to rear housing assembly.

5.15.14 Install gear (7) on shaft and secure with retaining ring (6).



WARNING



wc_gr002509

21

20

1817

16

14

151413

1211

109

19

228

7

6



5.16 Drive Motor


The drive motor is mounted to the gear cover of the drive housing.When replacing the drive motor, the complete drive housing must beremoved from the drum support.

Removal:


5.16.2 Remove drive housing from the drum support. See section DriveHousing.

5.16.3 Loosen two M12 screws (1) and remove the hydraulic drive motor (2).

5.16.4 Use a small propane torch and heat the countersunk screw (3) holdingthe drive pinion gear (4) to the motor. This will break down thethreadlocking sealant. Remove screw and washer (5), and pull drivepinion gear off motor.

Installation:

5.16.5 Install drive pinion gear (4) onto motor shaft with washer (5) and screw(3). Secure screw with Loctite 271 or an equivalent high strengththreadlocking compound.

5.16.6 Apply Loctite 515 gasket compound to face of gear cover where drivemotor mounts (a).

5.16.7 Mount hydraulic drive motor (2) with two M12 screws (1). Securescrews with Loctite 243 or an equivalent medium strengththreadlocking compound and torque to 90 ft.lbs. (122 Nm).

5.16.8 Align the hydraulic fittings (b) as shown.

Note: Failure to align fittings properly could make it difficult to connecthydraulic lines after drive assembly is installed.

5.16.9 Install Drive housing. See section Drive Housing.

Seal Kit:

5.16.10 Order Seal Kit P/N 76630 for replacement of internal motor seals andO-rings. Refer to installation instructions included with kit.

Note: Special knowledge and skill is required when working onhydraulic components. If you are lacking the necessary skills andknow-how, contact a competent hydraulic repair facility for assistance.



wc_gr002510

a

2

2

b

1817

4

1

5

3



5.17 Drive Housing Components


Disassembly:


5.17.2 Remove drive housing from the drum support. See section DriveHousing.

5.17.3 Drain oil from drive housing. See section Changing Oil.

5.17.4 Remove drive motor (see section Drive Motor) and brake assembly(see section Brake) from drive housing.

5.17.5 Loosen the five M8 screws (6) and lift gear cover (7) from drive housing(8).

5.17.6 Press shaft seal (9) from gear cover.

5.17.7 Remove retaining ring (10) holding gear (11) to drive axle (12). Usethree M12 x 90 hardened bolts (c) (P/N 11411) to push drive gear fromdrive housing and off of drive axle. If necessary, heat gear to aid in itsremoval.

5.17.8 Remove key (13) from drive axle (12) and pull axle from drive housing(8). If necessary, use three M16 x 55 screws (d) (P/N 11518) to pushaxle from drive housing.

5.17.9 Remove retaining ring (14) and press roller bearing cage (15) fromdrive housing (8).

5.17.10 Remove seals (16 & 17) from drive housing (8).

5.17.11 Remove key (18) from drive axle (12).

5.17.12 Use a small propane torch and heat inner bearing race (19) and spacer(20) sufficiently until they drop off axle.



wc_gr002511

6

7

910

11

142115

168

1719

2018

12

13

c

d


(Drive Housing Components continued)

Assembly:

5.17.13 Heat spacer ring (20) on a hot plate or in oil bath and press onto driveaxle (12).

5.17.14 Heat roller bearing race (19) and press onto drive axle.

5.17.15 Press shaft seal (16) into drive housing (8).

5.17.16 Apply a bead of silicone to area on drive housing (a) where wiper seal(17) will seat. Install seal on housing.

5.17.17 Apply a thin film of low-temp #2 grease to drive axle (b) to trap anyexcess dust.

5.17.18 Press bearing cage (15) in drive housing. Secure it to axle withretaining ring (14).

5.17.19 Slide axle into drive housing carefully to avoid damaging seal (16).

5.17.20 Place key (13) in drive axle.

5.17.21 Slide bearing washer (21) over axle and onto bearing.

5.17.22 Heat drive gear (11) for approximately one half hour in a 350° oven andthen press it onto axle (12).

5.17.23 Attach retaining ring (10) to secure drive gear on axle.

5.17.24 Press shaft seal (9) into gear cover (7).

5.17.25 Apply Loctite 515 or an equivalent gasket compound to machinedfaces (c) of drive housing (8), as shown.

5.17.26 Mount gear cover (7) to drive housing (8) using five M8 screws (6).Secure screws with Loctite 243 or an equivalent medium strengththreadlocking compound and torque to 18 ft.lbs (24 Nm).

5.17.27 Install drive motor and brake. See sections Drive Motor and Brake.

5.17.28 Add 8 oz. of SAE 30W oil to drivecase through fill plug opening. Seesection Changing Oil.

5.17.29 Install complete drive housing in drum support. See section DriveHousing. Re-check oil level.



WARNING



wc_gr002512

1213

11

8

9

10

7

6

12

1415

17

19

20

21

16a

b

c



5.18 Exciter Assembly Exploded View

wc_gr002513

19

1617

1614

11

15 15

7

12

1312

4

11

10

21 [L3] 23 [L3]24 [L3, T3]

40

27

27

2829

303122

32

35 [L5, T1]

36*36*

32

38 [L5, T4]

34

39 [L3, T1]

25 [L2, T2]

26 [L4, T1]

26 [L4, T1]

22

6 [L1]

5

57

7

6 [L1]

1 [L1]

9 [L2,T1]

20 [L2,T2]

32

33



5.19 Exciter Assembly Components

See Graphic wc_gr002513


1 Fitting-elbow 1 21 Cover 2

2 O-Ring 1 22 Bearing-roller 4

3 O-Ring 1 23 Cover-exciter base 1

4 Motor-hydraulic gear 1 24 Screw (M6x10) 10

5 Key-Woodruff 1 25 Screw (M8x16) 13

6 Fitting-elbow 2 26 Plug (M26x1.5) 2

7 O-Ring 2 27 Seal-ring 2

8 O-Ring 2 28 Cover-exciter gear 1

9 Screw (M10x25) 2 29 Retaining ring 2

10 Washer-lock 2 30 Gear-exciter 2

11 Coupling-flexshaft 1 31 Retaining ring-internal 2

12 Setscrew (5/16"x5/8) 2 32 Weight-variable 2

13 Sleeve-coupler 1 33 Shaft-exciter 2

14 Retaining ring-external 1 34 Key 2

15 Bearing-roller 2 35 Screw (M10x30) 4

16 Retaining ring-internal 2 36 Mount-weight 2

17 Spacer-bearing 1 37 Weight-exciter 4

18 Key-Woodruff (¼x1) 1 38 Screw (M16x70) 4

19 Gear-pinion 1 39 Screw (M10x12) 1

20 Screw (M8x18) 12 40 Seal-ring 1

[L1] 0079356 [L2] 0029311 [L3] 0070735 [L4] 0073287[T1] 36 ft.lbs. (49 Nm) [T2] 18 ft.lbs. (24 Nm) [T3] 7 ft.lbs. (10 Nm) [T4] 155 ft.lbs. (210 Nm)



5.20 Introduction

This section covers disassembly and assembly of the complete exciterassembly, including replacement of gears, bearings, exciter motor,and motor coupling.

CAUTION: Due to the high rpm and vibration present in thiscomponent during operation, it is important to follow sealant andtorque notes carefully during assembly.

5.21 Oil Requirements


The exciter bearings and gears run in an oil bath and are splashlubricated. When servicing exciter be sure to check oil level (a) beforeinstalling it back into drum.

Note: Although oil can be added through the oil level plug, it is easierto add oil before attaching the base cover during reassembly.

Capacity: 32 oz. (1000 ml) SAE 30W.

a

wc_gr002516



5.22 Exciter


Removal:

Note: The exciter is installed in the drum using threadlockingcompounds to secure screws. Heat screws before removal, using asmall propane torch, to break down the threadlocking compound.

5.22.1 Remove drum, drum support cover, and drive housing assembly. Seesections Drums, Drum Support Cover, and Drive Housing.

5.22.2 Tag and disconnect hydraulic lines from exciter motor. Cap and plugopen connections.

5.22.3 Remove eight M12 screws (1) holding the exciter assembly (2) to thedrum support (3).

5.22.4 Lift exciter assembly up and out of drum.

Installation:

5.22.5 Double check oil level. Add or drain oil as required.

5.22.6 Install exciter assembly (2) in drum support (3) using eight M12 screws(1). Secure screws using Loctite 271, or an equivalent high strengththreadlocking compound, and torque bolts to 88 ft. lbs. (120 Nm).

5.22.7 Connect hoses to fittings on exciter motor.

5.22.8 Install drum, drum support cover, and drive housing assembly. Seesections Drums, Drum Support Cover, and Drive Housing.



WARNING

wc_gr002517

2

1

3



5.23 Exciter Exploded View

wc_gr002518

41

21

20 2324

25

28

2629

3031

2234

33

35

36

37

38



5.24 Exciter DisassemblySee Graphic: wc_gr002518, wc_gr002519, wc_gr002520

Note: The exciter is assembled using threadlocking compounds tosecure bolts and screws. Heat screws before removal, using a smallpropane torch, to break down the threadlocking compound.

5.24.1 Remove drum, drum support cover, and drive housing assembly. Seesections Drums, Drum Support Cover, and Drive Housing.

5.24.2 Remove drain plug (26) from exciter gear cover (28) and drain oil.

5.24.3 Remove exciter assembly from drum support. See section Exciter.

Note: In the interests of environmental protection, place a plastic sheetand a container under the exciter to collect the liquid which drains off,and dispose of properly.

5.24.4 Invert exciter housing (41) and remove ten M6 screws (24) holding thebottom base cover (23) to the exciter housing. Remove bottom basecover.

5.24.5 Rotate exciter shafts (33) to gain access to weights (37).

The exciter weights can rotate freely. Use caution when removingweights to prevent pinching fingers or hands inside exciter housing.

5.24.6 Use a small propane torch and heat four M10 screws (35) securingmount (36) to weights (37). Remove screws and mount.

