Roller - Wacker Neuson

Transcription

www.wackergroup.com
0162632en
002
0507
en
Roller
RD 11
REPAIR MANUAL
0
1
6
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6
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Foreword
This manual covers machines with Item Number:
0007693, 0007694, 0007695
Operating / Parts Information
You must be familiar with the operation of this machine before you
attempt to troubleshoot or repair it. Basic operating and maintenance
procedures are described in the Operator’s Manual supplied with the
machine. Keep a copy of the Operator’s Manual with the machine at all
times. Use the separate Parts Book supplied with the machine to order
replacement parts. If you are missing either of the documents, please
contact Wacker Corporation to order a replacement.
Damage caused by misuse or neglect of the unit should be brought to
the attention of the operator to prevent similar occurrences from
happening in the future.
This manual provides information and procedures to safely repair and
maintain the above Wacker model(s). For your own safety and
protection from injury, carefully read, understand, and observe all
instructions described in this manual. THE INFORMATION
CONTAINED IN THIS MANUAL IS BASED ON MACHINES
MANUFACTURED UP TO THE TIME OF PUBLICATION. WACKER
CORPORATION RESERVES THE RIGHT TO CHANGE ANY
PORTION OF THIS INFORMATION WITHOUT NOTICE.
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Foreword
WARNING
CALIFORNIA
Proposition 65 Warning:
Engine exhaust, some of its constituents, and certain vehicle
components, contain or emit chemicals known to the State of
California to cause cancer and birth defects or other reproductive
harm.
Laws Pertaining to Spark Arresters
Notice: State Health Safety Codes and Public Resources Codes
specify that in certain locations spark arresters be used on internal
combustion engines that use hydrocarbon fuels. A spark arrester is a
device designed to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified and rated by
the United States Forest Service for this purpose.
In order to comply with local laws regarding spark arresters, consult
the engine distributor or the local Health and Safety Administrator.
All rights, especially copying and distribution rights, are reserved.
Copyright 2007 by Wacker Corporation
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.
Any type of reproduction or distribution not authorized by Wacker
Corporation represents an infringement of valid copyrights, and
violators will be prosecuted. We expressly reserve the right to make
technical modifications, even without due notice, which aim at
improving our machines or their safety standards.
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RD 11 Repair
1.
Safety Information
1.1
1.2
1.3
1.4
1.5
1.6
2.
Operating Safety ................................................................................ 12
Operator Safety While Using Internal Combustion Engines ............... 13
Service Safety .................................................................................... 14
Label Locations .................................................................................. 15
Safety Labels ...................................................................................... 16
Operating Labels ................................................................................ 17
21
Engine ................................................................................................ 21
Roller .................................................................................................. 22
Lubrication .......................................................................................... 23
Dimensions ......................................................................................... 24
Sound and Vibration Measurements .................................................. 25
Operation
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
4.
11
Technical Data
2.1
2.2
2.3
2.4
2.5
3.
Table of Contents
26
Information Regarding Operation ....................................................... 26
Operation and Service Locations ....................................................... 27
Starting (RD 11A / RD 11V) ............................................................... 29
Stopping/Parking (RD 11A / RD 11V) ................................................ 30
Direction and Speed (RD 11A / RD 11V) ........................................... 31
Braking Machine (RD 11A / RD 11V) ................................................. 32
Starting (RD 11AEC) .......................................................................... 33
Stopping/Parking (RD 11AEC) ........................................................... 34
Direction and Speed (RD 11AEC) ...................................................... 35
Braking Machine (RD 11AEC) ............................................................ 36
Vibration (RD 11A / RD 11V) .............................................................. 37
Vibration (RD 11AEC) ........................................................................ 38
Watering System ................................................................................ 38
Operator Presence System ................................................................ 39
Maintenance
4.1
4.2
41
Engine Maintenance ........................................................................... 41
Maintenance Schedule ....................................................................... 42
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Table of Contents
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26
5.
RD 11 Repair
Lifting Machine ....................................................................................43
Transporting Machine ..........................................................................44
Towing (RD 11A / RD 11V) .................................................................45
Towing (RD 11AEC) ............................................................................46
Engine Oil Drain ..................................................................................47
Engine Oil ............................................................................................48
Oil Filter (Honda) .................................................................................49
Oil Filter (Vanguard) ............................................................................49
Air Cleaner (Honda) ............................................................................50
Air Cleaner (Vanguard) .......................................................................51
Hydraulic System Cleanliness .............................................................52
Hydraulic Oil Requirements .................................................................53
Hydraulic Oil Level ..............................................................................54
Suction Filter .......................................................................................54
Changing Hydraulic Oil & Filter ...........................................................55
Bleeding the Hydraulic System ...........................................................56
Spark Plug ...........................................................................................57
Carburetor (Vanguard) ........................................................................58
Grease Fittings ....................................................................................59
Fuel Filter ............................................................................................60
Scraper Bars .......................................................................................61
Parking Brake Adjustment (RD 11A/RD 11V) .....................................62
Throttle Solenoid Adjustment ..............................................................63
Storage ................................................................................................64
Engine Starting Troubleshooting
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
66
Starting System Component Locations ...............................................66
Troubleshooting Flowcharts ................................................................68
Engine Does Not Crank—Flowchart 1A ..............................................69
Checking Battery .................................................................................70
Checking 20A Fuses ...........................................................................72
Checking Keyswitch ............................................................................74
Checking Neutral Switch .....................................................................76
Checking Starter Relay .......................................................................78
Checking Power to Starter Solenoid (Honda engines only) ................80
Engine Cranks but Does Not Start—Flowchart 2A ..............................81
Checking Fuel System ........................................................................82
Checking Seat Switch .........................................................................83
Checking Anti-Afterfire Solenoid .........................................................84
6
RD 11 Repair
6.
Table of Contents
Hydraulic System
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
6.24
6.25
6.26
6.27
6.28
6.29
6.30
6.31
6.32
6.33
6.34
6.35
6.36
6.37
6.38
6.39
87
Hydraulic System Precautions ........................................................... 87
Hydraulic System Service Basics ....................................................... 87
Hydraulic Schematic—RD 11A and RD 11V (parallel drive) .............. 88
Hydraulic Components—RD 11A and RD 11V (parallel drive) ........... 89
Hydraulic Diagram—RD 11A and RD 11V (parallel drive) ................. 90
Hydraulic Components—RD 11A and RD 11V (parallel drive) ........... 91
Hydraulic Piping—RD 11A, RD 11V (parallel drive) ........................... 92
Hydraulic Piping Components—RD 11A, RD 11V (parallel drive) ...... 93
Hydraulic Schematic—RD 11A, RD 11V (revisions 103–134) ........... 94
Hydraulic Components—RD 11A, RD 11V (revisions 103–134) ........ 95
Hydraulic Diagram—RD 11A, RD 11V (revisions 103–134) ............... 96
Hydraulic Components—RD 11A, RD 11V (revisions 103–134) ........ 97
Hydraulic Piping—RD 11A, RD 11V (revisions 103–134) .................. 98
Hydraulic Piping Components—RD 11A, RD 11V
(revisions 103–134) ............................................................................ 99
Hydraulic Schematic—RD 11A, RD 11V (revisions > 134) .............. 100
Hydraulic Components—RD 11A, RD 11V (revisions > 134) ........... 101
Hydraulic Diagram—RD 11A, RD 11V (revisions > 134) ................. 102
Hydraulic Components—RD 11A, RD 11V (revisions >134) ............ 103
Hydraulic Piping—RD 11A, RD 11V (revisions > 134) ..................... 104
Hydraulic Piping Components—RD 11A, RD 11V (revisions > 134) 105
Hydraulic Schematic—RD 11AEC ................................................... 106
Hydraulic Components—RD 11AEC ................................................ 107
Hydraulic Diagram—RD 11AEC ....................................................... 108
Hydraulic Diagram Components—RD 11AEC ................................. 109
Hydraulic Piping—RD 11AEC .......................................................... 110
Hydraulic Piping Components—RD 11AEC ..................................... 111
General Description .......................................................................... 112
Drive Circuit—RD 11A and RD 11V ................................................. 114
Drive Circuit—RD 11AEC ................................................................. 116
Vibration and Steering—All Models .................................................. 118
Hydraulic Manifold Blocks with Test Ports ....................................... 120
Testing Hydraulic Pressure .............................................................. 121
Checking Drive Circuit Pressures ..................................................... 123
Checking Vibration Circuit Pressures ............................................... 124
Checking Steering Circuit Pressures ................................................ 124
Adjusting Relief Valves ..................................................................... 125
Troubleshooting Flowcharts ............................................................. 126
Drive System Troubleshooting—Flowchart 3A ................................. 127
Checking Tow Valve (RD 11A and RD 11V only) ............................ 128
7
Table of Contents
6.40
6.41
6.42
6.43
6.44
6.45
6.46
6.47
6.48
6.49
6.50
6.51
7.
RD 11 Repair
Checking Brake (RD 11AEC only) ....................................................129
Checking Brake System Electrics .....................................................130
Adjusting the Drive Control Cable .....................................................131
Drive System Troubleshooting—Flowchart 3B ..................................132
Checking Drive Motor for Binding ......................................................133
Checking Drive Motors—Series Drive ...............................................134
Checking Drive Motors—Parallel Drive .............................................135
Vibration System Troubleshooting—Flowchart 4A ............................136
Checking Exciter Electrical System ...................................................138
Troubleshooting a System that Vibrates Poorly ................................140
Checking Exciter and Exciter Motor ..................................................141
Troubleshooting the Steering System ...............................................142
Electrical System
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
7.13
7.14
7.15
7.16
7.17
7.18
7.19
7.20
7.21
7.22
7.23
7.24
7.25
7.26
143
Checking Throttle Switch ...................................................................143
Checking Throttle Solenoid ...............................................................144
RD 11A Electrical Schematic (revisions 100–118) ............................146
RD 11A Electrical Components (revisions 100–118) ........................147
RD 11A Wiring Diagram (revisions 100–118) ...................................148
RD 11A Electrical Schematic (revisions > 141) .................................158
RD 11A Electrical Components (revisions > 141) .............................159
RD 11A Wiring Diagram (revisions > 141) ........................................160
RD 11A Electrical Components (revisions > 141) .............................161
RD 11V Electrical Schematic (revisions 100–118) ............................162
RD 11V Electrical Components (revisions 100–118) ........................163
RD 11V Wiring Diagram (revisions 100–118) ...................................164
RD 11V Electrical Schematic (revisions 119–138) ...........................166
RD 11V Wiring Diagram (revisions 119–138) ..................................168
8
RD 11 Repair
7.27
7.28
7.29
7.30
7.31
7.32
7.33
7.34
7.35
7.36
7.37
7.38
7.39
7.40
7.41
7.42
7.43
7.44
7.45
7.46
8.
Table of Contents
RD 11V Electrical Schematic (revisions 139–142) ........................... 170
RD 11V Electrical Components (revisions 139–142) ....................... 171
RD 11V Wiring Diagram (revisions 139–142) .................................. 172
RD 11V Electrical Components (revisions 139–142) ....................... 173
RD 11V Electrical Schematic (revisions > 142) ................................ 174
RD 11V Electrical Components (revisions > 142) ............................ 175
RD 11V Wiring Diagram (revisions > 142) ....................................... 176
RD 11V Electrical Components (revisions > 142) ............................ 177
RD 11AEC Electrical Schematic (revisions 100–111) ...................... 178
RD 11AEC Electrical Components (revisions 100–111) ................. 179
RD 11AEC Wiring Diagram (revisions 100–111) .............................. 180
RD 11AEC Electrical Components (revisions 100–111) ................. 181
RD 11AEC Electrical Schematic (revisions 112–125) ...................... 182
RD 11AEC Electrical Components (revisions 112–125) .................. 183
RD 11AEC Wiring Diagram (revisions 112–125) .............................. 184
RD 11AEC Electrical Components (revisions 112–125) .................. 185
RD 11AEC Electrical Schematic (revisions > 125) ........................... 186
RD 11AEC Electrical Components (revisions > 125) ....................... 187
RD 11AEC Wiring Diagram (revisions > 125) .................................. 188
RD 11AEC Electrical Components (revisions > 125) ....................... 189
Disassembly and Assembly
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
8.14
8.15
8.16
8.17
191
Tools ................................................................................................. 191
Ordering Parts .................................................................................. 191
Reference Numbers ( ) ..................................................................... 191
Weight Block .................................................................................... 191
Threadlocking Compounds .............................................................. 192
Front Drum Assembly Description .................................................... 192
Replacing the Exciter Motor ............................................................. 194
Removing the Front Drum ................................................................ 196
Installing the Front Drum .................................................................. 198
Replacing the Exciter and Exciter Bearings ..................................... 200
Front Drive Motor (RD 11A and RD11V series drive) ....................... 206
Front Drive Motor (RD 11A and RD 11V parallel drive) .................... 208
Front Drive Motor RD 11AEC ........................................................... 210
Rear Drum Assembly—Description .................................................. 212
Replacing Brake and Brake Cable ................................................... 214
Rear Drum (RD 11A and RD 11V revisions < 119) .......................... 218
Replacing Rear Drive Motor (RD 11A and RD 11V
revisions < 104) ................................................................................ 220
9
Table of Contents
8.18
8.19
8.20
8.21
8.22
8.23
8.24
8.25
8.26
8.27
8.28
8.29
8.30
8.31
8.32
8.33
8.34
8.35
RD 11 Repair
Replacing Rear Drive Motor (RD 11A and RD 11V
revisions 104–118) ............................................................................222
Removing the Rear Drum (RD 11A and RD 11V revisions > 118) ....224
Installing the Rear Drum (RD 11A and RD 11V revisions > 118) ......226
Removing Rear Drive Motor (RD 11A and RD 11V revisions > 118) 228
Installing Rear Drive Motor (RD 11A and RD 11V revisions > 118) ..230
Replacing Rear Drive Motor (RD 11AEC) .........................................232
Replacing the Articulated Steering Joint ...........................................234
Throttle/Choke Cables (revisions 100–118) ......................................238
Choke Cable (revisions > 118) ..........................................................240
Drive Control Cable (revisons 100–109) ...........................................242
Drive Control Cable (revisons > 109) ................................................244
Replacing the Water Tank .................................................................248
Replacing Water Valves ....................................................................250
Replacing the Fuel Tank ...................................................................252
Replacing Steering Cylinder ..............................................................256
Replacing the Drive Pump .................................................................258
Replacing the Exciter Pump ..............................................................260
Replacing the Engine ........................................................................262
10
RD 11 /...
1.
Safety Information
Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE and
NOTE callouts which must be followed to reduce the possibility of
personal injury, damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
DANGER
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
WARNING
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
CAUTION
NOTICE: Used without the safety alert symbol, NOTICE indicates a
hazardous situation which, if not avoided, could result in property
damage.
Note: Contains additional information important to a procedure.
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Safety Information
1.1
RD 11 /...
Operating Safety
WARNING
Familiarity and proper training are required for the safe operation of the
machine. Machines operated improperly or by untrained personnel
can be dangerous. Read the operating instructions contained in both
this manual and the engine manual and familiarize yourself with the
location and proper use of all controls. Inexperienced operators should
receive instruction from someone familiar with the machine before
being allowed to operate it.
1.1.1
ALWAYS disengage and stow the locking bar for the articulated
steering joint before operating the machine. The machine cannot be
steered when the locking bar is engaged.
1.1.2
ALWAYS check that all controls are functioning properly immediately
after start-up! DO NOT operate the machine unless all controls operate
correctly.
1.1.3
ALWAYS remain aware of changing positions and the movement of
other equipment and personnel on the job site.
1.1.4
ALWAYS remain seated at all times while operating the machine.
1.1.5
ALWAYS remain aware of changing surface conditions and use extra
care when operating over uneven ground, on hills, or over soft or
coarse material. The machine could shift or slide unexpectedly.
1.1.6
ALWAYS use caution when operating near the edges of pits, trenches
or platforms. Check to be sure that the ground surface is stable enough
to support the weight of the machine with the operator and that there
is no danger of the roller sliding, falling, or tipping.
1.1.7
ALWAYS wear protective clothing appropriate to the job site when
operating equipment.
1.1.8
ALWAYS keep hands, feet, and loose clothing away from moving parts
of the machine.
1.1.9
ALWAYS read, understand, and follow procedures in the Operator’s
Manual before attempting to operate the equipment.
1.1.10 ALWAYS store the equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the reach of
children.
1.1.11 ALWAYS operate the machine with all safety devices and guards in
place and in working order.
1.1.12 NEVER allow anyone to operate this equipment without proper
training. People operating this equipment must be familiar with the
risks and hazards associated with it.
1.1.13 NEVER touch the engine or muffler while the engine is on or
immediately after it has been turned off. These areas get hot and may
cause burns.
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RD 11 /...
1.2
Safety Information
1.1.14
NEVER use accessories or attachments that are not recommended by
Wacker. Damage to equipment and injury to the user may result.
1.1.15
NEVER leave machine running unattended.
1.1.16
NEVER operate the machine with the fuel cap loose or missing.
Operator Safety While Using Internal Combustion Engines
DANGER
wc_si000013gb.fm
Internal combustion engines present special hazards during operation
and fueling. Read and follow the warning instructions in the engine
owner’s manual and the safety guidelines below. Failure to follow the
warnings and safety guidelines could result in severe injury or death.
1.2.1
DO NOT smoke while operating the machine.
1.2.2
DO NOT smoke when refueling the engine.
1.2.3
DO NOT refuel a hot or running engine.
1.2.4
DO NOT refuel the engine near an open flame.
1.2.5
DO NOT spill fuel when refueling the engine.
1.2.6
DO NOT run the engine near open flames.
1.2.7
DO NOT run the machine indoors or in an enclosed area such as a
deep trench unless adequate ventilation, through such items as
exhaust fans or hoses, is provided. Exhaust gas from the engine
contains poisonous carbon monoxide gas; exposure to carbon
monoxide can cause loss of consciousness and may lead to death.
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 keep the area around a hot exhaust pipe free of debris to
reduce the chance of an accidental fire.
13
Safety Information
1.3
RD 11 /...
Service Safety
Poorly maintained machines can become a safety hazard! In order for
the machine to operate safely and properly over a long period of time,
periodic maintenance and occasional repairs are necessary.
WARNING
1.3.1
DO NOT attempt to clean or service the machine while it is running.
Rotating parts can cause severe injury.
1.3.2
DO NOT crank a flooded engine with the spark plug removed on
gasoline-powered engines. Fuel trapped in the cylinder will squirt out
the spark plug opening.
1.3.3
DO NOT test for spark on gasoline-powered engines if the engine is
flooded or the smell of gasoline is present. A stray spark could ignite
the fumes.
1.3.4
DO NOT use gasoline or other types of fuels or flammable solvents to
clean parts, especially in enclosed areas. Fumes from fuels and
solvents can become explosive.
1.3.5
DO NOT modify the machine without the express written approval of
the manufacturer.
1.3.6
ALWAYS check all external fasteners at regular intervals.
1.3.7
ALWAYS keep the area around the muffler free of debris such as
leaves, paper, cartons, etc. A hot muffler could ignite the debris and
start a fire.
1.3.8
ALWAYS replace worn or damaged components with spare parts
designed and recommended by Wacker Corporation.
1.3.9
ALWAYS disconnect the spark plug on machines equipped with
gasoline engines, before servicing, to avoid accidental start-up.
1.3.10 ALWAYS keep the machine clean and labels legible. Replace all
missing and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
1.3.11 ALWAYS switch off the power supply at the battery disconnect before
adjusting or maintaining the electrical equipment.
1.3.12 ALWAYS do Periodic Maintenance as recommended in the Operator’s
Manual.
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RD 11 /...
1.4
Safety Information
Label Locations
U
V
X
W
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15
Y
Safety Information
1.5
RD 11 /...
Safety Labels
Wacker machines use international pictorial labels where needed.
These labels are described below:
Ref.
Label
Meaning
A
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.
B
DANGER!
Before fueling, stop the engine. No
sparks, flames, or burning objects near
the machine. Use only fresh, clean fuel.
C
WARNING!
Hot surface!
D
WARNING!
Read and understand the supplied Operator’s Manual before operating the
machine. Failure to do so increases the
risk of injury to yourself or others.
E
CAUTION!
Read and understand the supplied Operator’s Manuals before operating this
machine. Failure to do so increases the
risk of injury to yourself or others.
F
WARNING!
To prevent hearing loss, wear hearing
protection when operating this machine.
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16
RD 11 /...
Ref.
Safety Information
Label
Meaning
G
WARNING!
Always wear seat belt when operating
roller.
H
CAUTION!
Lifting point.
I
WARNING!
Pinch point
1.6
Ref.
Operating Labels
Label
Meaning
J
Tie-down point.
K
Hydraulic oil drain.
L
Hydraulic oil reservoir fill tube.
M
Hydraulic oil reservoir level
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Safety Information
Ref.
RD 11 /...
Label
Meaning
N
Water level
O
Gas level
P
Torque battery hold-down nuts to 3.5 Nm
(2.5 ft.lbs.) max.
Q
Grease points: Inspect and lubricate
every 100 hours of operation.
R
Water control valve.
S
Guaranteed sound power level in dB(A).
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18
RD 11 /...
Ref.
Safety Information
Label
Meaning
T
A nameplate listing the model number,
item number, revision number, and serial
number is attached to each unit. Please
record the information found on this plate
so it will be available should the nameplate become lost or damaged. When
ordering parts or requesting service information, you will always be asked to specify the model number, item number,
revision number, and serial number of
the unit.
U
Variable speed throttle
V
Variable choke
W
Variable direction control
X
Vibration control
Y
Key switch, engine start:
Off
On
Start
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Safety Information
Ref.
RD 11 /...
Label
Meaning
This machine may be covered by one or
more patents.
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20
RD 11 /...
2.
Technical Data
Technical Data
2.1
Engine
Item No.
RD 11A
0007693
RD 11AEC
0007695
RD 11V
0007694
Engine
Engine Type
4-stroke, 2 cylinder, air cooled
Engine Make
Honda
Engine Model
kW (Hp)
Displacement
cm³ (in³)
Spark Plug
mm (in)
Engine Speed—full load
rpm
Engine Speed—idle
rpm
Valve Clearance (cold)
intake:
exhaust:
Battery
Briggs & Stratton
GX 610 QDF
Rated Power
Electrode Gap
Honda
Vanguard
350447
13.4 (18)
614 (37.5)
570 (34.7)
(NGK) BPR6ES / (NGK) BPR6ES
High Heat
Champion
RC12YC
0.71–0.79 (0.028–0.031)
0.76 (0.030)
3200
1800
mm (in.)
0.10–0.16 (0.004–0.006)
0.10–0.16 (0.004–0.006)
12 VDC
V
Air Cleaner
type
Dual Element
Fuel
type
Regular Unleaded Gasoline
Fuel Tank Capacity
Fuel Consumption
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l (gal.)
24 (6.3)
l (gal.)/hr.
4.6 (1.2)
21
Technical Data
2.2
RD 11 /...
Roller
Item No.
RD 11A
0007693
RD 11AEC
0007695
RD 11V
0007694
925 (2040)
1067 (2353)
925 (2040)
470 (18.4)
205 (8.1)
390 (15.4)
210 (8.7)
470 (18.4)
205 (8.1)
Roller
Dry Weight
Curb Clearance:
Right
Left
mm (in.)
Water Tank Capacity
l (gal.)
151 (40)
Outside Turning Radius
m (ft.)
2.8 (9.2)
m (ft.) /
min.
0–126 (0–414)
Forward / Reverse
Speed
Gradeability
Vibration Frequency
wc_td000022gb.fm
27% (12°)
65 (3900)
Hz (vpm)
22
RD 11 /...
2.3
Technical Data
Lubrication
Item No.
RD 11A
0007693
RD 11AEC
0007695
RD 11V
0007694
Lubrication
Engine Lubrication
type
l (pt.)
SAE 10W30 Class SG, SF,or SE rated
1.6 (3.5)
Hydraulic System
type
l (gal)
Premium grade, Anti-wear hydraulic fluid 10W30
21.6 (5.7)
Exciter
type
Wheel Bearing Grease Filmite EMB
Rear Drum Drive
Bearing
type
qty.
Shell Alvania RL2 Grease (1 grease fitting)
2–3 shots with hand-held grease gun
Front Drum Drive
Bearing
type
Sealed Bearings—No lubrication required
Articulated Joint
type
qty.
Shell Alvania RL2 Grease (1 grease fitting)
2–3 shots with hand-held grease gun
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23
Technical Data
2.4
RD 11 /...
Dimensions
2210 mm
(87 in.)
1530 mm
(60 in.)
560 mm
(22 in.)
1127 mm
(44 in.)
900 mm
(35 in.)
2100 mm
(83 in.)
1025 mm
(40 in.)
wc_gr000213
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24
RD 11 /...
2.5
Technical Data
Sound and Vibration Measurements
The required sound specification, Paragraph 1.7.4.f of 89/392/EEC
Machinery Directive, is:
The sound pressure level at operator’s location (LpA) = 89.1 dB(A).
The guaranteed sound power level (LWA) = 109 dB(A).
These noise values were obtained at the operator's location according
to ISO 3744 for the sound power level (LWA) and ISO 6081 for the
sound pressure level (LpA).
The weighted effective acceleration value, determined according to
ISO 8662 Part 1, is approximately:
Hands = 5.65 m/s2, Feet = 0.64 m/s2, Seat = 1.05 m/s2.
The sound and vibration measurements were obtained with the
machine operating on hard asphalt at maximum RPM and top speed.
wc_td000022gb.fm
25
Operation
3.
RD 11 Repair
Operation
3.1
Information Regarding Operation
The information regarding the operation of the machine included in this
manual is condensed. Refer to the Operator’s Manual for complete
operating instructions. Always read, understand, and follow the
procedures in the Operator’s Manual when operating the machine.
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26
RD 11 Repair
3.2
Operation
Operation and Service Locations
41
44
15 55
46
31
6
16
10
28
32
56
19
17
7
25
45
1
wc_gr000116
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27
Operation
RD 11 Repair
See Graphic: wc_gr000115 & wc_gr000116
Ref.
1
2
3
Description
Air cleaner
Articulated joint
Water level sight gauge
Ref.
29
30
31
4
5
6
7
8
9
Hand holds
Choke lever
Coupling—engine
Dipstick
Drain Plug—hydraulic tank
Drive motor
32
33
34
35
36
37
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
25
26
Drive pump
Engine hood
Engine throttle control
Vibration control button
Exciter motor
Exciter/steering pump
Filter—return line
Filter—suction line
Forward / reverse control
Forward / reverse control cable
Front Drum—vibratory
Fuel tank access door
Fuel filter (under floor panel)
Grease fitting—rear drum
Grease fittings—articulated joint
(4 places)
Hydraulic tank fill port
Identification plate
27
Ignition switch
55
28
Steering/exciter manifold
56
wc_tx000531gb.fm
53
54
28
Description
Water tank
Lockarm
Drive manifold assembly
(valve block)
Oil filter—engine
Rear drum fill/drain plug
Rear drum—static
Scraper bar (4 places)
Sightglass—hydraulic tank
Sprinkler tube (4)
Steering wheel
Steering cylinder
Tiedown (2 places)
Battery disconnect (RD 11AEC)
Water system control—front drum
Water system control—rear drum
Battery
Hour meter/tachometer
Suction line
Grease fitting—exciter (2 places)
Fuel level sight gauge
Lifting eye (4 places)
Step (2)
ROPS
Emergency stop pushbutton/
parking brake (RD 11AEC)
Horn switch (RD 11AEC)
Adjustable seat with seatbelt (RD
11AEC)
Brake release tow valve (RD
11AEC)
Horn (RD 11AEC)
RD 11 Repair
3.3
Operation
Starting (RD 11A / RD 11V)
See Graphic: wc_gr000123
3.3.1
If the engine is cold, place the choke lever in the closed position (b2).
If the engine is warm, place the choke control in the open position (b1).
3.3.2
Set the forward/reverse control in the neutral position (e2).
Note: The roller will not start unless the forward/reverse control is in
neutral. On revisions 143 and above of RD 11V models, and revisions
142 and above of RD 11A models, the roller will not start unless the
forward/reverse control is in neutral and the operator is positioned in
the driver’s seat.
3.3.3
Check that the parking brake is set (d).
3.3.4
Turn the ignition switch (f) to start the engine. If exciter indicator light
(g) is on, turn vibration off.
NOTICE: Do not crank the engine starter for more than 15 seconds at
one time. Longer cranking cycles could lead to starter damage.
3.3.5
Gradually place the choke lever to the open position (b1) as the engine
warms up. Allow the engine to warm up for a few minutes before
operating the roller.
b2
g
a2
a1
c
f
b1
d
e3 e2 e1
wc_gr000123
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29
Operation
3.4
RD 11 Repair
Stopping/Parking (RD 11A / RD 11V)
3.4.1
Turn vibration off.
3.4.2
Close both watering valves.
3.4.3
Return the engine throttle to idle (a1) by pressing the throttle switch,
and allow the engine to cool down.
3.4.4
Stop the engine by turning the ignition switch to OFF.
3.4.5
Set the parking brake. To set the brake (d), pull the brake lever up until
the brake pad engages the drum. To release, lower the lever. Always
set the parking brake before leaving the machine.
The parking brake is connected to the brake pads and can be adjusted
by turning the knob (c) on the end of the handle. See Parking Brake
Adjustment.
Note: The parking brake engages the rear drum only.
NOTICE: Avoid parking the roller on a hill or an incline. If the roller
must be parked on a hill, block the drums in addition to setting the
brake to prevent the roller from moving.
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30
RD 11 Repair
3.5
Operation
Direction and Speed (RD 11A / RD 11V)
The forward/reverse lever controls both the direction and speed of the
roller. Use the control lever, rather than the throttle, to control the
speed of the machine while compacting.
Daily, before operating, check the machine for drift (movement with the
forward/reverse control in the NEUTRAL position) and adjust as
needed. See section Adjusting the Drive Control Cable.
Speed is controlled by the amount the lever is moved in the direction
of travel—forward (e1) or reverse (e3).
While operating the machine, run it at full throttle. To run the machine
at full throttle, press and release the throttle switch (a2). This ensures
maximum travel speeds and will produce the best compaction results.
Operating the machine at slower engine speeds will reduce
compaction, slow down machine functions, and damage hydraulic
components.
NOTICE: Holding the throttle switch in for a period of time will trip the
circuit breaker.
Note: On revisions 143 and above of RD 11V models, and revisions
142 and above of RD 11A models, the engine will stop whenever the
operator rises from the driver’s seat. To restart the engine, return the
control lever to the NEUTRAL position, sit in the driver’s seat, turn the
key off then to start.
b2
g
a2
a1
c
f
b1
d
e3 e2 e1
wc_gr000123
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31
Operation
3.6
RD 11 Repair
Braking Machine (RD 11A / RD 11V)
The machine will brake automatically when the control lever is returned
to neutral (e2). If the machine continues to drift, shift the control lever
slightly in the opposite direction to stop movement and then return the
lever to neutral. If it will not remain stationary in neutral, adjust as
needed. See Adjusting the Drive Control Cable.
Note: Do not stop the machine using the parking brake! The parking
brake is not intended to be used to stop the machine.
wc_tx000531gb.fm
32
RD 11 Repair
3.7
Operation
Starting (RD 11AEC)
3.7.1
If the engine is cold, place the choke lever in the closed position (b2).
If the engine is warm, place the choke control in the open position (b1).
3.7.2
Set the forward/reverse control in the neutral position (c2).
Note: The roller will not start unless the forward/reverse control is in
neutral and the operator is positioned in the driver’s seat.
3.7.3
Push the emergency stop pushbutton (d) to make sure that the parking
brake is set.
3.7.4
Turn the ignition switch (e) to start the engine.
NOTICE: Do not crank the engine starter for more than 15 seconds at
one time. Longer cranking cycles could lead to starter damage.
a2
3.7.5
Gradually place the choke lever to the open position (b1) as the engine
warms up. Allow the engine to warm up for a few minutes before
operating the roller.
3.7.6
Disengage the parking brake by turning the emergency stop button (d)
until it pops out.
b2
d
e
b1
a1
c3 c2
c1
wc_gr000139
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33
Operation
3.8
RD 11 Repair
Stopping/Parking (RD 11AEC)
3.8.1
Turn vibration off.
3.8.2
Close both watering valves.
3.8.3
Return engine throttle to idle (a1) by pressing the throttle switch and
allow the engine to cool down.
3.8.4
Stop the engine by turning the ignition switch to the OFF position.
3.8.5
To engage the parking brake (d), push the emergency stop button.
This switch engages a hydraulically-activated brake on the drive
motors. Always set the parking brake before leaving the machine.
NOTICE: Avoid parking the roller on a hill or incline. If the roller must
be parked on a hill, block the drums in addition to setting the brake to
prevent the roller from moving.
wc_tx000531gb.fm
34
RD 11 Repair
3.9
Operation
Direction and Speed (RD 11AEC)
The forward/reverse lever controls both the direction and speed of the
roller. Use the control lever, rather than the throttle, to control the
speed of the machine while compacting.
Daily, before operating, check the machine for drift (movement with the
forward/reverse control in the NEUTRAL position) and adjust as
needed. See Adjusting the Drive Control Cable.
Speed is controlled by the amount the lever is moved in the direction
of travel—forward (c1) or reverse (c3).
During operation, to run the machine at full throttle (a2), quickly press
and release the throttle switch. This ensures maximum travel speeds
and will produce the best compaction results. Operating the machine
at slower engine speeds will reduce compaction, slow down machine
functions, and damage hydraulic components.
NOTICE: Holding the throttle switch in for a period of time will trip the
circuit breaker.
Note: This machine is fitted with an operator presence safety system
which prevents the machine from moving if an operator is not seated
in the driver’s seat.
Do not use the machine without the Roll Over Protection Structure
(ROPS) in place. The ROPS is designed to protect the operator in a
WARNING rollover accident.
Always wear the seat belt provided when operating the roller.
WARNING
a2
b2
d
e
b1
a1
c3 c2
c1
wc_gr000139
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35
Operation
RD 11 Repair
3.10 Braking Machine (RD 11AEC)
Automatic functions
The machine will brake automatically when the control lever is returned
to neutral. If the machine continues to drift, shift the control lever
slightly in the opposite direction to stop movement and then return the
lever to neutral. If the machine will not remain stationary in neutral,
adjust it. See section Adjusting the Drive Control Cable.
The emergency stop/parking brakes will automatically apply when:
•
The emergency stop button is pushed.
•
The engine is off.
•
A loss of hydraulic or electrical power occurs.
•
The operator rises from the driver’s seat, activating the operator
presence system.
Note: The operator presence system will only trip after a one-half
second delay.
Emergency stop pushbutton
When pushed, the emergency stop pushbutton not only stops all travel
(either forward or reverse) and applies the brake, but also stops exciter
vibration.
When the emergency stop pushbutton is reset, vibration will not
resume until it is turned ON. See section Vibration.
Before releasing the emergency stop pushbutton, place the forward/
reverse control in neutral.
wc_tx000531gb.fm
36
RD 11 Repair
Operation
3.11 Vibration (RD 11A / RD 11V)
Vibration is turned ON or OFF by a push button (a) located in the
uppermost portion of the forward/reverse control. Push the button to
turn vibration on; push it again to turn it off. Vibration can be turned on
while operating in either forward or reverse and will remain on until it is
switched off.
NOTICE: If the machine has been turned off with the vibration on, the
vibration will come on as soon as the machine is restarted. Therefore,
for easier starting and to keep the surface finish smooth, be ready to
switch vibration off should it come on while cranking the engine.
Note: Vibration will remain on even when the forward/reverse control
is in neutral. When operating on asphalt, to keep the surface finish
smooth, turn vibration off before stopping the roller.
wc_tx000531gb.fm
37
Operation
RD 11 Repair
3.12 Vibration (RD 11AEC)
Vibration is turned ON or OFF by a pushbutton (a) located in the
uppermost portion of the forward/reverse control. Press the
pushbutton to turn vibration on; press it again to turn it off. Vibration
can be turned on while operating in either forward or reverse and will
remain on until it is switched off.
Note: Vibration will always be OFF when the engine is started.
Note: Vibration will remain on even when the forward/reverse control
is in neutral. When operating on asphalt, to keep the surface finish
smooth, turn vibration off before stopping the roller.
Note: Pressing the emergency stop pushbutton will also stop vibration.
After the emergency stop pushbutton has been reset, press
pushbutton (a) to restart vibration.
3.13 Watering System
The watering system is controlled by two valves, one for each drum.
The valve handles (a) are located to the right of the operator. Rotate
the valve handles to control the amount of water being applied to the
drum.
a
wc_gr000118
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38
RD 11 Repair
Operation
3.14 Operator Presence System
All revisions of RD AEC models, revisions 143 and above of RD 11V
models, and revisions 142 and above of RD 11A models are equipped
with an “operator presence system”. This system is part of the driver's
seat and senses the weight of an operator in the seat. If the operator
is not sitting in the driver's seat, the roller will NOT drive, and the
exciter will NOT vibrate. If the operator leaves the driver's seat, the
roller will stop moving and vibrating. When the operator sits down
again, the forward/reverse lever must be placed in the neutral position
before the roller can be driven or the vibration can be started.
A one-half second delay keeps the system from tripping when the roller
passes over a bump.
On RD 11AEC models, the seat can be adjusted as follows:
•
Knob (a) for adjusting the seat tension to the driver's weight.
•
Lever (b) for adjusting the distance from the seat to the driving
controls.
Note: Do not change position of the driver’s seat while the machine is
moving. The “OPERATOR PRESENCE” safety device will prevent all
machine movements if an operator is not seated.
Always wear the seat belt provided when operating the roller.
WARNING
wc_tx000531gb.fm
39
Operation
wc_tx000531gb.fm
RD 11 Repair
40
RD 11 Repair
4.
Maintenance
Maintenance
4.1
Engine Maintenance
The chart below lists basic engine maintenance. Refer to the engine
manufacturer’s Operation Manual for additional information on engine
maintenance.
Honda
Daily
before
starting
Check fuel level.

