RT 560 RT 820 - Wacker Neuson

Transcription

www.wackergroup.com
0117935
005
0206
en
Roller
RT 560
RT 820
REPAIR MANUAL
0
1
1
7
9
3
5
Foreword
This manual covers machines with Item Number:
0009000, 0009001, 0009002, 0009003
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.
wc_tx000471gb.fm
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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 2006 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.
wc_tx000471gb.fm
ii
RT 560 / RT 820 Repair
1.
Safety Information
1.1
1.2
1.3
1.4
1.5
2.
6
Operating Safety .................................................................................. 6
Operator Safety while using Internal Combustion Engines .................. 9
Service Safety ...................................................................................... 9
Label Locations .................................................................................. 11
Warning and Informational Labels ...................................................... 13
Technical Data
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3.
Table of Contents
17
Revision Levels—Older Machines ..................................................... 17
Engine—Older Machines ................................................................... 17
Roller—Older Machines .................................................................... 18
Lubrication—Older Machines ............................................................. 18
Revision Levels—Newer Machines .................................................... 19
Engine—Newer Machines .................................................................. 19
Roller—Newer Machines .................................................................... 20
Lubrication—Newer Machines ........................................................... 20
Sound and Vibration Measurements .................................................. 21
Maintenance
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
3.15
3.16
3.17
22
Periodic Maintenance Schedule ......................................................... 22
Transporting Machine ......................................................................... 23
Lifting Machine ................................................................................... 23
Battery ................................................................................................ 24
Air Cleaner ......................................................................................... 26
Engine Oil System .............................................................................. 27
Engine Oil ........................................................................................... 28
Valve Clearances ............................................................................... 28
Engine Fuel Delivery System Maintenance ........................................ 29
Fuel Filter ........................................................................................... 29
Priming the Fuel System .................................................................... 30
Articulated Steering Joint & Steering Cylinder ................................... 30
Drive Gearcase .................................................................................. 31
Exciter Lubrication .............................................................................. 32
Cleaning Engine Cooling Fins ............................................................ 33
Scrapers ............................................................................................. 34
Shockmounts ...................................................................................... 34
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1
Table of Contents
3.18
3.19
3.20
3.21
3.22
3.23
3.24
3.25
3.26
3.27
3.28
3.29
3.30
3.31
3.32
3.33
3.34
3.35
3.36
3.37
4.
Cleaning CombiControl Transmitter ....................................................35
Hydraulic Oil Requirements .................................................................36
Hydraulic Fluid Level ...........................................................................36
Changing Hydraulic Oil & Filter ...........................................................37
Changing Drums .................................................................................38
Storage ................................................................................................39
Jobsite Storage ...................................................................................39
Hydrauic Schematic ............................................................................40
Hydraulic Schematic Components ......................................................41
Hydraulic Diagram ...............................................................................42
Hydraulic Diagram Components .........................................................43
Electrical Schematic (Main) .................................................................44
Electrical Schematic (Main) Components ...........................................44
Electrical Diagram (Main) ....................................................................46
Electrical Diagram (Main) Components ...............................................47
Electrical Schematic (Engine) .............................................................48
Electrical Schematic (Engine) .............................................................49
Electrical Diagram (Engine) .................................................................50
Electrical Diagram (Engine) .................................................................51
Troubleshooting ...................................................................................52
Hydraulic System
4.1
4.2
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
54
Hydraulic Flow Diagram—Older Machines .........................................54
Flow Diagram Components—Older Machines ....................................55
Flow Diagram—Newer Machines .......................................................56
Flow Diagram Components—Newer Machines ..................................57
Hydraulic System ................................................................................58
Hydraulic Hose Connections—Older Machines ..................................60
Hydraulic Hose Connection Components—Older Machines ...............61
Control Valve Block .............................................................................64
Control Valve Block Components .......................................................65
High-Speed Travel Circuit Description ................................................67
High-Speed Travel Circuit ...................................................................68
High-Speed Travel Circuit Components ..............................................69
Low-Speed Travel Circuit ....................................................................70
Low-Speed Travel Circuit Components ...............................................71
Low-Speed Travel Circuit Description .................................................72
Exciter Circuit Description ...................................................................73
Exciter Circuit ......................................................................................74
Exciter Circuit Components .................................................................75
2
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26
4.27
4.28
4.29
5.
Table of Contents
Steering Circuit Description ................................................................ 76
Steering Circuit ................................................................................... 77
Hydraulic System Cleanliness ............................................................ 78
Hydraulic Oil Requirements ................................................................ 78
Checking Hydraulic Pressures ........................................................... 79
Checking Drive Circuit ........................................................................ 80
Checking Steering Circuit ................................................................... 81
Checking Vibration Circuit .................................................................. 82
Testing Drive & Exciter Circuit Relief Valves ...................................... 82
System Pressures .............................................................................. 83
Troubleshooting Hydraulic System ..................................................... 84
Disassembly/Reassembly—Older Machines
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
5.14
5.15
5.16
5.17
5.18
5.19
5.20
5.21
5.22
5.23
5.24
5.25
5.26
5.27
85
Tools ................................................................................................... 85
Ordering Parts .................................................................................... 85
Reference Numbers ( ) ....................................................................... 85
Weight Block ...................................................................................... 85
Drum Assembly Exploded View ......................................................... 86
Drum Assembly Components ............................................................. 87
Drums ................................................................................................. 88
Drum Support Cover .......................................................................... 90
Drive Bearings and Seals ................................................................... 92
Drive Housing ..................................................................................... 94
Changing Oil ....................................................................................... 96
Drive Housing Assembly ................................................................. 98
Drive Housing Components ............................................................... 99
Brake ................................................................................................ 100
Servicing Brake ................................................................................ 102
Drive Motor ....................................................................................... 104
Drive Housing Components ............................................................. 106
Exciter Assembly Exploded View ..................................................... 110
Exciter Assembly Components ........................................................ 111
Introduction ....................................................................................... 112
Oil Requirements .............................................................................. 112
Exciter .............................................................................................. 113
Exciter Exploded View ...................................................................... 114
Exciter Disassembly ......................................................................... 115
Exciter Assembly .............................................................................. 117
Exciter Motor, Coupling, & Pinion Gear ............................................ 120
Exciter Motor, Coupling, & Pinion Gear Removal ............................ 121
3
Table of Contents
5.28
5.29
5.30
5.31
5.32
5.33
5.34
5.35
5.36
5.37
5.38
5.39
5.40
5.41
5.42
5.43
5.44
5.45
5.46
5.47
5.48
5.49
5.50
5.51
5.52
5.53
6.
Exciter Motor, Coupling, & Pinion Gear Installation ..........................122
Exciter Motor .....................................................................................124
Shockmounts .....................................................................................124
Shockmount Assembly .................................................................... 125
Replacing Outer Shockmounts ..........................................................126
Replacing Inner Shockmounts ..........................................................128
Hydraulic Hose Clamps .....................................................................130
Hydraulic Hose Clamp Components .................................................131
Drum Supports ..................................................................................131
Drum Support Exploded View ...........................................................132
Replacing Drum Supports .................................................................133
Articulated Joint and Steering Cylinder Exploded View ....................134
Articulated Joint and Steering Cylinder Components ........................135
Replacing Articulated Joint ................................................................136
Steering Cylinder ...............................................................................138
Drive Pump and Coupling Assembly Exploded View ........................140
Drive Pump and Coupling Assembly Components ...........................141
Replacing Drive Pump and Coupling ................................................142
Removing Engine Cover ...................................................................144
Removing Engine ..............................................................................146
Installing Engine ................................................................................148
Replacing Muffler ..............................................................................150
Replacing Engine Air Cleaner ...........................................................150
Engine Relays ...................................................................................151
Miscellaneous Engine Components ..................................................152
Engine Wiring ....................................................................................154
Disassembly/Reassembly—Newer Machines
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
157
Tools ..................................................................................................157
Ordering Parts ...................................................................................157
Reference Numbers ( ) ......................................................................157
Weight Block .....................................................................................157
Drum Support Exploded View ...........................................................158
Drum Support Components ...............................................................159
Identifying Drum Supports .................................................................160
Removing Drums ...............................................................................161
Installing Drums .................................................................................162
Opening Drum ...................................................................................162
Closing Drum .....................................................................................163
Disassembling Drive Hub ..................................................................164
4
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
7.
Table of Contents
Reassembling Drive Hub .................................................................. 166
Disassembling Slave Hub ................................................................ 168
Reassembling Slave Hub ................................................................. 170
Rebuilding Brake .............................................................................. 172
Exciter Exploded View ...................................................................... 174
Exciter Parts List .............................................................................. 175
Disassembling Exciter ...................................................................... 176
Reassembling Exciter ....................................................................... 178
Removing Drum Support .................................................................. 180
Installing Drum Support .................................................................... 182
CombiControl/Electrical System
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
184
CombiControl Features .................................................................... 184
CombiControl Operation ................................................................... 184
Decoder Module ............................................................................... 186
Setting Control Channels ................................................................. 186
CombiControl Control Cable ............................................................ 188
CombiControl Receiving Eye Module ............................................... 190
CombiControl Wiring ........................................................................ 192
CombiControl Transmitter Module ................................................... 193
Wiring Schematic—Decoder Module, Control Panel & Engine ........ 194
5
Safety Information
1.
RT 560 / RT 820
Safety Information
This manual contains DANGER, WARNING, CAUTION, 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 an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
DANGER
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
WARNING
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
CAUTION
CAUTION: Used without the safety alert symbol, CAUTION indicates
a potentially hazardous situation which, if not avoided, may result in
property damage.
Note: Contains additional information important to a procedure.
1.1
Operating Safety
WARNING
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Familiarity and proper training are required for the safe operation of
equipment. Equipment 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 equipment before
being allowed to operate the machine.
6
RT 560 / RT 820
wc_si000157gb.fm
Safety Information
1.1.1
ALWAYS operate machine with all safety devices and guards in place
and in working order. DO NOT modify or defeat safety devices. DO
NOT operate machine if any safety devices or guards are missing or
inoperative.
1.1.2
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.
1.1.3
ALWAYS check that all controls are functioning properly immediately
after start-up! DO NOT operate machine unless all controls operate
correctly.
1.1.4
ALWAYS remain aware of changing positions and the movement of
other equipment and personnel on the job site.
1.1.5
ALWAYS remain in visual contact with machine at all times while
operating controls.
1.1.6
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.
1.1.7
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.
1.1.8
ALWAYS position yourself safely when operating machine in reverse
or on hills. Leave enough space between yourself and the machine so
you will not be placed in a hazardous position should the machine slide
or tip.
1.1.9
ALWAYS use the neck strap for the SmartControl™ Transmitter
(control box) provided by WACKER. This neck strap is designed to
break away so that the operator will not be injured should the machine
slide, tip, or fall.
1.1.10
ALWAYS wear protective clothing appropriate to the job site when
operating equipment.
1.1.11
ALWAYS remain aware of moving parts and keep hands, feet, and
loose clothing away from the moving parts of the equipment.
1.1.12
ALWAYS read, understand, and follow procedures in the Operator’s
Manual before attempting to operate the equipment.
1.1.13
ALWAYS store the equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the reach of
children.
1.1.14
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.
7
Safety Information
wc_si000157gb.fm
RT 560 / RT 820
1.1.15
NEVER touch the engine or muffler while the engine is on or
immediately after it has been turned off. These areas get hot and may
cause burns.
1.1.16
NEVER use accessories or attachments that are not recommended by
Wacker. Damage to equipment and injury to the user may result.
1.1.17
NEVER leave machine running unattended.
1.1.18
NEVER start a defective unit in need of service or repair.
1.1.19
NEVER operate the machine with the fuel cap loose or missing.
8
RT 560 / RT 820
1.2
Operator Safety while using Internal Combustion Engines
DANGER
1.3
Safety Information
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 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.
1.2.2
DO NOT smoke while operating the machine.
1.2.3
DO NOT smoke when refueling the engine.
1.2.4
DO NOT refuel a hot or running engine.
1.2.5
DO NOT refuel the engine near an open flame.
1.2.6
DO NOT spill fuel when refueling the engine.
1.2.7
DO NOT run the engine near open flames.
1.2.8
ALWAYS refill the fuel tank in a well-ventilated area.
1.2.9
ALWAYS replace the fuel tank cap after refueling.
1.2.10
ALWAYS check the fuel lines and the fuel tank for leaks and cracks
before starting the engine. Do not run the machine if fuel leaks are
present or the fuel lines are loose.
1.2.11
ALWAYS keep the area around a hot exhaust pipe free of debris to
reduce the chance of an accidental fire.
Service Safety
Poorly maintained equipment can become a safety hazard! In order
for the equipment to operate safely and properly over a long period of
time, periodic maintenance and occasional repairs are necessary.
WARNING
wc_si000157gb.fm
1.3.1
Some service procedures require that the machine’s battery be
disconnected. To reduce the risk of personal injury, read and
understand the service procedures before performing any service to
the machine.
1.3.2
ALWAYS replace the safety devices and guards after repairs and
maintenance.
1.3.3
ALWAYS turn engine off before performing maintenance or making
repairs.
9
Safety Information
wc_si000157gb.fm
RT 560 / RT 820
1.3.4
ALWAYS secure the articulated steering joint using the locking bar
before lifting, jacking, and servicing the machine. Machine halves
could swing together unexpectedly and cause a serious injury.
1.3.5
ALWAYS replace missing and hard-to-read labels. See Parts Manual
for ordering information.
1.3.6
ALWAYS make sure slings, chains, hooks, ramps, jacks and other
types of lifting devices are attached securely and have enough weightbearing capacity to lift or hold the machine safely. Always remain
aware of the location of other people around when lifting the machine.
1.3.7
ALWAYS keep the area around the muffler free of debris such 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 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.
1.3.10
DO NOT open hydraulic lines or loosen hydraulic connections while
engine is running! Hydraulic fluid under pressure can penetrate the
skin, cause burns, blind, or create other potentially dangerous
hazards. Set all controls in neutral and turn engine off before loosening
hydraulic lines.
1.3.11
DO NOT attempt to clean or service the machine while it is running.
Rotating parts can cause severe injury.
1.3.12
DO NOT use gasoline or other types of fuels or flammable solvents to
clean parts, especially in enclosed areas. Fumes from fuels and
solvents can become explosive.
1.3.13
DO NOT modify the equipment without the express written approval of
the manufacturer.
10
RT 560 / RT 820
1.4
wc_si000157gb.fm
Safety Information
Label Locations
11
Safety Information
wc_si000157gb.fm
RT 560 / RT 820
12
RT 560 / RT 820
1.5
Safety Information
Warning and Informational Labels
Wacker machines use international pictorial labels where needed.
These labels are described below:
Label
Meaning
DANGER!
Engines emit carbon monoxide; operate only
in well-ventilated area. Read the Operator’s
Manual.
No sparks, flames, or burning objects near the
machine. Shut off the engine before refueling.
WARNING!
Hot surface!
WARNING!
Hot surface!
WARNING!
To prevent hearing loss, wear hearing protection when operating this machine.
WARNING!
Pinch point
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Safety Information
Label
RT 560 / RT 820
Meaning
Hydraulic oil reservoir fill tube
CAUTION!
Use only clean, filtered diesel fuel.
WARNING!
Read and understand the supplied Operator’s
Manual before operating this machine. Failure
to do so increases the risk of injury to yourself
or others.
CAUTION!
Engine oil may enter the cylinders if machine
tips over, causing possible engine damage.
WARNING!
Machine may receive stray signals if operated
near solid objects.
CAUTION!
Use only breakaway neck strap provided by
Wacker to avoid possible operator injury.
wc_si000157gb.fm
14
RT 560 / RT 820
Label
Safety Information
Meaning
Operator’s Manual must be stored on
machine. Replacement Operator’s Manual can
be ordered through your local Wacker distributor.
CAUTION!
Engine oil pressure is low! Stop the engine
and check the oil level.
CAUTION!
Low voltage! Stop the engine and check the
charging system.
Control with cable
Control with infrared
Charge infrared battery
Glow plug. Press to pre-heat intake manifold
before starting in cold weather.
Tie-down point
CAUTION!
Lifting point
wc_si000157gb.fm
15
Safety Information
Label
RT 560 / RT 820
Meaning
Torque battery hold-down nuts to 3.5 Nm (2.5
ft.lbs.) max.
A nameplate listing the model number, item
number, revision number, and serial number is
attached to each unit. Please record the 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.
This machine may be covered by one or more
patents.
Guaranteed sound power level in dB(A)
wc_si000157gb.fm
16
RT 560 / RT 820
2.
Technical Data
Technical Data
2.1
2.2
Revision Levels—Older Machines
Item Number
Revision
9000
120 & lower
9001
122 & lower
9002
123 & lower
9003
124 & lower
Engine—Older Machines
Item No.
RT820
0009002
0009003
RT560
0009000
0009001
Engine
Engine Type
2 cylinder, 4 cycle,
air cooled, diesel engine
Engine Make
Lombardini
Engine Model
12LD475-2
Rated Power
kW (Hp)
15.6 (20.9)
Alternator
Amp / V
12 / 16.5 @ 2600 rpm
Engine Speed - full load
Valve Clearance (cold)
intake / exhaust:
Air Cleaner
Battery
Fuel
Fuel Tank Capacity
Fuel Consumption
wc_td000156gb.fm
rpm
2600 ± 100
mm (in.)
0.20 (0.008)
Dry pleated paper elements
type
12V - Sealed - 800 cold starting amps
V / size
No. 2 Diesel
type
l (gal.)
21 (5.6)
l (gal.)/hr.
4.2 (1.1)
17
Technical Data
2.3
RT 560 / RT 820
Roller—Older Machines
Item No:
RT560
0009000
0009001
RT820
0009002
0009003
Roller
Overall Dimensions
Operating Weight
Area Capacity
Inside Turning Radius
mm
(in.)
kg (lb.)
2030 x 560 x 1220
(80 x 22 x 48)
2030 x 820 x 1220
(80 x 32 x 48)
1283 (2830)
1345 (2960)
690 (7500)
1016 (10900)
1.6 (63)
1.5 (58)
m² (ft²) / hr.
m (in.)
Low Speed
m (ft.)/min.
21 (68)
High Speed
m (ft.)/min.
136 (41)
Vibration Frequency
40 (2400)
Hz (vpm)
Gradeability with
Vibration
%
50
Gradeability without
Vibration
%
55
2.4
Lubrication—Older Machines
Item No:
RT820
0009002
0009003
RT560
0009000
0009001
Lubrication
Engine Crankcase
type
l (qt.)
SAE 10W30 Class CD rated
2.5 (2.5)
Hydraulic System
type
l (gal)
Premium grade, Anti-wear hydraulic fluid SAE 10W30
40 (10.5)
Exciter
type
ml (oz.)
SAE 10W30
950 (32)
Drum Drive Gearcase
type
ml (oz.)
SAE 10W30
240 (8.0)
Articulated Joint
type
qty.
Shell Alvania No. 2 Grease
As Required
Steering Cylinder
type
qty.
As Required
wc_td000156gb.fm
18
RT 560 / RT 820
2.5
2.6
Technical Data
Revision Levels—Newer Machines
Item Number
Revision
9000
121 & higher
9001
123 & higher
9002
124 & higher
9003
121 & higher
Engine—Newer Machines
Item No.
RT820
0009002
0009003
RT560
0009000
0009001
Engine
Engine Type
2 cylinder, 4 cycle,
air cooled, diesel engine
Engine Make
Lombardini
Engine Model
12LD475-2
Rated Power
kW (Hp)
15.6 (20.9)
Alternator
Amp / V
12 / 16.5 @ 2600 rpm
Engine Speed - full load
Valve Clearance (cold)
intake / exhaust:
Air Cleaner
Battery
Fuel
Fuel Tank Capacity
Fuel Consumption
wc_td000156gb.fm
rpm
2600 ± 100
mm (in.)
0.20 (0.008)
Dry pleated paper elements
type
12V - Sealed - 800 cold starting amps
V / size
No. 2 Diesel
type
l (gal.)
21 (5.6)
l (gal.)/hr.
4.2 (1.1)
19
Technical Data
2.7
RT 560 / RT 820
Roller—Newer Machines
RT820
0009002
0009003
RT560
0009000
0009001
Item No:
Roller
Overall Dimensions
Operating Weight
Area Capacity
Inside Turning Radius
mm
(in.)
kg (lb.)
2030 x 560 x 1220
(80 x 22 x 48)
2030 x 820 x 1220
(80 x 32 x 48)
1346 (2976)
1408 (3106)
690 (7500)
1016 (10900)
1.6 (63)
1.5 (58)
m² (ft²) / hr.
m (in.)
