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0117935 005
0206 en
Roller
RT 560
RT 820
REPAIR MANUAL
0 1 1 7 9 3 5
Foreword
wc_tx000471gb.fm i
Foreword
CALIFORNIA
Proposition 65 Warning:
Engine exhaust, some of its constituents, and certain vehicle
components, contain or emit chemicals known to the State of
WARNING California to cause cancer and birth defects or other reproductive
harm.
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RT 560 / RT 820 Repair Table of Contents
1. Safety Information 6
2. Technical Data 17
3. Maintenance 22
wc_br0117935en_004TOC.fm 1
Table of Contents RT 560 / RT 820 Repair
3.18 Cleaning CombiControl Transmitter ....................................................35
3.19 Hydraulic Oil Requirements .................................................................36
3.20 Hydraulic Fluid Level ...........................................................................36
3.21 Changing Hydraulic Oil & Filter ...........................................................37
3.22 Changing Drums .................................................................................38
3.23 Storage ................................................................................................39
3.24 Jobsite Storage ...................................................................................39
3.25 Hydrauic Schematic ............................................................................40
3.26 Hydraulic Schematic Components ......................................................41
3.27 Hydraulic Diagram ...............................................................................42
3.28 Hydraulic Diagram Components .........................................................43
3.29 Electrical Schematic (Main) .................................................................44
3.30 Electrical Schematic (Main) Components ...........................................44
3.31 Electrical Diagram (Main) ....................................................................46
3.32 Electrical Diagram (Main) Components ...............................................47
3.33 Electrical Schematic (Engine) .............................................................48
3.34 Electrical Schematic (Engine) .............................................................49
3.35 Electrical Diagram (Engine) .................................................................50
3.36 Electrical Diagram (Engine) .................................................................51
3.37 Troubleshooting ...................................................................................52
4. Hydraulic System 54
wc_br0117935en_004TOC.fm 2
RT 560 / RT 820 Repair Table of Contents
4.19 Steering Circuit Description ................................................................ 76
4.20 Steering Circuit ................................................................................... 77
4.21 Hydraulic System Cleanliness ............................................................ 78
4.22 Hydraulic Oil Requirements ................................................................ 78
4.23 Checking Hydraulic Pressures ........................................................... 79
4.24 Checking Drive Circuit ........................................................................ 80
4.25 Checking Steering Circuit ................................................................... 81
4.26 Checking Vibration Circuit .................................................................. 82
4.27 Testing Drive & Exciter Circuit Relief Valves ...................................... 82
4.28 System Pressures .............................................................................. 83
4.29 Troubleshooting Hydraulic System ..................................................... 84
5. Disassembly/ReassemblyOlder Machines 85
wc_br0117935en_004TOC.fm 3
Table of Contents RT 560 / RT 820 Repair
5.28 Exciter Motor, Coupling, & Pinion Gear Installation ..........................122
5.29 Exciter Motor .....................................................................................124
5.30 Shockmounts .....................................................................................124
5.31 Shockmount Assembly .................................................................... 125
5.32 Replacing Outer Shockmounts ..........................................................126
5.33 Replacing Inner Shockmounts ..........................................................128
5.34 Hydraulic Hose Clamps .....................................................................130
5.35 Hydraulic Hose Clamp Components .................................................131
5.36 Drum Supports ..................................................................................131
5.37 Drum Support Exploded View ...........................................................132
5.38 Replacing Drum Supports .................................................................133
5.39 Articulated Joint and Steering Cylinder Exploded View ....................134
5.40 Articulated Joint and Steering Cylinder Components ........................135
5.41 Replacing Articulated Joint ................................................................136
5.42 Steering Cylinder ...............................................................................138
5.43 Drive Pump and Coupling Assembly Exploded View ........................140
5.44 Drive Pump and Coupling Assembly Components ...........................141
5.45 Replacing Drive Pump and Coupling ................................................142
5.46 Removing Engine Cover ...................................................................144
5.47 Removing Engine ..............................................................................146
5.48 Installing Engine ................................................................................148
5.49 Replacing Muffler ..............................................................................150
5.50 Replacing Engine Air Cleaner ...........................................................150
5.51 Engine Relays ...................................................................................151
5.52 Miscellaneous Engine Components ..................................................152
5.53 Engine Wiring ....................................................................................154
wc_br0117935en_004TOC.fm 4
RT 560 / RT 820 Repair Table of Contents
6.13 Reassembling Drive Hub .................................................................. 166
6.14 Disassembling Slave Hub ................................................................ 168
6.15 Reassembling Slave Hub ................................................................. 170
6.16 Rebuilding Brake .............................................................................. 172
6.17 Exciter Exploded View ...................................................................... 174
6.18 Exciter Parts List .............................................................................. 175
6.19 Disassembling Exciter ...................................................................... 176
6.20 Reassembling Exciter ....................................................................... 178
6.21 Removing Drum Support .................................................................. 180
6.22 Installing Drum Support .................................................................... 182
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Safety Information RT 560 / RT 820
1. 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.