5.24.7 Heat four M16 screws (38) holding the weights (37) to shafts (33). Thiswill break down the threadlocking compound. Remove screws andweights.

5.24.8 Remove thirteen M8 screws (25) holding exciter gear cover (28) tohousing (41).

5.24.9 Remove retaining rings (29) holding exciter gears (30) to shafts.

5.24.10 Insert three M10 x 55 pusher bolts into threaded holes (a) on excitergear (30). Turn bolts in until exciter gear is pushed free from housing.Repeat for other gear.

5.24.11 Remove keys (34) from exciter shafts (33).

5.24.12 Remove large retaining rings (31) which secure gear side bearings(22) in housing (41).

5.24.13 From other side of exciter housing, loosen the M8 screws (20) andremove covers (21) from housing (41).

5.24.14 Press or use a rubber mallet to drive exciter shaft (33) and bearing (22)all the way through housing as shown (b). Remove variable weight(32) as shaft slides through housing. Repeat for other shaft.

5.24.15 Press remaining shaft bearings (22) from housing.

CAUTION



wc_gr002519

41

a

33

32

22

b

29

wc_gr002520

41

21

22b

32a

cb

29

3031

22b

22a

33

20



5.25 Exciter Assembly


5.25.1 Lightly lubricate each exciter shaft (33) with 10W30 and press innerbearing races (22a) onto both ends of shafts.

5.25.2 Install bearing cage (22b) into exciter housing (41). Outer edge of cageshould be flush with outer machined surface of housing.

5.25.3 Apply Loctite 515 or an equivalent gasket compound to cover (21), andfasten to housing (41) using 5 M8 screws (20). Secure screws usingLoctite 243 or an equivalent medium strength threadlockingcompound, and torque to 18 ft.lbs. (24 Nm).

5.25.4 Coat inside of weight (32) with oil. Insert shaft (33) into housing, slidingit through weight (32), and into bearing (22b).

5.25.5 Press bearing cage (22b) into gear side of housing and secure it inplace with retaining ring (31).

5.25.6 Repeat procedure for other shaft.

5.25.7 With keyways (a) pointing up, install keys (34) and place gears (30)onto shafts (33).

Note: Gears must be “timed”. To time gears, insert four M10 screwsinto upper push holes (b), lay a straight edge (c) across both gears atscrews and align screws to straight edge. The screws must line upwithin one gear tooth of each other as shown. Both shaft keys must befacing up (a).

5.25.8 Secure gears on shafts with retaining rings (29).

Note: Complete steps 9 through 14 with exciter casing inverted asshown.

5.25.9 Slide free weights (32) to center of exciter shafts (33).

5.25.10 Mount fixed weights (37) to exciter shaft (33) with M16 screws (38).Secure screws using Loctite 271, or an equivalent high strengththreadlocker, and torque to 155 ft.lbs. (210 Nm).

Note: The holes in the shafts are chamfered on one end. Installweights so bolts will thread into chamfered end.

5.25.11 Secure weight mounts (36) to weights (37) with M10 screws (35).Secure screws using Loctite 271, or an equivalent high strengththreadlocker, and torque to 36 ft.lbs. (49 Nm).

CAUTION: For proper machine performance, it is essential thatweight mounts (36) be mounted correctly. Fasten weight mounts asshown.

5.25.12 Add 32 oz. (946 ml) of 10W30 to exciter housing through baseopening.


5.25.13 Apply Loctite 515 or equivalent gasket compound to base of exciter
(d).

5.25.14 Mount exciter base cover to housing (41) with M6 screws. Securescrews using Loctite 243, or an equivalent medium strengththreadlocker, and torque to 7 ft.lbs. (10 Nm).

5.25.15 Apply Loctite 515, or equivalent gasket compound, to machined face(e) of exciter gear cover (28).

CAUTION: Be sure to coat around entire face of cover includingaround holes to prevent exciter from leaking.

5.25.16 Install M26 plugs (26) and seal rings (27) into gear cover (28). Secureplugs using Loctite 222, or an equivalent low strength threadlocker,and torque to 36 ft.lbs. (49 Nm).

5.25.17 Mount cover (28) to housing (41) with M8 screws (25). Secure screwsusing Loctite 243, or an equivalent medium strength threadlocker, andtorque to 18 ft.lbs. (24 Nm).

5.25.18 Install exciter assembly in drum support. See section Exciter.



wc_gr002521

36

32

37

41

3738

25

2627

e

28

35 d



5.26 Exciter Motor, Coupling, & Pinion Gear

wc_gr002522

15a

15b

19

18

15a17

16

26

28

23

41

1412a11a

15b

13

11

109

wc_gr002523

15a

15a

b



5.27 Exciter Motor, Coupling, & Pinion Gear Removal


Replacement of the exciter pinion gear, bearings, and couplingrequires removal of the exciter assembly from the drum support.Replacement, or service, to only the exciter motor can be performedby removing the drum support cover (see section Drum SupportCover) to gain access to the motor.

5.27.1 Remove drum, drum support cover, and drive housing assembly. Seesections Drums, Drum Support Cover, and Drive Housing Assembly.

5.27.2 Remove exciter assembly from drum support. See section Exciter.

Refer to section Exciter Components when completing steps 3, 4 & 5.

5.27.3 Remove drain plug (26) and drain oil.

5.27.4 Remove exciter base cover (23).

5.27.5 Remove exciter gear cover (28).

5.27.6 Remove two screws (9) and washers (10) mounting exciter motor (4)to exciter housing (41).

5.27.7 Pull sleeve coupler (13) from inner coupling (11a) on pinion gear shaft(19).

5.27.8 Reach through bottom of exciter housing and loosen set screw (12a)holding inner coupling (11a) to pinion gear shaft (19). Remove innercoupling by prying off with large screw driver or gear puller.

5.27.9 Remove retaining ring (14).

5.27.10 Remove key (18) from pinion gear shaft (19) in housing.

5.27.11 Use a press or rubber mallet to drive pinion gear (19) out of housing.

Note: The roller bearings (15a) will remain in the housing.

5.27.12 Remove spacer (17) and bearing race (15b) from pinion gear shaft.

5.27.13 Drive roller bearing (15a) out of housing using a rubber mallet andsteel punch as shown (b). The bearing will be damaged or destroyedin the process and must be replaced.

5.27.14 Remove retaining rings (16) from housing.

5.27.15 Press remaining bearing (15a) from housing.



5.28 Exciter Motor, Coupling, & Pinion Gear Installation


5.28.1 Press bearing race (15b) on pinion gear shaft (19).

5.28.2 Install retaining rings (16) in housing.

5.28.3 Press both roller bearing cages (15a) into housing against retainingrings.

5.28.4 Slide spacer (17) onto pinion gear shaft (19).

5.28.5 Slide pinion gear shaft into housing and through roller bearings asshown (c).

5.28.6 Face exciter housing down so pinion gear (19) is resting against a solidsurface. Press remaining bearing race (d) over shaft until it restsagainst spacer (17).

5.28.7 Install retaining ring (14).

5.28.8 Install woodruff key (18) on pinion gear shaft (19).

5.28.9 Install coupling (11a) onto pinion gear shaft with rubber mallet. ApplyLoctite 243, or an equivalent medium strength threadlocker to setscrew (12a) in coupling and tighten set screw against shaft.

5.28.10 Slide flex-coupling (13) onto coupling (11a).

5.28.11 Place key (5) onto shaft of exciter motor (11) and install coupling (11b).Apply Loctite 243, or an equivalent medium strength threadlocker toset screw (12b) in coupling and tighten it against shaft.

5.28.12 Mount exciter motor (11) on exciter housing (41) with lockwashers (10)and M10 screws (9). Secure screws using Loctite 243, or an equivalentmedium strength threadlocker, and torque to 36 ft.lbs. (49 Nm).

Refer to section Exciter Components when completing steps 13 & 14.

5.28.13 Mount exciter gear cover (28).

5.28.14 Mount exciter base cover (23).

5.28.15 Install exciter assembly in drum support. See section Exciter.



wc_gr002524

15a

16

19

17

15b

15a14 12a 12b18

5

11b1311a

16

d

c



5.29 Exciter Motor

Seal Kit:

Order Seal Kit P/N 80500 for replacement of internal motor seals andO-rings. Refer to installation instructions included with kit.

Note: Special knowledge and skill is required when working onhydraulic components. If you are lacking the necessary skills andknow-how, contact a competent hydraulic repair facility for assistance.

Indexing Fittings:

All hydraulic fittings should be installed on motor before assembly ontoexciter. Fittings must be installed as shown to ensure properconnection of hoses inside drum.

5.30 Shockmounts


Each drum support is shockmounted to the machine frame at sixplaces, two at the outer mount (a) and four at the inner mounts (b).

Inspect shockmounts at regular intervals for damage and wear.Replace shockmounts that are torn or split. The shockmounts isolateand protect the frame and upper components from excessive vibration.Running the machine with damaged shockmounts can cause wiringconnections to weaken and may eventually damage othercomponents. When replacing shockmounts it is recommended thatboth the left and right sides be done at the same time.

wc_gr002525

15˚

45˚

wc_gr002527b b

a a



5.31 Shockmount Assembly

Ref. Description Qty. Ref. Qty.

1 Frame-rear 1 6 Screw (M12x25) 24

2 Drum support 1 7 Bracket-shockmount 4

3 Spacer 6 8 Setscrew (M12x30) 12

4 Shock mount 6 9 Stud-shock mount 6

5 Washer-lock 24 10 Mount-scraper support 4

[L1] 0029311[T1] 63 ft.lbs. (85 Nm)

wc_gr002526

1

2

5[L1, T1] 6

[L1] 9

[L1] 8

[L1] 3

7

4

5

[L1, T1] 610



5.32 Replacing Outer Shockmounts


Removal:

5.32.1 Remove three M12 screws (6) and washers (5) holding theshockmount bracket (7) to the frame and one screw and washerholding bracket to shockmount (4). Remove bracket.