Low Speed
m (ft.)/min.
21 (68)
High Speed
m (ft.)/min.
136 (41)
Vibration Frequency
40 (2400)
Hz (vpm)
Gradeability with
Vibration
%
50
Gradeability without
Vibration
%
55
2.8
Lubrication—Newer Machines
RT820
0009002
0009003
RT560
0009000
0009001
Item No:
Lubrication
Engine crankcase
type
l (qt.)
SAE 10W30 Class CD rated
2.5 (2.5)
Hydraulic system
type
l (gal)
Premium grade, Anti-wear hydraulic fluid SAE 10W30
40 (10.5)
Exciter
type
ml (oz.)
SAE 10W30
950 (32)
Drum drive gearcase
type
ml (oz.)
SAE 10W30
370 (12.5)
Articulated joint
type
qty.
As Required
Steering cylinder
type
qty.
As Required
wc_td000156gb.fm
20
RT 560 / RT 820
2.9
Technical Data
Sound and Vibration Measurements
According to Appendix 1, paragraph 1.7.4.f of the EG-Machine
Regulation, the requested noise levels are:
The sound pressure level at operator's location (LpA) = 83 dB(A).
The guaranteed sound power level (LWA) = 109 dB(A).
These noise values were obtained at the operator's location according
to ISO 3744 for the sound power level (LWA) and ISO 6081 for the
sound pressure level (LpA).
Noise levels were measured while running the machine at full speed,
on crushed gravel, with vibration on.
Because this machine is operated using remote control the operator is
not exposed to vibration.
wc_td000156gb.fm
21
Maintenance
3.
RT 560 / RT 820
Maintenance
3.1
Periodic Maintenance Schedule
The chart below lists basic engine maintenance. Refer to the engine
manufacturer’s Operation Manual for additional information on engine
maintenance.
Lombardini Engine
Daily
before
starting
Check engine oil. Fill to correct level.
•
Replace air filter if indicator light is on.
•
Check condition and tension on fan belt.
•
Every
100
hrs.
Clean engine head and cylinder fins.
Every
250
hrs.
Every
300
hrs.
Every
500
hrs.
•
Change oil in engine crankcase.
•
Replace engine oil filter.
•
Check and adjust fan belt.
•
Replace fuel filter cartridge.
•
Clean injectors and check injector pressure.
•
Replace fan belt.
•
Check valve clearance.
•
Roller
Daily
before
starting
Check hydraulic oil. Fill to correct
level.
•
Clean control box / transmitter.
•
Every
100
hrs.
Grease articulated joint.
•
Grease steering cylinder.
•
Grease hood hinges.
•
Change oil in drive gearcase.
Every
500
hrs.
Once
A
Year
•
Change hydraulic system return line
filter.
•
Change hydraulic fluid.
•
Change exciter oil.
wc_tx000482gb.fm
Every
2
Years
•
22
RT 560 / RT 820
3.2
Maintenance
Transporting Machine
See Graphic: wc_gr000484
When transporting the machine, place blocks in front of and behind
each drum and use the tie down lugs (a) provided to securely fasten
the machine to the trailer.
Make sure that the joint locking bar (b) is engaged.
3.3
Lifting Machine
Lock front and rear machine halves together using the joint locking bar
(b) at the articulated steering joint on the machine. Use a lifting device
with sufficient weight-bearing capacity. Lift machine from lifting eye (c).
ALWAYS lock the articulated steering joint before lifting the machine.
wc_tx000482gb.fm
23
Maintenance
3.4
RT 560 / RT 820
Battery
Before servicing this machine, make sure the engine start switch is in
the off “O” position and that the battery is disconnected. Attach a “DO
NOT START” sign to the machine. This will notify other personnel that
the unit is being serviced and will reduce the chance of someone
inadvertently trying to start the unit.
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:
3.4.1
Stop the machine and shut down the engine.
3.4.2
Place all electrical switches in the OFF position.
3.4.3
Disconnect the negative battery cable from the battery.
3.4.4
Disconnect the positive battery cable from the battery.
To connect the battery:
1
3.4.5
Connect the positive battery cable to the battery.
3.4.6
Connect the negative battery cable to the battery.
2
3
4
wc_gr002565
wc_tx000482gb.fm
24
RT 560 / RT 820
Maintenance
The battery supplied on this machine is constructed to resist vibration
and provide long service life.
CAUTION
DO NOT use automotive-type batteries on this machine. Automotivetype batteries are not designed to withstand the heavy vibration
produced by this machine. The case on automotive-type batteries
could fail, causing battery acid to leak.
Inspect 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.
CAUTION: Observe the following to prevent serious damage to the
machine’s electrical system:
wc_tx000482gb.fm
•
Never disconnect the battery with the machine running.
•
Never attempt to run the machine without a battery.
•
Never attempt to jump-start a machine.
•
In the event that the machine has a dead battery, either replace
the battery with a fully charged battery or charge the battery using
an appropriate battery charger.
25
Maintenance
3.5
RT 560 / RT 820
Air Cleaner
Filter Indicator
The air intake system is equipped with a filter indicator (a). The
indicator is mounted to the air intake tube on the filter cannister and
can be viewed by opening the front hood. Replace filter element when
the indicator appears in or near the red line (b). Push in black rubber
button (c) on top of indicator to reset it after replacing filter element.
Check condition of air cleaner daily, before starting machine, and
replace element when needed.
Replacing Air Cleaner
Lift front hood and open access door on right side of machine. Remove
wing nut holding bottom cover (h) and remove cover. Screw off wing
nut (f) to remove filter element.
Clean inside of air cleaner cannister to remove dirt and dust, especially
in area where rubber gasket on filter (d) seals against air intake tube.
Inspect rubber washers (e) and O-ring (g). Replace if damaged. Install
new filter. Tighten wing nut snugly to ensure that both the top and
bottom of the filter is sealed.
c
``
`` `
``
`
``
``
```
`
`
`
``
`
``
``
``
`
``
``
``
``
`
``
``
```
``
`
`
`
`
`
`
`
`
`
``
`
`
`
`
`
`
``
`
``
`
b
a
wc_gr000473
wc_tx000482gb.fm
26
RT 560 / RT 820
3.6
Maintenance
Engine Oil System
See Graphic: wc_gr000057 & wc_gr000474
Check the engine oil level daily. Add oil as required.
To check oil:
Place the machine on a level surface, remove the dipstick and check
that the oil level is at the top mark. Add oil through the oil filler cap (a)
on top of engine, checking occasionally with dipstick; DO NOT overfill.
Suggested oil grades:
Use only diesel engine oil API service rating CD or equivalent.
ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATURE
Ambient
Temperature
-25ºC -20ºC
(-13ºF) (-4ºF)
-15ºC
(5ºF)
0ºC
(32ºF)
15ºC
(59ºF)
30ºC
(86ºF)
SAE 10W-30
SAE 15W-40, 20W-40
(Multi-grade)
SAE 5W-20
wc_gr000057
wc_tx000482gb.fm
27
Maintenance
3.7
RT 560 / RT 820
Engine Oil
Change the oil and oil filter (b) every 250 hours. On new machines,
change the oil after the first 50 hours of operation. Drain the oil while
the engine is still warm.
3.7.1
Remove the oil drain plug (c) to the drain oil.
Note: In the interests of environmental protection, place plastic
sheeting and a container under the machine to collect the liquid which
drains off. Dispose of this liquid properly.
3.7.2
Install the drain plug.
3.7.3
Remove the oil filler cap (a) and fill the engine crankcase with the
recommended oil.
Oil Capacity: 2.5 liters (2.5 qts.) SAE15W40, CD rated
3.7.4
3.8
Install the oil filler cap.
Valve Clearances
Check and adjust the valve clearance every 500 hours.
Set the clearance when the engine is cold.
3.8.1
Remove the rocker arm cover and check the gaskets for breakage.
3.8.2
Bring each cylinder piston to top dead center on the compression
stroke and set the clearance.
Valve clearance: 0.20 mm (0.008 in.).
3.8.3
Replace the rocker arm cover and tighten bolts to 19 Nm (14 ft.lbs.).
wc_gr000476
wc_tx000482gb.fm
28
RT 560 / RT 820
3.9
Maintenance
Engine Fuel Delivery System Maintenance
Maintenance to the engine fuel delivery system should be performed
by an experienced mechanic familiar with diesel engines. For detailed
maintenance procedures on the engine fuel system, refer to the engine
manual supplied with the machine at the time of shipment.
3.10 Fuel Filter
Change the engine fuel filter every 300 hours of operation.
3.10.1
Remove the filter (a) from the engine block.
3.10.2
Install a new filter. If necessary, prime the fuel lines as described in the
next section.
a
b
c
w c _ g r0 0 0 4 7 7
wc_tx000482gb.fm
29
Maintenance
RT 560 / RT 820
3.11 Priming the Fuel System
If the fuel tank has been run completely dry or drained for service, it will
be necessary to manually prime the fuel system.
To prime the fuel system:
3.11.1
Turn both the key switch on the machine, and the on-off switch on
control box, on. This will open the fuel valve.
3.11.2
Loosen the bleed screw on the fuel filter and pump the lever on the fuel
pump (b) until fuel flows freely from the bleed screw. Tighten the bleed
screw.
3.11.3
Repeat this procedure for the fuel line bleed screw (c).
3.12 Articulated Steering Joint & Steering Cylinder
Lubricate top and bottom bearing blocks (b) and cylinder knuckles (a)
every 100 hours using a hand-held grease gun. Cylinder knuckles can
be accessed through holes on side of machine.
Use Shell Alvania No. 2 or an equivalent No. 2 general purpose
grease.
a
b
w c _ g r0 0 0 4 7 8
wc_tx000482gb.fm
30
RT 560 / RT 820
Maintenance
3.13 Drive Gearcase
Any disassembly of the drive gearcase should be done on the opposite
side of graphic wc_gr000479.
CAUTION
Change the oil in the drive gearcase once a year or every 500 hours of
operation.
To change the oil:
3.13.1
Remove drum from drivecase side of machine. On the front drum this
will be on the left side, on the rear drum it is the right side.
3.13.2
Open fill plug (c) for venting and then remove drain plug (b) from
bottom of drum assembly.
wc_tx000482gb.fm
3.13.3
Install drain plug and remove level plug (a) from gearcase.
3.13.4
Add SAE 10W30 oil through fill plug opening until oil flows out of level
plug opening, approx. 370 ml (12.5 oz.).
3.13.5
Replace plugs and install drum.
31
Maintenance
RT 560 / RT 820
3.14 Exciter Lubrication
The exciter is a sealed unit and under normal conditions should not
require any periodic maintenance; however, an oil change once every
two years is recommended to ensure bearing life.
Exciter maintenance should be done on the right front (a) and left rear
(b) only.
CAUTION
Changing the exciter oil requires special tools and should be
performed by an experienced mechanic.
wc_tx000482gb.fm
32
RT 560 / RT 820
Maintenance
3.15 Cleaning Engine Cooling Fins
The engine is air-cooled and depends on the cylinder cooling fins to
dissipate heat. In dusty conditions the cooling fins may become
clogged or covered with dust, reducing engine cooling.
Remove the engine cover and inspect the engine cooling fins every
100 hours.
Remove dirt build-up using a brush and diesel fuel or kerosene. Dry
the engine using compressed air. Replace the inspection cover before
starting the engine.
wc_tx000482gb.fm
33
Maintenance
RT 560 / RT 820
3.16 Scrapers
Scrapers are provided on all four drums to prevent dirt from building up
on the drum surfaces. These scrapers should be inspected and
adjusted as required to remove as much dirt from the drums as
possible.
To adjust scraper, loosen the three screws (a) holding each scraper to
the drum casting. Position the scraper as close to the drum as
possible. Tighten screws and run machine to check that the scraper
does not rub against the drum surface.
3.17 Shockmounts
Inspect the drum shockmounts (a) every 300 hours for cracking,
splitting or tearing. Replace shockmounts as needed.
CAUTION: The shockmounts isolate the upper part of the machine
from the heavy vibrations produced in the drums. Operating the
machine with damaged shockmounts for an extended period of time
may eventually damage other machine parts.
wc_tx000482gb.fm
34
RT 560 / RT 820
Maintenance
3.18 Cleaning CombiControl Transmitter
The transmitter and switches are completely sealed to keep dust and
moisture out; however, contact with water should be kept to a
minimum. Even a small amount of moisture can cause connections
and contacts to corrode. Avoid immersing transmitter in water and do
not clean using a pressure wash.
To clean the transmitter, wash off using a damp cloth and allow to dry.
To remove dirt and dust trapped around switches, use compressed air.
Keeping the hydraulic oil clean is a vital factor affecting the service 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.
wc_tx000482gb.fm
35
Maintenance
RT 560 / RT 820
3.19 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.
3.20 Hydraulic Fluid Level
A hydraulic oil level sight gauge (e) is located on the hydraulic tank
inside the rear section of the machine.
Check that the oil level is within 25 mm (one inch) of the top of the sight
gauge. Add oil as required through the filter housing on top of
hydraulic tank.
If hydraulic oil continually needs to be added, inspect hoses and
connections for possible leaks. Repair hydraulic leaks immediately to
prevent damage to hydraulic components.
wc_tx000482gb.fm
36
RT 560 / RT 820
Maintenance
3.21 Changing Hydraulic Oil & Filter
3.21.1
Remove drain plug from bottom of frame and allow hydraulic fluid to
drain.
3.21.2
Clean filter housing cover. Remove cover from the filter housing and
remove the filter element (a).
Be extremely careful to avoid dropping anything into the filter housing
while cover is off.
CAUTION
wc_tx000482gb.fm
3.21.3
Install drain plug.
3.21.4
Fill hydraulic tank through filter housing (b) using clean hydraulic fluid.
3.21.5
Install new filter element (a) as shown in illustration. Replace housing
cover.
37
Maintenance
RT 560 / RT 820
3.22 Changing Drums
The drums can be changed to adjust the working width of the machine.
Drums are available in two standard sizes that provide a working width
of 560 mm (22 in.) or 820 mm (32 in.).
To change drum:
wc_tx000482gb.fm
3.22.1
Lock the articulated joint.
3.22.2
Remove scraper bars.
3.22.3
Use a screw jack, hoist or other type of lifting device to lift drums 25–
50 mm (1–2 inches) off the ground. Lift only one end of the machine.
Keep the other end in contact with the ground for stability.
3.22.4
Use a 22 mm wrench and remove the six screws which hold the drum
to the drum support.
3.22.5
Remove the three plugs (a) covering the pusher holes.
3.22.6
Insert three of the mounting screws into the pusher holes and thread
them in evenly to push drum off.
3.22.7
Install new drum and fasten to support. Secure mounting screws with
a medium-strength threadlocking adhesive.
3.22.8
Replace pusher hole plugs. Install the correct size scraper bars.
38
RT 560 / RT 820
Maintenance
3.23 Storage
If storing unit longer than 30 days the following steps are
recommended:
3.23.1
Change the engine oil.
3.23.2
Clean or change air cleaner elements.
3.23.3
Clean the engine cylinder cooling fins.
3.23.4
Drain any water that may have collected at the bottom of the fuel tank.
Replace the fuel filter. Refill the tank with fresh No. 2 diesel fuel.
Note: Diesel fuel is subject to bacterial growth which can contaminate
fuel lines. Allowing the tank to sit dry for a long period of time helps
promote such growth. The addition of a biocide to the fuel is
recommended to inhibit bacterial growth and protect the engine fuel
system.
3.23.5
Store the unit indoors in a clean dry area. If the unit must be stored
outside, cover it.
3.24 Jobsite Storage
Never allow the roller to sit overnight in a ditch, trench or other lowlying area which might fill with water during a heavy rain. Park the roller
on a flat level surface, out of the way of traffic patterns and congestion.
If the roller must be parked on an incline, chock the drums to prevent
any chance of movement.
If leaving the roller on the job site, remember to remove the key and
lock the control panel cover and engine hood to prevent tampering.
Both the front and rear hoods and access cover are equipped with a
locking ring (a) for use with a padlock for this purpose.
If desired, the CombiControl can be removed from the roller and stored
separately.
wc_tx000482gb.fm
39
Maintenance
RT 560 / RT 820
3.25 Hydrauic Schematic
wc_tx000482gb.fm
40
RT 560 / RT 820
Maintenance
3.26 Hydraulic Schematic Components
Ref.
Description
Ref.
Description
1
Brake (9001, 9003)
9
Oil cooler
2
Brake valve (9001, 9003)
10
Return filter
3
Drive motor
11
Steering cylinder
4
Drive pump
12
Steering valve
5
Exciter motor
13
Strainer
6
Exciter pump
14
Travel valve
7
Exciter (vibration) valve
15
Relief valve
8
Manifold
wc_tx000482gb.fm
41
Maintenance
RT 560 / RT 820
3.27 Hydraulic Diagram
wc_tx000482gb.fm
42
RT 560 / RT 820
Maintenance
3.28 Hydraulic Diagram Components
Ref.
Description
Ref.
Description
1
Brake (9001, 9003)
9
Oil cooler
2
Brake valve (9001, 9003)
10
Return filter
3
Drive motor
11
Steering cylinder
4
Drive pump
12
Steering valve
5
Exciter motor
13
Strainer
6
Exciter pump
14
Travel valve
7
Exciter (vibration) valve
15
Relief valve
8
Manifold
wc_tx000482gb.fm
43
Maintenance
RT 560 / RT 820
3.29 Electrical Schematic (Main)
"A "
B r
"B "
W
b
b 1
c
1
1
4
2
"2 "
4
"4 "
3
2
G
"1 "
3
R
B
W
d
C
B
e
"A "
G
W
A
"C "
"B "
A
"C "
C
B
O r/W
f
3 2
3 0
2 6
2 4
2 0
g
3 2
O r
2 8
G
3 0
2 6
W
2 4
G r
2 0
1 8
T /B
P r
k
1 4
Y /O r
T
1 2
1 0
B
6
P
A
B
m
P
B r
" 0 "
A
R
C
P
a
C
W
D
G /W
p
E
q
r
W
G /R
F
t
R
R
B r
B
T /R
G /B
j
B r
B
o
" 1 "
n
B
A
h
P
L
1 6
4
1 6
B
Y
b 2
1 8
A
s
B r
B
w c _ g r0 0 0 4 9 0
3.30 Electrical Schematic (Main) Components
Ref.
a
b
c
d
e
Description
Engine connector
Decoder module
Receptacle
Infra-red eye module
Control cord
wc_tx000482gb.fm
Ref.
k
m
n
o
p
44
Description
Glow plug
Tilt
Keyswitch
82 Ω resistor
Hour meter
RT 560 / RT 820
Maintenance
Ref. Description
Ref. Description
f
Hydraulic valves
q
Alternator
g
Backup safety
r
Oil
h
Reverse polarity module
s
Battery 12VDC
j
Control
t
To starter “30”
Note: Decoder has 10 second switchover delay for exciter outputs
Ref.
1
2
Ref.
32
30
28
26
24
22
20
18
Ref.
32
30
26
24
b1 Decoder Module Terminal Strip
Description
Ref. Description
Negative, ground
3
Not used
Signal, I.R.
4
Positive, 12VDC
b2 Decoder Module Terminal Strip
Description
Ref. Description
Reverse
16
Steering - right
Forward
14
High speed
Control light
12
Fuel valves
Vibration - high
10
Starter
Vibration - low
8
Not used
Not used
6
12V (positive)
Brake (9001, 9003)
4
Ground
Steering - left
f Hydraulic Valves
Ref. Description
20
Brake
18
Steering - left
16
Steering - right
14
High speed
Description
Reverse
Forward
Vibration - high
Vibration - low
Wire Colors
B
Black
R
Red
Y
Yellow
Or
Orange
G
Green
T
Tan
Br
Brown
Pr
Purple
L
Blue
V
Violet
Cl
Clear
Sh
Shield
P
Pink
W
White
Gr
Gray
LL
Light blue
wc_tx000482gb.fm
45
Maintenance
RT 560 / RT 820
3.31 Electrical Diagram (Main)
wc_tx000482gb.fm
46
RT 560 / RT 820
Maintenance
3.32 Electrical Diagram (Main) Components
Ref.
Description
Ref.
Description
1.
Engine connector
10.
Glow plug
2.
Decoder module
11.
Tilt
3.
Receptacle
12.
Keyswitch
4.
Infra-Red eye module
13.
82 Ω resistor
5.
Control cord
14.
Hour meter
6.