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
WARNING 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.
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RT 560 / RT 820 Safety Information
1.1.1 ALWAYS operate machine with all safety devices and guards in place
and in working order. DO NOT modify or defeat safety devices. 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 Operators
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.
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Safety Information 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.
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RT 560 / RT 820 Safety Information
1.2 Operator Safety while using Internal Combustion Engines
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Safety Information 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 weight-
bearing 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.
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RT 560 / RT 820 Safety Information
1.4 Label Locations
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Safety Information RT 560 / RT 820
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RT 560 / RT 820 Safety Information
1.5 Warning and Informational Labels
Label Meaning
DANGER!
Engines emit carbon monoxide; operate only
in well-ventilated area. Read the Operators
Manual.
No sparks, flames, or burning objects near the
machine. Shut off the engine before refueling.
WARNING!
Hot surface!
WARNING!
Hot surface!
WARNING!
To prevent hearing loss, wear hearing protec-
tion when operating this machine.
WARNING!
Pinch point
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Safety Information RT 560 / RT 820
Label Meaning
Hydraulic oil reservoir fill tube
CAUTION!
Use only clean, filtered diesel fuel.
WARNING!
Read and understand the supplied Operators
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.
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RT 560 / RT 820 Safety Information
Label Meaning
Operators Manual must be stored on
machine. Replacement Operators Manual can
be ordered through your local Wacker distribu-
tor.
CAUTION!
Engine oil pressure is low! Stop the engine
and check the oil level.
CAUTION!
Low voltage! Stop the engine and check the
charging system.
Tie-down point
CAUTION!
Lifting point
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Safety Information RT 560 / RT 820
Label Meaning
Torque battery hold-down nuts to 3.5 Nm (2.5
ft.lbs.) max.
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RT 560 / RT 820 Technical Data
2. Technical Data
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Technical Data RT 560 / RT 820
2.3 RollerOlder Machines
Roller
Overall Dimensions mm 2030 x 560 x 1220 2030 x 820 x 1220
(in.) (80 x 22 x 48) (80 x 32 x 48)
Operating Weight kg (lb.) 1283 (2830) 1345 (2960)
Area Capacity m (ft) / hr. 690 (7500) 1016 (10900)
Inside Turning Radius m (in.) 1.6 (63) 1.5 (58)
Low Speed m (ft.)/min. 21 (68)
High Speed m (ft.)/min. 136 (41)
Vibration Frequency Hz (vpm) 40 (2400)
Gradeability with % 50
Vibration
Gradeability without % 55
Vibration
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RT 560 / RT 820 Technical Data
2.5 Revision LevelsNewer Machines
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Technical Data RT 560 / RT 820
2.7 RollerNewer Machines
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RT 560 / RT 820 Technical Data
2.9 Sound and Vibration Measurements
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Maintenance RT 560 / RT 820
3. Maintenance
3.1 Periodic Maintenance Schedule
The chart below lists basic engine maintenance. Refer to the engine
manufacturers Operation Manual for additional information on engine
maintenance.
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RT 560 / RT 820 Maintenance
3.2 Transporting Machine
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Maintenance RT 560 / RT 820
3.4 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.
Explosion hazard. Batteries can emit explosive hydrogen gas. Keep all
sparks and flames away from the battery. Do not short-circuit battery
WARNING posts. Do not touch the machine frame or the negative terminal of the
battery when working on the positive terminal.
1 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.