5.32.2 Grasp the shockmount (4) with a large channel-lock pliers or a strapwrench and twist it until it breaks free from the spacer (3).

5.32.3 Remove shockmount (4) and scraper support mount (10).

Note: If the shockmount is difficult to remove, remove spacer with theshockmount attached.

5.32.4 Use a two-inch open end wrench, with extension, to loosen spacer (3)from the stud (9). If necessary, heat spacer using a small propanetorch to break down threadlocking compound.

Note: To remove shockmount from spacer, place spacer in vise (a)and turn it free.

5.32.5 The shockmount studs (9) are slotted and can be removed using alarge screwdriver (b). Heat studs thoroughly to break downthreadlocking sealant.

Installation:

5.32.6 If replacing shockmount stud (9), apply Loctite 243, or an equivalentmedium strength threadlocking compound, to threads on stud. Screwstud into frame until it protrudes equally on either side (x).

5.32.7 Screw shockmount spacer (3) onto stud (9) until tight.

5.32.8 Install setscrew into shockmount spacer (3). Secure setscrew usingLoctite 243 or an equivalent medium strength threadlockingcompound.

5.32.9 Slide scraper support mount (10) over setscrew.

5.32.10 Install shockmount (4) onto setscrew. Secure shockmount usingLoctite 243 or an equivalent medium strength threadlockingcompound.

5.32.11 Mount shockmount bracket (7) to shockmount (4) and frame withscrews (6) and washers (5). Secure screws using Loctite 243 or anequivalent medium strength threadlocking compound and torque to 63ft.lbs. (85 Nm).



WARNING

wc_gr002528

XX

7

3

6, 5

4

10

9 b

a



5.33 Replacing Inner Shockmounts


Removal:

5.33.1 Lock articulated joint. See section Articulated Joint Locking Bar.

5.33.2 Support machine with appropriate crane or hoist by the lifting eye (c).


5.33.3 Loosen (do not remove) M12 screws (6) holding outer shockmount (d)to the shockmount bracket (7).

5.33.4 Remove M12 screws (6) holding the inner shockmounts (e) to theframe.

5.33.5 Slowly raise machine and allow drum support to pivot down as shownin illustration. Position machine and drum support as needed to accessinner shockmounts and spacers.

CAUTION: Avoid straining hydraulic hoses. Lift machine only highenough to remove shockmounts.

Installation:

Remove and install shockmounts and spacers. See section ReplacingOuter Shockmounts.

5.33.6 Lower machine and position support drum to align shockmounts withholes in frame.

5.33.7 Mount shockmount (4) to frame with M12 screw (6) and washer (5).Secure screw using Loctite 243 or an equivalent medium strengththreadlocking compound and torque to 36 ft.lbs. (49 Nm).

5.33.8 Tighten screws (6) mounting outer shockmount bracket (7) toshockmount (4) and torque to 63 ft.lbs. (85 Nm).



WARNING

WARNING



wc_gr002526

2

5[L1, T1] 6

[L1] 9

[L1] 8

[L1] 3

7

4

5

[L1, T1] 610

wc_gr002546e

c

d



5.34 Hydraulic Hose Clamps

wc_gr002547

[L1] 12 2

3

54

6

63

6

3

2

3 13

12

9

112

7

10

[L1] 1

[L1] 1[L1] 1

[L1] 1



5.35 Hydraulic Hose Clamp Components


5.36 Drum Supports

See Graphic:wc_gr002548

The drum supports (a) contain both the exciter and drive assemblies,as well as all the connecting piping for the drive and exciter motors.Before removing the drum support it will be neccesary to first removeboth the drum support cover and drive housing assembly to gainaccess to the hydraulic piping inside.

To ease installation of hydraulic hoses and fittings later on, make noteof their orientation, placement and position. Cap and plug all openconnections to prevent contamination from entering hydraulic system.


1 Screw M8 x 60 6 8 Screw M8 x 20 1

2 Washer 6 9 Clamp-hose 1

3 Nut-lock M6 7 10 Adapter-clamp 1

4 Plate-clamping 2 11 Plate-clamping 2

5 Clamp-hose 1 12 Plate-clamping 2

6 Screw M6 x 50 7 13 Clamp-hose 1

7 Guard-hose 1 -- -- --

[L1] 0029311 [L2] 0070735

wc_gr002548a



5.37 Drum Support Exploded View

wc_gr002549

1

6 9

5

13

4

2

1112

6

5

78 10

3



5.38 Replacing Drum Supports

See Graphic: wc_gr002549Removal:

5.38.1 Lock articulated joint. See section Articulated Joint Locking Bar.

5.38.2 Support machine by lifting eye (1), using an appropriate crane or hoist.


5.38.3 Remove drums (2). See section Drums.

5.38.4 Remove drum support cover (3). See section Drum Support Cover.Disconnect hydraulic lines from drive motor and brake assembly ifapplicable. Cap or plug open connections.

5.38.5 Remove drive housing assembly (4). See section Drive Housing.Disconnect hydraulic hoses from exciter motor and cap or plug openhoses and fittings.

5.38.6 Remove screws (5) and washers (6) holding the shockmounts andbrackets to the frame.

5.38.7 Remove two M8 screws (7) and washers (8) holding the hose clamps(9) to the drum support (10).

5.38.8 Remove hose guard (11) from drum support.

5.38.9 Loosen slightly, but do not remove, two M16 screws (12) which holdthe rear hose clamps (9) together. This will allow hoses to slide easilythrough clamps and act as a guide when pulling them out of the drumsupport. Repeat for front drum clamps (13).

5.38.10 Slowly raise machine and carefully guide hydraulic hoses out of thedrum support.

Installation:

5.38.11 Install shockmounts on drum support (10). See sections ReplacingInner Shockmounts and Replacing Outer Shockmounts.

5.38.12 Place drum support under raised machine. Insert hydraulic linesthrough openings and lower machine over drum support.

5.38.13 Secure machine frame to shockmounts with screws (5) and washers(6). Secure screw using Loctite 243 or an equivalent medium strengththreadlocking compound and torque to 36 ft.lbs. (49 Nm).

5.38.14 Apply Loctite 545 hydraulic sealant, or equivalent, to fittings on exciterdrive motor and attach hydraulic hoses.

5.38.15 Install drive housing assembly (4) and connect hydraulic lines to drivemotor. See section Drive Housing.

WARNING


5.38.16 With all hydraulic hoses connected, tighten hose clamps (9, 13) around
hoses. Install hose clamps to drum supports with screws (7) andwashers (8) and attach hose guard (11). Secure screws using Loctite243 or an equivalent medium strength threadlocking compound.

5.38.17 Install drum support cover (3) and drums (2). See section DrumSupport Cover and section Drums.



5.39 Articulated Joint and Steering Cylinder Exploded View

WARNING

wc_gr002550

1 [T1]

8 [L1, T2]

11

12

11

12

13

14

15

1316

7

6

4532

417

9

10

1 [T1]

2

34

7

6 5



5.40 Articulated Joint and Steering Cylinder Components



1 Nut-lock (M16) 2 11 Screw (M12x20) 2

2 Washer 2 12 Washer 2

3 Bearing-ball 2 13 Fitting-hydraulic 2

4 Fitting-grease 6 O-Ring 2

5 Bracket-pivot 2 O-Ring 2

6 Pin-pivot 2 14 Hose assembly 1

7 Screw (M16x90) 2 15 Hose assembly 1

8 Screw (M12x40) 8 16 Bearing 2

9 Access cover 1 17 Cylinder-hydraulic 1

10 Screw (M8 x 16) 4

[L1] 0029312 [T1] 155 ft.lbs. (210 Nm) [T2] 94 ft. lbs. (128 Nm)

wc_gr002551

a

b

c



5.41 Replacing Articulated Joint

See Graphic: wc_gr002551and wc_gr002552

Prior to removal:

5.41.1 Remove scraper bars and drums from both right and left sides of therear half of machine. See section Drums.

5.41.2 Start machine and position machine as if turning left (a). This will helpgain access to articulated joint at point (b). Once in this position, turnmachine off.

5.41.3 Support each drum, both front and rear, with screw jacks (c) orblocking.

Only use blocks or jacks with a suitable load bearing capacity. Do notuse improvised blocks or jacks.

Removal:

5.41.4 Heat the M12 screws (8) holding pivot brackets (5), using a smallpropane torch to break down the threadlocking compound. Removescrews and bracket.

5.41.5 Remove M16 screw (7) from top and bottom joint.

5.41.6 Tap out pivot pin (6) from bracket portion of machine frame.

Note: Pivot pin is removed from top to bottom on uppermost bracketand from bottom to top on lower bracket.

5.41.7 Slide pivot bracket (5) and washer (2) out of machine frame.

5.41.8 After pivot bracket is off, place pivot pin (6) back into it as shown. Usean arbor or hydraulic press to push against pin (d) and press bearing(3) out of bracket.

Installation:

5.41.9 To prevent rust, repaint any areas of the pivot bracket damaged byheating during disassembly.

5.41.10 Press bearings (3) into pivot brackets (5).

Note: Bearing outer race is cracked. This is done during assemblyprocedure to install the inner bearing.

5.41.11 Place washer (2) into machine frame.

5.41.12 Slide (e) pivot bracket (5) over washer (2) and into machine frame.

5.41.13 Tap pivot pin (f) into bracket portion of machine frame and throughpivot bracket (5).

Note: Pivot pin is installed from bottom to top on uppermost bracketand from top to bottom on lower bracket.

5.41.14 Install M16 screw (7) and secure with locknut (1). Torque to 155 ft. lbs.(210 Nm).

WARNING


5.41.15 Secure pivot bracket (5) to rear half of machine frame with M12 screws
(8). Secure screws using Loctite 271, or an equivalent high strengththreadlocking compound and torque to 94 ft. lbs. (128 Nm).