Hydraulic valves
15.
Alternator
7.
Backup safety
16.
Oil
8.
Reverse polarity module
17.
Battery 12VDC
9.
Control
18.
Charging cable
Wire Colors
B
Black
R
Red
Y
Yellow
Or
Orange
G
Green
T
Tan
Br
Brown
Pr
Purple
L
Blue
V
Violet
Cl
Clear
Sh
Shield
P
Pink
W
White
Gr
Gray
LL
Light blue
wc_tx000482gb.fm
47
Maintenance
RT 560 / RT 820
3.33 Electrical Schematic (Engine)
wc_tx000482gb.fm
48
RT 560 / RT 820
Maintenance
3.34 Electrical Schematic (Engine)
Ref.
Description
Ref.
Description
a
Engine connector
g
Engine oil pressure
b
From battery
h
Starter relay
c
Starter
j
Anti-restart module
d
Alternator
k
Glow plug
e
Voltage regulator
m
Glow plug relay
f
QSD fuel valve
Wire Colors
B
Black
R
Red
Y
Yellow
Or
Orange
G
Green
T
Tan
Br
Brown
Pr
Purple
L
Blue
V
Violet
Cl
Clear
Sh
Shield
P
Pink
W
White
Gr
Gray
LL
Light blue
wc_tx000482gb.fm
49
Maintenance
RT 560 / RT 820
3.35 Electrical Diagram (Engine)
wc_tx000482gb.fm
50
RT 560 / RT 820
Maintenance
3.36 Electrical Diagram (Engine)
Ref.
Description
Ref.
Description
1.
Engine connector
7.
Engine oil pressure
2.
From battery
8.
Starter relay
3.
Starter
9.
Anti-restart module
4.
Alternator
10.
Glow plug
5.
Voltage regulator
11.
Glow plug relay
6.
QSD fuel valve
Wire Colors
B
Black
R
Red
Y
Yellow
Or
Orange
G
Green
T
Tan
Br
Brown
Pr
Purple
L
Blue
V
Violet
Cl
Clear
Sh
Shield
P
Pink
W
White
Gr
Gray
LL
Light blue
wc_tx000482gb.fm
51
Maintenance
RT 560 / RT 820
3.37 Troubleshooting
Problem / Symptom
ENGINE DOES NOT START
Reason / Remedy
• Fuel tank empty. Fill with No. 2 diesel fuel and prime
fuel lines.
• Wrong type of fuel.
• Old fuel. Drain tank, change fuel filter and fill with
fresh fuel.
• Fuel system not primed.
• Fuel filter restricted or plugged. Replace filter.
• Battery connections loose or corroded. Battery dead.
• Engine oil level too low.
• Air cleaner element plugged.
• Starter motor defective.
• Starter button on control box or transmitter defective.
• Fuel valve solenoids on engine inoperative.
• Starter relay inoperative.
• Electrical connections loose or broken.
• Machine out of infrared signal range.
ENGINE STOPS BY ITSELF
• Fuel tank empty.
• Fuel filter plugged.
• Fuel lines broken or loose.
• Machine out of infra-red range.
NO VIBRATION
• Machine in high speed travel mode.
• Defective switch or poor connection in control box or
transmitter.
• Solenoid on vibration valve inoperative.
• Exciter assembly damaged.
• Exciter motor coupling damaged.
• Exciter motor damaged.
• Exciter pump damaged.
wc_tx000482gb.fm
52
RT 560 / RT 820
Maintenance
Problem / Symptom
Reason / Remedy
NO TRAVEL or TRAVEL
ONLY IN ONE DIRECTION
transmitter.
• Solenoid on travel valve inoperative.
• Drive gearcase assembly damaged.
• Loose, broken or corroded wire connections.
• Drive motor damaged.
• Drive pump damaged.
NO HIGH SPEED TRAVEL
transmitter.
• Solenoid on manifold inoperative.
• Exciter pump worn or damaged.
• Vibration is turned on.
NO STEERING
transmitter.
• Solenoid on steering valve inoperative.
• Steering cylinder damaged.
• Locking bar is engaged.
wc_tx000482gb.fm
53
Hydraulic System
4.
RT 560 / RT 820
Hydraulic System
4.1
Hydraulic Flow Diagram—Older Machines
Return Lines
Motor Case Drains
High Pressure Lines
Supply Line
c
e
b
a
d
g
f
P1
i
E
F
l
P2
j
h
m
k
q
o
p
r
n
Front
Rear
wc_gr002481
wc_tx000472gb.fm
54
RT 560 / RT 820
4.2
Hydraulic System
Flow Diagram Components—Older Machines
Used on models:
0009000 revision 120 and lower
a
Suction strainer
g
Steering cylinder
m
Check valve
b
Return line filer
h
Brake valve
n
Front exciter motor
c
Hydraulic tank
i
Vibration valve
o
Front drive motor
d
Front pump
j
Main manifold
p
Brake assembly*
e
Rear pump
k
Travel valve
q
Rear drive motor
f
Oil cooler
l
Steering valve
r
Rear exciter motor
* Used only on machines 9001 & 9003
wc_tx000472gb.fm
55
Hydraulic System
4.3
RT 560 / RT 820
Flow Diagram—Newer Machines
Return Lines
Motor Case Drains
High Pressure Lines
Supply Line
c
b
a
e
d
f
g
P1
i
h
E
F
l
P2
j
m
k
p
o
Front
Rear q
r
n
wc_gr002482
wc_tx000472gb.fm
56
RT 560 / RT 820
4.4
Hydraulic System
Flow Diagram Components—Newer Machines
Used on models:
0009000 revision 121 and higher
a
Suction strainer
g
Steering cylinder
m
Check valve
b
Return line filer
h
Brake valve
n
Front exciter motor
c
Hydraulic tank
i
Vibration valve
o
Front drive motor
d
Front pump
j
Main manifold
p
Brake assembly*
e
Rear pump
k
Travel valve
q
Rear drive motor
f
Oil cooler
l
Steering valve
r
Rear exciter motor
wc_tx000472gb.fm
57
Hydraulic System
4.5
RT 560 / RT 820
Hydraulic System
See Graphic: wc_gr002481 and wc_gr002482
Description:
Pressure in the hydraulic system is generated by two gear pumps
mounted in tandem to the back of the engine. The pumps are driven
by a common shaft which is connected to the engine crankshaft
through a three-piece coupling. Capacity of the front pump (d) is
approximately 8 gpm (32 l/m) and is used to operate vibration or high
speed travel. Rear pump (e) capacity is approximately 4 gpm (16 l/m)
and is used for low speed travel.
A control valve block directs oil flow from the pumps to the motors and
steering cylinder. The control valve block is mounted beneath the
control panel at the rear of the machine. It consists of the manifold (j),
vibration (i), travel (k) and steering (l) valves. These valves are
solenoid operated. During operation, the solenoids respond to the
electrical signals being transmitted by the operator from the control
box. Two reliefs, located on the main manifold, limit exciter and drive
pressures to 3000 PSI (21 mPa). The steering circuit relief is mounted
on the steering valve and is set at 1000 PSI (7 mPa). See section
Control Valve Block for control valve components.
Oil from the hydraulic tank (c) flows through a suction strainer (a)
before it is drawn into the pump suction port. The suction strainer is
mounted in the tank and is magnetic for removing metal particles.
Hoses connect the output ports of the pumps to the main manifold (j)
on the control block. The main manifold directs oil flow into the
vibration (i) and travel (k) valves. These valves in turn supply hydraulic
pressure to operate the exciter and drive motors.
When operating in low-speed travel, the larger front pump is used to
operate the exciter motors (n, r), the smaller rear pump is used to
operate the drive motors (o, q). When operating in high-speed travel,
the main manifold redirects front pump oil flow away from the exciter
motors to the drive motors. Flow from the rear pump is directed back
to the tank. In high-speed travel the exciter motors do not operate. See
later sections in this unit for a detailed description of the exciter and
drive circuits.
Return oil from the drive circuit flows to the steering valve (l) which
directs it to the steering cylinder (g).
The hydraulic system is protected by a return line filter (b). The return
line filter removes particles down to 10 microns and includes a by-pass
for cold weather start-up.
wc_tx000472gb.fm
58
RT 560 / RT 820
Hydraulic System
Oil Cooler & Brake:
Return flow from the steering valve is directed through a check valve
(m) to the oil cooler (f) before returning to the hydraulic tank.
A hydraulic brake (p) is available on machines with item numbers 9001
& 9003. The brake is connected to the hydraulic system through the
main manifold (j) and brake valve (h). The brake is spring loaded and
normally set when the machine is off. When the hydraulic system is
pressurized, the brake is automatically released. The brake can be set
manually by setting the toggle switch on the transmitter module. This
activates the solenoid on the brake valve (h) and releases the
hydraulic pressure to the brake. This will also shut off the engine.
wc_tx000472gb.fm
59
Hydraulic System
4.6
RT 560 / RT 820
Hydraulic Hose Connections—Older Machines
h
19
16
4
f
e
d
12
9
2
b
a
8
7
10
1
1
6
24
25
4
5
17
18
11
16
14
j
22
18
k
i
23
15
26
20
l
19
18
n
32
37
27
34
o
25
21
36
29
p
32
31
27
q
33
5
27
35
27
27
r
33
18
wc_gr002483
wc_tx000472gb.fm
60
RT 560 / RT 820
4.7
Hydraulic System
Hydraulic Hose Connection Components—Older Machines
No
Description
Part No.
No
Description
Part No.
1
HOSE - Oil Cooler to
Check Valve
0086394
18
FITTING - Elbow 90,
Hydraulic
0078962
2
FITTING - Sae/orfs,
SDE45, 08x08st
0086581
O-RING .364 x .070 2-012
0080736
O-RING .644 x .087
DURO90 3-908
0080732
O-RING .468 x .078
DURO90 3-906
0080731
O-RING .489 x .070 2-014
0080737
FITTING - Male Adapter,
Straight
0078861
FITTING - Hydraulic
0083412
O-RING .364 x .070 2-012
0080736
O-RING .364 x .070 2-012
0080736
O-RING .468 x .078
DURO90 3-906
0080731
O-RING .468 x .078
DURO90 3-906
0080731
20
HOSE - Front Vibration
0117532
FITTING - Elbow 90,
Hydraulic
0078962
21
HOSE - Rear Vibration
0117534
O-RING .364 x .070 2-012
0080736
22
HOSE - Front Exciter to
Tank
0116693
O-RING .468 x .078
DURO90 3-906
0080731
23
HOSE - Front Drive to
Tank
0117535
FITTING - Hydraulic
0083411
24
HOSE - Brake Valve to
Blk-hd Fitng.
0117528
O-RING .364 x .070 2-012
0080736
25
HOSE - Check Valve to
Return Filter
0086392
26
HOSE - Manifold to Return
Filter
0081842
27
FITTING - Elbow 90,
Hydraulic
0081340
4
5
6
19
7
O-RING
0081913
8
HOSE - Oil Supply
0083446
O-RING .489 x .070 2-014
0080737
9
FITTING #8
0081583
O-RING .755 x .097
DURO90 3-91
0080733
O-RING .468 x .078
DURO90 3-906
0080731
FITTING - orfs, Blk-Hd,
E90 06 ST.
0086556
wc_tx000472gb.fm
61
28
Hydraulic System
RT 560 / RT 820
h
19
16
4
f
e
d
12
9
2
b
a
8
7
10
1
1
6
24
25
4
5
17
18
11
16
14
j
22
18
k
i
23
15
26
20
l
19
18
n
32
37
27
34
o
25
21
36
29
p
32
31
27
q
33
5
27
35
27
27
r
33
18
wc_gr002483
wc_tx000472gb.fm
62
RT 560 / RT 820
Hydraulic System
O-RING .489 x .070 2-014
0080737
O-RING .364 x .070 2-012
0080736
10
HOSE - Pump to Manifold
0116705
29
HOSE - Bulk-Head Fitting
to Brake
0117528
11
HOSE - Pump to Manifold
0116706
30
Manifold
0117531
12
HOSE - Brake Valve to
Tank
0086578
31
HOSE - Rear Drive to
Manifold
0117533
13
FITTING #8
0081583
32
FITTING - Elbow 90, st.
thd, Hyd.
0052713
O-RING .644 x .087
DURO90 3-908
0080732
O-RING .351 x .072
DURO90 3-904
0080730
O-RING .489 x .070 2-014
0080737
FITTING - str. thd. Connector
0079875
14
HOSE - Steering Cyl. to
Steering Valve
0117521
O-RING .755 x .097
DURO90 3-91
0080733
15
HOSE - Steering Cyl. to
Steering Valve
0117520
O-RING .489 x .070 2-014
0080737
16
FITTING - Hydraulic
0083434
34
HOSE - Rear Exciter to
Tank
0117526
O-RING .364 x .070 2-012
0080736
35
Rear Drive
0117530
O-RING .468 x .078
DURO90 3-906
0080731
36
HOSE - Front Exciter to
Rear Exciter
0117522
HOSE - Manifold to Brake
Valve
0116707
37
HOSE - Rear Drive to
Tank
0117525
17
33
a
Suction strainer
g
Steering cylinder
m
Check valve
b
Return line filer
h
Brake valve
n
Front exciter motor
c
Hydraulic tank
i
Vibration valve
o
Front drive motor
d
Front pump
j
Main manifold
p
Brake assembly*
e
Rear pump
k
Travel valve
q
Rear drive motor
f
Oil cooler
l
Steering valve
r
Rear exciter motor
wc_tx000472gb.fm
63
Hydraulic System
4.8
RT 560 / RT 820
Control Valve Block
1
13
14
2
3
16
12
4
SV
EV
P1
11
E
F
5
P2
10
TV
9
15
MN
8
7
6
wc_gr002484
WARNING
wc_tx000472gb.fm
The solenoids located on the vibration and travel valves are equipped
with manual over-rides. Use of these over-rides for testing machine
functions is not recommended. Pushing any of the over-ride buttons
while the engine is running will cause sudden machine movement and
could result in a serious or fatal injury. If testing must be done using
these over-rides, stand at side of machine and make sure feet are
away from drums before pushing button.
64
RT 560 / RT 820
4.9
Hydraulic System
Control Valve Block Components
1
Travel speed solenoid
11
Check valve for high speed travel
2
Reverse travel solenoid
12
Low amplitude vibration solenoid
3
Right steer solenoid
13
Manual over-ride button (4 places)
4
Left steer solenoid
14
Exciter circuit relief valve 3000 PSI
(21 MPa)
5
Flow regulating valve for steering
15
Steering circuit relief valve 1000
PSI (7 MPa)
6
Double check valve for drive circuit
16
Drive circuit relief valve
7
Foward travel solenoid
SV
Steering control valve
8
Vibration / high speed travel control
valve
TV
Travel valve (forward / reverse)
9
High amplitude vibration solenoid
EV
Exciter control valve
10
Outlet to brake valve
MN
Main manifold block
wc_tx000472gb.fm
65
Hydraulic System
RT 560 / RT 820
Notes
wc_tx000472gb.fm
66
RT 560 / RT 820
Hydraulic System
4.10 High-Speed Travel Circuit Description
Note: The diagram shows the direction of oil flow when operating in
forward at high speed travel, vibration switch in OFF position.
High speed travel is obtained by using the full flow from the larger front
pump (g) to operate the drive motors. This is accomplished by
switching flow from the front pump away from the exciter circuit and
into the drive circuit. The pilot-operated directional control valve (h)
located in the main manifold valve (k) is used to do the switching.
Oil flows from the rear pump (f) to the travel speed valve (c). When the
operator switches to high speed travel, the travel speed solenoid is
energized, which shifts the valve to the position shown. In this position,
oil flows through the valve and returns to the hydraulic tank. This
causes pilot oil pressure at the directional control valve (h) to drop, and
allows spring force in the valve to shift the spool to the position shown.
In this position, oil flow from the front pump is directed to the brake,
drive, and steering circuits. There is no flow to the exciter motors.
Relief valve (j) limits hydraulic pressure in the drive circuit to 3000 psi
(21 mPa). Check valve (i) prevents front pump oil flow from
pressurizing the pilot circuit and shifting the directional control valve.
Machine forward and reverse directions are controlled by the solenoidoperated travel valve (a) which switches the direction of oil flow
through the valve and drive motors.
When the operator switches to forward, the bottom solenoid on the
travel valve energizes, which shifts the valve spool to the position
shown. In this position, oil flows through the valve, rear drive motor (e),
front drive motor (d), and back through the valve to the steering circuit.
With the directional controls in neutral, both solenoids are off and
springs in the travel valve (a) return the spool to a neutral position.
Operation in reverse will cause oil through the travel valve (a) to flow
opposite the direction shown, reversing the direction of the drive
motors.
Note: Top or bottom as described above refers to the location of the
solenoids as installed on the machine.
A double check valve (b) provides a hydraulic lock to prevent the drive
motors from rotating while the machine is in neutral or is turned off.
When pressurized, the pilot port in each check valve opens the valve
and allows oil flow in both directions.
wc_tx000472gb.fm
67
Hydraulic System
RT 560 / RT 820
4.11 High-Speed Travel Circuit
1*
2
7
3
6
a
j
b
3000 PSI
(21 MPa)
i
5
h
d
3000 PSI
(21 MPa)
c
P1
P2
e
4
g
f
8
HIGH PRESSURE FLOW
RETURN FLOW
PILOT PRESSURE
INACTIVE LINE (NO PRESSURE)
wc_gr002485
wc_tx000472gb.fm
68
RT 560 / RT 820
Hydraulic System
4.12 High-Speed Travel Circuit Components
a
Travel valve
f
Rear pump
b
Double check valve
g
Front pump
c
Travel speed valve
h
Directional control valve
d
Front drive motor
i
Check valve
e
Rear drive motor
j
1*
To brake valve.
2
Return line to hydraulic tank.
3
To steering valve.
4
Valve (c) opens and directs flow from rear pump (f) into return line.
5
Spring pressure shifts valve (h) and directs flow from front pump (g) into drive
circuit.
6
To exciter (vibration valve).
7
From exciter motor case drain.
8
From hydraulic tank.
wc_tx000472gb.fm
69
Hydraulic System
RT 560 / RT 820
4.13 Low-Speed Travel Circuit
1*
2
7
3
6
a
j
3000 PSI
(21 MPa)
b
9
i
5
h
k
d
c
3000 PSI
(21 MPa)
P1
P2
e
4
g
f
8
HIGH PRESSURE FLOW
RETURN FLOW
PILOT PRESSURE
wc_gr002486
wc_tx000472gb.fm
70
RT 560 / RT 820
Hydraulic System
4.14 Low-Speed Travel Circuit Components
a
Travel valve
g
Front pump
b
Double check valve
h
c
Travel speed valve
i
Check valve
d
Front drive motor
j
e
Rear drive motor
k
Exciter circuit relief valve
f
Rear pump
1*
To brake valve.
2
3
To steering valve.
4
Valve (c) closes and directs flow from rear pump (f) through check valve (i) into
drive circuit.
5
Pressure from rear pump (f) shifts valve (h) and directs flow from front pump (g)
into exciter circuit.
6
To exciter (vibration valve).
7
From exciter motor case drain.
8
9
Pilot pressure.
wc_tx000472gb.fm
71
Hydraulic System
RT 560 / RT 820
4.15 Low-Speed Travel Circuit Description
Note: The diagram shows the direction of oil flow when operating at
low speed travel and going forward, vibration switch in OFF position.
Low speed travel is obtained by using oil flow from the smaller rear
pump (f) to operate the drive motors. This is accomplished by the
solenoid-operated travel speed valve (c), which directs flow from the
rear pump to the drive circuit.
Oil flows from the rear pump to the travel speed valve. When the
operator switches to low speed travel, the travel speed valve solenoid
(c) is turned off. This allows spring force in the valve to shift the spool
to the position shown. In this position, flow from the rear pump is
directed through check valve (i) and on to the drive and steering
circuits. High pressure oil is also directed to the pilot port of the
directional control valve (h). Spring resistance in the directional control
valve (h) is overcome by the increased oil pressure which shifts the
spool to the position shown. In this position, oil flow from the larger
front pump (g) is directed to the exciter circuit. A flow regulating valve
in the steering circuit always provides enough pressure to shift the
directional control valve even if the travel and steering function are in
neutral.
Relief valves (j, k) limit hydraulic pressure in the drive and exciter
circuits to 3000 psi (21 mPa).
Machine forward and reverse movements are controlled by the
solenoid-operated travel direction valve (a) which switches the
direction of oil flow through the valve and drive motors.