Check engine oil level.

Inspect air filter. Replace as needed.

After
first
20 hrs.
Every
50
hrs.
Every
100
hrs.
Every
300
hrs.
*
Change engine oil and filter.

Clean air cleaner.

*
Check and clean spark plug.

Clean sediment cup.

Check and adjust idle speed.

**
Check and adjust valve clearances.

**
Replace fuel filter.

**
* Service more frequently in dusty conditions.
**These items should be serviced by an authorized Honda dealer, unless the owner has the proper
tools and is mechanically proficient. See Honda shop manual.
Vanguard
Daily
before
starting
Check fuel level.

Check engine oil level.

Change engine oil.
After
first
8 hrs.
Every
50
hrs.

Change oil filter.
Every
100
hrs.
Every
300
hrs.

Clean air cleaner.

Check and clean spark plug.

Check and adjust valve clearances.

Replace fuel filter.

wc_tx000530gb.fm
41
Maintenance
4.2
RD 11 Repair
Maintenance Schedule
RD 11 /...
Daily
before
starting
Check external hardware.

Check level of hydraulic fluid.

Every
100
hrs.
Grease articulated joint.

Grease rear drum drive bearing.

Grease exciter bearing.

Every
600
hrs.
Change hydraulic system return line filter.

Check and adjust scraper bars.

Clean battery terminals.

Every
1200
hrs.
Change hydraulic oil.