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Maintenance RT 560 / RT 820
3.5 Air Cleaner
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wc_gr000473
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RT 560 / RT 820 Maintenance
3.6 Engine Oil System
SAE 10W-30
SAE 5W-20
wc_gr000057
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Maintenance RT 560 / RT 820
3.7 Engine Oil
wc_gr000476
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RT 560 / RT 820 Maintenance
3.9 Engine Fuel Delivery System Maintenance
a c
b
w c _ g r0 0 0 4 7 7
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Maintenance RT 560 / RT 820
3.11 Priming the Fuel System
b
w c _ g r0 0 0 4 7 8
wc_tx000482gb.fm 30
RT 560 / RT 820 Maintenance
3.13 Drive Gearcase
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.
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.
3.13.3 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.
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Maintenance RT 560 / RT 820
3.14 Exciter Lubrication
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RT 560 / RT 820 Maintenance
3.15 Cleaning Engine Cooling Fins
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Maintenance RT 560 / RT 820
3.16 Scrapers
3.17 Shockmounts
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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.
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Maintenance RT 560 / RT 820
3.19 Hydraulic Oil Requirements
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RT 560 / RT 820 Maintenance
3.21 Changing Hydraulic Oil & Filter
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Maintenance RT 560 / RT 820
3.22 Changing Drums
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RT 560 / RT 820 Maintenance
3.23 Storage
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Maintenance RT 560 / RT 820
3.25 Hydrauic Schematic
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RT 560 / RT 820 Maintenance
3.26 Hydraulic Schematic Components
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Maintenance RT 560 / RT 820
3.27 Hydraulic Diagram
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RT 560 / RT 820 Maintenance
3.28 Hydraulic Diagram Components
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Maintenance RT 560 / RT 820
3.29 Electrical Schematic (Main)
"A "
W
B r "B "
"C "
A
B
C
d
b c e
1 4 "1 " G G "A "
1
2 "2 " R B "B "
3 A C
b 1 4
2 3
"4 " W W "C " B
O r/W
f
3 2
3 0
2 6
2 4
2 0
A 1 8
g 1 6
k
B
3 2 O r P
3 0 Y A
2 8 G
2 6 W B
G r B
2 4
2 0 T /B
m
a
1 8 P r A B C
b 2 1 6 L
Y /O r
T /R
C
1 4
1 2 T
B W
1 0 D
6 P P
o G /W
E
B r
4 " 0 "
" 1 " p q
A B
n
j W
G /B
r G /R
F
t
R R
B r B r
h B r s
R P
B
w c _ g r0 0 0 4 9 0
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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
f Hydraulic Valves
Ref. Description Ref. Description
32 Reverse 20 Brake
30 Forward 18 Steering - left
26 Vibration - high 16 Steering - right
24 Vibration - low 14 High speed
Wire Colors
B Black R Red Y Yellow Or Orange
G Green T Tan Br Brown Pr Purple
L Blue V Violet Cl Clear Sh Shield
P Pink W White Gr Gray LL Light blue
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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
Wire Colors
B Black R Red Y Yellow Or Orange
G Green T Tan Br Brown Pr Purple
L Blue V Violet Cl Clear Sh Shield
P Pink W White Gr Gray LL Light blue
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Maintenance RT 560 / RT 820
3.33 Electrical Schematic (Engine)
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RT 560 / RT 820 Maintenance
3.34 Electrical Schematic (Engine)
Wire Colors
B Black R Red Y Yellow Or Orange
G Green T Tan Br Brown Pr Purple
L Blue V Violet Cl Clear Sh Shield
P Pink W White Gr Gray LL Light blue
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Maintenance RT 560 / RT 820
3.35 Electrical Diagram (Engine)
wc_tx000482gb.fm 50
RT 560 / RT 820 Maintenance
3.36 Electrical Diagram (Engine)
Wire Colors
B Black R Red Y Yellow Or Orange
G Green T Tan Br Brown Pr Purple
L Blue V Violet Cl Clear Sh Shield
P Pink W White Gr Gray LL Light blue
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Maintenance RT 560 / RT 820
3.37 Troubleshooting
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RT 560 / RT 820 Maintenance
Problem / Symptom Reason / Remedy
NO TRAVEL or TRAVEL Defective switch or poor connection in control box or
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 Defective switch or poor connection in control box or
transmitter.
Solenoid on manifold inoperative.
Loose, broken or corroded wire connections.
Exciter pump worn or damaged.
Vibration is turned on.