When the operator switches into forward, the bottom solenoid on the
travel valve energizes, which shifts the valve spool to the position
shown. In this position, oil flows through the valve, rear drive motor (e),
front drive motor (d) and back through the valve to the steering circuit.
When the operator switches into reverse, oil flow through the valve is
opposite the direction shown, reversing the direction of the drive
motors. When the machine is in neutral, both solenoids are off and
springs in the valve return the spool to neutral.
A double check valve (b) provides a hydraulic lock to prevent the drive
motors from rotating while the machine is in neutral or turned off. When
pressurized, the pilot port in each check valve opens the valve and
allows oil flow in both directions.
wc_tx000472gb.fm
72
RT 560 / RT 820
Hydraulic System
4.16 Exciter Circuit Description
Note: The diagram shows the direction of oil flow when operating at
low speed travel with the EXCITER switch set to LO.
Operating in low speed travel opens flow from the front pump to the
exciter circuit. When operating in high speed travel the exciter circuit is
closed and all flow is directed to the drive motors .
When the operator switches to low speed travel, the travel speed valve
(d) is turned off. This allows spring force in the valve to shift the spool
to the position shown. In this position, flow from the rear pump is
directed through check valve (h) and on to the drive and steering
circuits. High pressure oil is also directed to the pilot port of the
directional control valve (c). Spring resistance in the directional control
valve is overcome by the increased oil pressure which shifts the spool
to the position shown. In this position, oil flow from the larger front
pump (g) is directed to the exciter circuit. A flow regulating valve in the
steering circuit always provides enough pressure to shift the directional
control valve even if the travel and steering functions are in neutral.
Low or high amplitude vibration is controlled by the solenoid-operated
exciter valve (l). This valve switches the direction of oil flow through
exciter motors.
With the VIBRATION pushbutton switch set in the low position, the top
solenoid is energized and the valve spool will be at the position shown.
In this position, oil flows through the valve, rear exciter motor (i), to the
front exciter motor (j) and back through the valve to the hydraulic tank.
When the VIBRATION pushbutton switch is in the high position, the LO
solenoid is turned off and the valve returns to neutral. A timer in the
electrical circuit keeps the valve in neutral for approximately 7 seconds
before turning on the HI solenoid. This allows the exciter weights to
stop rotating before reversing direction. With the exciter switch set at
HI, oil flow through the motors is opposite of the direction shown,
causing the exciter motors to reverse direction.
Relief valve (e) limits hydraulic pressure in the exciter circuit to 3000
psi (21 mPa).
wc_tx000472gb.fm
73
Hydraulic System
RT 560 / RT 820
4.17 Exciter Circuit
1*
2
k
l
3
a
3000 PSI
(21 MPa)
h
j
c
i
e
d
3000 PSI
(21 MPa)
P1
P2
g
f
4
HIGH PRESSURE FLOW
RETURN FLOW
PILOT PRESSURE
wc_gr002487
wc_tx000472gb.fm
74
RT 560 / RT 820
Hydraulic System
4.18 Exciter Circuit Components
a
g
Front pump
b
Travel valve
h
Check valve
c
i
Rear exciter motor
d
Travel speed valve
j
Front exciter motor
e
Exciter circuit relief valve
k
Exciter valve
f
Rear pump
l
Exciter speed valve
1*
To brake valve.
2
3
To drive and steering valve.
4
wc_tx000472gb.fm
75
Hydraulic System
RT 560 / RT 820
4.19 Steering Circuit Description
See graphic: wc_gr002488
Note: The diagram shows the direction of oil flow when steering left.
The steering circuit consists of a flow regulating valve (c), pressure
relief valve (f), solenoid-operated control valve (g), and steering
cylinder (h).
Return oil from the drive circuit flows into the steering circuit and
through the flow regulating valve (c) before entering the solenoidoperated steering control valve (g). The flow regulating valve
maintains a constant 1 gpm flow rate in the steering circuit. This is
necessary to provide the same degree of steering control whether
operating in low or high speed travel. It also creates sufficient back
pressure in the system to shift the directional control valve in the main
manifold. This keeps the exciter circuit open when the steering and
travel valves are in neutral.
When the operator steers left, the top solenoid on the steering valve
(g) is energized and the valve spool shifts to the position shown. In this
position, oil flows out port “E” of the valve, to the rod end of the steering
cylinder (h). At the same time, oil from the head end of the cylinder
returns through port “F” and back to the hydraulic tank. This causes the
cylinder rod to retract, turning the machine left. When the operator
steers right, oil flows in the opposite direction causing the cylinder rod
to extend and turn the machine to the right. With steering in neutral,
both solenoids are turned off. Springs in the valve return the spool to
center which allows oil to pass through the valve, out port “T”, and back
to tank.
Relief valve (e) limits hydraulic pressure in the steering circuit to 1000
psi (7 mPa).
wc_tx000472gb.fm
76
RT 560 / RT 820
Hydraulic System
4.20 Steering Circuit
c
1000 PSI
(7 MPa)
1
f
T
a
2
g
b
E
F
h
d
e
HIGH PRESSURE FLOW
RETURN FLOW
PILOT PRESSURE
wc_gr002488
wc_tx000472gb.fm
77
Hydraulic System
RT 560 / RT 820
4.21 Hydraulic System Cleanliness
Keeping the hydraulic fluid 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 fluid.
• Use of the wrong type of hydraulic fluid.
• Leakage in lines and fittings.
To minimize hydraulic fluid contamination:
• Clean hydraulic connections before opening lines. When adding oil,
clean hydraulic tank filler cap and surrounding area before removing.
• Avoid opening pumps, motors or hose connections unless absolutely necessary.
• Plug or cap all open hydraulic connections while servicing system.
• Change hydraulic filters and fluids at the recommended service
intervals.
4.22 Hydraulic Oil Requirements
WACKER recommends the use of a good petroleum-based, anti-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.
Premium grade, anti-wear hydraulic fluid.
Viscosity: 10W30.
See Technical Data for quantity.
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.).
wc_tx000472gb.fm
78
RT 560 / RT 820
Hydraulic System
4.23 Checking Hydraulic Pressures
Before making pressure checks:
4.23.1
Inspect machine for hydraulic leaks.
4.23.2
Check level of hydraulic fluid in tank.
4.23.3
Check engine operating speed at full throttle. Set at 2600 RPM.
4.23.4
Run machine for 5-10 minutes before testing to allow time for hydraulic
system to warm up.
A test port is provided on the front (a) and rear (b) pumps for checking
system pressures.
Note: Test ports are equipped with quick disconnects and are
designed for use with WACKER hydraulic test equipment.
Before opening hydraulic connections, shut engine off.
WARNING
b
a
wc_gr002489
wc_tx000472gb.fm
79
Hydraulic System
RT 560 / RT 820
4.24 Checking Drive Circuit
Operating Pressure (Low Speed)
Check operating pressure with the machine on a level compactible
surface, such as gravel or dirt.
4.24.1
Install 5000 PSI gauge in rear pump test port (b).
4.24.2
Start engine and run at full throttle (2600 rpm).
4.24.3
Move joystick forward but not fully forward, and read forward
operating pressure. Record reading.
4.24.4
Move joystick in reverse and read reverse operating pressure. Record
reading.
Note: Operating pressures should be within range as shown in section
System Pressures. If pressure readings are above or below range,
refer to section Troubleshooting Hydraulic System.
Operating Pressure (High Speed)
Check operating pressure with the machine on a level compactible
surface, such as gravel or dirt.
4.24.5
Install 5000 PSI gauge in front pump test port (a).
4.24.6
Start engine and run at full throttle (2600 rpm).
4.24.7
Move joystick fully forward and read forward operating pressure.
Record reading.
4.24.8
Move joystick in reverse and read reverse operating pressure. Record
reading.
Relief Pressure
4.24.9
Block in front of and behind both drums to prevent machine from
moving, or deadhead machine against a solid concrete abutment.
Make sure blocks are large enough so machine will not climb over
them during testing.
WARNING
4.24.10 Install a 5000 PSI gauge in front pump test port (a).
4.24.11 Start engine and run machine at full throttle.
wc_tx000472gb.fm
80
RT 560 / RT 820
Hydraulic System
4.24.12 Push joystick fully forward until pressure on gauge tops out. This is
the high speed relief valve pressure. Make sure drums do not spin.
Record reading.
4.24.13 Stop engine. Install gauge in rear pump test port (b).
4.24.14 Push joystick forward but not fully forward until pressure on gauge
tops out. This is the low speed relief valve pressure. Record reading.
Note: Relief valve pressures should be within range as shown in
section System Pressures. If pressure readings are above or below
range, refer to section Troubleshooting Hydraulic System.
b
a
wc_gr002489
4.25 Checking Steering Circuit
4.25.1
Install 2000 PSI gauge in rear pump test port (b).
4.25.2
Start engine and run machine at full throttle (2600 rpm).
4.25.3
Move joystick right or left. Gauge will show operating pressure until
cylinder gets to end of stroke and then show relief pressure. Record
readings.
Note: Operating and relief pressures should be within range as shown
in section System Pressures. If pressure readings are above or below
range, refer to section Troubleshooting Hydraulic System.
wc_tx000472gb.fm
81
Hydraulic System
RT 560 / RT 820
4.26 Checking Vibration Circuit
Test vibration with drums on soil or gravel. If testing is done inside,
position drum on rubber tire or heavy mat to absorb vibration.
DO NOT run vibration on concrete.
CAUTION
Operating Pressure (High Amplitude)
4.26.1
4.26.2
Start engine and run machine at full throttle (2600 rpm) with joystick in
neutral.
4.26.3
Switch vibration to HI. Gauge will show relief pressure momentarily as
exciter starts and then fall to normal operating pressure as exciter
reaches full speed. Record reading.
Operating Pressure (Low Amplitude)
4.26.4
4.26.5
Start engine and run machine at full throttle (2600 rpm) with joystick in
neutral.
4.26.6
Switch vibration to LO. Gauge will show relief pressure momentarily as
exciter starts and then fall to normal operating pressure as exciter
reaches full speed. Record reading.
Note: Operating pressures should be within range as shown section
4.27 Testing Drive & Exciter Circuit Relief Valves
4.27.1
wc_tx000472gb.fm
Drive and exciter circuit relief valves are identical and set at the same
pressures. They can be tested for correct operation by simply
swapping positions with one another. Swap the one in question with
the other and test for correct pressure. If pressure is correct with the
second valve installed, the original valve is malfunctioning and will
require replacement.
82
RT 560 / RT 820
Hydraulic System
4.28 System Pressures
The table below lists normal operating pressures based on the
machine running over a level compactible surface. These pressures
are approximate and will vary for different operating conditions.
Operating pressure readings for the drive and steering circuits may be
higher when operating in extremely loose soils or on an incline.
Operating pressure readings will be lower when operating on flat, hard
surfaces where there is less surface resistance.
Normal Operating
Pressure @ 2600 RPM
PSI (mPa)
Relief Valve
Pressure
PSI (mPa)
Test
Port
Location
Forward or
Reverse in
LOW Speed
180 - 600 (1.2 - 4.2)
3000 (21)
Rear Pump
Forward or
Reverse in
HIGH Speed
300 - 800 (2.1 - 5.6)
3000 (21)
Front Pump
Exciter in
LOW Vibration
1050 - 1250 (7.3 - 8.7)
3000 (21)
Front Pump
Exciter in
HIGH Vibration
1200 - 1600 (8.4 - 11.2)
3000 (21)
Front Pump
300 - 800 (2.1 - 5.6)
1000 (7)
Rear Pump
(Low speed travel)
Steering
wc_tx000472gb.fm
83
Hydraulic System
RT 560 / RT 820
4.29 Troubleshooting Hydraulic System
Problem / Symptom
REASON / REMEDY
Drive circuit operating
pressures are too LOW
1. Testing surface is too hard or smooth. Check readings while
machine is on compactible soil.
2. Engine operating below 2600 rpm. Set throttle to deliver
2600 rpm.
3. Suction hose or fittings leaking, allowing air into pump inlet.
Tighten hose fittings as necessary.
4. Oil level is too low in tank. Make sure oil is at proper level.
5. Worn pump coupling. Remove and repair as necessary.
6. Malfunctioning relief valve. Test relief valve for proper operation.
Drive circuit operating
pressures are too
HIGH
(ABOVE 800 psi)
1. Wrong weight of oil in drive gearcase (viscosity too high).
Drain and fill with proper weight oil for operating conditions. If
pressures are still high, continue.
2. Engine operating above 2600 rpm. Set throttle to deliver
2600 rpm.
3. Drum binding due to dirt build-up between drums and drum
supports. Remove dirt build-up.
4. Drive assembly binding due to worn or improperly assembled
parts. Remove, inspect, repair and properly assemble drive
assembly.
5. Hoses routed incorrectly. Make sure hoses are routed properly.
Exciter circuit operating
pressure is too LOW
(Below 800 psi) - Drive
circuit pressure ok
1. Sticky spool in exciter or directional control valve, allowing
partial pressure loss. Check electrical circuits to make sure solenoids are functioning properly. If ok, continue. or Remove control valve and repair or replace if necessary.
2. Hoses leaking. Tighten fittings.
3. Worn exciter motor(s). Replace exciter motor(s).
4. Malfunctioning relief valve. Test relief valve for proper operation.
Exciter circuit operating
pressure is too HIGH
(Above 1800 psi) Drive circuit pressures
ok
1. Wrong weight of oil in exciter assembly (viscosity too high).
Drain and fill with proper weight oil for operating conditions.
2. Exciter assembly oil level too high. Remove, inspect, and
repair exciter assembly as necessary. Fill with oil to proper level
3. Binding in exciter assembly (bearings worn or damaged).
Remove, inspect, and replace exciter assembly as necessary.
Relief pressure too
LOW
1. Relief valve adjustment wrong. Adjust or replace valve as
necessary.
2. Worn pump or motor. Repair as necessary.
wc_tx000472gb.fm
84
RT Repair
5.
5.1
Tools
Because all possible problems encountered while repairing the
equipment 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.
5.2
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 unit.
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.
5.3
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.
5.4
Weight Block
The weight block symbol gives an approximate weight measurement
to aid the mechanic when lifting/hoisting larger components.
250 kg
(550 lbs.)
wc_gr000843
wc_tx000473gb.fm
85
5.5
RT Repair
Drum Assembly Exploded View
11
10
7 [L1,T1] 8 [L4]
6
9 [T2]
5
4 [G1]
12 [L2]
2
3
13 [L3]
1 [L1]
15[L3]
17 [L1,T5]
14[L1]
16
18
19
27
20 [L1,T3]
23
21
22 [L1,T3]
13 [L1,T1]
7 [L1,T1]
26
[L1,T4]
24
25
[L1,T4]
wc_tx000473gb.fm
wc_gr002501
86
RT Repair
5.6
Drum Assembly Components
See Graphic:wc_gr002501
Ref.
Description
1
Screw (M8 x 16)
2
Ref.
Description
6
14
Screw (M8 x 20)
2
Plate-retaining
1
15
Plate-cover
1
3
Seal-shaft
1
16
Washer-lock (A12)
6
4
Bearing-roller
1
17
Screw (M12 x 25)
6
5
Seal-shaft
1
18
Scraper-bar
2
6
Cover-support
1
19
Key
1
7
Screw (M10 x 20)
24
20
Stud- shockmount
1
8
Seal-shaft
1
21
Drum support
1
9
Nut-hex (1¼-18)
1
22
Screw (M12 x 35)
8
10
Washer (1-1/8")
1
23
Drum
2
11
Hub-drum
1
24
Washer (B17)
6
12
Plug (M26 x 1.5)
1
25
Screw (M16 x 16)
6
Seal-ring
1
26
Screw (M16 x 25)
12
Screw (M10 x 16)
6
27
Drivecase
1
13
[G1]
[L1]
[T1]
[T5]
Qty.
0066982 Unirex No. 2
0029311
[L2] 0073287
36 ft.lbs. (49 Nm)
[T2] 450 ft.lbs. (610 Nm)
63 ft.lbs. (85 Nm)
wc_tx000473gb.fm
87
[L3] 0070735
[T3] 88 ft.lbs. (120 Nm)
Qty.
[L4] Silicone
[T4] 155 ft.lbs. (210 Nm)
5.7
RT Repair
Drums
a
4
5
2
1
3
15
10
7
13
8
6
9
16
17
12
11
wc_gr002502
Removal:
wc_tx000473gb.fm
5.7.1
Lock articulated joint.
5.7.2
Lift machine by the lifting eye using an appropriate crane or hoist. Also
use jack stands (a) to support machine from underneath machine
frame.
88
RT Repair
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.
WARNING
Only use blocks or jacks with a suitable load bearing capacity. Do not
use improvised blocks or jacks.
WARNING
5.7.3
Loosen three M12 screws (1) and washers (2) mounting scraper bar
(3) and shim (4) to drum support (5).
5.7.4
Loosen four M8 screws (6), washers (7), and nuts (8) mounting outer
scraper (9) to bracket (10). Remove two M12 screws (11) and
washers (12) mounting outer scraper to drum support (5).
5.7.5
Remove six M16 screws (13) holding the drum (14) to the drive
housing (15).
5.7.6
Remove three M16 screws (16) and washers (17) and insert three M16
x 55 screws into the holes. Turn screws in to push drum off drive
housing.
Installation:
5.7.7
Mount drum (14) to drive housing (15) using M16 screws (13) . Secure
screws with Loctite 243, or an equivalent medium strength
threadlocking compound and torque to 155 ft.lbs. (210 Nm).
5.7.8
Install the three M16 x 16 screws (16) and washers (17) into pusher
holes to plug holes and protect threads. Secure screws with Loctite
243, or an equivalent medium strength threadlocking compound and
torque to 155 ft.lbs (210 Nm).
5.7.9
Mount scraper bar (3) and shim (4) to drum support (5) using M12
screws (1) and washers (2). Secure screws with Loctite 243 or an
equivalent medium strength threadlocking compound and torque to 63
ft.lbs. (85 Nm).
5.7.10
Mount outer scraper (9) to drum support (5) using M12 screws (11) and
washers (12). Secure screws with Loctite 243 or an equivalent
medium strength threadlocking compound.
5.7.11
Mount outer scraper (9) to bracket (10) using M8 screws (6), washers
(7), and nuts (8).
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
WARNING
wc_tx000473gb.fm
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
tightened.
89
5.8
RT Repair
Drum Support Cover
Removal:
5.8.1
Remove drums and scrapers bars. See section Drums.
5.8.2
Using a large breaker bar remove the 1-1/4" hex nut (1) and washer
(2) which holds the drum on the axle.
5.8.3
Insert three M16 x 55 screws (3) into alternating holes on hub in which
drum was mounted. Turn screws in to push drum hub (4) off support
cover (5).
5.8.4
Remove shaft seal (6) from support cover (5).
5.8.5
Remove the twelve M10 screws (7) holding the support cover (5) to the
drum support (8).
5.8.6
Remove the three M10 screws (9) in the support cover. Into these
holes insert three M10 x 55 screws. Turn screws in to push cover from
drum support.
Installation:
Drum drive housing must be in place before assembling drum support
cover. See section Drive Housing.
wc_tx000473gb.fm
5.8.7
Install support cover (5) on drum support (8) using twelve M10 screws
(7). Secure screws with Loctite 243, or an equivalent medium strength
threadlocking compound and torque to 36 ft. lbs. (49 Nm). Install the
three M10 screws (9) back into pusher holes to protect the threads.
5.8.8
Apply a bead of silicone to support cover (5) where shaft seal (6) will
seat. This will help hold shaft seal in place and prevent it from spinning.
Attach shaft seal to support cover.
5.8.9
Install drum hub (4) into drum support (8) with washer (2) and nut (1).
Secure nut by using Loctite 243 on axle shaft threads and torque nut
to 450 ft. lbs. (610 Nm).
5.8.10
Install drums and scraper bars. See section Drums.
90
RT Repair
7
1
2
5
3
8
6
4
9
wc_gr002503
wc_tx000473gb.fm
91
5.9
RT Repair
Drive Bearings and Seals
Disassembly:
5.9.1
Remove drum support cover. See Section 5.4 Drum Support Cover.
5.9.2
Clean drum hub (1) of all grease. Heat bearing race (2) with propane
torch. Once race is hot, use a chisel to pry race off drum hub far
enough to install a puller. It may be necessary to use an oxy-acetylene
torch in order to heat bearing race fast and hot enough for removal.
WARNING
Always wear safety glasses, gloves, and approprate clothing when
dealing with heat and open flames.
CAUTION: If using a torch, extreme care should be used to avoid
cutting through race and damaging hub.