Periodically:
•
Check operation of the parking brake, making sure it engages.
•
Check for leaks around hydraulic hoses and connections.
•
Clean engine exterior, cooling fins, and blower housing.
•
Check electrical wiring and connections.
•
Check operation of the neutral safety switch.
New machines:
•
Change the engine oil per engine schedule.
•
Replace the hydraulic system return line filter after the first month
or 100 hours of operation.
All machines:
•
wc_tx000530gb.fm
Increase air cleaner/filter inspections and cleaning under dusty
conditions.
42
RD 11 Repair
4.3
Maintenance
Lifting Machine
Lock the front and rear machine halves together using the lockarm (a)
at the articulation joint. Place slings or chains through each lifting eye
(b) on the machine (4 places). Use four slings or chains with a
minimum length of 2 meters (6 feet) on each leg connected to a central
lifting device, OR two slings or chains with a minimum length of 4
meters (12 feet), one connecting the front lifting eyes and one
connecting the rear lifting eyes, then brought together over the crane
hook. Ensure that all lifting devices have sufficient weight-bearing
capacity.
To avoid being pinched by the machine halves, set the lockarm before
lifting the machine for transport or repairs!
WARNING
NOTICE: Never use anything but the lifting eyes provided to lift the
machine, as severe damage to the machine can result.
b
b
a
wc_gr000205
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43
Maintenance
4.4
RD 11 Repair
Transporting Machine
When transporting the machine place blocks in front of and behind
each drum and use the front and rear tie-down lugs (a) provided to
securely fasten the machine to the trailer (2 places).
NOTICE: Never use anything but the tiedown lugs provided to tie down
the machine, as severe damage to the machine can result.
a
wc_gr000204
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44
RD 11 Repair
4.5
Maintenance
Towing (RD 11A / RD 11V)
The drive circuit is equipped with a towing valve to allow oil to bypass
the drive motors and let the roller freewheel for towing.
The towing valve should be used in emergency situations where the
machine has become bogged down in loose or muddy soil, or cannot
be driven due to an engine or hydraulic system failure.
To open the bypass, shut the engine off and loosen the jam nut (b) one
full turn counterclockwise. Then turn the valve (a) one full turn
counterclockwise.
When resuming machine operation, make sure the bypass is closed
tightly. Turn the valve (b) clockwise until fully seated. Then secure the
valve with the jam nut (a). If the valve is not closed completely, the
drive system may not respond or may perform sluggishly.
WARNING
With the tow valve open, the drive circuit has no braking action and the
machine will roll freely. Close the valve immediately after a towing
operation is complete to prevent the machine from rolling
unexpectedly.
NOTICE: Do not tow the roller long distances or at speeds greater than
3–5 km/h (2–3 mph). Damage to the drive motors may occur.
a
b
wc_gr000202
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45
Maintenance
4.6
RD 11 Repair
Towing (RD 11AEC)
The drive circuit is equipped with a brake release system to manually
release the brakes and allow the roller to freewheel for towing.
The brake release system should be used in emergency situations
where the machine has become bogged down in loose or muddy soil,
or cannot be driven due to an engine or hydraulic system failure.
To release the brakes:
•
Shut off the engine.
•
Push down on the brake override valve (a).
•
Stroke the brake release pump (b) just until firm resistance is felt.
Note: It will take approximately 25 strokes of the pump to release the
brakes.
WARNING
When resuming machine operation, pull up on the brake override valve
(a).
NOTICE: Do not tow the roller long distances or at speeds greater
than 3–5 km/h (2–3 mph). Damage to the drive motors may occur.
Note: The brake release system will automatically reset when the
engine is started.
With the brakes released, the drive circuit has no braking action and
the machine will roll freely. Pull up on the brake override valve
immediately after the towing operation is complete to prevent the
machine from rolling unexpectedly.
b
a
wc_gr000203
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46
RD 11 Repair
4.7
Maintenance
Engine Oil Drain
The engine oil drain (a) has been routed to the outside of the front half
of the RD 11. This is to make draining easier and to help keep the
engine compartment clean.
a
wc_gr000164
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47
Maintenance
4.8
RD 11 Repair
Engine Oil
See Graphic: wc_gr000173 (RD 11A / RD 11AEC)
See Graphic: wc_gr000172 (RD 11V)
Drain the oil while the engine is still warm. To drain the oil:
4.8.1
Remove the filler cap (a), drain screw, and washer. Drain the oil into a
suitable container.
Note: In the interests of environmental protection, place a plastic sheet
and a container under the machine to collect any liquid which drains
off. Dispose of this liquid in accordance with environmental protection
legislation.
4.8.2
Re-insert the drain screw and washer and tighten the screw securely.
4.8.3
Fill the engine with the recommended oil to the upper limit mark on the
dipstick (b). See Technical Data for correct oil type and amount.
Burn hazard! Care must be taken when draining hot engine oil. Hot oil
can burn!
WARNING
a
a
b
b
FULL
wc_gr000173
ADD
wc_gr000172
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48
RD 11 Repair
4.9
Maintenance
Oil Filter (Honda)
Replace the oil filter after every 200 hours of operation.
To change the filter:
4.9.1
Drain the engine oil. See Engine Oil. Remove the used filter.
4.9.2
Before installing a new filter, lightly oil the filter gasket (a) with fresh,
clean engine oil. Screw the filter on by hand until gasket makes
contact; then tighten an additional 7/8 turn.
4.9.3
Fill the engine with the recommended oil. See Engine Oil.
4.9.4
Start and run the engine to check for leaks. Stop the engine. Recheck
the oil level and add oil if required. Refer to the engine owner’s manual.
a
a
wc_gr000174
wc_gr000165
4.10 Oil Filter (Vanguard)
Replace the oil filter after every 100 hours of operation.
4.10.1
Drain the engine oil and replace it with fresh oil before removing the
used oil filter. See Technical Data for oil quantity and type.
legislation.
wc_tx000530gb.fm
4.10.2
Remove the used filter before installing a new filter, lightly oil the filter
gasket with fresh, clean engine oil.
4.10.3
Screw the filter (a) on by hand until the gasket makes contact, then
tighten an additional 1/2 to 3/4 turn.
4.10.4
Start and run the engine to check for leaks. Stop the engine. Recheck
the oil level and add oil if required. See Engine Lubrication.
49
Maintenance
RD 11 Repair
4.11 Air Cleaner (Honda)
The Honda engine is equipped with a dual-element air cleaner. To
service:
4.11.1 Remove the wing bolt (a) and cover (b).
4.11.2 Remove the 5 mm screws (e) from the cover and remove paper
element (d) from the cover.
4.11.3 To clean the paper element, tap it lightly on a flat surface. Replace the
paper element if it is damaged or heavily soiled. Reassemble the paper
element to the cover. Include the gaskets (c, f).
4.11.4 To clean the foam element (g), wash it in liquid detergent and water.
Squeeze it dry in a clean cloth. Once dry, saturate the foam element in
engine oil, then squeeze out the excess. Replace the foam element if
it is damaged or heavily soiled. Reinstall the foam element and
reassemble the air cleaner.
Note: Do not use petroleum solvents to clean the precleaner or the
cartridge. Petroleum-type solvents will damage them. Do not use
pressurized air to clean the cartridge. Pressurized air can also damage
the cartridge.
a
b
c
f
d
e
g
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50
RD 11 Repair
Maintenance
4.12 Air Cleaner (Vanguard)
To service air cleaner:
4.12.1
Remove the cover (a), knob (b), and retaining plate (c).
4.12.2
Remove the foam precleaner (e) from the filter cartridge (d).
4.12.3
Wash the precleaner in liquid detergent and water. Squeeze it dry in a
clean cloth. Saturate the precleaner in engine oil; squeeze out excess
oil. Replace the precleaner if it is damaged or heavily soiled.
4.12.4
To clean the cartridge, remove it and tap it lightly on a flat surface.
Replace the cartridge if it is damaged or heavily soiled.
Note: Do not use petroleum solvents to clean the precleaner or
cartridge. Petroleum-type solvents will damage them. Do not use
pressurized air to clean the cartridge. Pressurized air can also damage
the cartridge.
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51
Maintenance
RD 11 Repair
4.13 Hydraulic System Cleanliness
Keeping the hydraulic oil clean is a vital factor affecting the service life
of hydraulic components. Oil in hydraulic systems is used not only to
transfer power, but also to lubricate the hydraulic components used in
the system. Keeping the hydraulic system clean will help avoid costly
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 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 adding
oil, clean the hydraulic tank filler cap and surrounding area before
removing it.
AVOID opening the pumps, motors, or hose connections unless
absolutely necessary.
PLUG or cap all open hydraulic connections while servicing the
system.
CLEAN and cover the containers, funnels, and spouts used to store
and transfer the hydraulic oil.
CHANGE the hydraulic filters and oils at the recommended service
intervals.
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RD 11 Repair
Maintenance
4.14 Hydraulic Oil Requirements
Wacker recommends the use of a good petroleum-based, anti-wear
hydraulic oil in the hydraulic system of this equipment. Good anti-wear
hydraulic oils contain special additives to reduce oxidation, prevent
foaming, and provide for good water separation.
When selecting hydraulic oil for your machine, be sure to specify antiwear properties. Most hydraulic oil suppliers will provide assistance in
finding 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 does
not indicate the type of oil (engine, hydraulic, gear, etc.).
When selecting a hydraulic oil be sure it matches the specified SAE
viscosity rating and is intended to be used as a hydraulic oil. See
Technical Data—Lubrication.
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53
Maintenance
RD 11 Repair
4.15 Hydraulic Oil Level
A hydraulic oil level sightglass (a) is located near the bottom left side
of the machine below the engine compartment.
Check that the hydraulic oil level is visible in the sightglass. If it is not,
add oil through the filler port (b) inside the engine compartment. Use
only clean hydraulic oil.
Thoroughly clean the top of the filler cap before removing it from the
tank. Care should be taken to prevent smaller dirt particles from
entering the system.
If hydraulic oil continually needs to be added, inspect the hoses and
connections for possible leaks.
4.16 Suction Filter
A hydraulic filter (c) is located in the hydraulic tank. This filter will not
normally require service and does not need to be replaced when
changing the hydraulic oil.
e
a
c
d
b
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RD 11 Repair
Maintenance
4.17 Changing Hydraulic Oil & Filter
All oils eventually shear or thin out with use, reducing their lubricating
ability. In addition, heat, oxidation, and contamination may cause the
formation of sludge, gum, or varnish in the system. For these reasons,
it is important to change the hydraulic oil at specified intervals. See
Maintenance Schedule.
4.17.1
Remove the filler cap (b) from the top of the hydraulic tank.
4.17.2
Remove the drain plug (d) and allow the hydraulic fluid to drain.
legislation.
wc_tx000530gb.fm
4.17.3
Unscrew the return line filter (e) and replace the filter cartridge.
4.17.4
Install the drain plug.
4.17.5
Fill the hydraulic tank through the filler port with clean hydraulic fluid.
4.17.6
Bleed the hydraulic system. See Bleeding the Hydraulic System.
55
Maintenance
RD 11 Repair
4.18 Bleeding the Hydraulic System
4.18.1 Fill the hydraulic system with clean hydraulic oil until it is visible in the
sightglass. Do not re-use used hydraulic oil.
4.18.2 Disconnect the line (a) from the drive pump. Fill the pump case with
hydraulic oil through the open connection. Reconnect the line.
4.18.3 Disconnect the spark plug wires to prevent the engine from starting
and crank the engine 5–10 seconds. This will allow oil to fill inlet lines.
4.18.4 Reconnect the spark plug wires and place the forward/reverse control
lever in NEUTRAL. Start the engine and run the machine at idle for 3–
4 minutes.
4.18.5 With the engine still running at idle, move the control slowly back and
forth from forward to reverse for a short time to bleed air trapped in the
drive circuit.
4.18.6 Increase the engine speed to full throttle and operate all controls to
bleed the remaining air from the hydraulic lines.
4.18.7 Check the hydraulic oil level and add oil as required.
Note: If the drive pump chatters or operation is noisy, turn the machine
off and check for air leaks in the inlet line of the charge pump.
a
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RD 11 Repair
Maintenance
4.19 Spark Plug
Clean or replace the spark plug as needed to ensure proper operation.
Refer to the engine owner’s manual.
The muffler becomes very hot during operation and remains hot for a
while after stopping the engine. Do not touch the muffler while it is hot.
WARNING
Note: Refer to the Technical Data for the recommended spark plug
type and the electrode gap setting.
4.19.1
Remove the spark plug and inspect it.
4.19.2
Replace the spark plug if the insulator is cracked or chipped.
4.19.3
Clean the spark plug electrodes with a wire brush.
4.19.4
Set the electrode gap (a).
4.19.5
Tighten the spark plug securely.
NOTICE: A loose spark plug can become very hot and may cause
engine damage.
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Maintenance
RD 11 Repair
4.20 Carburetor (Vanguard)
Note: The air cleaner must be in place and the engine warm when
making adjustments to the carburetor.
To adjust:
4.20.1 With the engine running, place the throttle in the SLOW position and
rotate the carburetor throttle lever against the idle speed screw (a) and
hold it there.
4.20.2 Turn the idle speed screw to obtain 2000 rpm.
4.20.3 While still holding the throttle lever against the idle speed screw, turn
the idle mixture valve (b) midway between limits.
4.20.4 Readjust the idle speed to 1750 rpm and release the carburetor throttle
lever. The engine should accelerate smoothly when throttle is opened.
If it does not, readjust the idle mixture valve slightly counterclockwise.
a
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RD 11 Repair
Maintenance
4.21 Grease Fittings
See Technical Data—Lubrication.
Articulated Joint:
The articulated joint is equipped with grease fittings (a) for lubrication.
To avoid being pinched by the machine halves, set the lockarm before
greasing the articulating joint!
WARNING
Rear Drum:
The rear drum drive bearing is equipped with a grease fitting (b)
located at the center of the drum behind the right rear drum support.
Exciter:
The exciter is grease lubricated. There are two grease fittings (c), one
on each side of the machine, located behind the front drum supports.
a
a
b
c
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c
59
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Maintenance
RD 11 Repair
4.22 Fuel Filter
4.22.1 Change the in-line fuel filter (a) once per year. Check the fuel lines and
fittings daily for cracks or leaks. Replace as needed.
Gasoline is extremely flammable! Turn the engine off and allow the
engine to cool before replacing the fuel filter.
WARNING
Note: The fuel filter is located under the floor panel of the operating
platform.
a
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RD 11 Repair
Maintenance
4.23 Scraper Bars
Scraper bars, located in front of and behind each drum, are used to
prevent dirt and asphalt from sticking to and accumulating on the drum
surface. These bars must be adjusted periodically as they wear.
To adjust the scraper bar (a), loosen the bolts (b) connecting the
scraper bars to the shockmounts (c) on both sides of the drum. Using
a 9 mm (3/8") drive ratchet extension in the socket (d), rotate the
assembly away from the drum until the bolts are observed to have
rotated approximately 6 mm (1/4") in slots, then tighten the bolts.
Check that the scraper bar has a slight deflection where it contacts the
drum, and readjust as necessary.
Note: A large deflection of the scraper bar indicates excessive preloading of the rubber shockmounts, which will result in premature
scraper wear.
d
c
b
a
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Maintenance
RD 11 Repair
4.24 Parking Brake Adjustment (RD 11A/RD 11V)
The parking brake is located on the rear drive motor drum support and
is used to prevent the roller from moving when the roller is turned off.
Adjust the brake for proper holding force as follows:
4.24.1 Unscrew the brake lever knob (a) until the brake can be applied with
moderate force (approximately 30 lbs.).
4.24.2 Start the roller on level ground and try to travel forward and reverse
with the brake applied. If the roller drives through the brake, stop the
machine, tighten the lever knob one turn and repeat the process.
4.24.3 When the machine no longer moves with the brake applied, stop the
machine, turn the knob one more turn and the brake is properly set.
a
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RD 11 Repair
Maintenance
4.25 Throttle Solenoid Adjustment
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4.25.1
With the engine still operating, set the throttle lever stop screw (c) on
the engine to 3200 rpm.
4.25.2
Shut down the engine and then the turn key to the first position. (Do
not start the engine.) Activate the throttle solenoid. While holding the
throttle lever (b) on the engine to the fully engaged position (as set in
step 2), pull the cable tight through the throttle nut/set screw (d) and
secure the cable. Disengage the solenoid.
4.25.3
Turn the throttle lever stop screw (c) counter-clockwise three turns.
4.25.4
Start the engine and engage the solenoid. Using the 5/16-inch
mounting nuts on the threaded casing end, adjust the top speed to
3200 rpm.
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Maintenance
RD 11 Repair
4.26 Storage
If the unit is to be stored for more than 30 days:
wc_tx000530gb.fm
•
Drain the fuel tank and the water tank. Also drain the rear drum, if
ballast was added.
•
Open the water valves and drain the water from the sprinkling
system.
•
Change the engine oil.
•
Remove the spark plugs and pour approximately 3 ml (1 ounce)
of SAE 30W oil into each engine cylinder through the spark plug
opening.
•
Install the spark plugs. Leave the ignition wires disconnected to
prevent the engine from starting. Crank the engine for one or two
seconds to distribute oil inside engine cylinders. Connect the ignition wires.
•
Clean the entire roller and engine compartment.
•
Remove any dirt from the cooling fins on the engine cylinders and
on the blower housing.
•
Set the lockarm to secure the roller halves together.
•
Remove the battery from the machine and charge it periodically.
•
Cover the entire machine and place it in a dry, protected area.
64
RD 11 Repair
Maintenance
Notes:
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65
5.
RD 11 Repair
5.1
Starting System Component Locations
3
10
12
13
14
11
8
7
1, 18
4
9
6
16
5
17
15
2
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RD 11 Repair
Ref.
Description
Ref.
Description
1
20 Amp fuse
10
Magneto kill
2
Battery
11
Exciter solenoid
3
Key switch
12
Vibration switch
4
Starter relay
13
Forward/reverse control
5
Throttle solenoid
14
Neutral safety switch
6
Starter
15
Backup alarm (optional)
7
Regulator/rectifier
16
Throttle switch
8
Alternator
17
12VDC relay
9
Anti-backfire
18
20 Amp circuit breaker
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5.2
RD 11 Repair
Troubleshooting Flowcharts
The troubleshooting flowcharts are designed to take you through the
process of determining the source of a problem with engine starting or
machine operation. Many of the tests involve live voltages and
therefore should only be attempted by qualified personnel. Detailed
procedures for carrying out the tests are included in this manual. All
highlighted text within the flowcharts have matching sections in this
manual.
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RD 11 Repair
5.3
Engine Does Not Crank—Flowchart 1A
Engine does not Crank
Checking battery
Check condition of the battery.
Is the battery
OK?
No
Recharge or replace
the battery.
* Battery voltage
approximately 12V
Yes
Checking 20A Fuse
Replace the
20A fuse.
Check the 20A fuse.
Is 20A fuse
OK?
No
Yes
Checking neutral switch
Check the neutral switch.
Checking key switch
Is
the neutral switch
OK?
Check the key switch.
Is the key switch
OK?
Yes
No
Replace the
neutral switch.
No
Replace the
starter relay.
Yes
Checking starter relay
No
Check the function of
the starter relay.
Replace the key switch.
Is the starter relay
functioning?
Yes
Checking power to starter solenoid
Check power to the starter solenoid.
See
engine manufacturer’s
repair manual.
Yes
Is there
power (12V*) to the starter
solenoid?
No
Replace the
starter relay.
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5.4
RD 11 Repair
Checking Battery
WARNING
Explosion hazard. Batteries can emit explosive hydrogen gas. Keep all
sparks and flames away from the battery. Do not short-circuit battery
posts. Do not touch the machine frame or the negative terminal of the
battery when working on the positive terminal.
Battery fluid is poisonous and corrosive. In the event of ingestion or
contact with skin or eyes seek medical attention immediately.
WARNING
Dispose of dead batteries in accordance with local environmental
regulations.
To disconnect the battery:
5.4.1
Stop the machine and shut down the engine.
5.4.2
Place all electrical switches in the OFF position.
5.4.3
Disconnect the negative battery cable from the battery.
5.4.4
Disconnect the positive battery cable from the battery.
To connect the battery:
1
5.4.5
Connect the positive battery cable to the battery.
5.4.6
Connect the negative battery cable to the battery.
2
3
4
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RD 11 Repair
Inspect the battery periodically. Keep battery terminals clean and
connections tight.
When necessary, tighten the cables and grease the cable clamps with
petroleum jelly.
Maintain the battery at full charge to improve cold weather starting.
Dispose of dead batteries in accordance with local environmental
regulations.
NOTICE: Observe the following to prevent serious damage to the
machine’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.
•
If the machine has a dead battery, either replace the battery with
a fully charged battery or charge the battery using an appropriate
battery charger.
Test the battery’s voltage by measuring across its terminals with a
voltmeter or multimeter. An adequately charged battery will measure
11–13V.
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5.5
RD 11 Repair
Checking 20A Fuses
There are two 20A fuses (a and b) in the electric circuits of the RD 11.
One of the 20A fuses feeds power to the keyswitch. The other feeds
power to the voltage regulator. Both fuses are located within the
engine compartment and housed within a covered fuse holder (c). On
older model machines the fuses (d and e) are built into the wiring
harness and are found near the starter relay.
To check the fuses:
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5.5.1
Open the engine compartment.
5.5.2
If necessary, cut the wire tie securing the cover to the fuse holder and
then remove the cover.
5.5.3
Pull the fuses from the fuse holder.
5.5.4
Replace the fuse(s) if it is blown. Replace with a fuse of equal rating
only.
5.5.5
Secure the fuse cover with a new wire tie.
72
RD 11 Repair
c
b
a
d
e
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5.6
RD 11 Repair
Checking Keyswitch
It is unlikely that the keyswitch will fail; however, if you feel the
keyswitch is malfunctioning, carry out the following procedures.
Note: These procedures assume that the 20A fuse (feeding power to
the key switch) and the battery are both OK:
The keyswitch feeds power to two circuits depending on its position. In
the START position, power is fed to the starter motor solenoid via the
neutral safety switch and the starter relay. In the ON position, power is
fed to the anti-afterfire solenoid, the throttle switch, the vibration
switch, and the optional horn. When testing the key switch, both the
START position and the ON position will need to be tested. When the
key switch is in the OFF position, the engine’s magneto is shorted to
ground and no spark across the spark plug will occur. If the magneto
kill wire is unintentionally shorted to ground, the engine will not start.
Therefore, the OFF position should also be checked.
To check the ON position:
5.6.1
Place the key switch in the ON position. Measure the voltage between
the tan wire at the anti-afterfire solenoid and ground.
•
If 12VDC (battery voltage approximately 12V) is measured, the
ON position is functioning.
•
If 12VDC is not measured, go to step 3.
To check the START position:
5.6.2
Place the control lever in the neutral position. Then, place the key
switch in the START position. Measure the voltage between terminal
CP of the starter relay and ground.
•
START position is functioning. Problems with engine starting are
most likely to be within the starter motor. See the engine
manufacturer’s repair manual.
•
If 12VDC is not measured, continue.
5.6.3
Remove the control console (2) from the machine. Then, remove the