NO STEERING Defective switch or poor connection in control box or
transmitter.
Solenoid on steering valve inoperative.
Loose, broken or corroded wire connections.
Steering cylinder damaged.
Locking bar is engaged.
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Hydraulic System RT 560 / RT 820
4. Hydraulic System
4.1 Hydraulic Flow DiagramOlder Machines
Return Lines
Motor Case Drains
High Pressure Lines
Supply Line
c b
a
e d
g
f
P1 E
F
l
i P2
h j m
k
o q
p
r
n
Front Rear
wc_gr002481
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RT 560 / RT 820 Hydraulic System
4.2 Flow Diagram ComponentsOlder Machines
Used on models:
0009000 revision 120 and lower
0009001 revision 122 and lower
0009002 revision 119 and lower
0009003 revision 120 and lower
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Hydraulic System RT 560 / RT 820
4.3 Flow DiagramNewer Machines
Return Lines
Motor Case Drains
High Pressure Lines
Supply Line
c b
a
e d
f g
P1 E
F
i P2 l
m
h j
k
Front Rear q
o
n r
wc_gr002482
wc_tx000472gb.fm 56
RT 560 / RT 820 Hydraulic System
4.4 Flow Diagram ComponentsNewer Machines
Used on models:
0009000 revision 121 and higher
0009001 revision 123 and higher
0009002 revision 120 and higher
0009003 revision 121 and higher
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Hydraulic System RT 560 / RT 820
4.5 Hydraulic System
Description:
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 RT 560 / RT 820
4.6 Hydraulic Hose ConnectionsOlder Machines
h
19
4 16
f
e
d
12 b
a
9
8
7
2 10
1
1 6
25 24 4
5
17
18
11
16
14
j 18
15 23 i k 26
22
20
l
19
18
n
32
37
27
34
o 25
21
36
29
p
32
27 31
33 q
5
27
35 27
27 33 r
18
wc_gr002483
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RT 560 / RT 820 Hydraulic System
4.7 Hydraulic Hose Connection ComponentsOlder Machines
wc_tx000472gb.fm 61
Hydraulic System RT 560 / RT 820
h
19
4 16
f
e
d
12 b
a
9
8
7
2 10
1
1 6
25 24 4
5
17
18
11
16
14
j 18
15 23 i k 26
22
20
l
19
18
n
32
37
27
34
o 25
21
36
29
p
32
27 31
33 q
5
27
35 27
27 33 r
18
wc_gr002483
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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 0117528
to Brake
11 HOSE - Pump to Manifold 0116706 30 HOSE - Front Drive to 0117531
Manifold
12 HOSE - Brake Valve to 0086578 31 HOSE - Rear Drive to 0117533
Tank Manifold
13 FITTING #8 0081583 32 FITTING - Elbow 90, st. 0052713
thd, Hyd.
O-RING .644 x .087 0080732 O-RING .351 x .072 0080730
DURO90 3-908 DURO90 3-904
O-RING .489 x .070 2-014 0080737 33 FITTING - str. thd. Con- 0079875
nector
14 HOSE - Steering Cyl. to 0117521 O-RING .755 x .097 0080733
Steering Valve DURO90 3-91
15 HOSE - Steering Cyl. to 0117520 O-RING .489 x .070 2-014 0080737
Steering Valve
16 FITTING - Hydraulic 0083434 34 HOSE - Rear Exciter to 0117526
Tank
O-RING .364 x .070 2-012 0080736 35 HOSE - Front Drive to 0117530
Rear Drive
O-RING .468 x .078 0080731 36 HOSE - Front Exciter to 0117522
DURO90 3-906 Rear Exciter
17 HOSE - Manifold to Brake 0116707 37 HOSE - Rear Drive to 0117525
Valve Tank
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Hydraulic System RT 560 / RT 820
4.8 Control Valve Block
1 2
3
13 14 16
12
EV SV
P1 E
11 F
5
P2
10 TV
9
15
MN
8 6
7
wc_gr002484
The solenoids located on the vibration and travel valves are equipped
with manual over-rides. Use of these over-rides for testing machine
WARNING 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.
wc_tx000472gb.fm 64
RT 560 / RT 820 Hydraulic System
4.9 Control Valve Block Components
wc_tx000472gb.fm 65
Hydraulic System RT 560 / RT 820
Notes
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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 solenoid-
operated 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.