Note: Bearing must be replaced once race is removed.
5.9.3
Remove M8 screws (3) holding retaining plate (4) and press retaining
plate from support cover (5).
5.9.4
Press shaft seal (6) from the retaining plate (4).
Note: Shaft seal must be replaced once it is removed.
5.9.5
Press roller bearing cage (7) and shaft seal (8) from support cover (5).
Note: Shaft seal must be replaced once it is removed.
Assembly:
5.9.6
Press shaft seal (8) into support cover (5).
5.9.7
Separate roller bearing into race (2) and cage (7). Pack cage portion
of bearing (7) with bearing grease and press into support cover (5).
5.9.8
Press shaft seal (6) into retaining plate (4).
5.9.9
Install retaining plate (4) on support cover (5) with M8 screws (3).
Secure screws using Loctite 243 or an equivalent medium strength
threadlocking compound.
5.9.10
Press bearing race (2) onto drum hub (1).
Note: Heating race on a hot plate or hot oil bath will make installation
easier.
5.9.11
WARNING
wc_tx000473gb.fm
Install drum support cover. See Section 5.4 Drum Support Cover.
tightened.
92
RT Repair
2
8
1
7
4
5
6
3
wc_gr002504
wc_tx000473gb.fm
93
RT Repair
5.10 Drive Housing
Removal:
5.10.1
Remove drums and scrapers bars. See Section 5.3 Drums. Remove
support cover. See Section 5.4 Drum Support Cover.
5.10.2
Tag and disconnect hydraulic hoses from drive motor (1). Cap or plug
all open connections.
Note: Machines with Item Numbers 9001 & 9003 include a brake
assembly (2) on the front drum. On these machines it will also be
necessary to disconnect the hydraulic line that engages the brake.
5.10.3
Remove twelve M10 screws (3) holding the drive housing (4) to the
drum support (5).
Note: Before removing the drive housing, add reference marks to the
drum support and the drive housing. This will help align the two pieces
later on and make installation easier.
5.10.4
Remove three M10 screw plugs (6) in the drive assembly flange and
insert three M10 x 55 screws in their place. Turn screws in to push
drive housing (4) from drum support (5). Pull complete drive housing
from the drum support.
Installation:
Both the drive motor (1) and brake assembly (2) must be mounted to
the drive housing (4) before installing it in drum support (5). See
Sections 5.9 & 5.11.
5.10.5
Install drive housing (4) in drum support (5) using twelve M10 screws
(3). Secure screws using Loctite 243 or an equivalent medium
strength threadlocking compound and torque to 36 ft. lbs. (49 Nm).
5.10.6
Install three M10 screws (6) into pusher holes. Secure using Loctite
243 or an equivalent medium strength threadlocking compound.
5.10.7
Apply Loctite 545 or an equivalent hydraulic sealant to hydraulic fittings
and connect hydraulic lines to drive motor (1) and brake (2).
5.10.8
Clean inside of drum hub (7) and tapered end of axle. For Installation,
see Section 5.4 Drum Support Cover.
5.10.9
Check oil level in drive housing.
WARNING
wc_tx000473gb.fm
tightened.
94
RT Repair
7
2
4
5
1
wc_gr002505
6
3
wc_tx000473gb.fm
95
RT Repair
5.11 Changing Oil
The drum drive case is lubricated in an oil bath.
To drain oil:
5.11.1
Remove drum from the drive housing side of machine (see section
Drums). On the front of the machine this will be the right side, and on
the rear of the machine the left side.
5.11.2
Remove fill plug (b) for venting.
5.11.3
Remove drain plug (c) and drain oil from drum.
Note: In the interests of environmental protection, place a plastic sheet
and a container under the machine to collect the liquid which drains off,
and dispose of properly.
To add oil:
5.11.4
Install drain plug (c).
5.11.5
Remove level plug (a).
5.11.6
Add SAE 10W30 oil at fill plug until oil flows out of level plug opening.
Replace plugs.
Total Capacity: 8 oz. (240 ml).
5.11.7
wc_tx000473gb.fm
Install fill plug (b).
96
RT Repair
b
a
c
wc_tx000473gb.fm
wc_gr002506
97
RT Repair
5.12 Drive Housing Assembly
33
34
13[L1,T2]
2
11
3[L1,T1]
1
12
10
9
14
15
8
5 [L3]
4 [L1,T3]
16
17
16
19
20
21
18 [L1,T5]
50
51
52
27
53
54
31
23
6
30
29 [L2]
28 [L1,T4]
32 [L1,T4]
35
wc_gr002507
wc_tx000473gb.fm
98
RT Repair
5.13 Drive Housing Components
Ref.
Description
Ref.
Description
1
Brake assembly
1
18
Screw (M8x18)
5
2
Washer
6
19
Seal-shaft
1
3
Screw (M6x90)
6
20
Retaining ring
1
4
Screw (3/8-16x1)
1
21
Gear-drum drive
1
5
Cover-gear
1
22
Retaining ring
1
6
Axle-drive
1
23
Bearing-roller
1
7
Key
1
24
Seal-shaft
1
8
Washer
1
25
Set-plug
3
9
Gear-pinion
1
26
O-Ring
3
10
Motor-hydraulic drive
1
27
Housing-drive
1
11
Fitting-elbow
1
28
Screw (M10x20)
12
12
O-Ring
1
29
Seal-shaft
1
13
Screw (M12x 70)
2
30
Spacer-ring
1
14
O-Ring
2
31
Key
1
15
Fitting
1
32
Screw (M10x16)
3
16
O-Ring
2
33
Screw (M6x15)
6
17
O-Ring
1
34
Cover-brake
1
[L1] 0029311
[T1] 7 ft.lbs. (9 Nm)
[T5] 18 ft.lbs. (25 Nm)
wc_tx000473gb.fm
Qty.
[L2] Silicone
[T2] 90 ft.lbs. (122 Nm)
[L3] 0070735
[T3] 43 ft.lbs. (58 Nm)
99
Qty.
[T4] 36 ft.lbs. (49 Nm)
RT Repair
5.14 Brake
The brake is located on the front drum only and is mounted to the gear
cover of the drivecase. To remove the brake the complete drive
housing must be removed from the drum support.
Removal:
5.14.1
Remove drums from roller. See section Drums.
5.14.2
Remove drive housing from drum support. See section Drive Housing.
5.14.3
Remove the six M6 screws (1) and washers (2) holding brake
assembly (3) and remove brake assembly from drive housing.
Installation:
5.14.4
Apply Loctite 515 gasket compound to face of gear cover (4) where
brake mounts (a).
5.14.5
Mount the brake assembly (3) with six M6 screws (1) and washers (2).
Apply Loctite 271 or an equivalent high strength threadlocker to
screws, and torque to 7 ft.lbs. (9 Nm).
5.14.6
Position hydraulic fitting (5) on brake as shown.
5.14.7
Install drive housing to drum support. See section Drive Housing.
WARNING
wc_tx000473gb.fm
tightened.
100
RT Repair
2
1
a
3
4
5
wc_gr002508
wc_tx000473gb.fm
101
RT Repair
5.15 Servicing Brake
Disassembly:
5.15.1
Remove fitting (20).
5.15.2
Remove retaining ring (6) and pull gear (7) off shaft.
5.15.3
Remove three M6 screws (21) which hold the brake assembly
together.
Note: When removing last screw, rear housing may "pop" off front
housing due to spring tension.
5.15.4
Disassemble interior pieces (12–16).
5.15.5
Remove retaining ring (11) from front housing (8) and press out ball
bearing (10).
5.15.6
Remove seal (9).
5.15.7
Remove retaining ring (17) from rear housing (19) and press out ball
bearing (18).
Assembly:
5.15.8
Press bearings (10 & 18) into front and rear housings and secure in
place using retaining rings (11 & 17).
5.15.9
Install seal (9) into front housing (8).
5.15.10 Insert ring spacer (12) into front housing.
5.15.11 Set front housing on face and insert spring (13), O-rings (14), shaft (16)
and locking plate (15).
5.15.12 Secure rear housing assembly to front housing with three M6 screws
(21). Secure screws using Loctite 243 or an equivalent medium
strength threadlocking compound, and torque to 7 ft.lbs. (9 Nm).
5.15.13 Install fitting (20) to rear housing assembly.
5.15.14 Install gear (7) on shaft and secure with retaining ring (6).
WARNING
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20
19
21
18
17
16
14
22
13
12
8
14
15
11
7
9
10
6
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5.16 Drive Motor
The drive motor is mounted to the gear cover of the drive housing.
When replacing the drive motor, the complete drive housing must be
removed from the drum support.
Removal:
5.16.1
5.16.2
Remove drive housing from the drum support. See section Drive
Housing.
5.16.3
Loosen two M12 screws (1) and remove the hydraulic drive motor (2).
5.16.4
Use a small propane torch and heat the countersunk screw (3) holding
the drive pinion gear (4) to the motor. This will break down the
threadlocking sealant. Remove screw and washer (5), and pull drive
pinion gear off motor.
Installation:
5.16.5
Install drive pinion gear (4) onto motor shaft with washer (5) and screw
(3). Secure screw with Loctite 271 or an equivalent high strength
threadlocking compound.
5.16.6
Apply Loctite 515 gasket compound to face of gear cover where drive
motor mounts (a).
5.16.7
Mount hydraulic drive motor (2) with two M12 screws (1). Secure
screws with Loctite 243 or an equivalent medium strength
5.16.8
Align the hydraulic fittings (b) as shown.
Note: Failure to align fittings properly could make it difficult to connect
hydraulic lines after drive assembly is installed.
5.16.9
Install Drive housing. See section Drive Housing.
Seal Kit:
5.16.10 Order Seal Kit P/N 76630 for replacement of internal motor seals and
O-rings. Refer to installation instructions included with kit.
Note: Special knowledge and skill is required when working on
hydraulic components. If you are lacking the necessary skills and
know-how, contact a competent hydraulic repair facility for assistance.
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1
18
17
4
5
3
2
a
2
b
wc_gr002510
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5.17 Drive Housing Components
Disassembly:
5.17.1
5.17.2
Remove drive housing from the drum support. See section Drive
Housing.
5.17.3
Drain oil from drive housing. See section Changing Oil.
5.17.4
Remove drive motor (see section Drive Motor) and brake assembly
(see section Brake) from drive housing.
5.17.5
Loosen the five M8 screws (6) and lift gear cover (7) from drive housing
(8).
5.17.6
Press shaft seal (9) from gear cover.
5.17.7
Remove retaining ring (10) holding gear (11) to drive axle (12). Use
three M12 x 90 hardened bolts (c) (P/N 11411) to push drive gear from
drive housing and off of drive axle. If necessary, heat gear to aid in its
removal.
5.17.8
Remove key (13) from drive axle (12) and pull axle from drive housing
(8). If necessary, use three M16 x 55 screws (d) (P/N 11518) to push
axle from drive housing.
5.17.9
Remove retaining ring (14) and press roller bearing cage (15) from
drive housing (8).
5.17.10 Remove seals (16 & 17) from drive housing (8).
5.17.11 Remove key (18) from drive axle (12).
5.17.12 Use a small propane torch and heat inner bearing race (19) and spacer
(20) sufficiently until they drop off axle.
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7
11
10
9
14
16
8
15
6
21
17
18
20
19
12
13
c
d
wc_gr002511
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(Drive Housing Components continued)
Assembly:
5.17.13 Heat spacer ring (20) on a hot plate or in oil bath and press onto drive
axle (12).
5.17.14 Heat roller bearing race (19) and press onto drive axle.
5.17.15 Press shaft seal (16) into drive housing (8).
5.17.16 Apply a bead of silicone to area on drive housing (a) where wiper seal
(17) will seat. Install seal on housing.
5.17.17 Apply a thin film of low-temp #2 grease to drive axle (b) to trap any
excess dust.
5.17.18 Press bearing cage (15) in drive housing. Secure it to axle with
retaining ring (14).
5.17.19 Slide axle into drive housing carefully to avoid damaging seal (16).
5.17.20 Place key (13) in drive axle.
5.17.21 Slide bearing washer (21) over axle and onto bearing.
5.17.22 Heat drive gear (11) for approximately one half hour in a 350° oven and
then press it onto axle (12).
5.17.23 Attach retaining ring (10) to secure drive gear on axle.
5.17.24 Press shaft seal (9) into gear cover (7).
5.17.25 Apply Loctite 515 or an equivalent gasket compound to machined
faces (c) of drive housing (8), as shown.
5.17.26 Mount gear cover (7) to drive housing (8) using five M8 screws (6).
Secure screws with Loctite 243 or an equivalent medium strength
threadlocking compound and torque to 18 ft.lbs (24 Nm).
5.17.27 Install drive motor and brake. See sections Drive Motor and Brake.
5.17.28 Add 8 oz. of SAE 30W oil to drivecase through fill plug opening. See
section Changing Oil.
5.17.29 Install complete drive housing in drum support. See section Drive
Housing. Re-check oil level.
WARNING
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12
13
14
21
a
c
15
17
16
19
20
b
8
11
9
12
10
7
6
wc_gr002512
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5.18 Exciter Assembly Exploded View
7
15
12 14
16
11
6 [L1]
7
5
5
12
17
16
19
15
13
11
4
3
2
39 [L3, T1]
7
1 [L1]
40
6 [L1]
9 [L2,T1] 10
25 [L2, T2]
26 [L4, T1]
27
20 [L2,T2]
21 [L3]
22
23 [L3]
24 [L3, T3]
27
29
31
34
30
26 [L4, T1]
28
22
33
32
35 [L5, T1]
36*
36*
32
38 [L5, T4]
wc_gr002513
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5.19 Exciter Assembly Components
See Graphic wc_gr002513
Ref.
Description
Qty.
Ref.
Description
1
Fitting-elbow
2
1
21
Cover
2
O-Ring
1
22
Bearing-roller
4
3
O-Ring
1
23
Cover-exciter base
1
4
Motor-hydraulic gear
1
24
Screw (M6x10)
10
5
Key-Woodruff
1
25
Screw (M8x16)
13
6
Fitting-elbow
2
26
Plug (M26x1.5)
2
7
O-Ring
2
27
Seal-ring
2
8
O-Ring
2
28
Cover-exciter gear
1
9
Screw (M10x25)
2
29
Retaining ring
2
10
Washer-lock
2
30
Gear-exciter
2
11
Coupling-flexshaft
1
31
Retaining ring-internal
2
12
Setscrew (5/16"x5/8)
2
32
Weight-variable
2
13
Sleeve-coupler
1
33
Shaft-exciter
2
14
Retaining ring-external
1
34
Key
2
15
Bearing-roller
2
35
Screw (M10x30)
4
16
Retaining ring-internal
2
36
Mount-weight
2
17
Spacer-bearing
1
37
Weight-exciter
4
18
Key-Woodruff (¼x1)
1
38
Screw (M16x70)
4
19
Gear-pinion
1
39
Screw (M10x12)
1
20
Screw (M8x18)
12
40
Seal-ring
1
[L1] 0079356
[T1] 36 ft.lbs. (49 Nm)
wc_tx000473gb.fm
[L2] 0029311
[T2] 18 ft.lbs. (24 Nm)
[L3] 0070735
[T3] 7 ft.lbs. (10 Nm)
111
Qty.
[L4] 0073287
[T4] 155 ft.lbs. (210 Nm)
RT Repair
5.20 Introduction
This section covers disassembly and assembly of the complete exciter
assembly, including replacement of gears, bearings, exciter motor,
and motor coupling.
CAUTION: Due to the high rpm and vibration present in this
component during operation, it is important to follow sealant and
torque notes carefully during assembly.
5.21 Oil Requirements
The exciter bearings and gears run in an oil bath and are splash
lubricated. When servicing exciter be sure to check oil level (a) before
installing it back into drum.
Note: Although oil can be added through the oil level plug, it is easier
to add oil before attaching the base cover during reassembly.
Capacity: 32 oz. (1000 ml) SAE 30W.
a
wc_gr002516
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5.22 Exciter
Removal:
Note: The exciter is installed in the drum using threadlocking
compounds to secure screws. Heat screws before removal, using a
small propane torch, to break down the threadlocking compound.
5.22.1
Remove drum, drum support cover, and drive housing assembly. See
sections Drums, Drum Support Cover, and Drive Housing.
5.22.2
Tag and disconnect hydraulic lines from exciter motor. Cap and plug
open connections.
5.22.3
Remove eight M12 screws (1) holding the exciter assembly (2) to the
drum support (3).
5.22.4
Lift exciter assembly up and out of drum.
Installation:
5.22.5
Double check oil level. Add or drain oil as required.
5.22.6
Install exciter assembly (2) in drum support (3) using eight M12 screws
(1). Secure screws using Loctite 271, or an equivalent high strength
threadlocking compound, and torque bolts to 88 ft. lbs. (120 Nm).
5.22.7
Connect hoses to fittings on exciter motor.
5.22.8
Install drum, drum support cover, and drive housing assembly. See
WARNING
tightened.
3
2
1
wc_gr002517
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5.23 Exciter Exploded View
41
25
21
28
23
20
24
26
29
31
34
30
22
33
35
36
37
38
wc_gr002518
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5.24 Exciter Disassembly
See Graphic: wc_gr002518, wc_gr002519, wc_gr002520
Note: The exciter is assembled using threadlocking compounds to
secure bolts and screws. Heat screws before removal, using a small
propane torch, to break down the threadlocking compound.
5.24.1
5.24.2
Remove drain plug (26) from exciter gear cover (28) and drain oil.
5.24.3
Remove exciter assembly from drum support. See section Exciter.
and a container under the exciter to collect the liquid which drains off,
5.24.4
Invert exciter housing (41) and remove ten M6 screws (24) holding the
bottom base cover (23) to the exciter housing. Remove bottom base
cover.
5.24.5
Rotate exciter shafts (33) to gain access to weights (37).
The exciter weights can rotate freely. Use caution when removing
weights to prevent pinching fingers or hands inside exciter housing.
CAUTION
5.24.6
Use a small propane torch and heat four M10 screws (35) securing
mount (36) to weights (37). Remove screws and mount.
5.24.7
Heat four M16 screws (38) holding the weights (37) to shafts (33). This
will break down the threadlocking compound. Remove screws and
weights.
5.24.8
Remove thirteen M8 screws (25) holding exciter gear cover (28) to
housing (41).
5.24.9
Remove retaining rings (29) holding exciter gears (30) to shafts.
5.24.10 Insert three M10 x 55 pusher bolts into threaded holes (a) on exciter
gear (30). Turn bolts in until exciter gear is pushed free from housing.
Repeat for other gear.
5.24.11 Remove keys (34) from exciter shafts (33).
5.24.12 Remove large retaining rings (31) which secure gear side bearings
(22) in housing (41).
5.24.13 From other side of exciter housing, loosen the M8 screws (20) and
remove covers (21) from housing (41).
5.24.14 Press or use a rubber mallet to drive exciter shaft (33) and bearing (22)
all the way through housing as shown (b). Remove variable weight
(32) as shaft slides through housing. Repeat for other shaft.
5.24.15 Press remaining shaft bearings (22) from housing.
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b
33
a
32
22
41
29
wc_gr002519
29
30
31
33
22b
41
22a
b
21
22b
20
32
a
wc_gr002520
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5.25 Exciter Assembly
5.25.1
Lightly lubricate each exciter shaft (33) with 10W30 and press inner
bearing races (22a) onto both ends of shafts.
5.25.2
Install bearing cage (22b) into exciter housing (41). Outer edge of cage
should be flush with outer machined surface of housing.
5.25.3
Apply Loctite 515 or an equivalent gasket compound to cover (21), and
fasten to housing (41) using 5 M8 screws (20). Secure screws using
Loctite 243 or an equivalent medium strength threadlocking
compound, and torque to 18 ft.lbs. (24 Nm).
5.25.4
Coat inside of weight (32) with oil. Insert shaft (33) into housing, sliding
it through weight (32), and into bearing (22b).
5.25.5
Press bearing cage (22b) into gear side of housing and secure it in
place with retaining ring (31).
5.25.6
Repeat procedure for other shaft.
5.25.7
With keyways (a) pointing up, install keys (34) and place gears (30)
onto shafts (33).
Note: Gears must be “timed”. To time gears, insert four M10 screws
into upper push holes (b), lay a straight edge (c) across both gears at
screws and align screws to straight edge. The screws must line up
within one gear tooth of each other as shown. Both shaft keys must be
facing up (a).
5.25.8
Secure gears on shafts with retaining rings (29).
Note: Complete steps 9 through 14 with exciter casing inverted as
shown.