key switch (1) from the control console and disconnect the connector
plug (3).
5.6.4
Check the continuity between key switch terminals B and L when the
key switch is in the ON position.
5.6.5
Check the continuity between key switch terminals B and S when the
key switch is in the START position.
5.6.6
If the key switch fails either of the above continuity tests, replace it.
To check the OFF position:
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74
RD 11 Repair
5.6.7
Place the keyswitch in the OFF position and check the continuity
between terminals G and M. When checking the OFF position, also
check the connection and continuity of the magneto kill wire. Repair or
replace the wire as needed.
1
S
3
L
G
M
B
2
RD 11V
& RD 11A
a
b
RD 11 AEC
a
d
b
50 15
30
S L
e
75
G
B M
c
c
d
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Ref.
Description
Ref.
Description
a
Start
d
Battery 12VDC
b
On
e
Ground
c
Stop (magneto kill)
-
---
Switch position
Continuity across terminals
Voltage 12VDC
OFF
G-M
B
ON
B-L
L
START
B-S
S*
* The forward/reverse control must be in neutral
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75
5.7
RD 11 Repair
Checking Neutral Switch
The forward/reverse control is equipped with a neutral safety switch (a)
to prevent the engine from being started unless the forward/reverse
control lever (b) is positioned in neutral.
This switch is connected to the starter relay. When the forward/reverse
control is in neutral, the switch is closed, allowing the starter relay to
be energized and complete the circuit from the battery through the key
switch to the starter motor. If the forward/reverse control lever is shifted
away from neutral, the neutral switch is open and the starter relay
cannot be energized.
To check the neutral switch:
5.7.1
Remove the seat and seat plate to access the neutral switch.
5.7.2
Disconnect the wiring harness (c) from the wire connector.
5.7.3
Use an ohmmeter and check for continuity across the white and green
wires with the forward/reverse control lever in neutral.
5.7.4
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•
If no continuity exists, replace the switch.
•
If continuity does exist, continue.
With the ohmmeter still connected to the white and green wires, move
the control lever from the neutral position. Doing so should open the
connection between the wires.
•
If the connection opens (there ceases to be continuity), the
neutral switch is functioning.
•
If the connection remains closed (wires maintain continuity), the
neutral switch is malfunctioning; replace it.
76
RD 11 Repair
b
c
a
A
A
B
B
C
C
D
D
E
E
F
F
c
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5.8
RD 11 Repair
Checking Starter Relay
5.8.1
The starter relay receives power (battery voltage approximately
12VDC) in two places: 1) to its coil (labeled “CP” on the schematic);
and 2) to the to-be-switched terminal (labeled “SI” on the schematic).
When the relay’s coil receives power it energizes, the relay’s contacts
close, and power is switched to terminal SO and to the starter motor
solenoid through the pink wire. To check the function of the starter
relay, carry out the following procedures.
Note: These procedures require that the neutral switch be functioning
properly and that the connection between the battery and terminal SI
of the starter relay be secure.
Note: The starter relay coil on newer model machines is grounded
through the mounting bracket when mounted to a common ground.
Thus, there is no wire connected to terminal CG.
5.8.2
Place the control lever in the neutral position and place the start switch
in the START position.
NOTICE: When measuring voltages, do not energize the relay longer
than 15–20 seconds at a time or the coil may overheat.
5.8.3
Measure the voltage between terminal CP of the starter relay and
ground.
5.8.4
wc_tx000529gb.fm
•
If 12VDC is not measured, check the continuity of the wire
between the neutral switch and terminal CP of the starter relay.
Repair or replace the wire as needed.
•
If 12VDC is measured, continue.
Measure the voltage between terminal SO of the starter relay and
ground.
•
If 12VDC is not measured, the starter relay is malfunctioning.
Replace the starter relay.
•
If 12VDC is measured, the starter relay is functioning.
78
RD 11 Repair
New machines
Neuere Maschinen
Máquinas recientes
Machines récentes
Older machines
Ältere Maschinen
Máquinas antiguas
Anciennes machines
SO
SO
SI
CP
SI
CG
CP
CG
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5.9
RD 11 Repair
Checking Power to Starter Solenoid (Honda engines only)
The starter solenoid mounted to the starter motor receives power from
the starter relay via the red wire. To check the power to the starter
solenoid, carry out the following procedure:
5.9.1
Place the key switch in the START position.
5.9.2
Measure the voltage between the starter solenoid at the red wire (a)
and ground.
•
If 12VDC (battery voltage approximately 12V) is not measured,
check the continuity of the red wire. Repair or replace the red
wire as needed.
•
If 12VDC is measured, there is a problem with the starter
solenoid or starter motor. See the engine manufacturer’s repair
manual.
a
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RD 11 Repair
5.10 Engine Cranks but Does Not Start—Flowchart 2A
Engine Cranks but Does Not Start
Checking fuel system
Check condition of:
• Fuel in tank
• Fuel lines
• Fuel filter
Is
the fuel system
OK?
No
Replace fuel, fuel
lines, and fuel filter
as needed.
Yes
Check the condition
of the air filter.
Is the air filter
OK?
Yes
No
Check condition of the
spark plug(s).
Replace the
spark plug(s).
No
Replace the air filter.
Is
the spark plug
OK?
Yes
Checking seat switch
Check function of seat switch.
Checking anti-afterfire
solenoid
Yes
Check condition of the
anti-backfire solenoid.
Is the
anti-afterfire solenoid
OK?
Is the
seat switch
OK?
No
No
Replace the antiafterfire solenoid.
Yes
Replace the
seat switch.
See the engine
manufacturer’s service
manual for ignition
system service.
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RD 11 Repair
5.11 Checking Fuel System
Gasoline is extremely flammable! Turn the engine off and allow the
engine to cool before replacing the fuel filter.
WARNING
If a fuel system problem is suspected, check the following:
•
The condition of the fuel in the tank. If the age of the fuel in the
tank is unknown, drain the tank and fill the tank with fresh fuel.
•
The condition of the fuel filter. To access the fuel filter (b),
remove the screws which secure the floor panel (a) and remove
the floor panel. Replace the fuel filter according to the periodic
maintenance schedule.
•
The condition of the fuel hoses. Remove any blockages and
relieve any spots where the fuel hoses may be pinched. Repair or
replace the fuel hoses as needed.
a
b
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RD 11 Repair
5.12 Checking Seat Switch
The seat switch is a normally open switch. It is attached directly to the
underside of the seat. To check the seat switch, carry out the following
procedure:
5.12.1
Remove the screws that secure the seat mounting plate to the
machine and flip the seat and the seat mounting plate over to reveal
the seat switch.
5.12.2
Mark, then disconnect the wiring (a) to the seat switch.
5.12.3
Remove the seat switch (b) from the seat.
5.12.4
Check continuity across the terminals of the seat switch. When the
seat switch is depressed, there should be continuity. When the seat
switch is not depressed, there should be no continuity. If the seat
switch does not perform accordingly, replace it.
b
a
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RD 11 Repair
5.13 Checking Anti-Afterfire Solenoid
The engine carburetor is equipped with an anti-afterfire system. The
system contains a solenoid valve (a) controlled by the ignition switch.
When the ignition switch is in the OFF position, the solenoid valve is
de-energized and stops the fuel flow through the fixed high-speed jet
(b). When the switch is turned to the ON or START position, the
solenoid is energized, moving the plunger away from the fuel jet,
allowing normal fuel flow.
The solenoid is operating correctly if a “click” is heard when the ignition
switch is turned on and off. If no click is heard, the solenoid is not
operating and the engine will not start.
To test the solenoid of the anti-afterfire system, carry out the following
procedure:
5.13.1 Disconnect the solenoid from the tan wire of the engine harness. The
wire (c) from the solenoid is red on Vanguard engines, black and
yellow on Honda engines.
5.13.2 Connect the solenoid wire to the positive terminal of a 9V transistor
battery.
5.13.3 Connect the negative terminal of the battery to the body of the solenoid
or to a common ground. Listen for a click from the solenoid just as the
battery is connected. If a click is heard, the solenoid is functioning. If a
click is not heard, replace the solenoid.
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RD 11 Repair
a
c
b
c
9V
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Notes
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RD 11 Repair
RD 11 Repair
6.
Hydraulic System
Hydraulic System
6.1
Hydraulic System Precautions
WARNING
6.2
Escaping hydraulic oil under pressure, even a pinhole size leak, can
penetrate body tissue, causing serious injury, and possible death. If oil
is injected into your skin, you must be treated immediately by a doctor
familiar with this kind of injury.
•
Always use a board or cardboard when checking for hydraulic oil
leaks.
•
Relieve the hydraulic pressure before working on the machine.
•
Personal injury can result from contact with hot hydraulic oil.
•
Use extreme care and wear appropriate clothing, such as gloves
and safety glasses, when working with hot hydraulic oil.
Hydraulic System Service Basics
Many hydraulic system problems may be rectified by basic service and
maintenance tasks. Before attempting in-depth service procedures,
carry out the basic hydraulic service procedures listed below.
wc_tx000527gb.fm
•
Top off the hydraulic oil supply with the correct type and grade of
oil.
•
Clean and tighten all the hydraulic fittings. Check the hoses for
holes and/or leaks. Air within the hydraulic system can greatly
affect machine performance.
•
Check/change the hydraulic filter. Particles and debris in the filter
are signs of failing component(s). Change the hydraulic oil and
clean all components if there is debris found in the filter. Locate
and replace the failing component(s) before operating the
machine.
•
Carry out hydraulic tests with the machine/hydraulic oil warm.
Start and operate the machine at high idle for several minutes
before conducting troubleshooting procedures. The hydraulic oil
should be between 37.4–48.6°C (100–120°F).
87
Hydraulic System
6.3
RD 11 Repair
Hydraulic Schematic—RD 11A and RD 11V (parallel drive)
1
2
138 bar (2000 psi)
P
1
3
G1
4
2
19
3
48 bar
(700 psi)
6
L
5
P
T
R
18
17
200 bar
(2900 psi)
12 bar
(174 psi)
21
G2
15
13
8
14
16
7
G3
12
10
10 MICRON
T
11
20
22
9
23
1.7 bar
(25 psi)
1 bar
(14.5 psi)
wc_gr003014
wc_tx000527gb.fm
88
RD 11 Repair
6.4
Hydraulic System
Hydraulic Components—RD 11A and RD 11V (parallel drive)
Ref.
Description
Ref.
Description
1
Exciter relief valve
13
Tow valve
2
Exciter manifold
14
Charge pump
3
Exciter control valve (solenoid)
15
Drive pump
4
Exciter motor
16
Exciter pump
5
Steering cylinder
17
Charge-pressure relief valve
6
Steering valve
18
Drive pump, internal relief valves
7
Rear drive motor
19
Steering relief valve
8
Front drive motor
20
Return manifold
9
Filter bypass
21
Drive manifold
10
Return-line filter assembly
22
Tank
11
Suction filter
23
Backpressure valve
12
Pump assembly
wc_tx000527gb.fm
-
89
---
Hydraulic System
6.5
RD 11 Repair
Hydraulic Diagram—RD 11A and RD 11V (parallel drive)
11
9
8
1
12
6
5
4
3
2
7
Pressure / Druck / Presión / Pression
Return / Rückfluss / Retorno / Retour
wc_gr003015
wc_tx000527gb.fm
90
RD 11 Repair
6.6
Hydraulic System
Hydraulic Components—RD 11A and RD 11V (parallel drive)
Ref.
Description
Ref.
Description
1
Exciter manifold
Including:
Exciter solenoid valve
7
Rear drive motor
2
Return manifold
8
Drive control manifold
Including:
Tow valve
3
Steering valve
Including:
9
Front drive motor
4
Steering cylinder
-
---
5
Suction filter
11
Return line filter assembly
Including:
10 Micron filter
Filter bypass
Backpressure valve
6
Pump assembly
Including:
Drive pump
Exciter pump
Charge pump
Drive pump relief valves
Charge pressure relief valve
12
Exciter motor
wc_tx000527gb.fm
91
Hydraulic System
6.7
RD 11 Repair
Hydraulic Piping—RD 11A, RD 11V (parallel drive)
1
2
12
11
3
5
4
6
7
8
9
wc_gr003016
wc_tx000527gb.fm
92
RD 11 Repair
6.8
Hydraulic System
Hydraulic Piping Components—RD 11A, RD 11V (parallel drive)
Ref.
Description
Ref.
Description
1
Exciter manifold
Including:
7
Rear drive motor
2
Return manifold
8
Including:
Tow valve
3
Steering valve
Including:
9
Front drive motor
4
Steering cylinder
-
---
5
Suction filter
11
Including:
10 Micron filter
Filter bypass
Backpressure valve
6
Pump assembly
Including:
Drive pump
Exciter pump
Charge pump
12
Exciter motor
wc_tx000527gb.fm
93
Hydraulic System
6.9
RD 11 Repair
Hydraulic Schematic—RD 11A, RD 11V (revisions 103–134)
1
2
138 bar (2000 psi)
P
1
3
G1
4
2
19
3
48 bar
(700 psi)
6
L
5
P
T
R
18
17
200 bar
(2900 psi)
12 bar
(174 psi)
21
G2
8
7
15
13
14
16
G3
12
10
10 MICRON
T
11
20
22
9
23
1.7 bar
(25 psi)
1 bar
(14.5 psi)
wc_gr003013
wc_tx000527gb.fm
94
RD 11 Repair
Hydraulic System
6.10 Hydraulic Components—RD 11A, RD 11V (revisions 103–134)
Ref.
Description
Ref.
Description
1
13
Tow valve
2
Exciter manifold
14
Charge pump
3
15
Drive pump
4
Exciter motor
16
Exciter pump
5
Steering cylinder
17
6
Steering valve
18
7
Rear drive motor
19
8
Front drive motor
20
Return manifold
9
Filter bypass
21
Drive manifold
10
22
Tank
11
Suction filter
23
Backpressure valve
12
Pump assembly
wc_tx000527gb.fm
-
95
---
Hydraulic System
RD 11 Repair
6.11 Hydraulic Diagram—RD 11A, RD 11V (revisions 103–134)
11
9
8
1
12
6
5
4
3
2
7
wc_tx000527gb.fm
96
wc_gr003017
RD 11 Repair
Hydraulic System
6.12 Hydraulic Components—RD 11A, RD 11V (revisions 103–134)
Ref.
Description
Ref.
Description
1
Exciter manifold
Including:
7
Rear drive motor
2
Return manifold
8
Including:
Tow valve
3
Steering valve
Including:
9
Front drive motor
4
Steering cylinder
-
---
5
Suction filter
11
Including:
10 Micron filter
Filter bypass
Backpressure valve
6
Pump assembly
Including:
Drive pump
Exciter pump
Charge pump
12
Exciter motor
wc_tx000527gb.fm
97
Hydraulic System
RD 11 Repair
6.13 Hydraulic Piping—RD 11A, RD 11V (revisions 103–134)
1
2
12
11
3
5
4
6
7
8
9
wc_gr003012
wc_tx000527gb.fm
98
RD 11 Repair
Hydraulic System
6.14 Hydraulic Piping Components—RD 11A, RD 11V (revisions
103–134)
Ref.
Description
Ref.
Description
1
Exciter manifold
Including:
7
Rear drive motor
2
Return manifold
8
Including:
Tow valve
3
Steering valve
Including:
9
Front drive motor
4
Steering cylinder
-
---
5
Suction filter
11
Including:
10 Micron filter
Filter bypass
Backpressure valve
6
Pump assembly
Including:
Drive pump
Exciter pump
Charge pump
12
Exciter motor
wc_tx000527gb.fm
99
Hydraulic System
RD 11 Repair
6.15 Hydraulic Schematic—RD 11A, RD 11V (revisions > 134)
1
2
138 bar
(2000 psi)
P
1
G1
4
3
2
19
3
48 bar
(700 psi)
6
L
5
P
T
R
18
17
200 bar
(2900 psi)
12 bar
(174 psi)
21
G2
8
7
15
13
14
16
G3
12
10
10 MICRON
T
11
22
20
9
1,7 bar
(25 psi)
wc_gr002985
wc_tx000527gb.fm
100
RD 11 Repair
Hydraulic System
6.16 Hydraulic Components—RD 11A, RD 11V (revisions > 134)
Ref.
Description
Ref.
Description
1
12
Pump assembly
2
Exciter manifold
13
Tow valve
3
14
Charge pump
4
Exciter motor
15
Drive pump
5
Steering cylinder
16
Exciter pump
6
Steering valve
17
7
Rear drive motor
18
8
Front drive motor
19
9
Filter bypass
20
Return manifold
10
21
Drive manifold
11
Suction filter
22
Tank
wc_tx000527gb.fm
101
Hydraulic System
RD 11 Repair
6.17 Hydraulic Diagram—RD 11A, RD 11V (revisions > 134)
11
9
8
1
12
6
5
4
3
2
7
wc_tx000527gb.fm
102
wc_gr003018
RD 11 Repair
Hydraulic System
6.18 Hydraulic Components—RD 11A, RD 11V (revisions >134)
Ref.
Description
Ref.
Description
1
Exciter manifold
Including:
7
Rear drive motor
2
Return manifold
8
Including:
Tow valve
3
Steering valve
Including:
9
Front drive motor
4
Steering cylinder
-
---
5
Suction filter
11
Including:
10 Micron filter with bypass
6
Pump assembly
Including:
Drive pump
Exciter pump
Charge pump
12
Exciter motor
wc_tx000527gb.fm
103
Hydraulic System
RD 11 Repair
6.19 Hydraulic Piping—RD 11A, RD 11V (revisions > 134)
1
2
12
11
3
5
4
6
7
8
9
wc_gr003011
wc_tx000527gb.fm
104
RD 11 Repair
Hydraulic System
6.20 Hydraulic Piping Components—RD 11A, RD 11V (revisions >
134)
Ref.
Description
Ref.
Description
1
Exciter manifold
Including:
7
Rear drive motor
2
Return manifold
8
Including:
Tow valve
3
Steering valve
Including:
9
Front drive motor
4
Steering cylinder
-
---
5
Suction filter
11
Including:
10 Micron filter with bypass
6
Pump assembly
Including:
Drive pump
Exciter pump
Charge pump
12
Exciter motor
wc_tx000527gb.fm
105
Hydraulic System
RD 11 Repair
6.21 Hydraulic Schematic—RD 11AEC
1
138 bar
(2000 psi)
2
4
3
6
L
5
P
T
18
17
19
200 bar
(2900 psi)
12 bar
(174 psi)
G2
26
48 bar
(700 psi)
F2
21
13
15
24
14
8
7
23
25
22
F1
R1
12
T1
G1
10 Micron
11
27
P1
R2
16
R
P2
T
20
28
1 bar
(14.5 psi)
wc_tx000527gb.fm
10
9
1.7 bar
(25 psi)
106
wc_gr002992
RD 11 Repair
Hydraulic System
6.22 Hydraulic Components—RD 11AEC
Ref.
Description
Ref.
Description
1
15
Drive pump
2
Exciter manifold
16
Exciter pump
3
17
4
Exciter motor
18
Internal drive pump relief valves
5
Steering cylinder
19
6
Steering valve
20
Return manifold
7
Rear drive motor
21
Manual override valve
8
Front drive motor
22
Brake valve (solenoid)
9
Filter bypass
23
Hand pump
10
24
Shuttle valve
11
Suction filter
25
Pressure reducing valve
12
Pump assembly
26
13
Pump shunt valve (solenoid)
27
Brake manifold
14
Charge pump
28
Backpressure valve
wc_tx000527gb.fm
107
Hydraulic System
RD 11 Repair
6.23 Hydraulic Diagram—RD 11AEC
11
10
9
12
8
6
1
5
4
3
2
7
wc_tx000527gb.fm
108
wc_gr003019
RD 11 Repair
Hydraulic System
6.24 Hydraulic Diagram Components—RD 11AEC
Ref.
Description
Ref.
Description
1
Exciter manifold
Including:
7
Rear drive motor
2
Return manifold
8
Including:
Shuttle valve
3
Steering valve
Including:
9
Front drive motor
4
Steering cylinder
10
Brake manifold
Including:
Hand pump
5
Suction filter
11
Including:
10 Micron filter
Filter bypass
Backpressure valve
6
Pump assembly
Including:
Drive pump
Exciter pump
Charge pump
12
Exciter motor
wc_tx000527gb.fm
109
Hydraulic System
RD 11 Repair
6.25 Hydraulic Piping—RD 11AEC
1
2
12
3
5
11
4
6
7
8
10
9
wc_gr002986
wc_tx000527gb.fm
110
RD 11 Repair
Hydraulic System
6.26 Hydraulic Piping Components—RD 11AEC
Ref.
Description
Ref.
Description
1
Exciter manifold
Including:
7
Rear drive motor
2
Return manifold
8
Including:
Shuttle valve
3
Steering valve
Including:
9
Front drive motor
4
Steering cylinder
10
Brake manifold
Including:
Hand pump
5
Suction filter
11
Including:
10 Micron filter
Filter bypass
Backpressure valve
6
Pump assembly
Including:
Drive pump
Exciter pump
Charge pump
12
Exciter motor
wc_tx000527gb.fm
111
Hydraulic System
RD 11 Repair
6.27 General Description
The hydraulic system is powered by two pumps (exciter (a) and drive
(b)) mounted in tandem—connected along their shafts through a solidmounted coupling (c)—and driven directly by the engine crankshaft
through a flex coupling (d). The exciter pump is a fixed displacement
gear-type pump and provides a constant flow of oil to operate both the
vibration and steering circuits. The drive pump is a variable
displacement, axial piston pump and includes an integral charge pump
(e). Flow through the drive pump is controlled by varying its
displacement through the movement of the control lever (f) attached to
the pump’s control shaft. This allows a full range of operating speeds
in both forward and reverse.
All valves and test ports of the system are located in manifold blocks.
There are varying manifold blocks depending on the model. Early RD
11A and RD 11V models (revisions 100–102) include four manifold
blocks: exciter, drive, return-line filter head, and return. Later RD 11A
and RD 11V models (revisions 103–134) include three manifold
blocks: exciter, drive, and return. Model RD 11AEC includes five
manifold blocks: exciter, brake, return-line filter head, drive control,
and return.
The exciter manifold controls flow to both the exciter motor and the
steering valve. The exciter manifold also includes a pressure test port.
The drive manifold (models RD 11A and RD 11V only) includes
pressure test ports for the drive system. It also includes the towing
valve which, when open, allows oil flow to bypass the drive motors.
The return-line filter head manifold contains the back pressure valve
which maintains pressure of 1 bar (14.5 psi) to the inlet side of the
charge pump. This pressure ensures positive flow to the drive pump to
prevent cavitation. Note: On RD 11A and RD 11V models, the back
pressure valve was discontinued after revision 133.
The brake manifold (models RD 11AEC only) contains the brake valve,
the manual override valve, and the hand pump. This manifold and its
valve controls flow to the hydraulic bakes that are integral to the drive
motors on Model RD 11AEC.
The drive control manifold (model RD 11AEC only) contains the drivepump shunt valve, shuttle valve, and pressure reducing valve.
The hydraulic tank is equipped with a strainer at the fill port to trap large
objects or particles which may accidentally fall into the tank while
adding hydraulic fluid. Additional system protection is provided by a
suction filter mounted in-line with the exciter pump inlet.
wc_tx000527gb.fm
112
RD 11 Repair
Hydraulic System
The hydraulic system is protected by a return-line filter which removes
dirt particles down to 10 microns and includes a flow bypass for cold
weather start-up.
d
e
c
f
b
a
wc_gr003059
wc_tx000527gb.fm
113
Hydraulic System
RD 11 Repair
6.28 Drive Circuit—RD 11A and RD 11V
See Graphic: wc_gr002987 and wc_gr003020
The drive system is a closed-loop circuit, consisting of a drive pump
(a), charge pump (b), tow valve (c), relief valves (d), and front (e) and
rear (f) drive motors arranged in parallel or series.
The drive pump is a variable displacement, piston-type pump with an
integral charge pump. Charge pressure is supplied by return flow from
the exciter/steering circuit tapped at the return-line filter head manifold.
On RD 11A and RD 11V revisions 134 and higher, charge pressure is
tapped just after the outlet of the filter head. The charge pressure is
maintained at 14.5 bar (210 psi) through an internal relief valve (g).
Excess charge pump flow is returned to the tank through the return
manifold.
The drive pump is manually activated by the forward/reverse control
lever. When the control lever is shifted forward, oil is directed from the
high-pressure side of the pump to the drive manifold block, and
downstream to both the front and rear drive motors. Return flow from
the motors is directed back through the drive manifold and returns to
the low-pressure side of the drive pump. When operating in reverse,
the high- and low-pressure sides of the drive pump are reversed.
System pressure is limited to 200 bar (2900 psi) by the two relief valves
in the drive pump.
The drive system is equipped with a tow valve. When open, this valve
allows oil to flow directly across the ports of the drive manifold thus
bypassing the drive motors and allowing the roller to freewheel for
towing.
wc_tx000527gb.fm
114
RD 11 Repair
Hydraulic System
g
G2
e
f
d
a
c
b
G3
10 MICRON
T
wc_gr002987
G2
g
d
a
e
f
c
b
G3
10 MICRON
T
wc_gr003020
wc_tx000527gb.fm
115
Hydraulic System
RD 11 Repair
6.29 Drive Circuit—RD 11AEC
The drive system is a closed-loop circuit, consisting of a drive pump
(a), charge pump (b), internal relief valves (c), pump shunt valve (d),
shuttle valve (e), pressure reducing valve (f), brake valve (g), hand
pump (h), manual override valve (n), and front (i) and rear (j) drive
motors arranged in parallel.
The drive pump is a variable displacement, piston-type pump with an
integral charge pump. Charge pressure is supplied by return flow from
the exciter/steering circuit tapped at the return-line filter head manifold.
Charge pressure is maintained between 14.5 bar (210 psi) through an
internal relief valve (k). Excess charge pump flow is returned to the
tank through the return manifold.
The drive pump is manually activated by the forward/reverse control
lever. When the control lever is shifted forward, oil is directed from the
high-pressure side of the pump to the manifold block (port R1), through
the shuttle valve and downstream to both the front and rear drive
motors. Return flow from the motors is directed back through the
manifold (port R2) and returns to the low-pressure side of the drive
pump. Each drive motor includes a case drain.
When operating in reverse, the high- and low-pressure sides of the
drive pump are reversed, with port R2 being the high-pressure side
and port R1 the low-pressure side.
System pressure is limited to 200 bar (2900 psi) by two relief valves (f)
in the drive pump.
The pump shunt valve acts as a tow valve and provides the ability to
tow the machine without having to fight the flow of oil through the drive
pump system.
The shuttle valve provides oil flow to the pressure reducing valve
whether traveling forward or reverse. The pressure reducing valve
provides reduced pressure to disengage the brake. The manual
override valve provides a conduit for flow to the brake. If it becomes
necessary to disengage the brake with the engine shutdown, adequate
hydraulic pressure to disengage the brake can be provided by the
hand pump.
wc_tx000527gb.fm
116
RD 11 Repair
Hydraulic System
G2
P1
k
c
R2
F2
d
a
n
i
j
g
e
b
f
R1
T1
G1
10 Micron
h
F1
P2
T
wc_gr002990
wc_tx000527gb.fm
117
Hydraulic System