5.41.16 Attach drums and scraper bars.

5.41.17 Grease bearings, through fittings (4), using Shell Alvania #2 grease.



WARNING

wc_gr002552

d

63

63

4

57

6

4

3

28

31

6

5

2

e

f

6

7

3

21

7

2

2



5.42 Steering Cylinder


Removal:

5.42.1 Remove four M8 screws (10) mounting the cylinder access cover (9)to the machine.

5.42.2 Disconnect hoses (14, 15) from cylinder (17). Cap hoses and fittings(13).

5.42.3 Remove two M12 screws (11) and washers (12) mounting cylinder (17)to frame.

5.42.4 Pull steering cylinder (17) from rear frame.

Installation:

5.42.5 Mount steering cylinder (17) inside rear frame with M12 screw (11) andwasher (12).

5.42.6 With machine positioned with front in-line with rear, secure ram end ofsteering cylinder to front frame with M12 screw (11) and washer (12).

5.42.7 Apply Loctite 545, or equivalent hydraulic sealant, to fittings (13) andattach hoses (14, 15) to steering cylinder (17).

5.42.8 Mount steering cylinder access cover (9) to frame with M8 screws (10).



WARNING



wc_gr002553

11

13

13

14

15

17

9

10

12



5.43 Drive Pump and Coupling Assembly Exploded View

wc_gr002554

1 [L1]7 [L1, T2]

25 [L1, T1]

3

8

11

2627

2829

9

10

12

13

1718

1916

15

1718

19

20 [L2]

20 [L2, T2]

23 [L2, T2] 22 [L2]

14

4

26

5

15

24



5.44 Drive Pump and Coupling Assembly Components



1 Stud 6 16 Block-hydraulic 1

2 Washer-lock 6 17 O-Ring 2

3 Nut (M8) 6 18 Fitting #8 (incl. 17, 19) 2

4 Bolt 6 19 O-Ring 2

5 Plug 1 20 Hose assembly 1

6 Manifold-suction 1 21 Screw (M6x40) 4

7 Screw (M6x50) 4 22 Hose assembly 1

8 Clamp-hose 1 23 Screw (M6x80) 4

9 Hose-suction 1 24 Block-hydraulic 1

10 O-Ring 1 25 Screw (M10x30) 4

11 O-Ring 1 26 Adapter-pump 1

12 Pump-hydraulic 1 27 Adapter-internal 1

13 Fitting-adapter 2 28 Adapter-engine 1

14 O-Ring 2 29 Support-pump 1

15 O-Ring 2

[L1] 0029311 [L2] 0079356[T1] 36 ft.lbs. (79 Nm) [T2] 7 ft.lbs. (10 Nm)



5.45 Replacing Drive Pump and Coupling


Removal:

5.45.1 Loosen hose clamp (8) and disconnect suction hose (9) from suctionmanifold (6).

Danger of burns! Pump may be hot. Care must be taken whenremoving hydraulic components and oil. Hot oil can burn!

5.45.2 Tag, disconnect, and cap hydraulic hoses (20, 22).

5.45.3 Remove screws (7, 21, 23) mounting hydraulic blocks (6, 16, 24) fromdrive pump (12). This is to provide clearance for mounting screws (25).

5.45.4 Heat and remove two M10 screws (25), mounting the drive pump (12)to pump support (29).

5.45.5 Slide pump adapter couplings (26, 27) off pump (12).

5.45.6 Remove two M8 nuts (3) and washers (2) mounting pump support (29)to engine.

5.45.7 Remove two screws (4) mounting adapter (28) to engine.

Installation:

5.45.8 Grease adapter couplings (26, 27) with Shell Alvania #2 and installthem on drive pump (12).

Note: Pump adapter (26) must be installed with short end facingtoward pump as shown.

5.45.9 Mount adapter (26) to engine with screws (4).

5.45.10 Mount pump support (29) to engine studs. Apply Loctite 243 or anequivalent medium strength threadlocking compound to studs andsecure with nuts (3) and washers (2).

5.45.11 Mount drive pump (12) to pump support (29) with screws (25). Securescrews using Loctite 271, or equivalent high strength threadlocker, andtorque screws to 7 ft.lbs. (10 Nm).

Note: Make sure tangs (a) on internal adapter (27) fit into slots inengine adapter (28). Apply grease or anti-seize to tangs and opposingcouplers.

5.45.12 Mount hydraulic blocks (6, 16, 24) to drive pump (12) with screws (7,21, 23). Secure screws using Loctite 271, or equivalent, and torqueto 7 ft.lbs. (10 Nm).

5.45.13 Apply hydraulic sealant to fittings and attach hydraulic hoses (20, 22,9).

WARNING



wc_gr002555

12

3

4

7

6

8

9

12

22

20

16

21

25

24

23

2627

a28

29



5.46 Removing Engine Cover


General:

All machines are equipped with a two cylinder, 20 Hp (16 kW)Lombardini diesel engine - model 12LD475-2.

When servicing the engine or replacing parts, refer to the engineidentification plate located on the fan shroud for the serial number andmodel number of the engine.

Cover Removal:

5.46.1 Before removing the cover, loosen hose clamp (b) mounting aircleaner hose (c) to air cleaner (d). Remove air cleaner hose.

5.46.2 Remove two screws (e), nuts (f), and ground strap (k) mountingvoltage regulator (g) to inside of cover wall.

5.46.3 Remove eighteen M8 screws (h) mounting entire engine cover (j) tofront frame.



wc_gr002556

c

b

d

j

hh

k

f

g

e



5.47 Removing Engine


Stop and switch off the machine and disconnect the battery.

5.47.1 Remove cover from front frame. See section Removing Enigne Cover.

5.47.2 Loosen screws (1) holding throttle cable retainers (2) and pull retainersoff cable.

5.47.3 Remove nut (3) holding throttle cable (4) to engine mounting bracket.Pull cable out through bracket.

5.47.4 Tag and disconnect hydraulic hoses (5) from drive pump. Cap or plugall open connections.

5.47.5 Unplug wire harness (6).

5.47.6 Disconnect battery ground wire (7) from engine block.

5.47.7 Disconnect positive battery cable (8) from starter motor.

5.47.8 Remove screws (9) mounting radiator (10) to front frame. Keephydaulic hoses connected and place radiator assembly aside and clearfrom engine.

5.47.9 Disconnect fuel pressure line (11) from fuel solenoid and cap the hose.

5.47.10 Disconnect fuel return line by cutting hose (12) as close to crimpedclamp (13) as possible. Use a side cutter or other appropriate tool toremove crimped clamp from barbed nipple (14) on engine.

5.47.11 Remove cap (15) to drain oil from engine. Remove fitting and seal ringconnecting drain hose assembly (16) to engine.

Note: In the interests of environmental protection, place a plastic sheetand a container under the machine to collect the liquid which drains off,and dispose of properly.

5.47.12 Remove the four M16 screws (17) and nuts (18) securing engine tomachine frame.

5.47.13 Use an appropriate hoist and sling to lift engine up and off machineframe. Use lifting eyes (19) on engine for lifting.


5.47.14 Remove drive pump, couplings and support from engine. See sectionDrive Pump and Coupling.

WARNING



wc gr002557

2

1

15 16 17

18 11

19

12

13

14

5 7

8

5 6

43

10

9



5.48 Installing Engine


Replacement engines come equipped with a new voltage regulatorand pump coupling. They do not include the following:

• Exhaust System

• Air Cleaner

• Wiring Harness or Engine Relays

• Pressure Switch

• Engine Oil Drain

Remove these items from existing engine assembly for use on newengine. See the upcoming sections for removal and installationprocedures.

5.48.1 Line up mounting holes on engine with those on the front frame. Mountengine to frame with four M16 screws (1) and nuts (2).

5.48.2 Install seal ring (3) and drain hose assembly (4) into engine. Checkengine oil level. See Section 1.12 Lubrication Specifications.

5.48.3 Install throttle cable (5). Make sure cable is pushed all the way in athandle . Insert cable through bracket (6) and secure with nut (7).Adjust retainers (8) on cable end so machine runs at specified RPM atfull throttle control. See Tech Data for engine specifications.

5.48.4 Install drive pump and coupling. See section Drive Pump andCoupling.

5.48.5 Install cover assembly. See section Replacing Engine Cover.

5.48.6 Reconnect battery cables.



wc_gr002558

2

3

4

1

576

8



5.49 Replacing MufflerSee Graphic: wc_gr002559

Removal:

Danger of burns! Muffler may be hot–care must be taken whenremoving any muffler components.

5.49.1 Remove two M8 nuts (18) mounting muffler adapter (9) to engine.

5.49.2 Remove two M8 screws (10) mounting muffler bracket (11) to engine.

5.49.3 Remove muffler assembly from engine.

Installation:

5.49.4 Line up mounting holes on muffler bracket (11) with holes on engine.Mount muffler bracket with two M8 screws (10).

5.49.5 Mount muffler adapter (9) to studs on engine exhaust manifold with twonuts (18).

5.50 Replacing Engine Air CleanerSee Graphic: wc_gr002560

Removal:

5.50.1 Loosen hose clamps (12) and remove air cleaner hoses (13, 14).

5.50.2 Remove four M8 screws (15) mounting air cleaner (16) to air cleanermounting plate (17).

5.50.3 Remove air cleaner from engine.

Installation:

5.50.4 Line up mounting holes of air cleaner mounting plate (17) with those inthe air cleaner (16). Mount air cleaner with four M8 screws (15).

5.50.5 Slide air cleaner hose (13) over inlet on air cleaner and secure withhose clamp (12). Repeat for air cleaner hose (14).

WARNING

wc_gr002559

9

18

10

11

wc_gr002560

9

12 12

14

16

17 15



5.51 Engine Relays


Removal:

5.51.1 Remove three M8 locknuts (1) mounting air cleaner mounting plate (2)to engine. Save ground strap (3).

5.51.2 Remove three M8 studs (4) from engine.

Note: Relays are interchangeable for quick troubleshooting of possibledefective relay.

Installation:

5.51.3 Install three M8 studs (4) into engine. Secure studs using Loctite 271or an equivalent high strength threadlocking compound.

5.51.4 Inspect and secure glow plug relay (5), starter relay (6), and anti-restart module (7).

5.51.5 Line up mounting holes in air cleaner mounting plate (2) with studs (4)in engine. Secure plate to engine using M8 locknuts (1).