5.25.9
Slide free weights (32) to center of exciter shafts (33).
5.25.10 Mount fixed weights (37) to exciter shaft (33) with M16 screws (38).
Secure screws using Loctite 271, or an equivalent high strength
threadlocker, and torque to 155 ft.lbs. (210 Nm).
Note: The holes in the shafts are chamfered on one end. Install
weights so bolts will thread into chamfered end.
5.25.11 Secure weight mounts (36) to weights (37) with M10 screws (35).
Secure screws using Loctite 271, or an equivalent high strength
CAUTION: For proper machine performance, it is essential that
weight mounts (36) be mounted correctly. Fasten weight mounts as
shown.
5.25.12 Add 32 oz. (946 ml) of 10W30 to exciter housing through base
opening.
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5.25.13 Apply Loctite 515 or equivalent gasket compound to base of exciter
(d).
5.25.14 Mount exciter base cover to housing (41) with M6 screws. Secure
screws using Loctite 243, or an equivalent medium strength
5.25.15 Apply Loctite 515, or equivalent gasket compound, to machined face
(e) of exciter gear cover (28).
CAUTION: Be sure to coat around entire face of cover including
around holes to prevent exciter from leaking.
5.25.16 Install M26 plugs (26) and seal rings (27) into gear cover (28). Secure
plugs using Loctite 222, or an equivalent low strength threadlocker,
and torque to 36 ft.lbs. (49 Nm).
5.25.17 Mount cover (28) to housing (41) with M8 screws (25). Secure screws
using Loctite 243, or an equivalent medium strength threadlocker, and
torque to 18 ft.lbs. (24 Nm).
5.25.18 Install exciter assembly in drum support. See section Exciter.
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35
d
36
28
25
32
26
27
37
41
e
37
38
wc_gr002521
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5.26 Exciter Motor, Coupling, & Pinion Gear
19
18
15a
15a
17
12a 14
11a
15b
16
15b
13
41
26
28
11
9
10
23
wc_gr002522
15a
b
15a
wc_gr002523
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5.27 Exciter Motor, Coupling, & Pinion Gear Removal
Replacement of the exciter pinion gear, bearings, and coupling
requires removal of the exciter assembly from the drum support.
Replacement, or service, to only the exciter motor can be performed
by removing the drum support cover (see section Drum Support
Cover) to gain access to the motor.
5.27.1
sections Drums, Drum Support Cover, and Drive Housing Assembly.
5.27.2
Remove exciter assembly from drum support. See section Exciter.
Refer to section Exciter Components when completing steps 3, 4 & 5.
5.27.3
Remove drain plug (26) and drain oil.
5.27.4
Remove exciter base cover (23).
5.27.5
Remove exciter gear cover (28).
5.27.6
Remove two screws (9) and washers (10) mounting exciter motor (4)
to exciter housing (41).
5.27.7
Pull sleeve coupler (13) from inner coupling (11a) on pinion gear shaft
(19).
5.27.8
Reach through bottom of exciter housing and loosen set screw (12a)
holding inner coupling (11a) to pinion gear shaft (19). Remove inner
coupling by prying off with large screw driver or gear puller.
5.27.9
Remove retaining ring (14).
5.27.10 Remove key (18) from pinion gear shaft (19) in housing.
5.27.11 Use a press or rubber mallet to drive pinion gear (19) out of housing.
Note: The roller bearings (15a) will remain in the housing.
5.27.12 Remove spacer (17) and bearing race (15b) from pinion gear shaft.
5.27.13 Drive roller bearing (15a) out of housing using a rubber mallet and
steel punch as shown (b). The bearing will be damaged or destroyed
in the process and must be replaced.
5.27.14 Remove retaining rings (16) from housing.
5.27.15 Press remaining bearing (15a) from housing.
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5.28 Exciter Motor, Coupling, & Pinion Gear Installation
5.28.1
Press bearing race (15b) on pinion gear shaft (19).
5.28.2
Install retaining rings (16) in housing.
5.28.3
Press both roller bearing cages (15a) into housing against retaining
rings.
5.28.4
Slide spacer (17) onto pinion gear shaft (19).
5.28.5
Slide pinion gear shaft into housing and through roller bearings as
shown (c).
5.28.6
Face exciter housing down so pinion gear (19) is resting against a solid
surface. Press remaining bearing race (d) over shaft until it rests
against spacer (17).
5.28.7
Install retaining ring (14).
5.28.8
Install woodruff key (18) on pinion gear shaft (19).
5.28.9
Install coupling (11a) onto pinion gear shaft with rubber mallet. Apply
Loctite 243, or an equivalent medium strength threadlocker to set
screw (12a) in coupling and tighten set screw against shaft.
5.28.10 Slide flex-coupling (13) onto coupling (11a).
5.28.11 Place key (5) onto shaft of exciter motor (11) and install coupling (11b).
Apply Loctite 243, or an equivalent medium strength threadlocker to
set screw (12b) in coupling and tighten it against shaft.
5.28.12 Mount exciter motor (11) on exciter housing (41) with lockwashers (10)
and M10 screws (9). Secure screws using Loctite 243, or an equivalent
medium strength threadlocker, and torque to 36 ft.lbs. (49 Nm).
Refer to section Exciter Components when completing steps 13 & 14.
5.28.13 Mount exciter gear cover (28).
5.28.14 Mount exciter base cover (23).
5.28.15 Install exciter assembly in drum support. See section Exciter.
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d
14
12a
18
15a
5
16
15a
12b
16
c
19
17
11a
13
11b
15b
wc_gr002524
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5.29 Exciter Motor
Seal Kit:
Order Seal Kit P/N 80500 for replacement of internal motor seals and
O-rings. Refer to installation instructions included with kit.
Note: Special knowledge and skill is required when working on
hydraulic components. If you are lacking the necessary skills and
know-how, contact a competent hydraulic repair facility for assistance.
Indexing Fittings:
All hydraulic fittings should be installed on motor before assembly onto
exciter. Fittings must be installed as shown to ensure proper
connection of hoses inside drum.
15˚
45˚
a
a
b
b
wc_gr002527
wc_gr002525
5.30 Shockmounts
Each drum support is shockmounted to the machine frame at six
places, two at the outer mount (a) and four at the inner mounts (b).
Inspect shockmounts at regular intervals for damage and wear.
Replace shockmounts that are torn or split. The shockmounts isolate
and protect the frame and upper components from excessive vibration.
Running the machine with damaged shockmounts can cause wiring
connections to weaken and may eventually damage other
components. When replacing shockmounts it is recommended that
both the left and right sides be done at the same time.
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5.31 Shockmount Assembly
1
5
[L1, T1] 6
2
[L1] 9
[L1] 8
7
[L1] 3
[L1, T1] 6
10
wc_gr002526
4
5
Ref.
Description
Qty.
Ref.
1
Frame-rear
1
6
Screw (M12x25)
24
2
Drum support
1
7
Bracket-shockmount
4
3
Spacer
6
8
Setscrew (M12x30)
12
4
Shock mount
6
9
Stud-shock mount
6
5
Washer-lock
24
10
Mount-scraper support
4
[L1] 0029311
[T1] 63 ft.lbs. (85 Nm)
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Qty.
RT Repair
5.32 Replacing Outer Shockmounts
Removal:
5.32.1
Remove three M12 screws (6) and washers (5) holding the
shockmount bracket (7) to the frame and one screw and washer
holding bracket to shockmount (4). Remove bracket.
5.32.2
Grasp the shockmount (4) with a large channel-lock pliers or a strap
wrench and twist it until it breaks free from the spacer (3).
5.32.3
Remove shockmount (4) and scraper support mount (10).
Note: If the shockmount is difficult to remove, remove spacer with the
shockmount attached.
5.32.4
Use a two-inch open end wrench, with extension, to loosen spacer (3)
from the stud (9). If necessary, heat spacer using a small propane
torch to break down threadlocking compound.
Note: To remove shockmount from spacer, place spacer in vise (a)
and turn it free.
5.32.5
The shockmount studs (9) are slotted and can be removed using a
large screwdriver (b). Heat studs thoroughly to break down
threadlocking sealant.
Installation:
5.32.6
If replacing shockmount stud (9), apply Loctite 243, or an equivalent
medium strength threadlocking compound, to threads on stud. Screw
stud into frame until it protrudes equally on either side (x).
5.32.7
Screw shockmount spacer (3) onto stud (9) until tight.
5.32.8
Install setscrew into shockmount spacer (3). Secure setscrew using
compound.
5.32.9
Slide scraper support mount (10) over setscrew.
5.32.10 Install shockmount (4) onto setscrew. Secure shockmount using
compound.
5.32.11 Mount shockmount bracket (7) to shockmount (4) and frame with
screws (6) and washers (5). Secure screws using Loctite 243 or an
equivalent medium strength threadlocking compound and torque to 63
ft.lbs. (85 Nm).
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tightened.
WARNING
3
7
6, 5
a
4
10
X
9
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b
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5.33 Replacing Inner Shockmounts
Removal:
5.33.1
Lock articulated joint. See section Articulated Joint Locking Bar.
5.33.2
Support machine with appropriate crane or hoist by the lifting eye (c).
WARNING
chains.
5.33.3
Loosen (do not remove) M12 screws (6) holding outer shockmount (d)
to the shockmount bracket (7).
5.33.4
Remove M12 screws (6) holding the inner shockmounts (e) to the
frame.
5.33.5
Slowly raise machine and allow drum support to pivot down as shown
in illustration. Position machine and drum support as needed to access
inner shockmounts and spacers.
CAUTION: Avoid straining hydraulic hoses. Lift machine only high
enough to remove shockmounts.
Installation:
Remove and install shockmounts and spacers. See section Replacing
Outer Shockmounts.
5.33.6
Lower machine and position support drum to align shockmounts with
holes in frame.
5.33.7
Mount shockmount (4) to frame with M12 screw (6) and washer (5).
Secure screw using Loctite 243 or an equivalent medium strength
5.33.8
Tighten screws (6) mounting outer shockmount bracket (7) to
shockmount (4) and torque to 63 ft.lbs. (85 Nm).
WARNING
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5
[L1, T1] 6
2
[L1] 9
[L1] 8
7
[L1] 3
[L1, T1] 6
10
wc_gr002526
4
5
c
d
e
wc_gr002546
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5.34 Hydraulic Hose Clamps
2
[L1] 12
3
4
5
6
3
[L1] 1
6
2
12
3
7
[L1] 1
9
[L1] 1
[L1] 1
2
3
11
10
6
13
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5.35 Hydraulic Hose Clamp Components
Ref.
Description
Ref.
Description
1
Screw M8 x 60
6
8
Screw M8 x 20
1
2
Washer
6
9
Clamp-hose
1
3
Nut-lock M6
7
10
Adapter-clamp
1
4
Plate-clamping
2
11
Plate-clamping
2
5
Clamp-hose
1
12
Plate-clamping
2
6
Screw M6 x 50
7
13
Clamp-hose
1
7
Guard-hose
1
--
--
--
[L1] 0029311
Qty.
Qty.
[L2] 0070735
5.36 Drum Supports
See Graphic:wc_gr002548
The drum supports (a) contain both the exciter and drive assemblies,
as well as all the connecting piping for the drive and exciter motors.
Before removing the drum support it will be neccesary to first remove
both the drum support cover and drive housing assembly to gain
access to the hydraulic piping inside.
To ease installation of hydraulic hoses and fittings later on, make note
of their orientation, placement and position. Cap and plug all open
connections to prevent contamination from entering hydraulic system.
a
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5.37 Drum Support Exploded View
1
6
3
9
12
11
5
7
8
10
13
4
6
5
2
wc_gr002549
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5.38 Replacing Drum Supports
Removal:
5.38.1
Lock articulated joint. See section Articulated Joint Locking Bar.
5.38.2
Support machine by lifting eye (1), using an appropriate crane or hoist.
WARNING
chains.
5.38.3
Remove drums (2). See section Drums.
5.38.4
Remove drum support cover (3). See section Drum Support Cover.
Disconnect hydraulic lines from drive motor and brake assembly if
applicable. Cap or plug open connections.
5.38.5
Remove drive housing assembly (4). See section Drive Housing.
Disconnect hydraulic hoses from exciter motor and cap or plug open
hoses and fittings.
5.38.6
Remove screws (5) and washers (6) holding the shockmounts and
brackets to the frame.
5.38.7
Remove two M8 screws (7) and washers (8) holding the hose clamps
(9) to the drum support (10).
5.38.8
Remove hose guard (11) from drum support.
5.38.9
Loosen slightly, but do not remove, two M16 screws (12) which hold
the rear hose clamps (9) together. This will allow hoses to slide easily
through clamps and act as a guide when pulling them out of the drum
support. Repeat for front drum clamps (13).
5.38.10 Slowly raise machine and carefully guide hydraulic hoses out of the
drum support.
Installation:
5.38.11 Install shockmounts on drum support (10). See sections Replacing
Inner Shockmounts and Replacing Outer Shockmounts.
5.38.12 Place drum support under raised machine. Insert hydraulic lines
through openings and lower machine over drum support.
5.38.13 Secure machine frame to shockmounts with screws (5) and washers
(6). Secure screw using Loctite 243 or an equivalent medium strength
5.38.14 Apply Loctite 545 hydraulic sealant, or equivalent, to fittings on exciter
drive motor and attach hydraulic hoses.
5.38.15 Install drive housing assembly (4) and connect hydraulic lines to drive
motor. See section Drive Housing.
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5.38.16 With all hydraulic hoses connected, tighten hose clamps (9, 13) around
hoses. Install hose clamps to drum supports with screws (7) and
washers (8) and attach hose guard (11). Secure screws using Loctite
243 or an equivalent medium strength threadlocking compound.
5.38.17 Install drum support cover (3) and drums (2). See section Drum
Support Cover and section Drums.
WARNING
tightened.
5.39 Articulated Joint and Steering Cylinder Exploded View
1 [T1]
2
3
4
5
6
7
11
12
11
12
16
13
13
14
7
6
15
17
4
1 [T1]
4
5
3
2
9
8 [L1, T2]
10
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5.40 Articulated Joint and Steering Cylinder Components
Ref.
Description
1
Nut-lock (M16)
2
Ref.
Description
2
11
Screw (M12x20)
2
Washer
2
12
Washer
2
3
Bearing-ball
2
13
Fitting-hydraulic
2
4
Fitting-grease
6
O-Ring
2
5
Bracket-pivot
2
O-Ring
2
6
Pin-pivot
2
14
Hose assembly
1
7
Screw (M16x90)
2
15
Hose assembly
1
8
Screw (M12x40)
8
16
Bearing
2
9
Access cover
1
17
Cylinder-hydraulic
1
10
Screw (M8 x 16)
4
[L1] 0029312
[T1] 155 ft.lbs. (210 Nm)
Qty.
Qty.
[T2] 94 ft. lbs. (128 Nm)
a
b
c
wc_gr002551
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5.41 Replacing Articulated Joint
See Graphic: wc_gr002551and wc_gr002552
Prior to removal:
5.41.1
Remove scraper bars and drums from both right and left sides of the
rear half of machine. See section Drums.
5.41.2
Start machine and position machine as if turning left (a). This will help
gain access to articulated joint at point (b). Once in this position, turn
machine off.
5.41.3
Support each drum, both front and rear, with screw jacks (c) or
blocking.
Only use blocks or jacks with a suitable load bearing capacity. Do not
use improvised blocks or jacks.
WARNING
Removal:
5.41.4
Heat the M12 screws (8) holding pivot brackets (5), using a small
propane torch to break down the threadlocking compound. Remove
screws and bracket.
5.41.5
Remove M16 screw (7) from top and bottom joint.
5.41.6
Tap out pivot pin (6) from bracket portion of machine frame.
Note: Pivot pin is removed from top to bottom on uppermost bracket
and from bottom to top on lower bracket.
5.41.7
Slide pivot bracket (5) and washer (2) out of machine frame.
5.41.8
After pivot bracket is off, place pivot pin (6) back into it as shown. Use
an arbor or hydraulic press to push against pin (d) and press bearing
(3) out of bracket.
Installation:
5.41.9
To prevent rust, repaint any areas of the pivot bracket damaged by
heating during disassembly.
5.41.10 Press bearings (3) into pivot brackets (5).
Note: Bearing outer race is cracked. This is done during assembly
procedure to install the inner bearing.
5.41.11 Place washer (2) into machine frame.
5.41.12 Slide (e) pivot bracket (5) over washer (2) and into machine frame.
5.41.13 Tap pivot pin (f) into bracket portion of machine frame and through
pivot bracket (5).
Note: Pivot pin is installed from bottom to top on uppermost bracket
and from top to bottom on lower bracket.
5.41.14 Install M16 screw (7) and secure with locknut (1). Torque to 155 ft. lbs.
(210 Nm).
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5.41.15 Secure pivot bracket (5) to rear half of machine frame with M12 screws
(8). Secure screws using Loctite 271, or an equivalent high strength
threadlocking compound and torque to 94 ft. lbs. (128 Nm).
5.41.16 Attach drums and scraper bars.
5.41.17 Grease bearings, through fittings (4), using Shell Alvania #2 grease.
tightened.
WARNING
2
3
6
4
7
5
6
4
3
2
8
3
1
2
7
6
d
6
3
6
f
7
2
3
e
5
2
1
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5.42 Steering Cylinder
Removal:
5.42.1
Remove four M8 screws (10) mounting the cylinder access cover (9)
to the machine.
5.42.2
Disconnect hoses (14, 15) from cylinder (17). Cap hoses and fittings
(13).
5.42.3
Remove two M12 screws (11) and washers (12) mounting cylinder (17)
to frame.
5.42.4
Pull steering cylinder (17) from rear frame.
Installation:
5.42.5
Mount steering cylinder (17) inside rear frame with M12 screw (11) and
washer (12).
5.42.6
With machine positioned with front in-line with rear, secure ram end of
steering cylinder to front frame with M12 screw (11) and washer (12).
5.42.7
Apply Loctite 545, or equivalent hydraulic sealant, to fittings (13) and
attach hoses (14, 15) to steering cylinder (17).
5.42.8
Mount steering cylinder access cover (9) to frame with M8 screws (10).
WARNING
wc_tx000473gb.fm
tightened.
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11
12
13
13
17
14
15
9
10
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5.43 Drive Pump and Coupling Assembly Exploded View
1 [L1]
7 [L1, T2]
2
3
6
5
8
4
11
9
29
28
27
12
26
25 [L1, T1]
14
10
13
15
17
16
18
19
20 [L2]
15
24
20 [L2, T2]
17
18
23 [L2, T2]
19
22 [L2]
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5.44 Drive Pump and Coupling Assembly Components
Ref.
Description
1
Stud
2
Ref.
Description
6
16
Block-hydraulic
1
Washer-lock
6
17
O-Ring
2
3
Nut (M8)
6
18
Fitting #8 (incl. 17, 19)
2
4
Bolt
6
19
O-Ring
2
5
Plug
1
20
Hose assembly
1
6
Manifold-suction
1
21
Screw (M6x40)
4
7
Screw (M6x50)
4
22
Hose assembly
1
8
Clamp-hose
1
23
Screw (M6x80)
4
9
Hose-suction
1
24
Block-hydraulic
1
10
O-Ring
1
25
Screw (M10x30)
4
11
O-Ring
1
26
Adapter-pump
1
12
Pump-hydraulic
1
27
Adapter-internal
1
13
Fitting-adapter
2
28
Adapter-engine
1
14
O-Ring
2
29
Support-pump
1
15
O-Ring
2
[L1] 0029311
[T1] 36 ft.lbs. (79 Nm)
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Qty.
[L2] 0079356
[T2] 7 ft.lbs. (10 Nm)
141
Qty.
RT Repair
5.45 Replacing Drive Pump and Coupling
Removal:
5.45.1
Loosen hose clamp (8) and disconnect suction hose (9) from suction
manifold (6).
Danger of burns! Pump may be hot. Care must be taken when
removing hydraulic components and oil. Hot oil can burn!
WARNING
5.45.2
Tag, disconnect, and cap hydraulic hoses (20, 22).
5.45.3
Remove screws (7, 21, 23) mounting hydraulic blocks (6, 16, 24) from
drive pump (12). This is to provide clearance for mounting screws (25).
5.45.4
Heat and remove two M10 screws (25), mounting the drive pump (12)
to pump support (29).
5.45.5
Slide pump adapter couplings (26, 27) off pump (12).
5.45.6
Remove two M8 nuts (3) and washers (2) mounting pump support (29)
to engine.