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Hydraulic System RT 560 / RT 820
4.11 High-Speed Travel Circuit
1*
2
7 3
a
j
3000 PSI
b
(21 MPa)
5
h
3000 PSI c
(21 MPa)
P2 P1
e
4
g f
wc_gr002485
wc_tx000472gb.fm 68
RT 560 / RT 820 Hydraulic System
4.12 High-Speed Travel Circuit Components
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.
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Hydraulic System RT 560 / RT 820
4.13 Low-Speed Travel Circuit
1*
2
7 3
j
3000 PSI b
(21 MPa) 9
5
h
d
k c
3000 PSI
(21 MPa)
P2 P1
e
4
g f
wc_gr002486
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RT 560 / RT 820 Hydraulic System
4.14 Low-Speed Travel Circuit Components
1* To brake valve.
2 Return line to hydraulic tank.
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 From hydraulic tank.
9 Pilot pressure.
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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.
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 turned off. When
pressurized, the pilot port in each check valve opens the valve and
allows oil flow in both directions.
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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.
Note: Top or bottom as described above refers to the location of the
solenoids as installed on the machine.
Relief valve (e) limits hydraulic pressure in the exciter circuit to 3000
psi (21 mPa).
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Hydraulic System RT 560 / RT 820
4.17 Exciter Circuit
1*
2
l 3
a
3000 PSI
(21 MPa)
h
j
i
e d
3000 PSI
(21 MPa)
P2 P1
g f
wc_gr002487
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RT 560 / RT 820 Hydraulic System
4.18 Exciter Circuit Components
1* To brake valve.
2 Return line to hydraulic tank.
3 To drive and steering valve.
4 From hydraulic tank.
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Hydraulic System RT 560 / RT 820
4.19 Steering Circuit Description
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RT 560 / RT 820 Hydraulic System
4.20 Steering Circuit
c
1000 PSI
1 (7 MPa) f T
a
g 2
b
E F
wc_gr002488
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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.
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RT 560 / RT 820 Hydraulic System
4.23 Checking Hydraulic Pressures
WARNING
b a
wc_gr002489
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Hydraulic System RT 560 / RT 820
4.24 Checking Drive Circuit
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.
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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
4.25.1 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.
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Hydraulic System RT 560 / RT 820
4.26 Checking Vibration Circuit
See Graphic: wc_gr02489
Test vibration with drums on soil or gravel. If testing is done inside,
position drum on rubber tire or heavy mat to absorb vibration.
4.27.1 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.
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RT 560 / RT 820 Hydraulic System
4.28 System Pressures
wc_tx000472gb.fm 83
Hydraulic System RT 560 / RT 820
4.29 Troubleshooting Hydraulic System
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RT Repair Disassembly/ReassemblyOlder Machines
5. Disassembly/ReassemblyOlder Machines
5.1 Tools
250 kg
(550 lbs.)
wc_gr000843
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Disassembly/ReassemblyOlder Machines RT Repair
5.5 Drum Assembly Exploded View
11
10
7 [L1,T1] 8 [L4]
6
9 [T2]
5
4 [G1]
12 [L2]
3
2
13 [L3]
1 [L1]
15[L3]
14[L1]
16
17 [L1,T5]
18
19
27
20 [L1,T3]
23
21
22 [L1,T3]
13 [L1,T1]
7 [L1,T1]
26
[L1,T4]
24
25 wc_gr002501
[L1,T4]
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RT Repair Disassembly/ReassemblyOlder Machines
5.6 Drum Assembly Components
See Graphic:wc_gr002501
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Disassembly/ReassemblyOlder Machines RT Repair
5.7 Drums
4
2 5
1
3
15
10
7 8
13
6
9
16
17 12
11
wc_gr002502
Removal:
wc_tx000473gb.fm 88
RT Repair Disassembly/ReassemblyOlder Machines
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.
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
tightened.