Note: Install ground strap (3) on lower stud.

Testing Anti-Restart Module:

5.51.6 Ensure brown ground wire is securely attached to the engine.

5.51.7 The white wire connects the engine oil pressure switch to the engineoil pressure switch indicator light via the anti-restart module. Groundthe white wire to the engine frame and make sure the engine oil lightturns on. Try to start the engine.

5.51.8 To eliminate the anti-restart module, unplug the 3-position wireconnector. Ground the black wire from the plug end to the engine(opposite the anti-restart module) leading to the starter relay. Teststart the engine. If this allows the engine to start, replace the anti-restart module.

wc_gr002561

25

6

4

3

1

7



5.52 Miscellaneous Engine Components


Removal:

5.52.1 Remove banjo fitting (8) and seal rings (9) mounting pressure switchassembly (10) to engine.

Note: Pressure switch is normally closed

5.52.2 Remove clamp (11) securing end cap (12) to air manifold.

Installation:

5.52.3 Remove existing screw and mount pressure switch assembly (10) toengine with banjo fitting (8) and seal rings (9).

5.52.4 Remove existing clamp and secure cap (12) with clamp (11).Orientate clamp so neither hoses nor wires rub on sharp edges.



wc_gr002562

8

1112

9



5.53 Engine Wiring


Installation:

Replacement engines come equipped with a new voltage regulator (1)that needs to be modified. Make sure all regulators are grounded tothe engine by a seperate ground wire to ensure proper function.

5.53.1 Cut off connector and terminals from end of regulator per dimensiongiven. Strip and tin all five wires prior to crimping on terminals.

5.53.2 Crimp terminal (2) to purple wire of regulator and insert into position 5of the connector (3).

5.53.3 Crimp terminal (2) to green wire of regulator and insert into position 4of the connector (3).

5.53.4 Crimp terminal (2) to red wire of regulator and insert into position 3 ofthe connector (3).

5.53.5 Crimp terminal (2) to each yellow wire of regulator and insert intopositions 1 & 2 of the connector (3).

5.53.6 Insert white plug (4) into position 6 of the connector (3).

5.53.7 After all terminals are inserted into connector, assemble end cap (5).

The connector (6) attached to the alternator also needs to be modified.

5.53.8 Cut off connector and terminals from base of rubber boot. Strip and tinboth yellow wires prior to crimping on terminals.

5.53.9 Crimp terminal (7) to each yellow wire and insert into positions 1 & 2of the connector (8).

5.53.10 Insert red wire from harness (9) into position 3 of the connector (8).

5.53.11 Insert green/white wire from harness (9) into position 4 of theconnector (8).

5.53.12 Insert white wire from harness (9) into position 5 of the connector (8).

5.53.13 Insert white plug (4) into position 6 of the connector (8).

5.53.14 After all terminals are inserted into connector, assemble end cap (10).

5.53.15 Connect harness (9) to engine components (A–N).



Continued

wc_gr002563

1

10.5"(266.7 mm)

3

8

White PlugPosition 6

PurplePosition 5

White PlugPosition 6

White Position 5

GreenPosition 4

RedPosition 3

RedPosition 3

Green/WhitePosition 4

YellowPosition 2

YellowPosition 2

YellowPosition 1 Yellow

Position 1


(Engine wiring continued)
Ref. Connection Color Ref. Connection Color

A Voltage regulator White H Oil pressure switch White

B Voltage regulator Green/White I Upper fuel solenoid Tan

C Voltage regulator Red J Anti-restart module --

D Starter motor Black K Main wiring harness --

E Starter relay -- L GLow plug Pink

F Starter motor Red M Ground Brown

G Lower fuel solenoid Tan N Glow plug relay --

wc_gr002564

8

6

C

B

A

D

F

IJ

MNE

MH

L

G

83

1

9

0111872Connector

0111879Cap-retainer

0111878Cap-retainer

0111871Connector

0111873Plug

0111874Terminal16–18

0111876Terminal-pin16–18

7 2 4

5 10

3


RT Repair Disassembly/Reassembly—Newer Machines

6. Disassembly/Reassembly—Newer Machines

6.1 Tools

Because all possible problems encountered while repairing theequipment cannot be anticipated, it is up to the mechanic to usecommon sense and good judgement in tool selection.

The use of any special tools is recommended only for those operationswhere the use of conventional tools proves inadequate.

Before substituting another tool or procedure, you should be satisfiedthat neither personal injury nor damage to the component will result.

6.2 Ordering Parts

The repair procedures contained in this manual do not include partnumbers. For parts replacement information, refer to the Parts Bookoriginally supplied with the unit.

If the original Parts Book has been lost, a replacement may be orderedfrom Wacker Corporation. When ordering a replacement Parts Book,please list the model number, item number, revision level, and serialnumber of the machine. Parts Books are also available on the WackerCorporation Web site. See www.wackergroup.com. Enter the site as avisitor.

6.3 Reference Numbers ( )

Repair procedures contain reference numbers enclosed inparentheses ( ). These numbers refer to the item numbers shown onthe assembly drawings and other detailed drawings. They are includedto aid the mechanic in identifying parts and assembling components.

6.4 Weight Block


The weight block symbol gives an approximate weight measurementto aid the mechanic when lifting/hoisting larger components.

250 kg(550 lbs.)

wc_gr000843


Disassembly/Reassembly—Newer Machines RT Repair

6.5 Drum Support Exploded View

46

41

45

4243

40

4730

34

333231

39

9 10 111213 14

16

16

19

24

76

6

4

253

1

226

27

28

29

wc_gr002097

2021

2223

7

6

5

26

2728

4321

17

15

3635

38



6.6 Drum Support Components



1 2-1/8” nut 25 Seal

2 Washer 26 9/16-18 plug

3 Drum hub 27 O-Ring

4 M10 x 20 screw 28 Cover

5 Cover 29 Drum support

6 Roller bearing 30 Retaining ring

7 Retaining ring 31 M8 x 25 screw

8 O-Ring 32 Shaft seal

9 Plate 33 Ball bearing

10 M8 x 16 screw 34 Retaining ring

11 3/8-16 x 1 screw 35 Retaining ring

12 Washer 36 Ball bearing

13 Pinion gear 37 O-Ring

14 Drive motor 38 Screw

15 M12 x 60 screw 39 Cover

16 Key 40 Plate

17 Drive shaft 41 O-Ring

18 Key 42 Shaft

19 Retaining ring 43 Spring

20 M8 x 20 screw 44 Ring

21 Cover 45 Roll pin

22 Shaft seal 46 Housing

23 Pinion gear 47 Pinion gear

24 Retaining ring -- --



6.7 Identifying Drum Supports


6.7.1 The rear drum (1) contains a brake (a), a drive motor (b), an exciterassembly (c) with exciter motor (d).

6.7.2 The front drum (2) contains a drive motor (b) and an exciter assembly(c) with exciter motor (d).

6.7.3 When disassembling the drum support, always start on the exciter sideof the drum—it can be identified by the bulge (e) in the casting.



6.8 Removing Drums



6.8.2 Lift one end of the machine using an appropriate crane or hoist. Insertjack stands (x) to support machine from underneath.

6.8.3 Remove the M12 screws (a) and washers and remove the scrapers(b).

6.8.4 Remove the six M16x55 screws (d) securing the drum (e) to the drumsupport (f).

6.8.5 Remove the three M16 screws (c) and washers acting as plugs. Intheir place, insert three of the M16x55 removed in the previous step.Use these screws as pushers to push the drum off the drive housing.

wc_gr002052

a

b

d

c

f

e

x



6.9 Installing Drums



6.9.2 Lift one end of the machine using an appropriate crane or hoist. Insertjack stands (x) to support machine from underneath.

6.9.3 Place the drum (e) on the drum support (f) and secure it to the hubusing six M16x55 screws (d) and washers. Use Loctite 243 orequivalent on the screws and torque them to 210 Nm (154 ft.lbs.).

6.9.4 Install the scrapers (b) using M12 screws (a). Use Loctite 243 orequivalent on the screws and torque them to 120 Nm (88 ft.lbs.).

6.10 Opening Drum


6.10.1 Loosen the center hub nut (a) so that it is nearly off (2–3 threadsremaining on). Do so for both sides of the drum.

6.10.2 Remove the scrapers and the drums. See Section Removing Drums.

6.10.3 Position the drum support slightly off the floor and support it with jackstands.

6.10.4 Starting with the exciter side, remove the outer ring of bolts (b)securing the slave hub assembly onto the drum support.

6.10.5 Using three pusher bolts in position (c), gradually push the slave hubassembly off the drum support. When the hub releases from the taperof the drive shaft a distinct “pop” will be heard. Be sure to leave thecenter hub nut on the shaft 2–3 threads to prevent the hub assemblyfrom “popping” off the drum.

6.10.6 Once the slave hub assembly is free, remove the hub nut and removethe slave hub assembly (d) from the drum support.

6.10.7 If working on the rear drum support, disconnect the hydraulic line (e)to the brake. Cap the line immediately after disconnecting it to preventcontamination of the hydraulic system.

6.10.8 Disconnect the hydraulic lines to the drive motor (f). Cap all linesimmediately after disconnecting them to prevent contamination of thehydraulic system.

6.10.9 On the opposite side of the drum support, remove the outer ring ofbolts securing the drive hub assembly onto the drum support.

6.10.10 Using three pusher bolts, gradually push the drive hub assembly offthe drum support. With the help of an assistant, pull the drive hubassembly completely from the drum support. The assembly will includethe shaft, drive motor (g), and the brake (h) on rear drum supports.



6.11 Closing Drum


6.11.1 Reassemble drive and slave hubs. See sections Reassembling DriveHub and Reassembling Slave Hub.

6.11.2 With the aid of an assistant, position the drive hub assembly (shaft,drive hub, drive motor, and brake on rear drums) into the drum support.Secure the assembly to the drum support using twelve M10 x 20screws. Use Loctite 243 or equivalent on the screws and torque themto 49 Nm (36 ft.lbs.).