RD 11 Repair
6.30 Vibration and Steering—All Models
The vibration and steering system is an open loop, series circuit, driven
by a fixed displacement, gear-type pump (a) (exciter pump). It includes
separate relief valves (b* and c) for vibration and steering, an exciter
control valve (d*) (*integral to exciter manifold block (e)), exciter motor
(f), steering valve (g), and steering cylinder (h).
The exciter pump pulls oil from the tank (w) through the suction filter
(i) and sends it to the exciter manifold block. The vibration circuit is
controlled by the solenoid valve mounted on the exciter manifold block.
This valve is electrically operated by an ON/OFF switch located on the
end of the forward/reverse control lever. Supply oil from the exciter
pump enters the exciter manifold block at port “P” where it is directed
to the exciter control valve. When the ON/OFF switch is in the OFF
position, the exciter control valve is open, allowing oil to pass
downstream to the steering valve without driving the exciter motor.
When the ON/OFF switch is in the ON position, the exciter control
valve closes and directs oil from the exciter pump, out port “1” of the
exciter manifold block to the exciter motor which drives the eccentric
weights in the front drum. Return oil from the motor flows back into the
exciter manifold through port “2” and is directed downstream to the
steering valve. A relief valve (b) connected across the exciter control
valve limits system pressure to 138 bar (2000 psi).
Steering is controlled by a steering valve and cylinder. The steering
wheel is spline-mounted directly to the steering valve. The steering
valve reacts to the motion of the steering wheel to direct fluid to and
from the steering cylinder. Oil returning from the vibration circuit is
directed out port “3” of the exciter manifold block, to port “P” of the
steering valve. If steering is inactive, fluid passes through the steering
valve out port “T”, and back to the return-line filter manifold. or the filter
head. When the steering wheel is turned, the steering valve closes and
directs oil to the appropriate steering line (ports L and R) to extend or
retract the cylinder.
A relief valve is connected across the steering valve (c) and is set at
48 bar (700 psi).
The oil returning from the vibration and steering functions is directed
out port “T” of the steering manifold block to a return-line filter (x). A
filter bypass relief valve (y), set at 1.7 bar (25 psi), protects the system
by routing oil past the filter if the filter is clogged. Some models include
a back-pressure valve (z) located after the filter. It is used to maintain
1 bar (14.5 psi) to the inlet side of the charge pump. When pressure to
the inlet of the charge pump exceeds 1 bar (14.5 psi), the valve opens
and returns the excess flow back to the tank.
wc_tx000527gb.fm
118
RD 11 Repair
Hydraulic System
b
e
1
P
G1
f
d
2
c
g
L
3
h
P
T
R
a
i
T
z
x
y
wc_gr002989
w
wc_tx000527gb.fm
119
Hydraulic System
RD 11 Repair
6.31 Hydraulic Manifold Blocks with Test Ports
2
a
3
c
6
7
1
5
2
2
3
4
3
1
Ref.
d
b
Description
Ref.
wc_gr003021
Description
a
Drive manifold RD 11V & RD 11A
(parallel drive)
3
Forward drive test port
b
Drive manifold RD 11V & RD 11A
(series drive)
4
Pump shuttle valve
c
Drive control manifold RD 11AEC
5
Exciter solenoid (normally open)
d
Exciter/steering manifold
6
Exciter relief valve (138 bar/2000 psi)
1
Tow valve
7
Exciter/Steering test port
2
Reverse drive test port
-
---
wc_tx000527gb.fm
120
RD 11 Repair
Hydraulic System
6.32 Testing Hydraulic Pressure
Before making pressure checks:
6.32.1
Inspect the machine for hydraulic leaks.
6.32.2
Check the level of hydraulic fluid in the tank.
6.32.3
Check the engine operating speed at full throttle.
6.32.4
Run the machine for 5–10 minutes before testing to allow time for the
hydraulic system to warm up.
Note: Test ports are equipped with quick disconnects and are
designed for use with Wacker hydraulic test equipment.
Before opening hydraulic connections, shut the engine off and make
sure all controls are in neutral.
WARNING
4
a
c
2
b
3
2
3
1
5
6
wc_gr003001
wc_tx000527gb.fm
121
Hydraulic System
Ref.
RD 11 Repair
Description
Ref.
Description
1
Vibration and steering test port
4
Exciter manifold
2
Reverse test port
5
Drive manifold (RD 11A & RD 11V)
3
Forward test port
6
Drive control manifold (RD 11AEC)
Ref.
Description
Part no.
Part no.
a
Pressure gauges
10 mPa (1000 psi) 0077999
30 mPa (5000 psi) 0078000
b
Gauge adapter
0078005
-
c
Hose
0078002
-
Normal operating
pressure bar (psi)
Relief valve
pressure bar (psi)
Forward
27–41 (400–600)
200 (2900)
Reverse
27–41 (400–600)
200 (2900)
Exciter
55–69 (800–1000)
138 (2000)
Steering
13–35 (200–500)
48 (700)
Charge Pump
10–12 (150–174)
12 (174)
4
a
c
2
b
3
2
3
1
5
6
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6.33 Checking Drive Circuit Pressures
Operating Pressure:
Check operating pressures with the machine on a firm, level surface.
6.33.1
Install a 5000-psi gauge in the forward test port (3) on the drive
manifold block.
6.33.2
Start the engine and run the machine at full throttle.
6.33.3
Shift the control lever to forward and read the forward operating
pressure.
6.33.4
Stop the engine. Install a gauge in the reverse test port (2) and repeat
the procedure while operating in reverse.
Note: Operating pressures will increase significantly when running the
machine uphill, off road, or against an object.
Relief Pressure:
6.33.5
Place blocks in front of and behind both drums to prevent the machine
from moving, or dead head the machine against a solid concrete
abutment. Set the parking brake.
To avoid injury, make sure no one is in front of or behind the machine.
WARNING
6.33.6
Install a 5000-psi gauge in the forward test port (3) on the drive
manifold block.
6.33.7
Start the engine and run the machine at full throttle. Shift the forward/
reverse control slowly into forward until pressure on the gauge tops
out. This is the forward relief valve pressure.
Note: Make sure the drums do not spin.
6.33.8
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Install the gauge in the reverse test port (2) and repeat the procedure
while operating in reverse.
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6.34 Checking Vibration Circuit Pressures
Test the vibration with the front drum on soil or gravel. If testing is done
indoors, position the drum on a rubber tire or heavy mat to absorb the
vibration.
NOTICE: Do not run the vibration on concrete.
6.34.1 Install a 5000-psi gauge in the vibration test port (1).
6.34.2 Start the engine and run the machine at full throttle, with the forward/
reverse control in neutral.
6.34.3 Switch the vibration on. The gauge will read the relief pressure
momentarily as the exciter starts and then fall to the normal operating
pressure as the exciter reaches full speed.
If it is not possible to read the relief valve pressure accurately,
disconnect the exciter motor inlet line on the manifold. Cap off and plug
the open line connections. Start the engine and run the test. If the
pump is in good condition, the gauge will immediately come up to relief
valve pressure and remain there.
6.35 Checking Steering Circuit Pressures
6.35.1 Install a 1000-psi gauge in test port (1).
6.35.2 Start the engine and run the machine at full throttle.
6.35.3 Turn the steering wheel until it reaches the end of its stroke and hold it
there to read the steering circuit relief pressure.
If the relief pressure cannot be reached, the cylinder seals may be bad.
To check them, disconnect and cap off the hose connections to the
cylinder and repeat the pressure check.
NOTICE: Do not turn the vibration on at any time while checking the
steering circuit! Doing so will increase the line pressure and could
damage the gauge.
6.35.1
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6.36 Adjusting Relief Valves
Relief valves are preset at the factory and normally do not require
further adjustment. However, if a relief valve was replaced or
disassembled for inspection, adjustment may become necessary.
Adjust the relief valves slowly by turning the adjusting screws in small
increments.
NOTICE: Do not increase pressures above the machine
specifications! Higher pressures can damage the pumps and motors.
Drive Circuit Reliefs:
Current machines have relief valves built into the drive pump (1).
These reliefs are preset at 20 mPa (2900 psi) and do not require further
adjustment unless operating at below the recommended setting.
Exciter Relief Pressures:
DO NOT remove the plug or attempt to set the relief valve while the
engine is running or the system is under pressure!
WARNING
6.36.1
Turn the engine off.
6.36.2
Remove the plug (4) from the end of the valve (3) to expose the
adjusting screw.
6.36.3
Use a 1/4-inch Allen wrench (2) and turn the adjusting screw in or out
until the correct pressure is set.
Do not start the engine until the plug (1) is installed back in the valve.
WARNING
3
1
2
4
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6.37 Troubleshooting Flowcharts
The troubleshooting flowcharts are designed to take you through the
process of determining the source of a problem with engine starting or
machine operation. Many of the tests involve live voltages and
therefore should only be attempted by qualified personnel. Detailed
procedures for carrying out the tests are included in this manual. All
highlighted text within the flowcharts have matching sections in this
manual.
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6.38 Drive System Troubleshooting—Flowchart 3A
Roller does not Travel (propel)
Checking hydraulic oil
Check:
• Amount of oil in tank
• Type of oil in tank
• Condition of oil in tank
Is
hydraulic oil
OK?
Replace the hydraulic oil
with fresh, clean oil of the
correct specification.
No
Yes
Check the condition
of the hydraulic hoses.
No
Are the hydraulic
hoses OK?
Replace hydraulic
hoses as needed.
Yes
Checking tow valve
Check setting of tow valve.
Is the
tow valve set
correctly?
No
Correct
the setting.
Yes
Adjusting the drive control cable
Checking brake
Check function of drive control
cable.
No
Repair or replace
the drive control
cable.
Check function of brake.
Is the
drive control cable
OK?
Is the
brake functioning
properly?
Yes
Yes
See Flowchart 3B
See Flowchart 3B
No
Repair or replace
the drive control
manifold or motor.
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6.39 Checking Tow Valve (RD 11A and RD 11V only)
When checking the tow valve, check the position of the tow valve
handle. In order for the machine to operate properly, the tow valve
must be completely closed. First, back off the jam nut (a) one full turn
counterclockwise. Then, turn the tow valve handle (b) clockwise until
it is fully seated. Finally, secure the valve in the closed position by
turning the jam nut clockwise until it is tight.
WARNING
With the tow valve open, the drive circuit has no braking action and the
machine will roll freely. Close the tow valve immediately after a towing
operation is complete to prevent the machine from rolling
unexpectedly.
a
b
b
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6.40 Checking Brake (RD 11AEC only)
When the brakes are working properly, the hydraulic motors should not
be able to overpower the brakes in either direction (forward or
reverse). To test if the brakes are functioning properly, carry out the
following procedures:
6.40.1
Disconnect the wiring (a) from the brake solenoid valve.
6.40.2
Start the roller and attempt to drive through the brakes. Do so in both
forward and reverse.
6.40.3
If you are able to drive through the brakes, replace the drive motors.
6.40.4
Reconnect the brake solenoid.
If the brakes are not releasing, then the brake pressure is too low. Oil
pressure for the brake lines is tapped from the drive circuit. The drive
control manifold includes integral shuttle and pressure reducing
valves. Pressure to the brakes is reduced to between 12 and 30 bar. If
the pressure falls below 12 bar, the brakes will not disengage. To test
the pressure to the brakes carry out the following procedures:
6.40.5
Disconnect the hose (b) leading from the drive control manifold to the
brake manifold.
6.40.6
Connect a 1000-psi gauge to the hose.
6.40.7
Start the roller and check the pressure of the oil flowing to the brake
manifold.
6.40.8
If the pressure is less than 12 bar (174 psi), replace the drive control
manifold.
b
a
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6.41 Checking Brake System Electrics
When the roller’s engine is running, the solenoid (a) of the brake
manifold (b) receives power through the tan/black wire. When
energized, the brake solenoid valve shifts causing oil flow to the drive
motor brakes which releases the brakes. To check the function of the
brake’s electric system, carry out the following procedures:
6.41.1 Place the keyswitch in the ON position.
6.41.2 With your hand around the body of the brake solenoid (a), turn the
vibration switch ON and feel for movement of the plunger inside the
brake solenoid.
•
If movement of the plunger can be felt, the brake solenoid is
working. Note: If the brake solenoid is functioning, any problems
with the brakes are in the hydraulic circuit not the electrical system.
•
If the brake solenoid is not functioning, continue.
6.41.3 Disconnect the harness (c) from the brake solenoid.
6.41.4 Place the vibration switch in the ON position and measure the voltage
between the tan/black wire (d) and ground.
•
brake solenoid is receiving power. Check the wire (e) running to
the solenoid for continuity. If it has continuity, the solenoid should
be functioning. If the brake solenoid is not functioning, replace it.
•
6.41.5 Remove the seat to gain access to the vibration switch wiring.
6.41.6 Check the continuity of the wiring between the seat switch delay/
neutral start module and the brake solenoid.
•
If any of the wiring lacks continuity, repair or replace it.
•
If the wiring has
continuity, check
the wiring to the
seat switch delay/
neutral start module. Replace the
wiring and/or the
seat switch delay/
neutral start module if necessary.
a
d
c
b
e
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6.42 Adjusting the Drive Control Cable
If the roller tends to drift in either direction when the forward/reverse
control is in neutral, the drive control cable must be adjusted.
Check the adjustment with the machine on a hard level surface, the
engine running, and the forward/reverse control in NEUTRAL. The
pump control lever (a) should be centered. If the machine does not
remain stationary, loosen the jam nuts (b) and move the turnbuckle (c)
as needed until movement stops.
If adjusting the turnbuckle does not achieve the desired results, a
gross adjustment can be made at nut (d) and then fine-tuned as
described above.
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6.43 Drive System Troubleshooting—Flowchart 3B
Continued from Flowchart 3A
Checking drive circuit pressure
Check relief pressure.
Adjusting Relief Valves
No
Is relief pressure
OK?
Adjust exciter relief
valve pressure.
Yes
Is
relief pressure
OK?
No
Replace
drive pump.
Yes
Checking drive motor for binding
Check drive motors for binding.
Are drive motors
binding?
Yes
Replace
drive motor(s).
No
Check drive bearings.
Are drive bearings
OK?
Yes
Checking drive motors
Check drive motors.
No
Are drive motors
OK?
Replace
drive bearings.
Yes
Call
Wacker.
No
Replace
drive motors.
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6.44 Checking Drive Motor for Binding
Stop the machine, apply the parking brake, switch off the engine, and
disconnect the battery.
High operating pressures indicate binding in the drive system. Binding
can occur in the drive motor or may be the result of a poor or failing
drive bearing on the right side of the drum.
To check for binding in the drive motor:
6.44.1
Remove the drive motor cover (4), drum support cover (3), and the
drum support (2).
6.44.2
Support the machine before separating the drive plate from the drum
by placing blocks or jacks under the front frame just behind the drum.
Only use blocks or jacks with a suitable load-bearing capacity. Do not
use improvised blocks or jacks.
WARNING
6.44.3
Separate the drive plate (5) from the left side of the drum.
6.44.4
Disconnect the hydraulic lines (1) to the motor.
6.44.5
Rotate the drive plate by hand and make sure the motor is turning
freely.
Failure of the drive circuit to reach operating pressures is normally
caused by a worn or damaged drive pump; however, the problem
could also be the result of a badly worn motor. Questions regarding the
testing and troubleshooting of drive components should be referred to
Wacker Corporation.
2
3
1
5
4
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6.45 Checking Drive Motors—Series Drive
With revision 103 and thereafter, the drive motors on the RD 11A and
RD 11V models are plumbed in series. Oil flow through one motor is
virtually identical to the flow through the other, unless a problem with
one of the motors exists. To test the drive motors, carry out the
following procedure:
Crushing hazard. Use extreme care when carrying out the following
procedure.
WARNING
6.45.1 Start the engine and allow the hydraulic oil to warm up. Shut off the
engine.
6.45.2 Using a crane or overhead lift with enough load-bearing capacity to
support the machine, lift the machine off the ground so that the drums
are 2–5 cm (1–2 inches) off the ground.
6.45.3 Place a piece of tape or boldly mark each drum. This will aid in
observing the rotation of the drums.
6.45.4 Start the engine and slowly shift the forward/reverse control lever into
the forward position. Observe the drum rotation for any sign of
difference in the rotation of the drums. If one drum is rotating slower
than the other, the drum with the slower rotation is suspect.
6.45.5 With the engine running and the drums rotating, slowly apply the
parking brake to the rear drum. Observe the speed of both drums as
the brake is applied. Both drums should slow down at the same rate.
Apply the brake until the rear drum stops rotating. Note: If the brake
cannot stop the rear drum from rotating, the brake requires repair or
replacement. With the rear drum held from rotating by the brake, the
front drum should not be rotating. If it is, the seals of the rear drive
motor are failing. Rebuild or replace the rear drive motor.
Release the brake from the rear drum.
6.45.6 Conduct the same test on the front drum. Use a sturdy piece of wood
such as a 2x4 as an external brake. Wedge the piece of wood between
the drum and the machine frame to stop the drum rotation.
WARNING
Do not jam the piece of wood between the drum and the floor. The
roller may move.
If the rear drum rotates when the front drum is held from rotating by the
external brake, the seals of the front drive motor are failing. Rebuild or
replace the front drive motor.
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6.46 Checking Drive Motors—Parallel Drive
With the release of the machines, and up to and including revision 102,
the drive motors on the RD 11A and RD 11V models were plumbed in
parallel. The drive motors on all revisions of model RD 11AEC are
plumbed in parallel. With parallel drive, each drive motor works
independently of the other. To test the drive motors, carry out the
following procedure:
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6.46.1
Start the engine and allow the hydraulic oil to warm up.
6.46.2
Position the machine on a smooth, horizontal surface.
6.46.3
Shut off the engine.
6.46.4
Block the drums with appropriate devices so that the machine cannot
move.
6.46.5
Disconnect the case drain line from one of the drive motors and place
it in a suitable container.
6.46.6
Start the machine. Slowly shift the forward-reverse lever into forward,
then reverse. Observe the flow from the case drain line. A steady
series of drops dripping from the line is tolerable. A steady flow of oil
indicates the motor’s seals are going bad and the pump should be
rebuilt or replaced.
6.46.7
Reconnect the drain line and conduct the test with the other drive
motor.
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6.47 Vibration System Troubleshooting—Flowchart 4A
Roller does not Vibrate
Checking hydraulic oil
Check:
• Amount of oil in tank
• Type of oil in tank
• Condition of oil in tank
Is
hydraulic oil
OK?
No
Replace the hydraulic oil
with fresh, clean oil of the
correct specification.
Yes
Check the condition
of the hydraulic hoses.
Are the hydraulic
hoses OK?
No
Replace hydraulic
hoses as needed.
Yes
Checking exciter electrical system
Check the function of the exciter
solenoid.
Is the
exciter solenoid
working?
Yes
See section Troubleshooting
a System that Vibrates Poorly
No
Check the function of the
vibration switch.
Is the
vibration switch
working?
Yes
Replace
the exciter
solenoid.
No
Replace
the vibration
switch.
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Notes
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6.48 Checking Exciter Electrical System
When the roller’s engine is running, the solenoid (a) of the exciter
manifold (b) receives power through the white wire via the vibration
switch. When energized, the exciter solenoid valve shifts causing oil
flow to the exciter motor. To check the function of the exciter electric
system, both the exciter solenoid and the exciter switch should be
tested.
To check the exciter solenoid:
6.48.1 Place the key switch in the ON position.
6.48.2 With your hand around the body of the exciter solenoid (a), turn the
vibration switch ON and feel for movement of the plunger inside the
exciter solenoid. Note: If the movement of the plunger is hard to
detect, remove the solenoid from the exciter manifold to make it easier.
•
If the exciter solenoid is functioning, any problems with vibration
are in the hydraulic circuit not the electrical system.
•
If the exciter solenoid is not functioning, continue.
6.48.3 Disconnect (c) the harness from the exciter solenoid.
6.48.4 Place the vibration switch in the ON position and measure the voltage
between the white wire (d) and ground.
•
exciter solenoid is receiving power. Check the brown wire (e) for
continuity. If it has continuity, the solenoid should be functioning.
If the exciter solenoid is not functioning, replace it.
•
If 12VDC is not measured, go to step 5.
6.48.5 Remove the seat to gain access to the vibration switch wiring.
6.48.6 Disconnect the control lever electronics from the harness (f).
6.48.7 To test the function of the exciter switch, press the exciter switch ON
and OFF while checking the continuity across the pink and white wires.
•
If the vibration switch has no continuity, replace it.
•
If the vibration switch has continuity, continue.
6.48.8 Check the continuity of the wiring between the key switch and the
vibration switch and also between the vibration switch and the exciter
solenoid.
•
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If any of the wiring lacks continuity, repair or replace it.
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b
a
e
d
f
c
A
A
B
B
C
C
D
D
E
E
F
F
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6.49 Troubleshooting a System that Vibrates Poorly
The exciter pump is designed to put out a constant flow of oil at a set
engine speed. This ensures that the vibration frequency remains
steady. When troubleshooting the exciter circuit, the vibration speed
should be measured along with the operating and relief pressures to
help determine the cause of any problems.
To measure vibration speed:
6.49.1 Start the machine and run it for several minutes to bring the hydraulic
fluid up to normal operating temperatures.
6.49.2 Check the engine RPM using a tachometer. The engine must be
running at the correct RPM to accurately measure vibration.
6.49.3 Position the roller on a rubber mat and start vibration. Hold the
vibrotach (P/N 53397) against the outer rim of the drum and measure
the vibration speed.
Engine RPM
Minimum Vibration Speed
3200–3300
3800
3500–3600
4200
6.49.4 The vibration speed along with the operating and relief valve pressures
can be used to determine the condition of the exciter system as shown
in the chart below.
If the exciter is binding, causing high operating pressures, it will be
necessary to disconnect and remove the exciter motor from the
housing to determine if the binding is occurring in the exciter bearings
or the motor. Turn the motor shaft and exciter shaft by hand and check
that they turn freely.
Operating
Pressure
Pump Relief
Pressure
Exciter
Speed
N
N
N
H
N
N or L
N or L
N
L
Exciter motor worn
L
L
L
Exciter pump damaged or worn, relief
valve defective, or needs adjusting
Probable Cause
System OK
Exciter bearings or motor binding
N = Normal, L = Low, H = High
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6.50 Checking Exciter and Exciter Motor
6.50.1
Remove the two screws (a) which secure the exciter motor (b) to the
housing.
6.50.2
Rotate the exciter (c) and the motor shaft by hand. Each should turn
freely. Replace the exciter or the exciter motor if either are binding.
c
a
b
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6.51 Troubleshooting the Steering System
Low hydraulic pressure in the steering circuit can be the result of a
defective or worn steering valve or poor seals in the steering cylinder.
To isolate the problem, recheck the steering relief pressure with the
cylinder removed from the circuit and the hydraulic connections to it
capped or plugged. If the hydraulic pressure remains low, the problem
is in the steering valve. If the hydraulic pressure increases, the
problem is in the cylinder.
DO NOT drive the machine with the steering cylinder disconnected or
inoperative!
WARNING
A badly worn exciter pump will affect both the steering and the
vibration circuits, because these circuits operate in series using the
same supply. If pressure to both circuits falls below operating
pressures, replace the exciter pump.