5.45.7
Remove two screws (4) mounting adapter (28) to engine.
Installation:
5.45.8
Grease adapter couplings (26, 27) with Shell Alvania #2 and install
them on drive pump (12).
Note: Pump adapter (26) must be installed with short end facing
toward pump as shown.
5.45.9
Mount adapter (26) to engine with screws (4).
5.45.10 Mount pump support (29) to engine studs. Apply Loctite 243 or an
equivalent medium strength threadlocking compound to studs and
secure with nuts (3) and washers (2).
5.45.11 Mount drive pump (12) to pump support (29) with screws (25). Secure
screws using Loctite 271, or equivalent high strength threadlocker, and
torque screws to 7 ft.lbs. (10 Nm).
Note: Make sure tangs (a) on internal adapter (27) fit into slots in
engine adapter (28). Apply grease or anti-seize to tangs and opposing
couplers.
5.45.12 Mount hydraulic blocks (6, 16, 24) to drive pump (12) with screws (7,
21, 23). Secure screws using Loctite 271, or equivalent, and torque
to 7 ft.lbs. (10 Nm).
5.45.13 Apply hydraulic sealant to fittings and attach hydraulic hoses (20, 22,
9).
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7
1
2
3
6
8
4
9
29
28
a
27
26
12
25
16
20
24
21
23
22
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5.46 Removing Engine Cover
General:
All machines are equipped with a two cylinder, 20 Hp (16 kW)
Lombardini diesel engine - model 12LD475-2.
When servicing the engine or replacing parts, refer to the engine
identification plate located on the fan shroud for the serial number and
model number of the engine.
Cover Removal:
wc_tx000473gb.fm
5.46.1
Before removing the cover, loosen hose clamp (b) mounting air
cleaner hose (c) to air cleaner (d). Remove air cleaner hose.
5.46.2
Remove two screws (e), nuts (f), and ground strap (k) mounting
voltage regulator (g) to inside of cover wall.
5.46.3
Remove eighteen M8 screws (h) mounting entire engine cover (j) to
front frame.
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c
b
d
j
g
e
f
k
h
h
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5.47 Removing Engine
Stop and switch off the machine and disconnect the battery.
5.47.1
Remove cover from front frame. See section Removing Enigne Cover.
5.47.2
Loosen screws (1) holding throttle cable retainers (2) and pull retainers
off cable.
5.47.3
Remove nut (3) holding throttle cable (4) to engine mounting bracket.
Pull cable out through bracket.
5.47.4
Tag and disconnect hydraulic hoses (5) from drive pump. Cap or plug
all open connections.
5.47.5
Unplug wire harness (6).
5.47.6
Disconnect battery ground wire (7) from engine block.
5.47.7
Disconnect positive battery cable (8) from starter motor.
5.47.8
Remove screws (9) mounting radiator (10) to front frame. Keep
hydaulic hoses connected and place radiator assembly aside and clear
from engine.
5.47.9
Disconnect fuel pressure line (11) from fuel solenoid and cap the hose.
5.47.10 Disconnect fuel return line by cutting hose (12) as close to crimped
clamp (13) as possible. Use a side cutter or other appropriate tool to
remove crimped clamp from barbed nipple (14) on engine.
5.47.11 Remove cap (15) to drain oil from engine. Remove fitting and seal ring
connecting drain hose assembly (16) to engine.
and a container under the machine to collect the liquid which drains off,
5.47.12 Remove the four M16 screws (17) and nuts (18) securing engine to
machine frame.
5.47.13 Use an appropriate hoist and sling to lift engine up and off machine
frame. Use lifting eyes (19) on engine for lifting.
WARNING
chains.
5.47.14 Remove drive pump, couplings and support from engine. See section
Drive Pump and Coupling.
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3
4
8
2
5
1
18
15
16
6
11
5
17
7
19
10
14
12
13
9
wc gr002557
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5.48 Installing Engine
Replacement engines come equipped with a new voltage regulator
and pump coupling. They do not include the following:
•
Exhaust System
•
Air Cleaner
•
Wiring Harness or Engine Relays
•
Pressure Switch
•
Engine Oil Drain
Remove these items from existing engine assembly for use on new
engine. See the upcoming sections for removal and installation
procedures.
wc_tx000473gb.fm
5.48.1
Line up mounting holes on engine with those on the front frame. Mount
engine to frame with four M16 screws (1) and nuts (2).
5.48.2
Install seal ring (3) and drain hose assembly (4) into engine. Check
engine oil level. See Section 1.12 Lubrication Specifications.
5.48.3
Install throttle cable (5). Make sure cable is pushed all the way in at
handle . Insert cable through bracket (6) and secure with nut (7).
Adjust retainers (8) on cable end so machine runs at specified RPM at
full throttle control. See Tech Data for engine specifications.
5.48.4
Install drive pump and coupling. See section Drive Pump and
Coupling.
5.48.5
Install cover assembly. See section Replacing Engine Cover.
5.48.6
Reconnect battery cables.
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6 7
5
8
2
3
4
1
wc_gr002558
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5.49 Replacing Muffler
Removal:
Danger of burns! Muffler may be hot–care must be taken when
removing any muffler components.
WARNING
5.49.1
Remove two M8 nuts (18) mounting muffler adapter (9) to engine.
5.49.2
Remove two M8 screws (10) mounting muffler bracket (11) to engine.
5.49.3
Remove muffler assembly from engine.
Installation:
5.49.4
Line up mounting holes on muffler bracket (11) with holes on engine.
Mount muffler bracket with two M8 screws (10).
5.49.5
Mount muffler adapter (9) to studs on engine exhaust manifold with two
nuts (18).
9
9
12
12
18
14
10
16
11
wc_gr002559
wc_gr002560
17
15
5.50 Replacing Engine Air Cleaner
Removal:
5.50.1
Loosen hose clamps (12) and remove air cleaner hoses (13, 14).
5.50.2
Remove four M8 screws (15) mounting air cleaner (16) to air cleaner
mounting plate (17).
5.50.3
Remove air cleaner from engine.
Installation:
wc_tx000473gb.fm
5.50.4
Line up mounting holes of air cleaner mounting plate (17) with those in
the air cleaner (16). Mount air cleaner with four M8 screws (15).
5.50.5
Slide air cleaner hose (13) over inlet on air cleaner and secure with
hose clamp (12). Repeat for air cleaner hose (14).
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5.51 Engine Relays
Removal:
5.51.1
Remove three M8 locknuts (1) mounting air cleaner mounting plate (2)
to engine. Save ground strap (3).
5.51.2
Remove three M8 studs (4) from engine.
Note: Relays are interchangeable for quick troubleshooting of possible
defective relay.
Installation:
5.51.3
Install three M8 studs (4) into engine. Secure studs using Loctite 271
or an equivalent high strength threadlocking compound.
5.51.4
Inspect and secure glow plug relay (5), starter relay (6), and antirestart module (7).
5.51.5
Line up mounting holes in air cleaner mounting plate (2) with studs (4)
in engine. Secure plate to engine using M8 locknuts (1).
Note: Install ground strap (3) on lower stud.
Testing Anti-Restart Module:
5.51.6
Ensure brown ground wire is securely attached to the engine.
5.51.7
The white wire connects the engine oil pressure switch to the engine
oil pressure switch indicator light via the anti-restart module. Ground
the white wire to the engine frame and make sure the engine oil light
turns on. Try to start the engine.
5.51.8
To eliminate the anti-restart module, unplug the 3-position wire
connector. Ground the black wire from the plug end to the engine
(opposite the anti-restart module) leading to the starter relay. Test
start the engine. If this allows the engine to start, replace the antirestart module.
5
2
7
6
4
1
3
wc_gr002561
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5.52 Miscellaneous Engine Components
Removal:
5.52.1
Remove banjo fitting (8) and seal rings (9) mounting pressure switch
assembly (10) to engine.
Note: Pressure switch is normally closed
5.52.2
Remove clamp (11) securing end cap (12) to air manifold.
Installation:
wc_tx000473gb.fm
5.52.3
Remove existing screw and mount pressure switch assembly (10) to
engine with banjo fitting (8) and seal rings (9).
5.52.4
Remove existing clamp and secure cap (12) with clamp (11).
Orientate clamp so neither hoses nor wires rub on sharp edges.
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11
12
8
9
wc_gr002562
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5.53 Engine Wiring
Installation:
Replacement engines come equipped with a new voltage regulator (1)
that needs to be modified. Make sure all regulators are grounded to
the engine by a seperate ground wire to ensure proper function.
5.53.1
Cut off connector and terminals from end of regulator per dimension
given. Strip and tin all five wires prior to crimping on terminals.
5.53.2
Crimp terminal (2) to purple wire of regulator and insert into position 5
of the connector (3).
5.53.3
Crimp terminal (2) to green wire of regulator and insert into position 4
5.53.4
Crimp terminal (2) to red wire of regulator and insert into position 3 of
the connector (3).
5.53.5
Crimp terminal (2) to each yellow wire of regulator and insert into
positions 1 & 2 of the connector (3).
5.53.6
Insert white plug (4) into position 6 of the connector (3).
5.53.7
After all terminals are inserted into connector, assemble end cap (5).
The connector (6) attached to the alternator also needs to be modified.
5.53.8
Cut off connector and terminals from base of rubber boot. Strip and tin
both yellow wires prior to crimping on terminals.
5.53.9
Crimp terminal (7) to each yellow wire and insert into positions 1 & 2
5.53.10 Insert red wire from harness (9) into position 3 of the connector (8).
5.53.11 Insert green/white wire from harness (9) into position 4 of the
connector (8).
5.53.12 Insert white wire from harness (9) into position 5 of the connector (8).
5.53.13 Insert white plug (4) into position 6 of the connector (8).
5.53.14 After all terminals are inserted into connector, assemble end cap (10).
5.53.15 Connect harness (9) to engine components (A–N).
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10.5"
(266.7 mm)
1
White Plug
Position 6
Yellow
Position 1
Yellow
Position 1
Purple
Position 5
Yellow
Position 2
White
Position 5
Yellow
Position 2
Green
Position 4
3
Red
Position 3
8
White Plug
Position 6
Red
Position 3
Green/White
Position 4
wc_gr002563
Continued
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(Engine wiring continued)
0111879
Cap-retainer
8
0111872
Connector
5
0111876
Terminal-pin
16–18
7
0111878
Cap-retainer
3
0111871
Connector
10
0111874
Terminal
16–18
2
4
0111873
Plug
6
8
C
3
B
M
A
H
E
N
D
M
L
1
F
9
J
G
wc_gr002564
I
Ref.
Connection
Color
Ref.
Connection
Color
A
Voltage regulator
White
H
Oil pressure switch
White
B
Voltage regulator
Green/White
I
Upper fuel solenoid
Tan
C
Voltage regulator
Red
J
Anti-restart module
--
D
Starter motor
Black
K
Main wiring harness
--
E
Starter relay
--
L
GLow plug
Pink
F
Starter motor
Red
M
Ground
Brown
G
Lower fuel solenoid
Tan
N
Glow plug relay
--
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6.
6.1
Tools
Because all possible problems encountered while repairing the
equipment 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.
6.2
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 unit.
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.
6.3
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.
6.4
Weight Block
The weight block symbol gives an approximate weight measurement
to aid the mechanic when lifting/hoisting larger components.
250 kg
(550 lbs.)
wc_gr000843
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6.5
RT Repair
Drum Support Exploded View
30
47 31
32
33
34
46
45
2
1
3
35
36
43
4
42
5
38
41
40
39
6
7
26
27
28
9
10
11
12
13
14
15
16
23
22
17
21
20
19
16
24
7
6
6
4
29
25
3
28
27
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158
2
1
RT Repair
6.6
Drum Support Components
Ref.
Description
Ref.
Description
1
2-1/8” nut
25
Seal
2
Washer
26
9/16-18 plug
3
Drum hub
27
O-Ring
4
M10 x 20 screw
28
Cover
5
Cover
29
Drum support
6
Roller bearing
30
Retaining ring
7
Retaining ring
31
M8 x 25 screw
8
O-Ring
32
Shaft seal
9
Plate
33
Ball bearing
10
M8 x 16 screw
34
Retaining ring
11
3/8-16 x 1 screw
35
Retaining ring
12
Washer
36
Ball bearing
13
Pinion gear
37
O-Ring
14
Drive motor
38
Screw
15
M12 x 60 screw
39
Cover
16
Key
40
Plate
17
Drive shaft
41
O-Ring
18
Key
42
Shaft
19
Retaining ring
43
Spring
20
M8 x 20 screw
44
Ring
21
Cover
45
Roll pin
22
Shaft seal
46
Housing
23
Pinion gear
47
Pinion gear
24
Retaining ring
--
--
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6.7
RT Repair
Identifying Drum Supports
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6.7.1
The rear drum (1) contains a brake (a), a drive motor (b), an exciter
assembly (c) with exciter motor (d).
6.7.2
The front drum (2) contains a drive motor (b) and an exciter assembly
(c) with exciter motor (d).
6.7.3
When disassembling the drum support, always start on the exciter side
of the drum—it can be identified by the bulge (e) in the casting.
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6.8
Removing Drums
6.8.1
6.8.2
Lift one end of the machine using an appropriate crane or hoist. Insert
jack stands (x) to support machine from underneath.
6.8.3
Remove the M12 screws (a) and washers and remove the scrapers
(b).
6.8.4
Remove the six M16x55 screws (d) securing the drum (e) to the drum
support (f).
6.8.5
Remove the three M16 screws (c) and washers acting as plugs. In
their place, insert three of the M16x55 removed in the previous step.
Use these screws as pushers to push the drum off the drive housing.
x
a
b
f
d
e
c
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6.9
RT Repair
Installing Drums
6.9.1
6.9.2
Lift one end of the machine using an appropriate crane or hoist. Insert
jack stands (x) to support machine from underneath.
6.9.3
Place the drum (e) on the drum support (f) and secure it to the hub
using six M16x55 screws (d) and washers. Use Loctite 243 or
equivalent on the screws and torque them to 210 Nm (154 ft.lbs.).
6.9.4
Install the scrapers (b) using M12 screws (a). Use Loctite 243 or
equivalent on the screws and torque them to 120 Nm (88 ft.lbs.).
6.10 Opening Drum
6.10.1
Loosen the center hub nut (a) so that it is nearly off (2–3 threads
remaining on). Do so for both sides of the drum.
6.10.2
Remove the scrapers and the drums. See Section Removing Drums.
6.10.3
Position the drum support slightly off the floor and support it with jack
stands.
6.10.4
Starting with the exciter side, remove the outer ring of bolts (b)
securing the slave hub assembly onto the drum support.
6.10.5
Using three pusher bolts in position (c), gradually push the slave hub
assembly off the drum support. When the hub releases from the taper
of the drive shaft a distinct “pop” will be heard. Be sure to leave the
center hub nut on the shaft 2–3 threads to prevent the hub assembly
from “popping” off the drum.
6.10.6
Once the slave hub assembly is free, remove the hub nut and remove
the slave hub assembly (d) from the drum support.
6.10.7
If working on the rear drum support, disconnect the hydraulic line (e)
to the brake. Cap the line immediately after disconnecting it to prevent
contamination of the hydraulic system.
6.10.8
Disconnect the hydraulic lines to the drive motor (f). Cap all lines
immediately after disconnecting them to prevent contamination of the
hydraulic system.
6.10.9
On the opposite side of the drum support, remove the outer ring of
bolts securing the drive hub assembly onto the drum support.
6.10.10 Using three pusher bolts, gradually push the drive hub assembly off
the drum support. With the help of an assistant, pull the drive hub
assembly completely from the drum support. The assembly will include
the shaft, drive motor (g), and the brake (h) on rear drum supports.
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6.11 Closing Drum
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6.11.1
Reassemble drive and slave hubs. See sections Reassembling Drive
Hub and Reassembling Slave Hub.
6.11.2
With the aid of an assistant, position the drive hub assembly (shaft,
drive hub, drive motor, and brake on rear drums) into the drum support.
Secure the assembly to the drum support using twelve M10 x 20
screws. Use Loctite 243 or equivalent on the screws and torque them
to 49 Nm (36 ft.lbs.).
6.11.3
Tighten the hub nut. Torque the hub nut to 816 Nm (600 ft.lbs.).
6.11.4
Connect the drive motor and brake hydraulic lines.
6.11.5
On the exciter side of the drum support, position the slave hub on the
drum support. Secure the assembly to the drum support using twelve
M10 x 20 screws. Use Loctite 243 or equivalent on the screws and
torque them to 49 Nm (36 ft.lbs.).
6.11.6
Tighten the hub nut. Torque the nut to 816 Nm (600 ft.lbs.).
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6.12 Disassembling Drive Hub
6.12.1
Remove drum. See Section Removing Drum.
6.12.2
Open drum. See Section Opening Drum.
6.12.3
Remove drive motor (a) and brake (b) (on rear hubs).
6.12.4
Remove oil from drive hub. Dispose of oil properly.
6.12.5
Remove five screws (c) securing gear cover (d) and remove the gear
cover.
Note: Because gasket eliminator is applied to the mating surfaces of
the hub and the gear cover during assembly, it may be necessary to
tap the gear cover to break it loose.
6.12.6
Press the shaft seal (e) from the gear cover.
6.12.7
Remove the retaining ring (f).
6.12.8
Leave the hub nut (g) on the shaft and using three pusher bolts (h), pull
the gear off the shaft.
6.12.9
Pull the lip seal off the shaft.
6.12.10 With the hub nut loose but still on the shaft, tap the hub from the
opposite side to break the hub loose from the taper on the shaft.
Note: Leaving the hub nut threaded on the shaft prevents the hub from
“popping” off the shaft when the hub releases from the taper on the
shaft.
6.12.11 Pull the key from the shaft.
6.12.12 Invert the hub as shown and using a propane torch heat the bearing
inner race quickly. When heated to the proper temperature, the
bearing race will slide off the hub. Pull it from the shaft if necessary.
6.12.13 Remove the retaining ring from the gear cover and remove the outer
bearing race.
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6.13 Reassembling Drive Hub
6.13.1
Insert the replacement bearing outer race (6) (markings side in first)
into the gear cover (5) and secure it with the retaining ring (7).
6.13.2
Press the inner bearing race (a) onto the hub and add a new seal (b)
to the hub. When hub nut is tightened, the seal seats into gear cover
(5).
6.13.3
Insert the key (16) and the retaining ring (19) on the shaft (17). Cool
the shaft with cold water and apply a thin film of oil to the shoulder of
the shaft (c) where the gear will rest. Heat the gear to 400°F (use a hot
plate or similar source). Then, slide or press the shaft into the gear (23)
up to the retaining ring.
Note: When heated to the correct temperature, very little pressure is
required to press the shaft into the gear.
6.13.4
Allow the gear and shaft to cool. Slide the shaft assembly through the
gear cover.
6.13.5
Apply Loctite flexible anaerobic gasket or equivalent on the gear cover
and connect the gear casing cover (21) to the gear cover using five
M8x20 screws (4). Use Loctite 243 or equivalent on the screws and
torque the screws to 41 Nm (30 ft.lbs.).
6.13.6
Add key (d) and seal (e) to shaft.
6.13.7
Place the hub (3) onto the shaft and secure it with washer (2) and hub
nut (1).
6.13.8
Fill hub with 12.5 oz. of 10W30. See specification chart.
6.13.9
Apply Loctite flexible anaerobic gasket (f) or equivalent between face
of gear casing cover and the drive motor. Install the drive motor (g)
using three M12 screws. Use Loctite 243 or equivalent on the screws.
6.13.10 Apply Loctite flexible anaerobic gasket or equivalent between face of
gear casing cover and the brake. Install the brake (h) using three M8
screws. Use Loctite 243 or equivalent on the screws and torque them
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8
1
10
23
2
4
3
12
13
14
9
11
16
22
15
c
26
27
28
17
21
20
6
5
19
7
18
a
b
d
e
g
e
f
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6.14 Disassembling Slave Hub
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6.14.1
Remove the retaining ring (a) and remove the disc (b).
6.14.2
Remove the bearing outer race (c) from the cover.
6.14.3
Press the seal (d) from the cover.
6.14.4
Invert the hub as shown and using a propane torch heat the bearing
inner race quickly. When heated to the proper temperature, the
bearing race will slide off the hub. Pull it from the shaft if necessary.
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62
64
57
59
758
60
53
52
70
71
672
671
c
b
a
d
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6.15 Reassembling Slave Hub
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6.15.1
Press new seal (a) into cover.
6.15.2
Apply a liberal amount of EMB lubriplate white grease or equivalent to
the replacement bearing outer race (b) and insert it into the gear cover.