6.11.3 Tighten the hub nut. Torque the hub nut to 816 Nm (600 ft.lbs.).

6.11.4 Connect the drive motor and brake hydraulic lines.

6.11.5 On the exciter side of the drum support, position the slave hub on thedrum support. Secure the assembly to the drum support using twelveM10 x 20 screws. Use Loctite 243 or equivalent on the screws andtorque them to 49 Nm (36 ft.lbs.).

6.11.6 Tighten the hub nut. Torque the nut to 816 Nm (600 ft.lbs.).



6.12 Disassembling Drive Hub


6.12.1 Remove drum. See Section Removing Drum.

6.12.2 Open drum. See Section Opening Drum.

6.12.3 Remove drive motor (a) and brake (b) (on rear hubs).

6.12.4 Remove oil from drive hub. Dispose of oil properly.

6.12.5 Remove five screws (c) securing gear cover (d) and remove the gearcover. Note: Because gasket eliminator is applied to the mating surfaces ofthe hub and the gear cover during assembly, it may be necessary totap the gear cover to break it loose.

6.12.6 Press the shaft seal (e) from the gear cover.

6.12.7 Remove the retaining ring (f).

6.12.8 Leave the hub nut (g) on the shaft and using three pusher bolts (h), pullthe gear off the shaft.

6.12.9 Pull the lip seal off the shaft.

6.12.10 With the hub nut loose but still on the shaft, tap the hub from theopposite side to break the hub loose from the taper on the shaft.Note: Leaving the hub nut threaded on the shaft prevents the hub from“popping” off the shaft when the hub releases from the taper on theshaft.

6.12.11 Pull the key from the shaft.

6.12.12 Invert the hub as shown and using a propane torch heat the bearinginner race quickly. When heated to the proper temperature, thebearing race will slide off the hub. Pull it from the shaft if necessary.

6.12.13 Remove the retaining ring from the gear cover and remove the outerbearing race.



6.13 Reassembling Drive Hub


6.13.1 Insert the replacement bearing outer race (6) (markings side in first)into the gear cover (5) and secure it with the retaining ring (7).

6.13.2 Press the inner bearing race (a) onto the hub and add a new seal (b)to the hub. When hub nut is tightened, the seal seats into gear cover(5).

6.13.3 Insert the key (16) and the retaining ring (19) on the shaft (17). Coolthe shaft with cold water and apply a thin film of oil to the shoulder ofthe shaft (c) where the gear will rest. Heat the gear to 400°F (use a hotplate or similar source). Then, slide or press the shaft into the gear (23)up to the retaining ring. Note: When heated to the correct temperature, very little pressure isrequired to press the shaft into the gear.

6.13.4 Allow the gear and shaft to cool. Slide the shaft assembly through thegear cover.

6.13.5 Apply Loctite flexible anaerobic gasket or equivalent on the gear coverand connect the gear casing cover (21) to the gear cover using fiveM8x20 screws (4). Use Loctite 243 or equivalent on the screws andtorque the screws to 41 Nm (30 ft.lbs.).

6.13.6 Add key (d) and seal (e) to shaft.

6.13.7 Place the hub (3) onto the shaft and secure it with washer (2) and hubnut (1).

6.13.8 Fill hub with 12.5 oz. of 10W30. See specification chart.

6.13.9 Apply Loctite flexible anaerobic gasket (f) or equivalent between faceof gear casing cover and the drive motor. Install the drive motor (g)using three M12 screws. Use Loctite 243 or equivalent on the screws.

6.13.10 Apply Loctite flexible anaerobic gasket or equivalent between face ofgear casing cover and the brake. Install the brake (h) using three M8screws. Use Loctite 243 or equivalent on the screws and torque themto 41 Nm (30 ft.lbs.).



b

wc_gr002355

a

d

g

f

c

e

e

1 2

34

823

22

9

10

11

1213 14

15

17

16

1920

21

1865 7

2627

28



6.14 Disassembling Slave Hub


6.14.1 Remove the retaining ring (a) and remove the disc (b).

6.14.2 Remove the bearing outer race (c) from the cover.

6.14.3 Press the seal (d) from the cover.

6.14.4 Invert the hub as shown and using a propane torch heat the bearinginner race quickly. When heated to the proper temperature, thebearing race will slide off the hub. Pull it from the shaft if necessary.



59

52

7071

6457

62

53

671672

60

758

b

wc_gr002353

c

d

a



6.15 Reassembling Slave Hub


6.15.1 Press new seal (a) into cover.

6.15.2 Apply a liberal amount of EMB lubriplate white grease or equivalent tothe replacement bearing outer race (b) and insert it into the gear cover.Secure it with the disc (c) and retaining ring (d).

6.15.3 Press the inner bearing race (e) onto the hub and add newreplacement seal (f).



59

52

7071

6457

62

53

671672

60

758

ba

cd f

e

wc_gr002356



6.16 Rebuilding Brake


Disassembly:

6.16.1 Open the drum. See Section Opening the Drum.

6.16.2 Remove drive hub. See Section Disassembling Drive Hub.

6.16.3 Remove the three screws (698) securing the brake to the hub andremove the brake. Note: Gasket eliminator is applied to the mating surfaces of the huband the brake during assembly, it may be necessary to tap the brakecover to break it loose from the hub.

6.16.4 Remove fitting and drain hydraulic oil from casing; dispose of hydraulicoil properly.

6.16.5 Remove the retaining ring (90) and remove gear (56).

6.16.6 Remove the six screws (693) securing the cover (81) and remove thecover.

6.16.7 Remove O-ring (a) from cover.

6.16.8 Remove the plate (83) and inner O-ring (94) from housing (80).

6.16.9 Remove the retaining ring (89) and pull bearing (87) from cover.

6.16.10 Pull the shaft (82) from inside the housing.

6.16.11 Remove the ring spacer (84) and spring (85).

6.16.12 Remove the retaining ring (88) and pry bearing (b) out of housing.

6.16.13 Pull seal (c) from housing.

Reassembly:

6.16.14 Insert the seal (c) into housing.

6.16.15 Insert bearing (86) into housing (80) and secure with retaining ring(88).

6.16.16 Dip O-ring (94) in hydraulic oil and position on face of housing.

6.16.17 Insert bearing (87) into cover (81) and secure with retaining ring (89).

6.16.18 Align holes in plate (83) with pins and place plate on housing.

6.16.19 Add spring (85) and gear to shaft and insert shaft assembly intohousing.

6.16.20 Apply Loctite 243 or equivalent to six screws (693) and secure cover(81) to housing.

6.16.21 Add gear (56) to shaft and secure with retaining ring (90).



80

69

92

82

8485

83

5690

88

8691

698

81

87

69

89

693

b

wc gr002354

c

a



6.17 Exciter Exploded View

10

5

12

8

2

4

1

13

692

702

12

14

695

14702

12

71

70

4

13

3

8

11

692

720

125

9



6.18 Exciter Parts List

Ref.Pos.

Part No.Artikel Nr.

Qty.St.

DescriptionBeschreibung

DescripciónDescription

Measurem./Abm.

Torque/Drehm.

Norm

SealantSchmierstoff

1 0116902 1 Drum supportBandagenträger

Basa del tamborSupport de tambour

2 0119224 1 Exciter shaftErregerwelle

Eje del excitadorArbre de l'excitatrice

3 0119225 1 Exciter shaftErregerwelle

Eje del excitadorArbre de l'excitatrice

4 0119226 2 Eccentric weightUnwucht

Masa excéntricaBalourd excentrique

5 0119227 2 Eccentric weightUnwucht

Masa excéntricaBalourd excentrique

8 0116318 2 GearZahnrad

EngranajeEngrenage

9 0116958 1 CoverDeckel

TapaCouvercle

10 0116959 1 Bearing coverLagerdeckel

Tapa del rodamientoCouvercle du roulement

11 0119314 1 Exciter motorErregermotor

Motor excitadorMoteur d'excitatrice

12 0080742 4 Roller bearingRollenlager

Rodamiento de rodillosRoulement à rouleaux

14 0080211 2 CoverDeckel

TapaCouvercle

67 0116872 1 Key (square)Keil

ChavetaClavette

A14 x 9 x 50 DIN6885

70 0014398 3 O-RingO-Ring

Anillo-OJoint torique

12 x 2

71 0078269 3 Plug (threaded)Schraubverschluß

Tapón roscadoBouchon

9/16-18in

692 0011457 12 ScrewSchraube

TornilloVis

M8 x 25

25Nm/18ft.lbs

DIN933

0029311


TornilloVis

M8 x 20

41Nm/30ft.lbs

DIN912

0029311


TornilloVis

M8 x 16

25Nm/18ft.lbs 0029311

720 0033988 2 LockwasherFederring

Arandela elásticaRondelle de ressort

10

wc_gr002351



6.19 Disassembling Exciter



6.19.2 Remove the two screws (a) securing the exciter motor (b) to the drumsupport and remove the exciter motor.

6.19.3 Remove the screws securing the exciter housing cover. Use two of thelonger screws (c) as pushers to push off the exciter housing cover (d).

6.19.4 Pull the exciter shaft (e) and drive gear from the exciter housing.

6.19.5 Remove the screws securing the bearing cover (f) to the exciterhousing. Remove the bearing cover by tapping it from inside theexciter housing.

6.19.6 On the opposite side of the machine, remove the exciter housing coverand the bearing cover as stated above.

6.19.7 Pull the second exciter shaft and drive gear from the exciter housing.

6.19.8 Using a properly-sized adapter plug (g), tap the bearing from theexciter housing.

6.19.9 Using an Arbor press, press the bearing from the exciter housing cover(h) that the exciter motor mounts to.

6.19.10 Using an inside-style puller, pull the bearing from the other exciterhousing cover (i).

6.19.11 Tap on the small eccentric weight (j) to remove the bearing race fromthe exciter shaft.

6.19.12 Using a gear puller (k), pull the gear and the inner bearing race off theexciter shaft.



6.20 Reassembling Exciter


6.20.1 Using an Arbor press, press new outer bearing races (a) into theexciter housing covers.

6.20.2 Install the eccentric weight (b) and key (c) on exciter shaft. Then, pressthe gear (d) and the bearing race (e) onto the exciter shaft. Do so forboth exciter shafts.