Note: In some cases the exciter pump may be good enough to operate
the steering circuit but not the vibration circuit. This is due to the much
lower pressure requirements of the steering circuit.
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7.
Electrical System
Electrical System
7.1
Checking Throttle Switch
To check the function of the throttle switch:
7.1.1
Remove the throttle switch (a) from the machine.
7.1.2
Check the throttle switch for continuity between the upper two spades
(b) and the lower two spades (c) when the switch is in the FAST
position.
•
If there is continuity, the throttle switch is functioning.
•
If there is no continuity, replace the throttle switch.
a
b
c
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7.2
RD 11 Repair
Checking Throttle Solenoid
To check the function of the throttle solenoid:
7.2.1
Place the key switch in the ON position. Do not start the engine.
7.2.2
Place the throttle switch in the FAST position. A noticeable click should
be heard as the relay sends power to the solenoid. You should also
see the arm of the solenoid move.
7.2.3
7.2.4
7.2.5
7.2.6
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•
If the arm of the solenoid moved, the solenoid is functioning. If
you are still having problems with the FAST position, check the
throttle cable.
•
If the arm of the solenoid did not move, continue.
Disconnect the throttle solenoid. With a multimeter, measure DC
voltage (battery voltage approximately 12) between the connector (a)
where the pink-red wire is connected and ground; do so with the key
switch in the ON position and the throttle switch in the FAST position.
•
If 12VDC is measured, replace the throttle solenoid.
•
Disconnect the 12V relay (throttle solenoid relay) (b). With a
multimeter, measure DC voltage (battery voltage approximately 12)
between red-white wire and ground.
•
If 12VDC is not measured, check the continuity of the red-white
wire from the connector through the 20A circuit breaker and back
to the starter on models with Honda engine or back to the starter
relay on models with the Vanguard engine. Repair or replace the
wire as needed.
•
If 12VDC is measured, continue.
With the 12V relay still disconnected, measure DC voltage (battery
voltage approximately 12) between the connector where the pink wire
is connected and ground; do so with the key switch in the ON position
and the throttle switch in the FAST position.
•
If 12VDC is measured, replace the 12V relay.
•
Check the continuity of the pink wire from the connector back to the
throttle switch.
•
If the wire has no continuity, replace it.
•
If the wire has continuity, check the function of the throttle switch.
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a
b
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7.3
RD 11 Repair
RD 11A Electrical Schematic (revisions 100–118)
A
B
B
B
P
G
B
B
D
R
B
C
G
A
W
P
w
4
Br
5
1
2
3
P
T
W/B
T/R
Br
R
R
Br W
B
T
T/R
14
13
12
11
T
R
B
B
16
S I
15
A
10
8
Br
R
6 15A
7 20A
9
B
B
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7.4
Electrical System
RD 11A Electrical Components (revisions 100–118)
Ref.
Description
Ref.
Description
1
Vibration switch
9
Battery
2
Forward/reverse switch
10
Starter
3
11
Voltage regulator
4
12
Anti-afterfire solenoid
5
Keyswitch
13
Alternator
6
15-Amp fuse
14
Magneto kill
7
20-Amp fuse
15
Exciter control solenoid
8
Starter relay
16
Engine
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
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7.5
RD 11 Repair
RD 11A Wiring Diagram (revisions 100–118)
14
12
16
13
11
15
Br
T/R
10
Br
6
15A
B
8
B
W
7
20A
R
B
R
1
9
Br
2
B
B
W
G
3
P
6
3
B
T
W
W/B
P
P
T/R
B
R
R
Br
5
G
4
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7.6
Electrical System
Ref.
Description
Ref.
Description
1
Vibration switch
9
Battery
2
10
Starter
3
11
Voltage regulator
4
12
5
Keyswitch
13
Alternator
6
15-Amp fuse
14
Magneto kill
7
20-Amp fuse
15
8
Starter relay
16
Engine
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_tx000528gb.fm
149
Electrical System
7.7
RD 11 Repair
RD 11A Electrical Schematic (revisions 119–123)
P
12
W
15
P
13
Br
B
14
5
3
P/R
R/W
P
Br
T
W/B
T/R
Br
R
Br
Br
R
W
P/R
17
19
85
87
86
30
P
3
P/B
6
16
2
5
10
7
R
8
20
9
6
T
S I
11
A
18
2
B
R
B
20A
4
1
30A
20A
wc_gr003025
wc_tx000528gb.fm
150
RD 11 Repair
7.8
Electrical System
Ref.
Description
Ref.
Description
1
20-Amp fuse
11
2
Battery
12
Vibration switch
3
Keyswitch
13
4
30-Amp fuse
14
5
Throttle solenoid
15
6
Starter
16
Throttle switch
7
Magneto kill
17
12VDC relay
8
Alternator
18
Starter relay
9
19
Vibration system indicator light
10
Engine
20
Voltage regulator
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_tx000528gb.fm
151
Electrical System
7.9
RD 11 Repair
RD 11A Wiring Diagram (revisions 119–123)
7
T
P/B
9
10
8
11
Br
20
R
16
6
B
T/R
1
B
20A
P
17
30A
4
18
R
B
P/R
W
R
1
Br
20A
R/W
R
5
B
12
Br
2
Br
T
13
B
B
W
G
14
P
6
3
B
R
Br
W
W/B
P
P
T/R
B
19
G
R
Br
W
3
15
wc_gr003055
wc_tx000528gb.fm
152
RD 11 Repair
Electrical System
7.10 RD 11A Electrical Components (revisions 119–123)
Ref.
Description
Ref.
Description
1
20-Amp fuse
11
2
Battery
12
Vibration switch
3
Keyswitch
13
4
30-Amp fuse
14
5
Throttle solenoid
15
6
Starter
16
Throttle switch
7
Magneto kill
17
12VDC relay
8
Alternator
18
Starter relay
9
19
10
Engine
20
Voltage regulator
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_tx000528gb.fm
153
Electrical System
RD 11 Repair
7.11 RD 11A Electrical Schematic (revisions 124–141)
P
A
W
B
P
Gr
B
D
B
C
W/B
A
12
13
5
Br
3
14
P/R
P
Br
R/W
T
W/B
T/R
Br
R/L
Br
R/W
P
W
Br
4
17
P/R
85
87
86
30
P
16
2
3
6
P/B
R/W
19
T/R
5
Gr
Gr
B/Y
W/L
W
B
Gr
Gr
w
W/L
W
B
10
8
7
B/Y
T
B
B
11
Br
Br
6
T
P/B
P
CP
SO
20
R
CG
R/W
R/L
SI
1
Br
2
R
R/Y
R/Y
9
B
1
18
R/W
Br
R/L
P/R
P
wc_gr002981
wc_tx000528gb.fm
154
RD 11 Repair
Electrical System
Ref.
Description
Ref.
Description
1
20-Amp fuse
11
2
Battery
12
Vibration switch
3
Keyswitch
13
4
14
5
Throttle solenoid
15
6
Starter
16
Throttle switch
7
Voltage regulator
17
12VDC relay
8
Alternator
18
20-Amp circuit breaker
9
19
Magneto kill
10
Engine
20
Starter relay
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_tx000528gb.fm
155
Electrical System
RD 11 Repair
7.13 RD 11A Wiring Diagram (revisions 124–141)
19
B/Y
T
P/B
T
9
10
8
11
7
W
R/Y
16
6
B
1
P/B
T/R
P
20A
R/Y
20
R/L
18
R/W
R
P
17
20A
R/W
P/R
W
R
1
Br
Br
20A
R/W
5
R/L
B
B
12
Br
2
B
B
W
G
14
Br
T
13
P
6
3
B
R
Br
W
W/B
P
P
T/R
B
4
Gr
R/L
Br
W
3
15
wc_gr003056
wc_tx000528gb.fm
156
RD 11 Repair
Electrical System
Ref.
Description
Ref.
Description
1
20-Amp fuse
11
2
Battery
12
Vibration switch
3
Keyswitch
13
4
14
5
Throttle solenoid
15
6
Starter
16
Throttle switch
7
Voltage regulator
17
12VDC relay
8
Alternator
18
9
19
Magneto kill
10
Engine
20
Starter relay
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_tx000528gb.fm
157
Electrical System
RD 11 Repair
7.15 RD 11A Electrical Schematic (revisions > 141)
P
A
W
B
P
Gr
B
D
B
C
W/B
A
12
13
5
Br
3
14
P/R
P
Br
R/W
T/Y
21
W/B
T/R
Br
R/L
Br
R/W
T
P
W
Br
4
17
P/R
85
87
86
30
P
16
2
3
6
P/B
R/W
19
T/R
5
Gr
Gr
B/Y
W/L
W
B
Gr
Gr
w
W/L
W
B
10
8
7
B/Y
T
B
B
11
Br
Br
6
T
P/B
P
CP
SO
20
R
CG
R/W
R/L
SI
1
Br
2
R
R/Y
R/Y
9
B
1
18
R/W
Br
R/L
P/R
P
wc_gr003581
wc_tx000528gb.fm
158
RD 11 Repair
Electrical System
7.16 RD 11A Electrical Components (revisions > 141)
Ref.
Description
Ref.
1
20-Amp fuse
12
Vibration switch
2
Battery
13
3
Keyswitch
14
4
15
5
Throttle solenoid
16
Throttle switch
6
Starter
17
12VDC relay
7
Voltage regulator
18
8
Alternator
19
Magneto kill
9
20
Starter relay
10
Engine
21
Seat switch
11
-
Description
---
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_tx000528gb.fm
159
Electrical System
RD 11 Repair
7.17 RD 11A Wiring Diagram (revisions > 141)
21
19
B/Y
T
P/B
T
9
10
8
7
11
W
R/Y
16
6
B
1
P/B
T/R
P
20A
R/Y
20
R/L
18
R/W
R
P
17
20A
R/W
P/R
W
R
1
Br
Br
20A
R/W
5
R/L
B
B
12
Br
2
B
B
W
G
14
Br
T/Y
13
P
6
3
B
R
Br
W
W/B
P
P
T/R
B
4
Gr
R/L
Br
W
3
15
wc_gr003582
wc_tx000528gb.fm
160
RD 11 Repair
Electrical System
7.18 RD 11A Electrical Components (revisions > 141)
Ref.
Description
Ref.
1
20-Amp fuse
12
Vibration switch
2
Battery
13
3
Keyswitch
14
4
15
5
Throttle solenoid
16
Throttle switch
6
Starter
17
12VDC relay
7
Voltage regulator
18
8
Alternator
19
Magneto kill
9
20
Starter relay
10
Engine
21
Seat switch
11
-
Description
---
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_tx000528gb.fm
161
Electrical System
RD 11 Repair
7.19 RD 11V Electrical Schematic (revisions 100–118)
A
B
B
B
B
B
D
R
C
G
A
W
P
w
4
P
G
Br
B
5
1
2
3
P
T
W/B
T/R
Br
R
R
Br W
B
T
T/R
14
13
12
11
T
R
B
B
16
S I
15
A
10
8
Br
R
6 15A
7 20A
9
B
B
wc_gr003022
wc_tx000528gb.fm
162
RD 11 Repair
Electrical System
7.20 RD 11V Electrical Components (revisions 100–118)
Ref.
Description
Ref.
Description
1
Vibration switch
9
Battery
2
10
Starter
3
11
Voltage regulator
4
12
5
Keyswitch
13
Alternator
6
15-Amp fuse
14
Magneto kill
7
20-Amp fuse
15
8
Starter relay
16
Engine
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_tx000528gb.fm
163
Electrical System
RD 11 Repair
7.21 RD 11V Wiring Diagram (revisions 100–118)
14
12
16
13
11
15
Br
T/R
10
Br
6
15A
B
8
B
W
7
20A
R
B
R
1
9
Br
2
B
B
W
G
3
P
6
3
B
T
W
W/B
P
P
T/R
B
R
R
Br
5
G
4
wc_gr003054
wc_tx000528gb.fm
164
RD 11 Repair
Electrical System
Ref.
Description
Ref.
Description
1
Vibration switch
9
Battery
2
10
Starter
3
11
Voltage regulator
4
12
5
Keyswitch
13
Alternator
6
15-Amp fuse
14
Magneto kill
7
20-Amp fuse
15
8
Starter relay
16
Engine
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_tx000528gb.fm
165
Electrical System
RD 11 Repair
P
12
W
15
P
13
Br
B
14
5
3
P/R
R/W
P
Br
T
W/B
T/R
Br
R
Br
Br
R
W
P/R
17
21
85
87
86
30
P
3
P/B
6
16
2
5
10
7
R
8
20
9
T
6
S I
11
18
2
Br
B
19
1
15A
4
30A
20A
wc_gr003024
wc_tx000528gb.fm
166
RD 11 Repair
Electrical System
Ref.
Description
Ref.
1
20-Amp fuse
12
Vibration switch
2
Battery
13
3
Keyswitch
14
4
30-Amp fuse
15
5
Throttle solenoid
16
Throttle switch
6
Starter
17
12VDC relay
7
Magneto kill
18
Starter relay
8
Alternator
19
15-Amp fuse
9
20
Voltage regulator
10
Engine
21
11
-
Description
---
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_tx000528gb.fm
167
Electrical System
RD 11 Repair
7
T
P/B
9
10
8
11
Br
20
R
16
6
T/R
19
15A
P
17
30A
4
18
R
P/R
W
1
Br
20A
R/W
R
5
B
R
12
Br
2
Br
T
13
B
B
W
G
14
P
6
3
B
R
Br
W
W/B
P
P
T/R
B
21
G
R
Br
W
3
15
wc_gr003055
wc_tx000528gb.fm
168
RD 11 Repair
Electrical System
Ref.
Description
Ref.
1
20-Amp fuse
12
Vibration switch
2
Battery
13
3
Keyswitch
14
4
30-Amp fuse
15
5
Throttle solenoid
16
Throttle switch
6
Starter
17
12VDC relay
7
Magneto kill
18
Starter relay
8
Alternator
19
15-Amp fuse
9
20
Voltage regulator
10
Engine
21
11
-
Description
---
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_tx000528gb.fm
169
Electrical System
RD 11 Repair
P
A
W
B
P
Gr
B
D
13
B
C
14
W/B
A
12
5
Br
3
P/R
P
Br
R/W
T
W/B
T/R
Br
R/L
Br
R/W
P
W
Br
4
17
P/R
85
87
86
30
P
16
2
3
6
P/B
R/W
19
T/R
5
10
Y
7
8
Y
R
R/Y
T
R
R
T
B
11
B
B
CP
CG
Br
Br
6
T
P/B
SO
20
SI
R/Y
1
R/Y
Br
B
R
R/L
R/W
2
1
18
R/W
Br
R/L
P/R
P
wc_gr002997
wc_tx000528gb.fm
170
RD 11 Repair
Electrical System
Ref.
Description
Ref.
Description
1
20-Amp fuse
11
2
Battery
12
Vibration switch
3
Keyswitch
13
4
14
5
Throttle solenoid
15
6
Starter
16
Throttle switch
7
Voltage regulator
17
12VDC relay
8
Alternator
18
9
19
Magneto kill
10
Engine
20
Starter relay
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_tx000528gb.fm
171
Electrical System
RD 11 Repair
19
R
T
T
P/B
T
9
10
8
11
Y
Y
7
R
16
6
R/Y
Br
P/B
T/R
1
20A
P
17
20A
B
R/Y
18
20
R/W
R/W
R/L
P/R
W
1
Br
20A
R/W
R/L
R
5
B
R
B
12
Br
2
Br
T
13
B
B
W
G
14
P
6
3
B
R
Br
W
W/B
P
P
T/R
B
4
Gr
R/L
Br
W
3
15
wc_gr003058
wc_tx000528gb.fm
172
RD 11 Repair
Electrical System
Ref.
Description
Ref.
Description
1
20-Amp fuse
11
2
Battery
12
Vibration switch
3
Keyswitch
13
4
14
5
Throttle solenoid
15
6
Starter
16
Throttle switch
7
Voltage regulator
17
12VDC relay
8
Alternator
18
9
19
Magneto kill
10
Engine
20
Starter relay
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_tx000528gb.fm
173
Electrical System
RD 11 Repair
7.31 RD 11V Electrical Schematic (revisions > 142)
P
A
W
B
P
Gr
B
D
B
C
W/B
A
12
13
5
Br
3
14
P/R
P
Br
R/W
T/Y
W/B
T/R
Br
R/L
Br
R/W
21
P
W
Br
4
17
P/R
85
87
86
30
P
16
2
3
6
P/B
R/W
19
T/R
5
10
Y
7
8
Y
R
R/Y
T
R
R
T
B
11
B
B
CP
CG
Br
Br
6
T
P/B
SO
20
SI
R/Y
1
R/Y
Br
B
R
R/L
R/W
2
1
18
R/W
Br
R/L
P/R
P
wc_gr003583
wc_tx000528gb.fm
174
RD 11 Repair
Electrical System
7.32 RD 11V Electrical Components (revisions > 142)
Ref.
Description
Ref.
1
20-Amp fuse
12
Vibration switch
2
Battery
13
3
Keyswitch
14
4
15
5
Throttle solenoid
16
Throttle switch
6
Starter
17
12VDC relay
7
Voltage regulator
18
8
Alternator
19
Magneto kill
9
20
Starter relay
10
Engine
21
Seat switch
11
-
Description
---
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_tx000528gb.fm
175
Electrical System
RD 11 Repair
7.33 RD 11V Wiring Diagram (revisions > 142)
21
19
R
T
T
P/B
T
9
10
8
Y
Y
7
11
R
16
6
R/Y
Br
P/B
T/R
1
20A
P
17
20A
B
R/Y
18
20
R/W
R/W
R/L
P/R
W
1
Br
20A
R/W
R/L
R
5
B
R
B
12
Br
2
Br
T
13
B
B
W
G
14
P
6
3
B
R
Br
W
W/B
P
P
T/R
B
4
Gr
R/L
Br
W
3
15
wc_gr003584
wc_tx000528gb.fm
176
RD 11 Repair
Electrical System
7.34 RD 11V Electrical Components (revisions > 142)
Ref.
Description
Ref.
1
20-Amp fuse
12
Vibration switch
2
Battery
13
3
Keyswitch
14
4
15
5
Throttle solenoid
16
Throttle switch
6
Starter
17
12VDC relay
7
Voltage regulator
18
8
Alternator
19
Magneto kill
9
20
Starter relay
10
Engine
21
Seat switch
11
-
Description
---
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
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Electrical System
RD 11 Repair
7.35 RD 11AEC Electrical Schematic (revisions 100–111)
P
E
B
W
F
B
P
B
B
G
D
C
R
G
A
W
14
15
19
16
B
W/B
18
T
20
T/B
P
Y
17
W/B
Br
Y
P
T
W/B
R
3
P
P
T/B
R Br W B
T T
10
7
8
9
R
T
21
B
6
G/W
22
11
1
5
Br
R
12
4
4
13
2
T/B
T/B
B
Br
wc_gr002027
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RD 11 Repair
Electrical System
7.36 RD 11AEC Electrical Components (revisions 100–111)
Ref.
Description
Ref.
Description
1
Battery disconnect
12
Brake solenoid
2
Battery
13
Pump shunt solenoid
3
Keyswitch
14
Vibration switch
4
20-Amp fuse
15
5
Starter relay
16
6
Starter
17
Seat switch
7
Regulator/Rectifier
18
Seat switch delay and neutral start
module
8
Alternator
19
9
20
10
Engine
21
Horn switch
11
22
Horn
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
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Electrical System
RD 11 Repair
7.37 RD 11AEC Wiring Diagram (revisions 100–111)
5
1
6
4
4
R
2
R
7
8
R
3
T
T
P
9
W/B
W
10
Br
11
T/B
12
Br
T/B
Br
14
13
P 11
P7
W/B
T/B
B
T
20
W
P8
15
P9
16
17
A
A
B
B
C
C
D
D
E
E
F
F
21
P 13
G
G/W
19
22
W/B
18
wc_tx000528gb.fm
Br
A
A
B
B
C
C
D
D
E
E
F
F
180
wc_gr002029
RD 11 Repair
Electrical System
Ref.
Description
Ref.
Description
1
Battery disconnect
12
Brake solenoid
2
Battery
13
Pump shunt solenoid
3
Keyswitch
14
Vibration switch
4
20-Amp fuse
15
5
Starter relay
16
6
Starter
17
Seat switch
7
Regulator/Rectifier
18
module
8
Alternator
19
9
20
10
Engine
21
Horn switch
11
22
Horn
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
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181
Electrical System
RD 11 Repair
7.39 RD 11AEC Electrical Schematic (revisions 112–125)
19
P
E
B
Y
F
B
P
B
B
G
D
C
R
G
A
W
B
W/B
14
15
16
Y
W
20
18
T/B
P
Br
R
17
W/B
Br
P
T
W/B
R
3
P
P
T/B
R Br W B
T T
10
7
8
9
R
T
21
B
6
G/W
22
11
1
5
Br
R
12
4
4
13
2
T/B
T/B
B
Br
wc_gr002028
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RD 11 Repair
Electrical System
Ref.
Description
Ref.
Description
1
Battery disconnect
12
Brake solenoid
2
Battery
13
Pump shunt solenoid
3
Keyswitch
14
Vibration switch
4
20-Amp fuse
15
5
Starter relay
16
6
Starter
17
Seat switch
7
Regulator/Rectifier
18
module
8
Alternator
19
9
20
10
Engine
21
Horn switch
11
22
Horn
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_tx000528gb.fm
183
Electrical System
RD 11 Repair
7.41 RD 11AEC Wiring Diagram (revisions 112–125)
5
1
6
4
4
R
2
R
7
8
R
3
T
T
P
9
W/B
W
10
Br
11
T/B
12
Br
T/B
Br
14
13
P 11
P7
W/B
T/B
B
20
W
P8
15
P9
16
17
A
A
B
B
C
C
D
D
E
E
F
F
21
P 13
G
G/W
Y
19
22
W/B
18
wc_tx000528gb.fm
Br
A
A
B
B
C
C
D
D
E
E
F
F
184
wc_gr002030
RD 11 Repair
Electrical System
Ref.
Description
Ref.
Description
1
Battery disconnect
12
Brake solenoid
2
Battery
13
Pump shunt solenoid
3
Keyswitch
14
Vibration switch
4
20-Amp fuse
15
5
Starter relay
16
6
Starter
17
Seat switch
7
Regulator/Rectifier
18
module
8
Alternator
19
9
20
10
Engine
21
Horn switch
11
22
Horn
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_tx000528gb.fm
185
Electrical System
RD 11 Repair
7.43 RD 11AEC Electrical Schematic (revisions > 125)
19
P
Y
E
F
14
P
B
15
G
D
B
C
A
16
W/B
Y
20
23
Y
W
T/B
W
T/B
Br
P
R
18
W/B
Br
17
Br
P/R
P
Br
R/W
Br
P
B
24
P
B/P
T/R
3
P
P
Gr
Gr
B/Y
W/L
W
W/L
B
B
27
T
B/Y
T
21
P
P/B
R
B
10
8
7
R/W
9
6
B
B
CP
G/W
R/W
5
22
1
2
Br
Br
R
26
P
P
Br
25
Br
Br
2
5
P/B
wc_gr002991
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186
RD 11 Repair
Electrical System
7.44 RD 11AEC Electrical Components (revisions > 125)
Ref.
Description
Ref.
Description
1
Battery disconnect
15
2
Battery
16
3
Keyswitch
17
Seat switch
4
20-Amp fuse
18
module
5
Starter relay
19
6
Starter
20
7
Voltage regulator
21
Horn switch
8
Alternator
22
Horn
9
23
Throttle solenoid
10
Engine
24
12VDC relay
11
25
Throttle switch
12
Brake solenoid
26
13
Pump shunt solenoid
27
Magneto kill
14
Vibration switch
-
---
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_tx000528gb.fm
187
Electrical System
RD 11 Repair
7.45 RD 11AEC Wiring Diagram (revisions > 125)
5
P
R
R
1
6
4
4
R/L
2
R/Y
W/B
Br
B/P
G
3
T
T/R
P
W
8
7
W
S L
B M
27
9
T
10
R/W
Br
Br
23
P/R
11
26
R/W
T/B
12
B
Br
Br
24
P
T/B
R/W
Br
3
6
25
2
14
13
5
P/B
P 11
P7
W/B
T/B
B
20
W
P8
15
P9
16
17
A
A
B
B
C
C
D
D
E
E
F
F
P 13
21
G
G/W
Y
19
22
W/B
18
Br
A
A
B
B
C
C
D
D
E
E
F
F
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188
RD 11 Repair
Electrical System
7.46 RD 11AEC Electrical Components (revisions > 125)
Ref.
Description
Ref.
Description
1
Battery disconnect
15
2
Battery
16
3
Keyswitch
17
Seat switch
4
20-Amp fuse
18
module
5
Starter relay
19
6
Starter
20
7
Voltage regulator
21
Horn switch
8
Alternator
22
Horn
9
23
Throttle solenoid
10
Engine
24
12VDC relay
11
25
Throttle switch
12
Brake solenoid
26
13
Pump shunt solenoid
27
Magneto kill
14
Vibration switch
-
---
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_tx000528gb.fm
189
Electrical System
RD 11 Repair
Notes
wc_tx000528gb.fm
190
RD 11 Repair
8.
8.1
Tools
Because all possible problems encountered while repairing the
machine cannot be anticipated, it is up to the mechanic to use common
sense and good judgement in tool selection.
The use of any special tools is recommended only for those operations
where the use of conventional tools proves inadequate.
Before substituting another tool or procedure, you should be satisfied
that neither personal injury nor damage to the component will result.
8.2
Ordering Parts
The repair procedures contained in this manual do not include part
numbers. For parts replacement information, refer to the Parts Book
originally supplied with the machine.
If the original Parts Book has been lost, a replacement may be ordered
from Wacker Corporation. When ordering a replacement Parts Book,
please list the model number, item number, revision level, and serial
number of the machine. Parts Books are also available on the Wacker
Corporation Web site. See www.wackergroup.com. Enter the site as a
visitor.
8.3
Reference Numbers ( )
Repair procedures contain reference numbers enclosed in
parentheses ( ). These numbers refer to the item numbers shown on
the assembly drawings and other detailed drawings. They are included
to aid the mechanic in identifying parts and assembling components.
8.4
Weight Block
The weight block symbol gives an approximate weight measurement
to aid the mechanic when lifting/hoisting larger components.
250 kg
(550 lbs.)
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191
8.5
RD 11 Repair
Threadlocking Compounds
Due to the heavy vibration inherent in this type of equipment, the repair
and service procedures described in this manual specify the use of
threadlocking compounds. These compounds should be used where
indicated to prevent the fasteners from becoming loose.
Although Loctite® is referred to throughout this manual, any equivalent
type of sealant such as Hernon, Prolock, or Omnifit may be used.
Clean the screw threads and wipe off any oil or grease before applying
a threadlocking compound.
For a complete list of recommended sealing and locking compounds,
refer to the Use of Threadlockers and Sealants chart at the end of this
Repair Manual.
8.6
Front Drum Assembly Description
The front drum is designed to apply high frequency vibrations to the
ground to aid in compaction. Vibrations are produced by an eccentric
weight which rotates at a high speed inside the drum assembly. The
centrifugal force created by the revolving weight helps compress the
asphalt. This method of compaction produces results equal to or better
than those produced by larger and heavier static type rollers.
The front drum is driven by a single hydraulic motor (1) mounted to a
drive plate (2), which is shockmounted directly to the left side of the
drum. The drive motor is designed to provide low speeds and high
torques without the need for any type of speed reduction gears, belts
or pulleys.
The exciter assembly is driven by a gear-type hydraulic motor (3)
coupled directly to the exciter shaft. The exciter shaft turns inside the
drum and is supported on each end by heavy duty roller bearings (4).
The exciter is grease lubricated. There are two grease fittings, one on
each side of the machine, located behind the front drum supports.
A sealed drive bearing (5), along with three large shockmounts (6),
support the right side of the drum.
Weight plate (7) is used on early machines only (prior to REV. #103).
Note: Wacker Corporation does not recommend the disassembly or
attempted repair of hydraulic components (pumps, motors, or steering
cylinder) by anyone other than a trained hydraulic repair technician.
The repair and rebuilding of hydraulic components may be available
from component manufacturers. Hydraulic component parts are not
available from Wacker Corporation.
wc_tx000526gb.fm
192
RD 11 Repair
250 kg
(550 lbs.)
wc_gr000843
5
6
3
7
4
2
2
2
1
c
1
b
1
a
Ref.
a.
Description
RD 11AEC
wc_tx000526gb.fm
wc_gr001555
Ref.
Description
b.
RD 11A Parallel Drive
c.
RD 11A/V Series Drive
193
8.7
RD 11 Repair
Replacing the Exciter Motor
Removal:
8.7.1
Disconnect the hydraulic fittings (a) running to the exciter motor (b).
Cap all the fittings to reduce the risk of contaminating the hydraulic
system.
Note: If you need only to access the exciter, the hydraulic fittings can
remain connected to the exciter motor.
8.7.2
Remove the two screws (c) which secure the exciter motor to the drum
hub (d) and remove the exciter motor.
Installation:
wc_tx000526gb.fm
8.7.3
Place the key and the gear (e) of the coupling on the shaft of the exciter
motor (b). There is a set screw on the gear; do not tighten the set screw
at this time.
8.7.4
To obtain the correct placement of the gear on the shaft of the exciter
motor, insert the exciter motor into the drum so that the gear on the
motor shaft contacts the gear (f) on the exciter (g). Allow the gear on
the exciter to push the gear on the shaft. Be sure to position the exciter
motor so that its mounting flange meets the mating mounting surface
(h) of the drum hub.
8.7.5
Pull the exciter motor back out of the drum hub. Mark the position of
the gear on the motor’s shaft, then slide the gear 3 mm (1/8 in.) closer
to the exciter motor and tighten the set screw.
NOTICE: Do not slide the gear so far that it contacts the housing of the
exciter motor; damage to the exciter motor and the gear will result.
Also, there may be insufficient contact within the coupling.
8.7.6
Install the flexible portion (i) of the coupling onto the exciter.
8.7.7
Position the exciter motor back into the drum hub so that the gear on
the exciter motor’s shaft slides into the flexible portion of the coupling.
Using Loctite 243 or an equivalent on two screws (c), secure the
exciter motor to the drum hub. Torque the screws to 85 Nm (65 ft.lbs.).
194
RD 11 Repair
d
c
i
a
b
h
g
e
f
3 mm
(1/8 in.)
b
d
i
wc_gr003028
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195
8.8
RD 11 Repair
Removing the Front Drum
NOTICE: Before removing the drum, clean and wash the complete
drum assembly to remove as much dirt as possible. Be especially
thorough when cleaning the area around the tube and hose
connections on the motors. This will minimize the chance of
contamination when opening the hydraulic lines.
8.8.1
Block the back drum.
8.8.2
Open the tow valve.
8.8.3
Disconnect the battery.
8.8.4
Support the front end of the machine with an appropriate crane, jack
stands (a), or screw jacks.
Only use cranes, stands, or jacks with a suitable load-bearing capacity.
WARNING
8.8.5
On the right side of the machine (exciter motor side), remove the four
screws (b) which secure the drum support cover (c) to the drum
support and remove the drum support cover.
8.8.6
Remove the two screws (d) which secure the exciter motor (e) to the
drum support and place the exciter motor to the side.
8.8.7
On the right side of the machine remove the three nuts (f) which secure
the drum support (g) to the shock mount plate (h).
8.8.8
On the right side of the machine remove the four screws which secure
the drum support to the machine. Slide the drum support away from
the machine.
8.8.9
On the left side (drive motor side), remove the four screws (i) which
secure the drum support cover (j) to the drum support and remove the
drum support cover.
8.8.10 Remove the screw and clamp (k) which secures the hydraulic tube to
the manifold block.
8.8.11 Disconnect the hydraulic tubes (l and m) to the front drive motor. Plug