Secure it with the disc (c) and retaining ring (d).
6.15.3
Press the inner bearing race (e) onto the hub and add new
replacement seal (f).
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RT Repair
62
64
57
59
758
60
53
52
70
672
71
671
b
a
e
c
f
d
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6.16 Rebuilding Brake
Disassembly:
6.16.1
Open the drum. See Section Opening the Drum.
6.16.2
Remove drive hub. See Section Disassembling Drive Hub.
6.16.3
Remove the three screws (698) securing the brake to the hub and
remove the brake.
Note: Gasket eliminator is applied to the mating surfaces of the hub
and the brake during assembly, it may be necessary to tap the brake
cover to break it loose from the hub.
6.16.4
Remove fitting and drain hydraulic oil from casing; dispose of hydraulic
oil properly.
6.16.5
Remove the retaining ring (90) and remove gear (56).
6.16.6
Remove the six screws (693) securing the cover (81) and remove the
cover.
6.16.7
Remove O-ring (a) from cover.
6.16.8
Remove the plate (83) and inner O-ring (94) from housing (80).
6.16.9
Remove the retaining ring (89) and pull bearing (87) from cover.
6.16.10 Pull the shaft (82) from inside the housing.
6.16.11 Remove the ring spacer (84) and spring (85).
6.16.12 Remove the retaining ring (88) and pry bearing (b) out of housing.
6.16.13 Pull seal (c) from housing.
Reassembly:
6.16.14 Insert the seal (c) into housing.
6.16.15 Insert bearing (86) into housing (80) and secure with retaining ring
(88).
6.16.16 Dip O-ring (94) in hydraulic oil and position on face of housing.
6.16.17 Insert bearing (87) into cover (81) and secure with retaining ring (89).
6.16.18 Align holes in plate (83) with pins and place plate on housing.
6.16.19 Add spring (85) and gear to shaft and insert shaft assembly into
housing.
6.16.20 Apply Loctite 243 or equivalent to six screws (693) and secure cover
(81) to housing.
6.16.21 Add gear (56) to shaft and secure with retaining ring (90).
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90
698
91
86
56
88
80
92
89
84
85
87
69
82
693
69
83
81
a
b
c
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6.17 Exciter Exploded View
8
4
13
3
5
12
9
692
11
702
14
12
692
720
695
13
10
12
8
5
2
4
70
71
1
12
14
702
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6.18 Exciter Parts List
Measurem./Abm.
Norm
Torque/Drehm.
Sealant
Schmierstoff
Chaveta
Clavette
A14 x 9 x 50
DIN6885
O-Ring
O-Ring
Anillo-O
Joint torique
12 x 2
Plug (threaded)
Schraubverschluß
Tapón roscado
Bouchon
9/16-18in
692 0011457 12
Screw
Schraube
Tornillo
Vis
M8 x 25
DIN933
25Nm/18ft.lbs
0029311
695 0011543
2
Screw
Schraube
Tornillo
Vis
M8 x 20
DIN912
41Nm/30ft.lbs
0029311
702 0012361 12
Screw
Schraube
Tornillo
Vis
M8 x 16
720 0033988
Lockwasher
Federring
Arandela elástica
Rondelle de ressort
10
Ref.
Pos.
Part No.
Artikel Nr.
Qty.
St.
Description
Beschreibung
Descripción
Description
1
0116902
1
Drum support
Bandagenträger
Basa del tambor
Support de tambour
2
0119224
1
Exciter shaft
Erregerwelle
Eje del excitador
Arbre de l'excitatrice
3
0119225
1
Exciter shaft
Erregerwelle
Eje del excitador
Arbre de l'excitatrice
4
0119226
2
Eccentric weight
Unwucht
Masa excéntrica
Balourd excentrique
5
0119227
2
Eccentric weight
Unwucht
Masa excéntrica
Balourd excentrique
8
0116318
2
Gear
Zahnrad
Engranaje
Engrenage
9
0116958
1
Cover
Deckel
Tapa
Couvercle
10 0116959
1
Bearing cover
Lagerdeckel
Tapa del rodamiento
Couvercle du roulement
11 0119314
1
Exciter motor
Erregermotor
Motor excitador
Moteur d'excitatrice
12 0080742
4
Roller bearing
Rollenlager
Rodamiento de rodillos
Roulement à rouleaux
14 0080211
2
Cover
Deckel
Tapa
Couvercle
67 0116872
1
Key (square)
Keil
70 0014398
3
71 0078269
3
2
25Nm/18ft.lbs
0029311
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6.19 Disassembling Exciter
6.19.1
6.19.2
Remove the two screws (a) securing the exciter motor (b) to the drum
support and remove the exciter motor.
6.19.3
Remove the screws securing the exciter housing cover. Use two of the
longer screws (c) as pushers to push off the exciter housing cover (d).
6.19.4
Pull the exciter shaft (e) and drive gear from the exciter housing.
6.19.5
Remove the screws securing the bearing cover (f) to the exciter
housing. Remove the bearing cover by tapping it from inside the
exciter housing.
6.19.6
On the opposite side of the machine, remove the exciter housing cover
and the bearing cover as stated above.
6.19.7
Pull the second exciter shaft and drive gear from the exciter housing.
6.19.8
Using a properly-sized adapter plug (g), tap the bearing from the
exciter housing.
6.19.9
Using an Arbor press, press the bearing from the exciter housing cover
(h) that the exciter motor mounts to.
6.19.10 Using an inside-style puller, pull the bearing from the other exciter
housing cover (i).
6.19.11 Tap on the small eccentric weight (j) to remove the bearing race from
the exciter shaft.
6.19.12 Using a gear puller (k), pull the gear and the inner bearing race off the
exciter shaft.
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6.20 Reassembling Exciter
6.20.1
Using an Arbor press, press new outer bearing races (a) into the
exciter housing covers.
6.20.2
Install the eccentric weight (b) and key (c) on exciter shaft. Then, press
the gear (d) and the bearing race (e) onto the exciter shaft. Do so for
both exciter shafts.
6.20.3
On the opposite side of each shaft, install the eccentric weight (f) and
press the inner race (g) onto the exciter shaft. Do so for both exciter
shafts.
6.20.4
Insert the bearing outer race (h) into the follower side of the exciter
housing.
6.20.5
Insert the follower-side exciter shaft assembly into the exciter housing.
6.20.6
Apply Loctite 515 gasket eliminator or equivalent to the bearing cover
(i) and secure the follower-side bearing cover to the exciter housing
with six screws. Torque screws to 25 Nm (18 ft.lbs.)
6.20.7
Insert the exciter-side bearing outer race into the exciter housing.
Apply Loctite 515 gasket eliminator or equivalent to the bearing cover
and secure the cover with six M8x16 screws. Use Loctite 243 or
equivalent on screws and torque to 25 Nm (18 ft.lbs.).
6.20.8
Fill exciter housing with oil.
6.20.9
Insert driven exciter assembly into the exciter housing so that weights
are even and level with each other (j).
6.20.10 Apply Loctite 515 gasket eliminator or equivalent to the bearing cover
and secure the cover with six M8x25 screws. Use Loctite 243 or
equivalent on screws and torque to 25 Nm (18 ft.lbs.).
6.20.11 Apply Loctite 515 gasket eliminator or equivalent to the exciter motor
and secure with two M8x20 screws. Use Loctite 243 or equivalent on
screws and torque to 25 Nm (18 ft.lbs.).
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d
b
a
c
e
f
g
h
i
j
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6.21 Removing Drum Support
6.21.1
6.21.2
Disconnect the hydraulic lines (a) at the exciter motor. Plug hydraulic
lines immediately after disconnecting to prevent contamination of the
hydraulic system.
6.21.3
Remove the exciter components (weights, shafts, covers). See
Section Rebuilding Exciters.
6.21.4
Empty the drum support of oil.
6.21.5
Label positions of all the hoses (b).
6.21.6
Cut the wire tie (c).
6.21.7
Using an appropriate hoist or crane, raise the machine approximately
six inches off the ground. Using an appropriate hoist or crane, secure
the drum support in the raised position (d). Using jack stands (e) or
screw jacks, secure the machine frame in position. Secure the
machine frame and the drum support using separate devices. You
will be required to lower the drum support in upcoming steps while
retaining the position of the machine frame.
6.21.8
Remove the shock mount screws (f) at the outer and the upper inner
locations.
6.21.9
Lower the drum support to gain access to the upper hose clamp.
6.21.10 Loosen the nuts (g) of the hose clamps. Remove the screws (h)
securing the hose clamps to the drum support.
6.21.11 Remove the brake line (i) from the bulkhead fitting and pull the brake
line from the drum support.
6.21.12 Lower the drum support to the floor. Guide the hoses through it as it is
being lowered.
6.21.13 Remove the screw (j) securing the lower inner shock mount.
6.21.14 Continue guiding the hoses through the drum support and pull the
drum support completely away from the frame.
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f
i
b
c
d
j
a
e
6" (15 cm)
g
h
h
g
i
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6.22 Installing Drum Support
6.22.1
With shock mounts attached to drum support, position drum support on
the floor and under frame of machine. As you position it, guide the
hydraulic hoses into the drum support.
6.22.2
Attach upper and lower hose clamps to drum support. During mounting
of hose clamps on rear drums, attach hose guard (15). Do not tighten
hose clamps around hoses at this time.
6.22.3
Lower the machine frame so that the outer shock mounts can be
secured. Use Loctite 243 or equivalent on the screws and torque them
6.22.4
Continue lowering machine until innermost shock mounts can be
secured. Use Loctite 243 or equivalent on the screws and torque them
6.22.5
Cut the head off an M10 screw. Insert it into the drum support in an
upper location and use it as a guide pin. With the aid of an assistant or
appropriate crane, position the drive hub assembly so that the shaft is
approximately halfway in to the drum support. Connect the hydraulic
line leading to the hydraulic fitting (b) on the drive motor that is closest
to the drive hub. Using the pin as a guide, slide the drive hub assembly
the rest of the way into the drum support.
6.22.6
Use Loctite 243 or equivalent on twelve M10x20 screws and secure
the drive hub assembly to the drum support. Torque the screws to 49
Nm (36 ft.lbs.).
6.22.7
Attach the rest of the hydraulic lines and add wire tie.
6.22.8
Tighten hose clamps around hoses.
6.22.9
Grease inner seal (c) with white lithium grease and place it
approximately halfway on the taper portion of the drive shaft.
6.22.10 Install the key on drive shaft and install the hub with hub nut. Torque
hub nut to 816 Nm (600 ft.lbs.). Also torque drive-side hub nut.
6.22.11 Install drums and scrapers. See Section Installing Drums.
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685
682
15
694
685
682
777
719
46
47
680
702
16
371
3
709
718
704
718
72
48
685
777
682
49
a
b
c
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7.
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7.1
CombiControl Features
This machine is designed specifically for remote control operation.
This feature protects the operator by allowing him or her to stand at a
distance from the machine, and the work area, during operation. When
used in excavations, it allows the operator to stand safely above the
trench, rather than in it.
The CombiControl transmitter is designed for both cable-controlled
and infra-red (IR) remote-controlled operations.
The Infra-red System includes the transmitter and receiving eye. This
system provides wireless line-of-sight operation up to 65 feet (20 m). It
uses a hand-held transmitter to transmit signals to a receiving eye on
the machine to control machine operation.
7.2
CombiControl Operation
The Infra-Red Control System will only operate if the control cable is
connected to the receiving eye receptacle on the roller (b).
During operation, keep the transmitter pointed at the receiving eye on
the machine to continue operation. The amber light on top of the
machine will blink slowly to show that the machine is receiving signals
from the transmitter. When the joystick is pressed fully forward, the
roller will go into high-speed travel, and the amber light will blink
rapidly.
The CombiControl transmitter batteries can be recharged at the end of
operations by connecting the transmitter receptacle (a) to the battery
charging cable (c).
The Cable Control System will only operate if the control cable is
disconnected from the receiving eye and connected to the transmitter
receptacle (a, d). In this mode, the CombiControl transmitter batteries
charge while the machine is in operation.
Always use the neck strap for the CombiControl transmitter provided
by WACKER. This neck strap is designed to break away so that the
operator will not be injured should the machine slide, tip, or fall.
WARNING
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b
a
c
d
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7.3
RT Repair
Decoder Module
The decoder module (d) is positioned behind the rear panel at the back
of the machine. It receives, decodes and outputs the signal from either
the control cable or IR transmitter. It is also the power supply for all
electronic functions. It includes a channel selection microswitch.
A channel selection microswitch is also included in the transmitter
module. For operation of the remote control systems BOTH switches
must be set to the SAME channel.
The LED's (green and red) are there for diagnostic aiding. They are:
7.4
•
The green LED (f) will light when the decoder is receiving a control signal (joystick movement).
•
The red LED (g) will be constantly on for machines 9000 & 9002.
Setting Control Channels
The remote control system can be tuned to 3 different channels. This
allows three machines to operate in the same area without
interference.
A channel selection microswitch (e) is included in the CombiControl
transmitter module and in the decoder module (d), which is located
under the rear panel at the back of the machine.
For operation of the remote control systems BOTH switches must be
set to the SAME channel.
The channel comes preset from the factory to Channel 1.
To change the control channels:
Remove the four screws holding the CombiControl Transmitter box
together and carefully pull it apart. Remove the rear panel covering the
decoder module. Press both of the microswitches to change the
channel to any of the three channel positions.
Make a note of the channel in use, and label the CombiControl
Transmitter box and machine to identify the correct channel.
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RT Repair
Note: To check that the machine and the CombiControl Transmitter
box are set to the same channel, turn them both on. The amber light
on the machine will come on but it will NOT blink if the decoder module
and the transmitter module are not set to the same channel.
wc_gr002569
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7.5
RT Repair
CombiControl Control Cable
Removal:
Stop and switch off the machine and disconnect the battery.
7.5.1
Remove six M8 screws (1) mounting rear cover (2) to rear frame.
7.5.2
Unscrew connector end of cable (3) from decoder module (4).
7.5.3
Remove two M5 screws (5) and nuts (6) holding nylon clamp (7)
around cable (8).
Note: You may need to unscrew strain relief from swivel mount to gain
slack in cable for easier removal of clamp.
7.5.4
Remove M12 locknut (9) and washer (10) mounting swivel mount (11)
to pivot (12).
7.5.5
Unscrew strain relief from swivel mount (11) and pull cable (8) from
machine.
Installation:
Note: If the pivot (12) was removed, it is important to mount the pivot
with the window as shown. This will allow the cord to move into the
operating and stored positions.
7.5.6
Slide swivel mount (11) over pivot (12) and secure with washer (10)
and locknut (9).
7.5.7
Route cable end (3) through swivel mount (11) and plug into decoder
module (4). Plug other end of cable into either the transmitter module
or the I.R. receiving eye module.
7.5.8
Attach nylon clamp (7) onto cable (8) on underside of frame below
pivot (12). Secure clamp with two M5 screws (5) and nuts (6).
7.5.9
Mount rear cover (2) to rear frame using six M8 screws (1).
WARNING
wc_tx000475gb.fm
tightened.
188
RT Repair
9
10
11
12
8
6
7
5
3
2
5
1
wc_gr002570
wc_tx000475gb.fm
189
7.6
RT Repair
CombiControl Receiving Eye Module
Removal:
7.6.1
Remove four M5 screws (13) and nuts (14) mounting cap (15), cap
mount (16), and bracket (17) to center cover (18).
7.6.2
Remove two M4 screws (19) and nuts (20) mounting receiving eye
module (21) to center cover (18).
7.6.3
Remove four M3 screws (22) and nuts (23) mounting connector end
(24) to bracket (17).
7.6.4
To test receiving eye (21), note condition of the green LED. With the
machine and transmitter “ON”, the control cable must be secured to
the connector end (24). The green LED will turn and stay “ON” as long
as the transmitter is “ON” and directed toward the receiving eye. If
there is no green LED, check the cable to make sure.
Installation:
7.6.5
Drop connector end (24) through center cover (18) and mount to
bracket (17) with four M3 screws (22) and nuts (23).
7.6.6
Mount receiving eye module (21) to center cover (18) with two M4
screws (19) and nuts (20).
7.6.7
Align holes in cap (15) and cap mount (16). Place over receiving eye
module (21) on center cover.
7.6.8
Align holes in bracket (17) with holes of cap (15) and cap mount (16).
Secure with four M5 screws (13) and nuts (14).
WARNING
wc_tx000475gb.fm
tightened.
190
RT Repair
DECODER MODULE
NEGATIVE, GND
SIGNAL, I.R.
+ POSITIVE, 12VDC
RECEPTACLE
1
1
2
3
4
2
CONTROL CORD
4 #1 GREEN
GREEN "A"
#2 RED
BLACK "B"
#4 WHITE
WHITE "C"
A
C
B
3
wc_gr002572
13
15
19
21
18
16
21
21
14
22
23 17
wc_gr002571
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191
7.7
RT Repair
CombiControl Wiring
P
R
W
G/B-W
P
P
B
P
P
G/W
G/R G/W
Br
G/B G/B
P
R
B
wc_gr002573
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_tx000475gb.fm
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RT Repair
7.8
CombiControl Transmitter Module
The CombiControl transmitter is not intended to be a serviceable
component other than easily replaceable parts such as:
•
Joystick Knob
•
Rubber Boot
•
Battery Pack
•
Cord Connector
•
Cap
•
Neck Strap
Inspect the transmitter for visual damage, loose parts or wires, and
moisture. If transmitter is found to be damaged in any way and not
functioning properly, consult WACKER Corporation for repair options.
To gain access to inside of the transmitter:
7.8.1
Remove four screws (1) mounting lower housing (2) to upper housing
(3).
7.8.2
Slowly pull the two halves apart being careful not to pull the internal
wires A or connector B from the circuit board.
CAUTION: If battery wires should be separated from circuit board and
reconnected wrong, the transmitter will not draw power from the
battery.
3
A
Red
Brown
Blue
2
wc_gr002574
1
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193
7.9
RT Repair
Wiring Schematic—Decoder Module, Control Panel & Engine
"A"
BROWN "B"
DECODER MODULE
BGLPRTWY-
RECEPTACLE
NEGATIVE, GND. 1
2
SIGNAL,I.R.
+ POSITIVE, 12VDC
WIRE COLORS
INFRA-RED EYE MODULE
PANEL MOUNT
C
B
A
WHITE "C"
1
4
3
4
2
#1 GREEN
GREEN "A"
#2 RED
BLACK
"B"
#4 WHITE
WHITE
"C"
CONTROL CORD
CONNECTOR END
A
C
B
BLACK
GREEN
BLUE
PINK
RED
TAN
WHITE
YELLOW
Br - BROWN
Gr - GRAY
Or - ORANGE
Pr - PURPLE
3
HYDRAULIC VALVES
Or/W
REVERSE
FORWARD
VIBRATION HIGH
VIBRATION LOW
BRAKE
STEERING LEFT
STEERING RIGHT
HIGH SPEED
DECODER HAS 10 SEC
SWITCHOVER DELAY
FOR EXCITER OUTPUTS
A
BACKUP
SAFETY
ENGINE
CONNECTOR
B
REVERSE
FORWARD
CONTROL LIGHT
VIBRATION-HIGH
VIBRATION-LOW
(NOT USED)
BRAKE
STEERING-LEFT
STEERING-RIGHT
HIGH SPEED
FUEL VALVES
STARTER
(NOT USED)
12 V (POSITIVE)
GROUND
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
Or
Y
G
W
Gr
P
A
GLOW PLUG SWITCH
B
B
TILT
T/B
Pr
L
Y/Or
T
B
A B C
T/R
C
W
D
82
B
Br
Resistor
G/W
P
E
OFF
A
B
ALT
HOUR
ON
KEYSWITCH
G/B
CONTROL
R
Br
Br
OIL
W
TO
STARTER
‘30’
BATTERY
12 VDC
Br
P
F
R
REVERSE POLARITY
MODULE
R
G/R
B
ENGINE
CONNECTOR
Pi
A
B
B
B
STARTER
RELAY
C
T
R
W
D
E
GLOW
PLUG
RELAY
T
G/W
ANTI-RESTART
MODULE
F
FROM
BATTERY
G/R
ENGINE
OIL
PRESSURE
R
R
30
G
50
STARTER
ALT.
G
B
L
C
QSD FUEL
VALVE
GLOW
PLUG
Br
VOLTAGE
REGULATOR
wc_gr002575
wc_tx000475gb.fm
194
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

RT 560 RT 820 - Wacker Neuson

Transcription

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