6.20.3 On the opposite side of each shaft, install the eccentric weight (f) andpress the inner race (g) onto the exciter shaft. Do so for both excitershafts.

6.20.4 Insert the bearing outer race (h) into the follower side of the exciterhousing.

6.20.5 Insert the follower-side exciter shaft assembly into the exciter housing.

6.20.6 Apply Loctite 515 gasket eliminator or equivalent to the bearing cover(i) and secure the follower-side bearing cover to the exciter housingwith six screws. Torque screws to 25 Nm (18 ft.lbs.)

6.20.7 Insert the exciter-side bearing outer race into the exciter housing.Apply Loctite 515 gasket eliminator or equivalent to the bearing coverand secure the cover with six M8x16 screws. Use Loctite 243 orequivalent on screws and torque to 25 Nm (18 ft.lbs.).

6.20.8 Fill exciter housing with oil.

6.20.9 Insert driven exciter assembly into the exciter housing so that weightsare even and level with each other (j).

6.20.10 Apply Loctite 515 gasket eliminator or equivalent to the bearing coverand secure the cover with six M8x25 screws. Use Loctite 243 orequivalent on screws and torque to 25 Nm (18 ft.lbs.).

6.20.11 Apply Loctite 515 gasket eliminator or equivalent to the exciter motorand secure with two M8x20 screws. Use Loctite 243 or equivalent onscrews and torque to 25 Nm (18 ft.lbs.).



a

wc_gr002350

bc

d

i

j

e

g

h

f



6.21 Removing Drum Support



6.21.2 Disconnect the hydraulic lines (a) at the exciter motor. Plug hydrauliclines immediately after disconnecting to prevent contamination of thehydraulic system.

6.21.3 Remove the exciter components (weights, shafts, covers). SeeSection Rebuilding Exciters.

6.21.4 Empty the drum support of oil.

6.21.5 Label positions of all the hoses (b).

6.21.6 Cut the wire tie (c).

6.21.7 Using an appropriate hoist or crane, raise the machine approximatelysix inches off the ground. Using an appropriate hoist or crane, securethe drum support in the raised position (d). Using jack stands (e) orscrew jacks, secure the machine frame in position. Secure themachine frame and the drum support using separate devices. Youwill be required to lower the drum support in upcoming steps whileretaining the position of the machine frame.

6.21.8 Remove the shock mount screws (f) at the outer and the upper innerlocations.

6.21.9 Lower the drum support to gain access to the upper hose clamp.

6.21.10 Loosen the nuts (g) of the hose clamps. Remove the screws (h)securing the hose clamps to the drum support.

6.21.11 Remove the brake line (i) from the bulkhead fitting and pull the brakeline from the drum support.

6.21.12 Lower the drum support to the floor. Guide the hoses through it as it isbeing lowered.

6.21.13 Remove the screw (j) securing the lower inner shock mount.

6.21.14 Continue guiding the hoses through the drum support and pull thedrum support completely away from the frame.



a

b dc

wc_gr002706

e

f

h h

j

6" (15 cm)

g

i

i

g



6.22 Installing Drum Support


6.22.1 With shock mounts attached to drum support, position drum support onthe floor and under frame of machine. As you position it, guide thehydraulic hoses into the drum support.

6.22.2 Attach upper and lower hose clamps to drum support. During mountingof hose clamps on rear drums, attach hose guard (15). Do not tightenhose clamps around hoses at this time.

6.22.3 Lower the machine frame so that the outer shock mounts can besecured. Use Loctite 243 or equivalent on the screws and torque themto 86 Nm (63 ft.lbs.).

6.22.4 Continue lowering machine until innermost shock mounts can besecured. Use Loctite 243 or equivalent on the screws and torque themto 86 Nm (63 ft.lbs.).

6.22.5 Cut the head off an M10 screw. Insert it into the drum support in anupper location and use it as a guide pin. With the aid of an assistant orappropriate crane, position the drive hub assembly so that the shaft isapproximately halfway in to the drum support. Connect the hydraulicline leading to the hydraulic fitting (b) on the drive motor that is closestto the drive hub. Using the pin as a guide, slide the drive hub assemblythe rest of the way into the drum support.

6.22.6 Use Loctite 243 or equivalent on twelve M10x20 screws and securethe drive hub assembly to the drum support. Torque the screws to 49Nm (36 ft.lbs.).

6.22.7 Attach the rest of the hydraulic lines and add wire tie.

6.22.8 Tighten hose clamps around hoses.

6.22.9 Grease inner seal (c) with white lithium grease and place itapproximately halfway on the taper portion of the drive shaft.

6.22.10 Install the key on drive shaft and install the hub with hub nut. Torquehub nut to 816 Nm (600 ft.lbs.). Also torque drive-side hub nut.

6.22.11 Install drums and scrapers. See Section Installing Drums.



694

709

719

3

680

718

685

682

72

48

704

718

685

682

777

49

371

46

4716

702

777

15

685

682

wc_gr002359

a

c

b


CombiControl/Electrical System RT Repair

7. CombiControl/Electrical System

7.1 CombiControl Features


This machine is designed specifically for remote control operation.This feature protects the operator by allowing him or her to stand at adistance from the machine, and the work area, during operation. Whenused in excavations, it allows the operator to stand safely above thetrench, rather than in it.

The CombiControl transmitter is designed for both cable-controlledand infra-red (IR) remote-controlled operations.

The Infra-red System includes the transmitter and receiving eye. Thissystem provides wireless line-of-sight operation up to 65 feet (20 m). Ituses a hand-held transmitter to transmit signals to a receiving eye onthe machine to control machine operation.

7.2 CombiControl Operation


The Infra-Red Control System will only operate if the control cable isconnected to the receiving eye receptacle on the roller (b).

During operation, keep the transmitter pointed at the receiving eye onthe machine to continue operation. The amber light on top of themachine will blink slowly to show that the machine is receiving signalsfrom the transmitter. When the joystick is pressed fully forward, theroller will go into high-speed travel, and the amber light will blinkrapidly.

The CombiControl transmitter batteries can be recharged at the end ofoperations by connecting the transmitter receptacle (a) to the batterycharging cable (c).

The Cable Control System will only operate if the control cable isdisconnected from the receiving eye and connected to the transmitterreceptacle (a, d). In this mode, the CombiControl transmitter batteriescharge while the machine is in operation.

Always use the neck strap for the CombiControl transmitter providedby WACKER. This neck strap is designed to break away so that theoperator will not be injured should the machine slide, tip, or fall.

WARNING


RT Repair CombiControl/Electrical System

wc_gr002567

wc_gr002568

a

b

c

d



7.3 Decoder Module


The decoder module (d) is positioned behind the rear panel at the backof the machine. It receives, decodes and outputs the signal from eitherthe control cable or IR transmitter. It is also the power supply for allelectronic functions. It includes a channel selection microswitch.

A channel selection microswitch is also included in the transmittermodule. For operation of the remote control systems BOTH switchesmust be set to the SAME channel.

The LED's (green and red) are there for diagnostic aiding. They are:

• The green LED (f) will light when the decoder is receiving a con-trol signal (joystick movement).

• The red LED (g) will be constantly on for machines 9000 & 9002.

7.4 Setting Control Channels


The remote control system can be tuned to 3 different channels. Thisallows three machines to operate in the same area withoutinterference.

A channel selection microswitch (e) is included in the CombiControltransmitter module and in the decoder module (d), which is locatedunder the rear panel at the back of the machine.

For operation of the remote control systems BOTH switches must beset to the SAME channel.

The channel comes preset from the factory to Channel 1.

To change the control channels:

Remove the four screws holding the CombiControl Transmitter boxtogether and carefully pull it apart. Remove the rear panel covering thedecoder module. Press both of the microswitches to change thechannel to any of the three channel positions.

Make a note of the channel in use, and label the CombiControlTransmitter box and machine to identify the correct channel.


Note: To check that the machine and the CombiControl Transmitterbox are set to the same channel, turn them both on. The amber lighton the machine will come on but it will NOT blink if the decoder moduleand the transmitter module are not set to the same channel.
wc_gr002569



7.5 CombiControl Control Cable


Removal:

Stop and switch off the machine and disconnect the battery.

7.5.1 Remove six M8 screws (1) mounting rear cover (2) to rear frame.

7.5.2 Unscrew connector end of cable (3) from decoder module (4).

7.5.3 Remove two M5 screws (5) and nuts (6) holding nylon clamp (7)around cable (8).

Note: You may need to unscrew strain relief from swivel mount to gainslack in cable for easier removal of clamp.

7.5.4 Remove M12 locknut (9) and washer (10) mounting swivel mount (11)to pivot (12).

7.5.5 Unscrew strain relief from swivel mount (11) and pull cable (8) frommachine.

Installation:

Note: If the pivot (12) was removed, it is important to mount the pivotwith the window as shown. This will allow the cord to move into theoperating and stored positions.

7.5.6 Slide swivel mount (11) over pivot (12) and secure with washer (10)and locknut (9).

7.5.7 Route cable end (3) through swivel mount (11) and plug into decodermodule (4). Plug other end of cable into either the transmitter moduleor the I.R. receiving eye module.

7.5.8 Attach nylon clamp (7) onto cable (8) on underside of frame belowpivot (12). Secure clamp with two M5 screws (5) and nuts (6).

7.5.9 Mount rear cover (2) to rear frame using six M8 screws (1).


WARNING



wc_gr002570

9

8

6

7

5

10

11

12

5

3

2

1



7.6 CombiControl Receiving Eye Module


Removal:

7.6.1 Remove four M5 screws (13) and nuts (14) mounting cap (15), capmount (16), and bracket (17) to center cover (18).

7.6.2 Remove two M4 screws (19) and nuts (20) mounting receiving eyemodule (21) to center cover (18).

7.6.3 Remove four M3 screws (22) and nuts (23) mounting connector end(24) to bracket (17).

7.6.4 To test receiving eye (21), note condition of the green LED. With themachine and transmitter “ON”, the control cable must be secured tothe connector end (24). The green LED will turn and stay “ON” as longas the transmitter is “ON” and directed toward the receiving eye. Ifthere is no green LED, check the cable to make sure.