WARNING
wc_tx000473gb.fm 89
Disassembly/ReassemblyOlder Machines RT Repair
5.8 Drum Support Cover
Installation:
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.
wc_tx000473gb.fm 90
RT Repair Disassembly/ReassemblyOlder Machines
7
1
2
5
8 3
4
6
wc_gr002503
wc_tx000473gb.fm 91
Disassembly/ReassemblyOlder Machines RT Repair
5.9 Drive Bearings and Seals
wc_tx000473gb.fm 92
RT Repair Disassembly/ReassemblyOlder Machines
8 1
7
6 5
4
wc_gr002504
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Disassembly/ReassemblyOlder Machines RT Repair
5.10 Drive Housing
wc_tx000473gb.fm 94
RT Repair Disassembly/ReassemblyOlder Machines
7
2
5
1
wc_gr002505
6
3
wc_tx000473gb.fm 95
Disassembly/ReassemblyOlder Machines RT Repair
5.11 Changing Oil
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 Install fill plug (b).
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RT Repair Disassembly/ReassemblyOlder Machines
c wc_gr002506
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Disassembly/ReassemblyOlder Machines RT Repair
5.12 Drive Housing Assembly
33 2 13[L1,T2]
34
3[L1,T1] 11
1
12
10
9 14
8 15
5 [L3] 16 16
4 [L1,T3]
17
19
21 20
18 [L1,T5]
50
51
52
27
53
54
31
29 [L2]
23
6
30
28 [L1,T4] 32 [L1,T4]
35
wc_gr002507
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RT Repair Disassembly/ReassemblyOlder Machines
5.13 Drive Housing Components
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Disassembly/ReassemblyOlder Machines 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.
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
tightened.
WARNING
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RT Repair Disassembly/ReassemblyOlder Machines
2
1
5
wc_gr002508
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Disassembly/ReassemblyOlder Machines RT Repair
5.15 Servicing Brake
Note: When removing last screw, rear housing may "pop" off front
housing due to spring tension.
wc_tx000473gb.fm 102
RT Repair Disassembly/ReassemblyOlder Machines
20
19
21
18
17
16
14
22 15
8 13 14
12
11
9 10
7
6 wc_gr002509
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Disassembly/ReassemblyOlder Machines RT Repair
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 Remove drums from roller. See section Drums.
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
threadlocking compound and torque to 90 ft.lbs. (122 Nm).
5.16.8 Align the hydraulic fittings (b) as shown.
Note: Failure to align fittings properly could make it difficult to 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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RT Repair Disassembly/ReassemblyOlder Machines
18
17
5
3
2
wc_gr002510
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Disassembly/ReassemblyOlder Machines RT Repair
5.17 Drive Housing Components
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RT Repair Disassembly/ReassemblyOlder Machines
11 9
10
14
21 6
15
8 16
17
19
20
18
12
13
d
wc_gr002511
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Disassembly/ReassemblyOlder Machines RT Repair
(Drive Housing Components continued)
wc_tx000473gb.fm 108
RT Repair Disassembly/ReassemblyOlder Machines
12
13 c
21 14
15
a
16 17
19
20
11
9 12
10
7
6
wc_gr002512
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Disassembly/ReassemblyOlder Machines RT Repair
5.18 Exciter Assembly Exploded View
7
19
15 15
12 14 16
17
16
11
7 5 13
12
6 [L1]
11
5
4
3
2
7 39 [L3, T1]
1 [L1] 40
6 [L1]
9 [L2,T1] 10 25 [L2, T2]
26 [L4, T1]
20 [L2,T2] 27
22 24 [L3, T3]
21 [L3] 23 [L3]
26 [L4, T1]
27
29
30 28
34 31
22
33
32
32
38 [L5, T4]
wc_gr002513
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RT Repair Disassembly/ReassemblyOlder Machines
5.19 Exciter Assembly Components
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Disassembly/ReassemblyOlder Machines RT Repair
5.20 Introduction
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.
a
wc_gr002516
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RT Repair Disassembly/ReassemblyOlder Machines
5.22 Exciter
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
sections Drums, Drum Support Cover, and Drive Housing.
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
tightened.
WARNING
wc_gr002517
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Disassembly/ReassemblyOlder Machines RT Repair
5.23 Exciter Exploded View
41
25
21
28
24
20 23
26
29
31 30
34
22
33
35
36
37
38
wc_gr002518
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RT Repair Disassembly/ReassemblyOlder Machines
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 Remove drum, drum support cover, and drive housing assembly. See
sections Drums, Drum Support Cover, and Drive Housing.