the fittings to reduce the risk of contamination to the hydraulic system.
8.8.12 Remove the four screws (p) which secure the left-side drum support
(q) to the machine.
8.8.13 Pull the drum (r) out from underneath the front frame.
wc_tx000526gb.fm
196
RD 11 Repair
g
c
b
h
d
f
f
e
l
m
g
p
j
k
q
r
i
a
wc_gr003029
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197
8.9
RD 11 Repair
Installing the Front Drum
wc_tx000526gb.fm
8.9.1
On the right side of the machine use Loctite 243 or an equivalent on
four screws and secure the right-side drum support to the machine.
Torque the screws to 118 Nm (87 ft.lbs.).
8.9.2
Position the drum underneath the machine. On the right side of the
machine install the three nuts (f) which secure the drum support (g) to
the shock mount plate (h).
8.9.3
Using Loctite 243 or an equivalent on two screws (d) secure the exciter
motor (e) to the drum support.
8.9.4
Using Loctite 243 or an equivalent on four screws (p) secure the leftside drum support (q) to the machine. Torque the screws to 118 Nm
(87 ft.lbs.).
8.9.5
Reconnect the hydraulic tubes (l and m). Install the screw and clamp
(k) which secures the hydraulic tube to the manifold block.
8.9.6
Using four screws for each, secure the drum support covers (c and j)
to the drum supports.
8.9.7
Close the tow valve.
8.9.8
Reconnect the battery
198
RD 11 Repair
g
d
h
f
f
e
p
j
q
l
i
m
k
c
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199
RD 11 Repair
8.10 Replacing the Exciter and Exciter Bearings
Exciter Removal:
8.10.1 Disconnect the exciter motor (a) from the drum hub.
8.10.2 Remove the four screws which secure the right-side drum support (b)
and position the drum support to the side.
8.10.3 To aid in installation, label or mark the position (c) of the shoulder on
the bearing flange.
8.10.4 Remove the six screws (d) which secure the bearing flange (e) and the
shockmount plate (f) to the drum hub and remove the bearing flange
and the shockmount plate.
8.10.5 Mark on the drum the position (g) of the drum hub (i).
8.10.6 Remove the six screws (h) securing the drum hub (i) to the drum and
carefully remove the drum hub from the drum. The exciter will drop out
of the drum hub when the drum hub is removed.
Note: The photos show the drum in an upright position; however, it is
not necessary to stand the drum on end to remove the drum hub.
8.10.7 Remove the exciter (j) from the drum.
Note: The photos show the drum in an upright position; however, it is
not necessary to stand the drum on end to remove the exciter.
wc_tx000526gb.fm
200
RD 11 Repair
f
e
a
c
d
b
i
h
j
g
j
wc_gr003031
wc_tx000526gb.fm
201
RD 11 Repair
Bearing removal:
8.10.1 On the exciter side of the drum, two bearings and their flanges make
up the drum hub (d). To disassemble the drum hub, carry out the
following procedures:
•
Remove the retaining ring (e).
•
Use a puller to pull the smaller bearing flange (f) and bearing (h)
from the shaft of the larger bearing flange (g). Then, use a press
to press out the bearing (h) from the smaller bearing flange.
•
On the larger bearing flange, remove the outer seal (i) and use
the two set screws (j) to push the outer bearing race (k1) from the
larger bearing flange.
•
Remove the inner seal (l) if necessary.
8.10.2 In order to remove the drive-motor-side exciter bearing, first remove
the drive motor and the left-side drum support from the machine. See
section Front Drive Motor.
8.10.3 Remove the six screws (a) which secure the drive-motor-side bearing
flange (b) and remove the bearing flange. Note: The drive-motor-side
bearing flange is removed from inside the drum.
8.10.4 Remove the two screws (m) from the drive-motor-side bearing flange
(b). In their place, insert two M8 pusher screws. Use the screws to
push the outer bearing race (c1) from the drive-motor-side bearing
flange (b).
8.10.5 Use a puller to remove the inner bearing races (c2 and k2) from the
exciter.
wc_tx000526gb.fm
202
RD 11 Repair
e
h
f
i
g
l
m
k1
j
d
a
c1
b
h
e
f
d
g
i
j
k2
c2
wc_gr003032
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203
RD 11 Repair
Bearing installation:
8.10.1 Press new inner bearing races (c2 and k2) onto the exciter.
8.10.2 Install the outer bearing race into the drive-motor-side bearing flange
(b).
8.10.3 Using Loctite 234 or an equivalent on six screws (a) secure the drivemotor-side bearing flange to the drum. Torque the screws to 49 Nm (36
ft.lbs.).
8.10.4 Be sure set screws (j) are recessed on the larger bearing flange (g).
Install a new inner seal (l). Lightly grease the outer bearing race and
press it into the larger bearing flange.
8.10.5 Install a new outer seal (i) on the shaft of the larger bearing flange.
8.10.6 Press the bearing (h) into the smaller bearing flange (f).
8.10.7 Press the two bearing flanges together to create the drum hub.
8.10.8 Install the retaining ring (e).
8.10.9 Lubricate the exciter bearings with wheel bearing grease Filmite EMB
or equivalent.
8.10.10 See Exciter Installation for procedures regarding installing the drum
hub.
Exciter Installation:
8.10.1 Install the key and the gear (h) of the exciter motor coupling onto the
exciter. Secure the gear to the exciter with the set screw.
8.10.2 Slide the exciter (a) through the drum and into the drive-motor-side
bearing race. Note: The photo shows the drum in an upright position;
however, it is not necessary to stand the drum on end to install the
exciter.
8.10.3 Temporarily install the exciter-side drum hub onto the drum using three
screws (b). Check the exciter for end-play. To do so, grab the exciter
(a) with a needle-nosed pliers and pull and push it back and forth inside
the drum. There needs to be 5±1 mm (3/16±1/16 in.) of end-play for
correct performance. If the correct amount of end-play is not found,
remove the drum hub and install shims (d) as needed to obtain the
correct amount of end-play. Then, using Loctite 243 or an equivalent
on six screws, secure the drum hub to the drum. Torque the screws to
49 Nm (36 ft.lbs.).
8.10.4 Using Loctite 243 or equivalent on six screws (e), secure the bearing
cover (f) and the shockmount plate (g) to the drum support. Torque the
screws to 50 Nm (36 ft.lbs.).
wc_tx000526gb.fm
204
RD 11 Repair
c
b
a
b
h
5 mm
(3/16 in.)
a
d
c
d
g
f
e
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8.11 Front Drive Motor (RD 11A and RD11V series drive)
Removal:
8.11.1 Remove the front drum. See section Removing the Front Drum.
8.11.2 With the drum standing on end, remove the three nuts (a) which secure
the drive motor assembly (b) to the drum.
8.11.3 Using an appropriate crane, lift the drive motor assembly out of the
drum and secure it in a vise as shown.
8.11.4 Back off the large nut (c) on the end of the drive motor until it is flush
with the end of the shaft of the drive motor.
8.11.5 Using a dead-blow hammer, strike the nut/shaft until the tapered motor
shaft is free from the drive hub assembly (d). Remove the nut
completely and slide the drive motor assembly from the hub assembly.
Note: If this method does not work, remove the six screws securing the
drive plate to the drum hub. Then, use a puller to pull the drum hub
from the drive motor.
8.11.6 Remove the four screws (e) which secure the motor guard (f) and
remove the motor guard.
8.11.7 Remove the four screws (g) which secure the drive motor (h) to the
drum support (i) and remove the drive motor.
8.11.8 Remove the hydraulic lines (j) and fittings from the drive motor.
Installation:
8.11.9 Install the hydraulic fittings to the drive motor (h).
8.11.10 Using Loctite 243 or an equivalent on four screws (g), secure the drive
motor (h) to the drum support (i). Torque the screws to 49 Nm (36
ft.lbs.)
8.11.11 Using Loctite 243 or an equivalent on six screws, secure the hub (d) to
the drive plate (l). Torque the screws to 49 Nm (36 ft.lbs.)
8.11.12 Install the key (k).
8.11.13 Place the hub/drive plate assembly onto the drive motor. Using Loctite
243 or an equivalent on nut (c) secure the hub/drive plate assembly to
the drive motor. Torque the nut to 410–540 Nm (300–400 ft.lbs.).
8.11.14 Attach the hydraulic lines (j) to the drive motor.
8.11.15 Using four screws (e), secure the motor guard (f) to the drum support.
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8.12 Front Drive Motor (RD 11A and RD 11V parallel drive)
Removal:
8.12.1 Remove the drive motor assembly from the drum. See Front Drum.
Place the drive motor assembly on a clean work bench.
8.12.2 Disconnect the hydraulic fitting (1) from the drive motor (2).
8.12.3 Remove the four screws (3) that mount the motor guard (4) to the drum
support (5).
8.12.4 Loosen the nut (6) on the end of the drive motor shaft. Rap on the end
of the shaft to break the shaft free of the taper in the drum hub (7). If
the shaft does not break free, employ a puller.
8.12.5 Remove the four screws (8) that mount the drive motor to the drum
support.
8.12.6 Remove the six screws (9) and the washers (10) that secure the drum
hub to the drive plate (11).
Installation:
8.12.7 Attach the drive motor (2) to the drum support (5). Secure the screws
(8) using Loctite 271 or an equivalent high-strength threadlocker and
torque the screws to 86 Nm (63 ft.lbs.).
8.12.8 Install the Woodruff key (12) in the motor shaft.
8.12.9 Attach the motor guard (4).
8.12.10 Install the drum hub (7) to the drive plate (11). Secure the screws (9)
using Loctite 271 or an equivalent and torque the screws to 49 Nm (36
ft.lbs.).
8.12.11 Place the drive plate and the hub on the motor shaft. Install the nut (6)
and torque it to 410–540 Nm (300–400 ft.lbs.).
8.12.12 Inspect the fitting and the piping O-rings for cracks and deterioration;
replace if necessary.
8.12.13 Fasten the hydraulic fitting (1) to the drive motor (2).
8.12.14 Connect the tube assemblies (13) to the drive motor.
WARNING
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Note: See sealant and torque reference charts in the back of this
manual for appropriate threadlocking adhesives and torque values.
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
tightened.
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8.13 Front Drive Motor RD 11AEC
Removal:
8.13.1 Remove the drive motor assembly from the drum. See Front Drum.
8.13.2 Disconnect the hydraulic fitting (1) from the drive motor (2).
8.13.3 Remove the four screws (3) that secure the motor guard (4) to the
drum support (5).
8.13.4 Remove the four screws (6) and washers (7) that secure the drum
support to the drive motor.
8.13.5 Remove the five screws (8) and washers (9) that secure the drive
motor to the drive plate (10).
Installation:
8.13.6 Secure the drive motor (2) to the drive plate (10). Secure screws (8)
and washers (9) using Loctite 271 or an equivalent high strength
threadlocker and torque them to 86 Nm (63 ft.lbs.).
8.13.7 Secure the drum support (5) to the drive motor. Secure the screws (6)
using Loctite 271 or an equivalent and torque them to 86 Nm (63
ft.lbs.).
8.13.8 Attach the motor guard (4).
8.13.9 Inspect the fitting and piping O-rings for cracks and deterioration;
replace if neccessary.
8.13.10 Fasten the hydraulic fitting (1) to the drive motor (2).
8.13.11 Install the completed drive assembly to the drum. Attach the drive plate
to the shockmounts (11) using locknuts (12).
8.13.12 Secure the bolts (13) holding the drum support to the frame using
Loctite 271 or an equivalent high strength threadlocker. Torque the
bolts to 118 Nm (88 ft.lbs.).
WARNING
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8.14 Rear Drum Assembly—Description
The rear drum operates as a static roller to aid in smoothing and
finishing. A plug (1) is provided on the right side, allowing the inside of
the drum to be filled with ballast. If water is used in areas where
temperatures are below freezing, add antifreeze or drain drum after
use.
Note: Drum capacity: 114 liters (30.2 gal.)
Added weight (water ballast): 113 kg (250 lbs.).
The rear drum is driven by a single hydraulic motor (2) mounted to a
drive plate (3), which is mounted directly to the left side of the drum.
The drive motor is designed to provide low speeds and high torques
without the need for any type of speed reduction gears, belts, or
pulleys.
On RD 11V & RD 11A machines (shown), a mechanical parking brake
(4) is attached to the drive plate on the left side and is engaged by the
operator.
On RD11 AEC machines, the parking brake is incorporated into the
drive motor and is automatically engaged.
The right side of the drum axle (5) is supported by a bearing block (6)
mounted directly to the drum support (7).
Note: Wacker Corporation does not recommend the disassembly or
attempted repair of hydraulic components (pumps, motors, steering
cylinder) by anyone other than a trained hydraulic repair technician.
The repair and rebuilding of hydraulic components may be available
from component manufacturers. Hydraulic component parts are not
available from Wacker Corporation.
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1
250 kg
(550 lbs.)
3
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8.15 Replacing Brake and Brake Cable
Removal:
8.15.1 Remove the screws which secure the seat plate and remove the seat/
seat plate assembly.
8.15.2 Disconnect the battery.
8.15.3 Remove the two screws (a) which secure the hand brake (b) and
remove the brake from the upper frame.
8.15.4 Remove the four screws (c) which secure the drum support plate (d)
and remove the drum support plate.
8.15.5 Remove the hitch pin (e) and the clevis pin (f) from the end of the
cable.
8.15.6 Remove the two screws (g), nuts, and bracket which secure the cable
to the machine.
8.15.7 Pull the cable (h) through the drum support and out from the machine.
8.15.8 Remove the cotter pin (i) from the castle nut (j) and remove the castle
nut.
8.15.9 Remove the arm (k) and the spring (l).
8.15.10 Remove the two screws (m) which secure the brake assembly to the
drive plate.
8.15.11 Remove the four screws (n) and nuts which secure the brake caliper
(o) together and remove the brake caliper from the machine.
Alternative
method
removing brake caliper:
for
8.15.1 Support the rear of the
machine with an appropriate
crane or hoist.
8.15.2 Disconnect the brake cable
from (z) the brake caliper (y).
x
8.15.3 Remove the two screws (x)
which hold the brake caliper.
8.15.4 Remove the three screws
(w) which secure the drive
plate to the shock mount
plate.
w
y
z
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8.15.5 Raise the machine (the drum should remain on the ground) enough to
remove the brake caliper.
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Installation:
8.15.1 Away from the machine, loosely install the four screws (n) and nuts (p)
which hold the brake caliper (o) together; do not tighten nuts.
8.15.2 Slide the brake caliper (o) around the drive plate; then tighten the four
screws (n) and nuts (p).
8.15.3 Place the brake caliper into position so that when installed the two
screws (m) will hold the brake caliper. Then, using Loctite 243 or an
equivalent on the two screws (m), secure the two screws to the brake
bracket.
8.15.4 Install the spring (l) and the arm (k).
8.15.5 Install the castle nut (j) and the cotter pin (i).
8.15.6 Install the two screws (g), nuts, and bracket which secure the cable (h)
to the machine.
8.15.7 Install the hitch pin (e) and the clevis pin (f).
8.15.8 Run the cable (h) through the drum support and connect it to the brake
handle.
8.15.9 Using two screws (a), secure the brake handle (b) to the upper frame.
8.15.10 Using four screws (c), secure the drum support plate (d) to the drum
support.
8.15.11 Reconnect the battery.
8.15.12 Using four screws, secure the seat/seat plate assembly to the machine
frame.
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8.16 Rear Drum (RD 11A and RD 11V revisions < 119)
Removal:
Stop the machine, apply the parking brake, switch off the machine, set
the locking arm and disconnect the battery.
thorough when cleaning the area around tube and hose connections
on the motors. This will minimize the chance of contamination when
opening the hydraulic lines.
8.16.1 Block the front drum.
8.16.2 Support the rear machine frame by placing blocks or screw jacks (20)
under the frame in front of both sides of the drum.
Only use blocks or jacks with a suitable load-bearing capacity. Do not
use improvised blocks or jacks.
WARNING
8.16.3 Open the tow valve. See Towing Valve.
8.16.4 Tag and disconnect the hoses to the tube assemblies (2). Cap or plug
all open connections to prevent spillage.
WARNING
Before dismantling the hydraulic connectors or hoses, ensure that all
pressure has been bled from the circuit. See Bleeding the Hydraulic
System.
and a container under the machine to collect the liquid which drains off
and dispose of them properly.
8.16.5 Remove the three screws (18) holding the brake bracket (19) to the
drum. Rotate the drum to gain access to all screws.
8.16.6 Remove the pin (14) that mounts the brake cable (15) to the brake
lever (16). Remove the nuts (17) from the cable clamp.
8.16.7 Remove the four screws (3) that mount the drum support cover (4) to
the drum support (5) on the right side.
8.16.8 Remove the four screws (6) that mount the drum support to the rear
frame.
8.16.9 Loosen the two set screws (7) which secure the bushing in the bearing
housing (8) to the drum axle (9).
8.16.10 Attach ropes or chains to the lifting eye of the drum support and
remove it from the drum.
WARNING
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Only use steel ropes or chains for hoisting. Ropes or chains must have
the suitable specified lifting capacity. Do not use improvised ropes or
chains.
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RD 11 Repair
8.16.11 Remove the four screws (10) that mount the drum support cover (11)
to the drum support (12) on the left side.
8.16.12 Remove the four screws (13) that mount the drum support to the
frame.
8.16.13 Pull the drum assembly out from the right side of the machine.
4
3
5
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9
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8
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8.17 Replacing Rear Drive Motor (RD 11A and RD 11V revisions <
104)
Removal:
8.17.1 Remove the drive motor assembly from the drum. See section Rear
Drum. Place it on a clean work bench.
support (3).
8.17.3 Loosen the nut (4) on the end of the shaft on the drive motor (5). Rap
on the end of the shaft to break the shaft free of the taper in the drum
hub (6). If the shaft does not break free, use a puller.
Note: Remove the six screws (10) and back disc away from the hub
(6). The puller can be used against the hub.
8.17.4 Remove the four screws (7) and nuts (8) that secure the drive motor
and brake bracket (9) to the drum support.
8.17.5 Remove the six screws (10) and washers (11) that mount the drum hub
to the drive plate (12).
8.17.6 Disconnect the hydraulic fitting (13) from the drive motor.
Installation:
8.17.7 Fasten the hydraulic fitting (13) to the drive motor.
8.17.8 Mount the drive motor (5) to the drum support (3). Secure the screws
torque to 86 Nm (63 ft.lbs.).
8.17.9 Secure the brake bracket (9) over the screw studs (7) and fasten with
locknuts (8).
8.17.10 Attach the motor guard (2) with screws (1).
8.17.11 Install the drum hub (6) to the drive plate (12). Secure the screws (10)
using Loctite 271 or an equivalent and torque screws to 49 Nm (36
ft.lbs.).
8.17.12 Place the drive plate and the hub on the motor shaft. Install the nut (4)
and torque to 410–540 Nm (300–400 ft.lbs.).
WARNING
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8.18 Replacing Rear Drive Motor (RD 11A and RD 11V revisions
104–118)
Removal:
8.18.1 Remove the drive motor assembly from the drum. See section Rear
Drum. Place it on a clean work bench.
support (3).
8.18.3 Loosen the nut (4) on end of the shaft on the drive motor (5). Rap on
end of the shaft to break it free of the taper in the drum hub (6). If the
shaft does not break free, use a puller.
Note: Remove the six screws (10) and back disc away from the hub
(6). The puller can be used against the hub.
8.18.4 Remove the four screws (7) and nuts (8) that mount the drive motor
and the brake bracket (9) to the drum support.
8.18.5 Remove the six screws (10) and washers (11) that mount the drum hub
to the drive plate (12).
Installation:
8.18.8 Mount the drive motor (5) to the drum support (3). Secure the screws
8.18.9 Mount the brake bracket (9) over screw studs (7) and fasten with
locknuts (8).
8.18.10 Install the Woodruff key (14) in the motor shaft.
8.18.12 Install the drum hub (6) to the drive plate (12). Secure screws (10)
using Loctite 271 or an equivalent and torque screws to 49 Nm (36
ft.lbs.).
8.18.13 Place the drive plate and hub on the motor shaft. Install the nut (4) and
torque to 410–540 Nm (300–400 ft.lbs.).
WARNING
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4
7
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2
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8.19 Removing the Rear Drum (RD 11A and RD 11V revisions > 118)
thorough when cleaning the area around the tube and hose
connections on the motors. This will minimize the chance of
contamination when opening the hydraulic lines.
8.19.1 Block the front drum.
8.19.2 Open the tow valve.
8.19.3 Support the rear of the machine with an appropriate crane, jack stands,
or screw jacks.
Only use cranes, stands, or jacks with a suitable load-bearing capacity.
WARNING
8.19.5 Disconnect and remove the battery.
8.19.6 Remove the screws (a) which secure the battery bracket (b) to the
upper frame and remove the battery bracket.
8.19.7 Remove the screw (c) which secures the bracket (d) and remove the
bracket.
8.19.8 Label, then disconnect the hydraulic hoses (e).
8.19.9 Remove the four screws (f) which secure the drum support plate (g) to
the drum support and remove the drum support plate.
8.19.10 Remove the hitch pin (h) and the clevis pin (i) from the brake
assembly. Also remove the two screws (j) which secure the cable
retaining bracket. Route the brake cable (o) away from the rear drum.
8.19.11 On the right side of the drum (side opposite that with the drive motor),
remove the four screws (k) which secure the bearing cover (l) to the
drum support.
8.19.12 On the left side of the drum (side with the drive motor) remove the four
screws (m) which secure the drum support (n) to the machine.
8.19.13 With the aid of an assistant or an appropriate crane, pull the rear drum
from the machine.
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8.20 Installing the Rear Drum (RD 11A and RD 11V revisions > 118)
8.20.1 On the right side of the drum (side opposite that with the drive motor),
use four screws (k) to secure the bearing cover (l) to the drum support.
8.20.2 Position the rear drum underneath the machine and into the bearing of
the right-side drum support.
8.20.3 On the left side of the drum (drum with the drive motor) use Loctite 243
or an equivalent on four screws (m) and secure the drum support (n)
to the machine. Torque the screws to 118 Nm (87 ft.lbs.).
8.20.4 Route the brake cable (o) through the drum support and to the brake.
Connect the cable to the brake with the clevis pin (i) and the hitch pin
(h).
8.20.5 Secure the cable bracket around the brake cable with screws (j).
8.20.6 Use four screws (f) to secure the drum support plate (g) to the drum
support.
8.20.7 Reconnect the hydraulic hoses (e).
8.20.8 Secure the hydraulic lines with the bracket (d) using screw (c).
8.20.9 Use four screws (a) to secure the battery bracket (b) to the upper
frame.
8.20.11 Use four screws to secure the seat/seat plate assembly to the frame.
8.20.12 Remove the jacks, jack stands, and blocks.
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8.21 Removing Rear Drive Motor (RD 11A and RD 11V revisions >
118)
8.21.1 Remove the rear drum from the machine. See section Removing the
Rear Drum.
8.21.2 Rotate the drive motor assembly as needed to reach the three screws
(a) which mount the drive plate to the drum. Remove the three screws.
Note: If the motor assembly is difficult to turn, you may need to loosen
the caps on the hydraulic lines leading to the motor to allow the release
of any hydraulic pressure. These are the caps connected to the lines
while removing the drum.
Using an appropriate crane, lift the drum support (b), with the drive
motor still attached, up and off of the drum.
8.21.3 Remove the brake assembly (c). See section Replacing the Brake.
8.21.4 Mount the assembly in a vise as shown.
8.21.5 Back off the large nut (d) until it reaches the end of the shaft.
8.21.6 Using a dead-blow hammer, strike the nut/shaft until the tapered motor
shaft is free from the drive hub assembly. Remove the nut completely
and slide the drive motor assembly from the hub assembly.
Note: If this method does not work, remove the six screws securing the
drive plate to the drum hub. Then, use a puller to pull the drum hub
from the drive motor.
8.21.7 Remove the four screws (e) which secure the motor protector plate (f)
and remove the motor protector plate.
8.21.8 Remove the nuts (g) which secure the brake bracket (h) and remove
the brake bracket.
8.21.9 Remove the screws (i) which secure the drive motor to the drum
support and remove the drive motor from the drum support.
8.21.10 Remove the hydraulic lines (j) and fittings from the drive motor.
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8.22 Installing Rear Drive Motor (RD 11A and RD 11V revisions >
118)
8.22.1 Install the fittings and hydraulic lines (j) to the drive motor.
8.22.2 Using Loctite 243 or an equivalent on four screws (i), secure the drive
motor to the drum support. Torque the screws to 85 Nm (62 ft.lbs.).
8.22.3 Secure the brake bracket (h) with nuts (g).
8.22.4 Use four screws (e) to secure the motor protector plate (f) to the drum
support.
8.22.5 Install the key on the drive motor. Place the hub/drive plate assembly