Installation:

7.6.5 Drop connector end (24) through center cover (18) and mount tobracket (17) with four M3 screws (22) and nuts (23).

7.6.6 Mount receiving eye module (21) to center cover (18) with two M4screws (19) and nuts (20).

7.6.7 Align holes in cap (15) and cap mount (16). Place over receiving eyemodule (21) on center cover.

7.6.8 Align holes in bracket (17) with holes of cap (15) and cap mount (16).Secure with four M5 screws (13) and nuts (14).


WARNING



wc_gr002571

15

19

13

21

16

18

21

21

2223

1417

wc_gr002572

1

2 3

CB

A

1234

4NEGATIVE, GNDSIGNAL, I.R.

+ POSITIVE, 12VDC

DECODER MODULE RECEPTACLE CONTROL CORD

#1 GREEN GREEN "A"

#2 RED BLACK "B"

#4 WHITE WHITE "C"



7.7 CombiControl Wiring

Wire Colors





wc_gr002573

G/B-WP

P G/W

G/R G/W

G/BBr G/B

P

P

P

R

WB

PR B



7.8 CombiControl Transmitter Module


The CombiControl transmitter is not intended to be a serviceablecomponent other than easily replaceable parts such as:

• Joystick Knob

• Rubber Boot

• Battery Pack

• Cord Connector

• Cap

• Neck Strap

Inspect the transmitter for visual damage, loose parts or wires, andmoisture. If transmitter is found to be damaged in any way and notfunctioning properly, consult WACKER Corporation for repair options.

To gain access to inside of the transmitter:

7.8.1 Remove four screws (1) mounting lower housing (2) to upper housing(3).

7.8.2 Slowly pull the two halves apart being careful not to pull the internalwires A or connector B from the circuit board.

CAUTION: If battery wires should be separated from circuit board andreconnected wrong, the transmitter will not draw power from thebattery.

wc_gr002574

3

A

2

1

RedBrownBlue



7.9 Wiring Schematic—Decoder Module, Control Panel & Engine

Pi

B

T

W

G/W

G/R

R

G G B L C30

50

R

B

T

R

Br

A

B

C

D

E

F

G/B

R

B

G/R

RBr

A B

OrYGWGr

T/BPrLY/OrTB

BBr

Br

Or/W

A

B

C

D

E

F

P

B

T/R

W

G/W

A B C

1

2 3

CB

A

1234

4

A

B

ABC

"A"

"B"

"C"

"A"

"B"

"C"

PR

P82 Resistor

Br

W

WIRE COLORS

B - BLACK Br - BROWNG - GREEN Gr - GRAYL - BLUE Or - ORANGEP - PINK Pr - PURPLER - REDT - TANW - WHITEY - YELLOW

DECODER MODULE

NEGATIVE, GND. SIGNAL,I.R.

+ POSITIVE, 12VDC

DECODER HAS 10 SECSWITCHOVER DELAY

FOR EXCITER OUTPUTS

REVERSE 32FORWARD 30

CONTROL LIGHT 28VIBRATION-HIGH 26VIBRATION-LOW 24

(NOT USED) 22BRAKE 20

STEERING-LEFT 18STEERING-RIGHT 16

HIGH SPEED 14FUEL VALVES 12

STARTER 10(NOT USED) 8

12 V (POSITIVE) 6GROUND 4

RECEPTACLE

BACKUPSAFETY

CONTROL

INFRA-RED EYE MODULEPANEL MOUNT

CONTROL CORDCONNECTOR END

HYDRAULIC VALVES

REVERSEFORWARDVIBRATION HIGHVIBRATION LOWBRAKESTEERING LEFTSTEERING RIGHTHIGH SPEED

GLOW PLUG SWITCH

TILT

ON

KEYSWITCH

OFFHOUR

OIL

ALT

BATTERY12 VDC

TOSTARTER

‘30’

ENGINECONNECTOR

ENGINECONNECTOR

FROMBATTERY

STARTER VOLTAGEREGULATOR

ALT.

QSD FUELVALVE

ENGINEOILPRESSURE

STARTERRELAY

GLOWPLUG

RELAYANTI-RESTARTMODULE

GLOWPLUG

#1 GREEN

#2 RED

#4 WHITE

GREEN

BLACK

WHITE

BROWN

WHITE

REVERSE POLARITYMODULE

wc_gr002575


Threadlockers and Sealants


Threadlocking adhesives and sealants are specified throughout thismanual by a notation of “S” plus a number (S#) and should be usedwhere indicated. Threadlocking compounds normally break down attemperatures above 175°C (350°F). If a screw or bolt is hard toremove, heat it using a small propane torch to break down the sealant.When applying sealants, follow instructions on container. The sealantslisted are recommended for use on Wacker equipment.

TYPE( ) = Europe COLOR USAGE

PART NO. –SIZE

Loctite 222Hernon 420Omnifit 1150 (50M)

Purple Low strength, for locking threads smaller than 6 mm (1/4”).Hand tool removable.Temp. range: -54 to 149°C (-65 to 300°F)

73287 - 10 ml


Blue Medium strength, for locking threads larger than 6 mm (1/4”).Hand tool removable.Temp. range: -54 to 149°C (-65 to 300°F)

29311 - .5 ml17380 - 50 ml

Loctite 271/277Hernon 427Omnifit 1550 (220M)

Red High strength, for all threads up to 25 mm (1”).Heat parts before disassembly.Temp. range: -54 to 149°C (-65 to 300°F)

29312 - .5 ml26685 - 10 ml73285 - 50 ml

Loctite 290Hernon 431Omnifit 1710 (230LL)

Green Medium to high strength, for locking preassembled threads and for sealing weld porosity (wicking).Gaps up to 0.13 mm (0.005”)Temp. range: -54 to 149°C (-65 to 300°F)

28824 - .5 ml25316 - 10 ml

Loctite 609Hernon 822Omnifit 1730 (230L)

Green Medium strength retaining compound for slip or press fit of shafts, bearings, gears, pulleys, etc.Gaps up to 0.13 mm (0.005”) Temp. range: -54 to 149°C (-65 to 300°F)

29314 - .5 ml


Brown Hydraulic sealantTemp. range: -54 to 149°C (-65 to 300°F)

79356 - 50 ml

Loctite 592Hernon 920Omnifit 790

White Pipe sealant with Teflon for moderate pressures.Temp. range: -54 to 149°C (-65 to 300°F)

26695 - 6 ml73289 - 50 ml

Loctite 515Hernon 910Omnifit 10

Purple Form-in-place gasket for flexible joints.Fills gaps up to 1.3 mm (0.05”)Temp. range: -54 to 149°C (-65 to 300°F)

70735 - 50 ml


Threadlockers and Sealants (continued)

Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container. The sealants listed are recommended for use on Wacker equipment.

TYPE( ) = Europe COLOR USAGE

PART NO. –SIZE

Loctite 496Hernon 110Omnifit Sicomet 7000

Clear Instant adhesive for bonding rubber, metal and plastics; general purpose.For gaps up to 0.15 mm (0.006”)Read caution instructions before using.Temp. range: -54 to 82°C (-65 to 180°F)

52676 - 1oz.

Loctite Primer THernon Primer 10Omnifit VC Activator

AerosolSpray

Fast curing primer for threadlocking, retaining and sealing compounds. Must be used with stainless steel hardware. Recommended for use with gasket sealants.

2006124-6 oz.

Torque Values

Torque Values

Metric Fasteners (DIN)

TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE

Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch

M3 1.2 *11 1.6 *14 2.1 *19 5.5 7/32 2.5 –

M4 2.9 *26 4.1 *36 4.9 *43 7 9/32 3 –

M5 6.0 *53 8.5 6 10 7 8 5/16 4 –

M6 10 7 14 10 17 13 10 – 5 –

M8 25 18 35 26 41 30 13 1/2 6 –

M10 49 36 69 51 83 61 17 11/16 8 –

M12 86 63 120 88 145 107 19 3/4 10 –

M14 135 99 190 140 230 169 22 7/8 12 –

M16 210 155 295 217 355 262 24 15/16 14 –

M18 290 214 405 298 485 357 27 1-1/16 14 –

M20 410 302 580 427 690 508 30 1-1/4 17 –

1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm

8.8 10.9 12.9

Torque Values

Torque Values (continued)

Inch Fasteners (SAE)

Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch

No.4 0.7 *6 1.0 *14 1.4 *12 5.5 1/4 – 3/32

No.6 1.4 *12 1.9 *17 2.4 *21 8 5/16 – 7/64

No.8 2.5 *22 3.5 *31 4.7 *42 9 11/32 – 9/64

No.10 3.6 *32 5.1 *45 6.8 *60 – 3/8 – 5/32

1/4 8.1 6 12 9 16 12 – 7/16 – 3/32

5/16 18 13 26 19 33 24 13 1/2 – 1/4

3/8 31 23 45 33 58 43 – 9/16 – 5/16

7/16 50 37 71 52 94 69 16 5/8 – 3/8

1/2 77 57 109 80 142 105 19 3/4 – 3/8

9/16 111 82 156 115 214 158 – 13/16 – –

5/8 152 112 216 159 265 195 24 15/16 – 1/2

3/4 271 200 383 282 479 353 – 1-1/8 – 5/8

1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm

Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. +852 2406 60 32 · Fax: +852 2406 60 21

RT 560 RT 820 - Wacker Neusonproducts.wackerneuson.com/manuals/Repair/0117935_005Rep.pdf · RT 560...

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Transcript of RT 560 RT 820 - Wacker Neusonproducts.wackerneuson.com/manuals/Repair/0117935_005Rep.pdf · RT 560...