onto the drive motor. Using Loctite 243 on nut (d), secure the hub/drive
plate assembly to the drive motor. Torque the nut to 410–540 Nm
(300–400 ft.lbs.).
8.22.6 Reinstall the brake (c).
8.22.7 Using an appropriate crane, position the drum support/drive motor
assembly (b) on the drum. Using Loctite 243 or an equivalent on three
screws (a), secure the drive motor assembly to the drum. Torque the
8.22.8 Reinstall the rear drum. See section Removing the Rear Drum.
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8.23 Replacing Rear Drive Motor (RD 11AEC)
Removal:
8.23.1 Remove the drive motor assembly from the drum. See Rear Drum.
8.23.2 Remove the four screws (1) and washers that secure the motor guard
(2) to the drum support (3).
8.23.3 Remove the four screws (4) and washers (5) that secure the drum
support to the drive motor (6).
8.23.4 Remove the five screws (7) and washers (8) that secure the backing
plate (9) and drive plate (10) to the drive motor.
Installation:
8.23.7 Secure the drum support (3) to the drive motor (6). Secure the screws
8.23.9 Secure the drive plate (10) and backing plate (9) to the drive motor.
Secure the screws (7) using Loctite 271 or an equivalent and torque
WARNING
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7
4
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8.24 Replacing the Articulated Steering Joint
Removal:
8.24.1 Stop the machine, apply the parking brake, switch off the machine, and
8.24.2 Remove the front panel (a) and the floor (b).
8.24.3 Support the rear machine frame by placing blocks or screw jacks under
the frame both in front of and behind the drum.
8.24.4 Support the front half of the machine with an appropriate crane.
8.24.5 Remove the two screws (c) that mount each pillow block (d) to the
frame.
8.24.6 Disconnect the steering cylinder (f) from the pivot plate (h) by
removing the screws (e) and nuts. Place the steering cylinder in the
frame.
8.24.7 Remove the four screws (g) that mount the pivot plate (h) to the
articulated steering joint housing (l).
8.24.8 Remove the pin (i) and locknut (j) from the end of the articulated
steering joint shaft (k).
8.24.9 Remove the housing (l) from the shaft (k).
8.24.10 Inspect the bearings (n), (o), and (p) and replace them if necessary.
Use pullers to remove the bearings.
8.24.11 Remove the eight screws (m) that mount the articulated steering joint
shaft to the front frame.
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Installation:
This procedure requires Loctite 603 or an equivalent retaining
compound.
8.24.12 Press the bearings (n and p) into the articulated joint housing (l).
8.24.13 Using Loctite 243 or an equivalent on eight screws (m), secure the
articulated steering joint shaft (k) to the front frame. Torque the screws
to 118 Nm (87 ft.lbs.).
8.24.14 Place the seals (q) into the pillow blocks (d) and press the bearings (o)
into the pillow blocks. Lubricate the bearings with Shell Alvania No. 2
grease or equivalent.
8.24.15 Slide the housing (l) over the shaft (k) and secure it with a locknut (j).
Torque the locknut to 271 Nm (199 ft.lbs); then, insert the pin (i).
8.24.16 Using Loctite 243 or an equivalent on four screws, secure the pivot
plate (h) to the housing (l).
8.24.17 Secure the steering cylinder (f) to the pivot plate (h) with two screws
(e) and nuts. Torque the screws to 86 Nm (63 ft.lbs.).
8.24.18 Apply Loctite 603 or an equivalent retaining compound to the shafts of
the housing and install the bearing sleeves (q).
8.24.19 Using Loctite 243 or an equivalent on four screws, secure each pillow
block (d) to the frame. Torque the screws to 210 Nm (154 ft.lbs.).
8.24.20 Install the front panel (a) and the floor (b).
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d
c
h
o
f
j
q
g
l
p
i
n
k
q
o
m
d
c
g
h
m
g
c
a
d
b
e
e
f
c
d
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8.25 Throttle/Choke Cables (revisions 100–118)
Removal:
To replace either the throttle or choke cable:
8.25.1 Remove all the screws (1) holding the cover (2) to the steering column
and the frame.
Note: If the clip nuts (3) should loosen and fall out, save them for
installation of the cover.
8.25.2 Remove the cap (4) and nut (5) that secure the steering wheel (17) and
remove the steering wheel.
8.25.3 Remove all the screws (6) holding the control housing (7) to the
column bracket (8).
8.25.4 Remove the two screws (9) and nuts mounting the throttle/choke
bracket (11) to the column bracket.
8.25.5 Disconnect either throttle or choke cable from the engine.
8.25.6 Pull the cable (12) through the casing (13) and the lever (14).
To remove the casing:
Remove the screws (15) holding the clamp (16) to the throttle/choke
bracket.
Note: The throttle clamp, casing, and the cable are shown.
Installation:
8.25.7 Feed the cable (12) through the lever (14) and the casing (13).
8.25.8 Reconnect on the engine.
8.25.9 Assemble the throttle/choke bracket (11) to the column bracket (8) and
secure with screws (9).
8.25.10 Assemble the control housing (7) to the column bracket (8) and secure
with screws (6).
8.25.11 Assemble the steering wheel (17) onto the column and secure with nut
(5). Place the cap (4) over the nut.
8.25.12 With all the clip nuts (3) in place assemble the cover (2) to the steering
column and the frame.
WARNING
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4
5
12
14
17
6
9
7
8
2
3
15
11
1
13
16
1
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8.26 Choke Cable (revisions > 118)
Removal:
8.26.1 Loosen the two screws (a) which retain the cable to the engine.
8.26.2 Remove the front console plate (b).
8.26.3 Remove the shoulder bolt (c).
8.26.4 Remove the two screws and nuts which secure the cable clamp (d)
and remove the cable clamp.
8.26.5 Feed the choke cable (e) through the engine compartment, through the
control console, and up and out of the machine.
Installation:
8.26.6 Feed the choke cable (e) through the control console, through the
machine, and into the engine compartment.
8.26.7 Using Loctite 243 or an equivalent on the shoulder bolt (c), secure the
choke lever to the bracket.
8.26.8 Using two screws and nuts, secure the cable with the cable clamp (d).
8.26.9 Connect the cable to the engine with screws (a).
8.26.10 Reinstall the front console plate (b).
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d
e
b
a
c
d
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8.27 Drive Control Cable (revisons 100–109)
Removal:
Stop the machine, apply the parking brake, switch off the machine, and
8.27.1 Remove the two front screws (1) holding the drive control (2) to the
frame. Loosen the two rear screws (3) only half way and remove the
complete drive control assembly from the rear frame.
Removing the drive control cable:
8.27.2 Disconnect the cable (4) from the hydraulic pump (8) in the front
section.
8.27.3 Remove the pin (5) from the cable swivel connector (6).
8.27.4 Loosen the clamp (7) holding the cable to the lower bracket and
remove the cable.
Removing the neutral safety switch:
8.27.5 Disconnect the wiring (9) from the main harness.
8.27.6 Remove the two black wires (10) from the connector (positions E and
F).
8.27.7 Remove the screw (11) which secures the switch (12) to the lower
bracket.
8.27.8 Remove the pin (13) holding the switch to the lever arm.
Removing the hand grip housing:
8.27.9 Remove the screws (14) holding the grip housing (15) and switch cap
(16) to gain access to the switch.
Installation:
Installing the neutral safety switch:
8.27.10 Place the end of the mounting switch (12) into the hole of the lever arm
bracket, and assemble the washer (17) and insert pin (13).
8.27.11 Secure the other end of the switch to the lower bracket. Secure the
switch with screw (11) and nut (21).
Note: Make sure the spacer (18), washer (19), and star washer (20)
are assembled as shown.
8.27.12 Reconnect the two black wires (10) to the connector (E & F).
8.27.13 Reconnect the wiring (9) to the main harness.
Installing the drive control cable:
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8.27.14 Route the cable through the clamp (7) and place the end of the cable
(4) with the cable swivel connector (6) into the hole of the lever arm
bracket and insert the pin (5) into the swivel connector.
8.27.15 Secure the cable to the lower bracket by tightening the clamp.
8.27.16 Route the cable through the rear frame and across the articulated joint.
Secure the cable to the hydraulic pump (8).
Note: For adjusting the cable, see Adjusting the Drive Control Cable.
8.27.17 When mounting the drive control (2), the frame is to be in between the
upper black plate (22) and the lower bracket (23). Secure it with screws
(1) and (3).
WARNING
tightened.
14
16
15
2
1
14
8
3
22
5
6
13
17
12
11
21
20
23
19
7
4
18
10
9
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8.28 Drive Control Cable (revisons > 109)
Removal:
8.28.3 Disconnect the wiring harness from the forward/reverse control at the
connector (a).
8.28.4 Remove the screws (b) which secure the forward/reverse control to the
upper frame and remove the forward/reverse control from the upper
frame.
8.28.5 Remove the nut (c) which secures the cable to the control arm (d) of
the drive pump.
8.28.6 Remove the turnbuckle (e) from the cable as shown.
8.28.7 Remove the nut (f) which secures the cable to the machine frame.
Slide the nut and the lockwasher off the end of the cable.
8.28.8 Cut the two wire (g) ties at the articulating steering joint.
8.28.9 Pull the cable through the machine frame and out of the machine.
8.28.10 Remove pin (h) from the cable swivel connector (i).
8.28.11 Loosen the clamp (j) holding the cable to the lower bracket and remove
the cable.
8.28.12 To remove the neutral safety switch (k), remove the screw (l) and hitch
pin.
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b
d
e
c
f
i
h
g
k
l
j
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Installation:
8.28.1 Install the neutral safety (k) switch with the screw (l), washer and hitch
pin (m). Be sure the star washer (x), washer (y), and spacer (z) are
positioned as shown.
8.28.2 Connect the cable with pin (h) and swivel connector (i).
8.28.3 Secure the cable to the lower bracket with clamp (j).
8.28.4 Feed the cable through the rear frame, across the articulated steering
joint, and into the front frame. Arrange the cables as shown and secure
the cables with two new wire ties (g1 and g2).
g1
3
4
5
6
2
g2
1
9
8
7
wc_gr003060
1
Choke cable
6
Water hose
2
Brake cable
7
Drive control cable
3
Electrical
8
Reverse hydraulic hose
4
Forward hydraulic hose
9
Pressure hose
5
Tank hydraulic hose
-
---
8.28.5 Secure the cable to the front frame with nut (f).
8.28.6 Install the turnbuckle (e) to the end of the cable.
8.28.7 Secure the cable to the control arm (d) with nut (c).
8.28.8 Secure the forward/reverse control to the upper frame with four screws
(b) and plate (n).
8.28.9 Connect the wiring harness (a).
8.28.11 Reinstall the seat/seat plate.
8.28.12 Adjust the drive control cable. See section Adjusting the Drive Control
Cable.
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h
k
b
l
j
h
i
m
a
x
y
k
z
l
n
g1
g2
d
f
e
c
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8.29 Replacing the Water Tank
Removal:
8.29.1 Using an appropriate crane, support the ROPS (a).
8.29.2 Remove the screws (b) which secure the ROPS and remove the
ROPS.
8.29.3 Remove the seven screws (c) which secure the back panel (d) and
remove the back panel.
8.29.4 Remove the four screws (e) from underneath the frame and pull the
water tank (f) slightly out of the machine. Then, remove the two hoses
(g) connected to the water tank.
8.29.5 Remove the water tank fully from the machine.
Installation:
8.29.6 Position the water tank (f) within the frame.
8.29.7 Connect the two hoses (g) to the water tank.
8.29.8 Secure the water tank to the frame with four screws (e).
8.29.9 Secure the back panel (d) with seven screws (c).
8.29.10 Using Loctite 243 or an equivalent on screws (b), secure the ROPS (a)
to the frame. Torque the screws to 120 Nm (88 ft.lbs.).
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c
f
e
a
d
b
c
g
f
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8.30 Replacing Water Valves
Removal:
8.30.1 Remove water tank. See section Replacing Water Tank.
8.30.2 Remove the two screws and nuts from each water-valve control rod
(a). Unscrew each rod from each valve.
Note: The handles (b) on each rod are pressed on. If you have
difficulty keeping the handles on the rods, use a high-strength
adhesive to bond the handles to the rods.
8.30.3 Make note of the positions of the valve-turning brackets (c); then
remove them.
8.30.4 Remove the hoses (d) from the valves.
8.30.5 Remove the two screws (e) which secure each valve (f) to the valve
mounting brackets; remove the valves from the machine.
Installation:
8.30.6 Secure each valve (f) to the valve mounting bracket with two screws
(e).
8.30.7 Connect the hoses (d) to each valve.
8.30.8 Install the valve-turning brackets (c).
8.30.9 Thread the water-valve control rod (a) onto the valve and secure it with
two screws and nuts.
8.30.10 Install the water tank. See section Replacing Water Tank.
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a
c
e
f
a
c
e
f
d
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8.31 Replacing the Fuel Tank
Removal:
8.31.2 Disconnect and remove the battery.
8.31.3 Support the ROPS with an appropriate overhead crane.
8.31.4 Remove the screws which secure the ROPS and remove the ROPS.
8.31.5 Remove the seven screws securing the back panel and remove the
back panel (a).
8.31.6 Remove the four screws underneath the frame which secure the water
tank. Disconnect the water hoses (b) from the water tank (c) and
remove the water tank. See section Replacing Water Tank.
8.31.7 Disconnect the wiring harness (d) from the forward/reverse control at
the connector. Remove the screws which secure the forward/reverse
control to the upper frame and remove the forward/reverse control (e)
from the upper frame.
8.31.8 Remove the two screws and nuts from the water-valve control rods (f).
Unscrew each rod from each valve.
8.31.9 Remove the screws which secure the brake handle and remove the
brake handle from the upper frame.
8.31.10 Remove the four nuts which secure the fuel tank nozzle (g) to the
upper frame.
8.31.11 Remove the screws which secure the front plate (h) and remove the
front plate.
8.31.12 Remove the screws which secure the floor plate (i) and remove the
floor plate.
8.31.13 Remove the eight screws which secure the upper frame (j). Then, with
the aid of an assistant, pull the upper frame up and off the machine.
8.31.14 Remove the four screws which secure the fuel gauge (k) to the lower
frame.
8.31.15 Disconnect and plug the fuel hose at the fuel filter.
8.31.16 Remove the two screws which secure the fuel tank (l) to the lower
frame, and the two screws which secure the fuel tank to the lower
frame from underneath the frame. With the aid of an assistant, pull the
fuel tank up and out of the lower frame.
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a
j
i
b
c
h
l
e
d
f
k
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Installation:
8.31.1 Position the fuel tank (l) within the frame. Secure it to the frame with
four screws.
8.31.2 Connect the fuel hose at the fuel filter.
8.31.3 Secure the fuel gauge (k) with four screws.
8.31.4 With the aid of an assistant, position the upper frame (j) on the lower
frame and secure it with eight screws.
8.31.5 Secure the floor plate (i) to the lower frame.
8.31.6 Secure the front plate (h) to the lower frame and control tower.
8.31.7 Secure the fuel tank nozzle (g) to the upper frame.
8.31.8 Secure the brake handle to the upper frame with two screws.
8.31.9 Screw the water-valve control rods (f) onto the valves and secure them
with screws and nuts.
8.31.10 Secure the forward/reverse control (e) to the upper frame and
reconnect the wiring harness (d).
8.31.11 Position the water tank into the frame. Reconnect the water hoses (b)
to the water tank (c).
8.31.12 Install the back panel (a).
8.31.13 Reinstall the ROPS.
8.31.14 Reinstall and reconnect the battery.
8.31.15 Reinstall the seat/seat plate assembly.
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j
i
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l
e
d
b
a
c
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8.32 Replacing Steering Cylinder
Removal:
8.32.2 Remove the front console plate (a).
8.32.3 Disconnect the wiring harness (b) from the key switch (c), throttle
switch (d), and vibration indicator light (e).
8.32.4 Remove the plastic cap (f) from the center of the steering wheel.
8.32.5 Remove the nut (g) which secures the steering wheel and remove the
steering wheel.
8.32.6 Remove the three screws (h) which secure the control console cover.
8.32.7 Remove the two screws (i) which secure the choke cable bracket (j).
Allow the bracket with the choke lever attached to dangle freely.
8.32.8 Remove the control console cover (k) from the machine.
8.32.9 Label the four hydraulic hoses (l) leading into the steering valve. Then,
disconnect the hydraulic hoses and cap them as soon as they are
disconnected to reduce the risk of contaminating the hydraulic system.
8.32.10 Remove the four screws (m) securing the steering valve (n) to the
machine and remove the steering valve.
Installation:
8.32.11 Using four screws (m), secure the steering valve (n) to the machine.
Torque the screws to 25 Nm (18 ft.lbs.)
8.32.12 Connect the four hydraulic hoses (l) to the steering valve.
8.32.13 Position the control console cover (k) on the machine but do not
secure it to the machine.
8.32.14 Using two screws (i), secure the choke cable bracket (j) to the
machine.
8.32.15 Using the three screws (h), secure the control console cover.
8.32.16 Position the steering wheel and secure it to the machine with nut (g).
Install plastic cap (f).
8.32.17 Connect the wiring harness (b) to the throttle switch (c), key switch (d),
and vibration indicator light (e).
8.32.18 Install the front console plate (a).
8.32.19 Connect the battery.
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c
f
g
b
d
k
h
i
n
j
a
n
i
m
j
l
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8.33 Replacing the Drive Pump
NOTICE: The failure of a drive pump or motor caused by factors other
than normal wear can contaminate the drive circuit with metal particles.
Removal:
8.33.1 Thoroughly clean the pump and hose connections.
Burn hazard! The pump may be hot; use care when working with
hydraulic components and oil. Hot oil can burn!
WARNING
8.33.2 Tag and disconnect the hose lines (6) from the pump. Cap or plug all
open connections to reduce the risk of contaminating the hydraulic
system.
WARNING
System.
8.33.3 Disconnect the cable (7) from the control lever (5).
8.33.4 Remove the support bracket (8) from the exciter pump (9). Save the
locknuts (10) and washers (11) for installation.
8.33.5 Remove the two locknuts (12) holding the exciter pump to the drive
pump (13).
8.33.6 Remove the two screws (14) holding the drive pump to the engine/
pump adapter.
8.33.7 Remove the control lever (5), hydraulic fittings (4), O-ring (3), coupling
(2), and key (1), and transfer them to the new pump.
Installation:
8.33.8 Install the new pump and fasten it to the engine/pump adapter. Secure
the mounting screws (14) using Loctite 271 or an equivalent highstrength threadlocker.
8.33.9 Install the exciter pump (9) to the new drive pump using locknuts (12).
8.33.10 Install the support bracket (8) to the exciter pump using locknuts (10)
and washers (11).
8.33.11 Reconnect the hose lines (6) to the fittings.
8.33.12 Bleed the drive circuit.
NOTICE: It is recommended that the drive circuit be flushed after a
pump failure to remove any contaminants which may be trapped in the
lines.
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tightened.
WARNING
6
4
6
4
14
1
13
2
5
4
3
11
7
9
10
6
12
8
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8.34 Replacing the Exciter Pump
Removal:
8.34.1 Thoroughly clean the pump and hose connections.
Burn hazard! The pump may be hot; use care when working with
hydraulic components and oil. Hot oil can burn!
WARNING
8.34.2 Tag and disconnect the hose lines (1) from the exciter pump (3). Cap
or plug all open connections to reduce the risk of contaminating the
hydraulic system.
WARNING
System.
8.34.3 Remove the support bracket (2) from the exciter pump (3). Save
locknuts (4) and washers (5) for installation.
8.34.4 Remove the two locknuts (6) holding the exciter pump to the drive
pump (7).
8.34.5 Remove the O-ring (8), coupling (9) and fittings (10) and transfer them
to the new pump.
Installation:
8.34.6 Install the new exciter pump (3) to the drive pump (7) using locknuts
(6).
8.34.7 Install the support bracket (2) to the exciter pump using locknuts (4)
and washers (5).
8.34.8 Reconnect the hose lines (1) to the fittings (10).
8.34.9 Bleed the hydraulic system before starting the engine.
WARNING
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1
9
8
5
3
4
6
10
2
1
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8.35 Replacing the Engine
Removal:
Stop the machine, apply the parking brake, switch off the machine and
8.35.1 Tag and disconnect all the electrical connections, hoses and the
throttle cable that are attached to the engine.
8.35.2 Tag and disconnect all the hose lines from the exciter and the drive
pumps. Disconnect the control lever cable mounted to the drive pump
(1). Cap all open connections.
WARNING
System.
8.35.3 Remove the pump support bracket at the front of the exciter pump (2).
8.35.4 Remove the muffler (3). Save all hardware (4) and gaskets (5) for
remounting to the new engine.
8.35.5 Attach lifting ropes or chains to the engine’s lifting device.
the suitable lifting capacity. Do not use improvised ropes or chains.
WARNING
8.35.6
Remove the screws (6) and nuts (7) that secure the engine to the
frame.
8.35.7 Leaving the pump mounted to the engine, lift the engine slightly to
check that it is correctly balanced.
8.35.8 Lift and remove the engine from the machine.
Do not stand under, or get near the engine, while it is being hoisted or
moved.
WARNING
8.35.9 Remove the engine/pump adapter (8), shaft coupling (9), shaft spacer
(10), and key (11).
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4
5
3
10
9
13
7
11
14
12
8
1
2
15
6
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Installation:
8.35.10 Slide the shaft spacer (10) on to the engine crankshaft.
8.35.11 Place the key (11) in the groove of the shaft and tap the shaft coupling
(9) over it against the end of the spacer.
8.35.12 Apply a medium-strength threadlocker to the set screw (12) and
tighten it down to secure the coupling in place.
8.35.13 Mount the adapter (8) and the muffler bracket (13) to the engine.
Torque the screws (14) to 31 Nm (23 ft. lbs.).
8.35.14 Attach the pump assembly (15) to the engine.
8.35.15 Attach the lifting ropes or chains to the engine’s lifting device.
the suitable lifting capacity. Do not use improvised ropes or chains.
WARNING
8.35.16 Lift the engine and place it into the machine.
8.35.17 Install the pump support bracket onto the exciter pump.
8.35.18 Secure the engine to the frame reusing the screws (6) and nuts (7).
8.35.19 Attach the pump support bracket to the frame.
8.35.20 Attach the muffler (3) to the engine reusing the gaskets (5) and nuts
(4).
8.35.21 Attach all the hose lines to the pumps.
8.35.22 Attach all electrical wiring and the throttle cable to the engine.
8.35.23 Attach the control cable to the drive pump (1). The drive control cable
may need to be adjusted. See Adjusting the Drive Control Cable.
8.35.24 The engine speed (RPM) may need to be adjusted. See Engine Speed
Adjustment.
WARNING
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264
Threadlockers and Sealants
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
Loctite 222
Hernon 420
Omnifit 1150 (50M)
COLOR USAGE
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)
Blue
Medium strength, for locking threads
Loctite 243
Hernon 423
larger than 6 mm (1/4”).
Omnifit 1350 (100M)
Hand tool removable.
Loctite 271/277
Red
High strength, for all threads up to 25 mm
Hernon 427
(1”).
Omnifit 1550 (220M)
Heat parts before disassembly.
Loctite 290
Green Medium to high strength, for locking
Hernon 431
preassembled threads and for sealing
Omnifit 1710 (230LL)
weld porosity (wicking).
Gaps up to 0.13 mm (0.005”)
Loctite 609
Green Medium strength retaining compound for
Hernon 822
slip or press fit of shafts, bearings, gears,
Omnifit 1730 (230L)
pulleys, etc.
Gaps up to 0.13 mm (0.005”)
Loctite 545
Brown Hydraulic sealant
Hernon 947
Omnifit 1150 (50M)
Loctite 592
White
Pipe sealant with Teflon for moderate
Hernon 920
pressures.
Omnifit 790
Loctite 515
Purple Form-in-place gasket for flexible joints.
Hernon 910
Fills gaps up to 1.3 mm (0.05”)
Omnifit 10
PART NO. –
SIZE
73287 - 10 ml
29311 - .5 ml
17380 - 50 ml
29312 - .5 ml
26685 - 10 ml
73285 - 50 ml
28824 - .5 ml
25316 - 10 ml
29314 - .5 ml
79356 - 50 ml
26695 - 6 ml
73289 - 50 ml
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
Loctite 496
Clear
Instant adhesive for bonding rubber, metal
Hernon 110
and plastics; general purpose.
Omnifit Sicomet 7000
For gaps up to 0.15 mm (0.006”)
Read caution instructions before using.
Loctite Primer T
Aerosol Fast curing primer for threadlocking,
Hernon Primer 10
Spray
retaining and sealing compounds. Must
Omnifit VC Activator
be used with stainless steel hardware.
Recommended for use with gasket
sealants.
PART NO. –
SIZE
52676 - 1oz.
2006124-6 oz.
Torque Values
Torque Values
Metric Fasteners (DIN)
TORQUE VALUES (Based on Bolt Size and Hardness)
8.8
10.9
WRENCH SIZE
12.9
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
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 90
Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957
Wacker 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