5.24.2 Remove drain plug (26) from exciter gear cover (28) and drain oil.
5.24.3 Remove exciter assembly from drum support. See section Exciter.
Note: In the interests of environmental protection, place a plastic sheet
and a container under the exciter to collect the liquid which drains off,
and dispose of properly.
5.24.4 Invert exciter housing (41) and remove ten M6 screws (24) holding 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
32
22
41
29
wc_gr002519
29
30
31
33 22b
41
22a
b c
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
threadlocker, and torque to 36 ft.lbs. (49 Nm).
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
threadlocker, and torque to 7 ft.lbs. (10 Nm).
5.25.15 Apply Loctite 515, or equivalent gasket compound, to machined face
(e) of exciter gear cover (28).
CAUTION: Be sure to coat around entire face of cover 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
32 25
26
37 27
41 e
37
38
wc_gr002521
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5.26 Exciter Motor, Coupling, & Pinion Gear
19
18
15a
17
15a
15b
12a 14
11a 16
15b
13
41
26
28
11
10
9
23
wc_gr002522
b
15a
15a
wc_gr002523
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5.27 Exciter Motor, Coupling, & Pinion Gear Removal
5.27.1 Remove drum, drum support cover, and drive housing assembly. See
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
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14 12a 18 12b
15a 5
16
15a
16
19
17 11a 13 11b
15b
wc_gr002524
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Disassembly/ReassemblyOlder Machines RT Repair
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.
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
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5.31 Shockmount Assembly
5
[L1, T1] 6
[L1] 9 2
[L1] 8
7
[L1] 3
[L1, T1] 6
10
wc_gr002526
4
5
[L1] 0029311
[T1] 63 ft.lbs. (85 Nm)
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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
Loctite 243 or an equivalent medium strength threadlocking
compound.
5.32.9 Slide scraper support mount (10) over setscrew.
5.32.10 Install shockmount (4) onto setscrew. Secure shockmount using
Loctite 243 or an equivalent medium strength threadlocking
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).
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
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Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
tightened.
WARNING
7 6, 5 a
4
10
X X
9 b wc_gr002528
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5.33 Replacing Inner 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
threadlocking compound and torque to 36 ft.lbs. (49 Nm).
5.33.8 Tighten screws (6) mounting outer shockmount bracket (7) to
shockmount (4) and torque to 63 ft.lbs. (85 Nm).
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING
tightened.
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5
[L1, T1] 6
[L1] 9 2
[L1] 8
7
[L1] 3
[L1, T1] 6
10
wc_gr002526
4
5
e
wc_gr002546
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5.34 Hydraulic Hose Clamps
[L1] 12 2
3
4
5
[L1] 1
12 2
6
3 7
[L1] 1
9
[L1] 1
[L1] 1
2 11 10
13 6
3
wc_gr002547
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5.35 Hydraulic Hose Clamp Components
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 wc_gr002548
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5.37 Drum Support Exploded View
6 3
9
5 12 7
8 10
11
13
4
6
2 5
wc_gr002549
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5.38 Replacing Drum Supports
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
threadlocking compound and torque to 36 ft.lbs. (49 Nm).
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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Disassembly/ReassemblyOlder Machines RT Repair
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.
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
tightened.
WARNING
1 [T1]
2
3
4
6 5
11
11 12
12
13 13
16
7 14
6
15
17
4
1 [T1] 4
5
3
2
9
8 [L1, T2]
10
wc_gr002550
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5.40 Articulated Joint and Steering Cylinder Components
[L1] 0029312
[T1] 155 ft.lbs. (210 Nm) [T2] 94 ft. lbs. (128 Nm)
c
wc_gr002551
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5.41 Replacing Articulated Joint
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.
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
tightened.
WARNING
2
6
3
4
7 5
6
4
3
2
8
1 2
3
d
6
3 6
f 7
2 7
3 6
5 2
1
wc_gr002552
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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).
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING
tightened.
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11
12
13
13
17
14
15
9
10
wc_gr002553
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Disassembly/ReassemblyOlder Machines RT Repair
5.43 Drive Pump and Coupling Assembly Exploded View
1 [L1]
2 7 [L1, T2]
3 6
5 8
4
11
9
29
28
27
26 12
14 10
25 [L1, T1] 13
15
17
18
16 19
20 [L2]
20 [L2, T2]
15
24 17
18
19
23 [L2, T2] 22 [L2]
wc_gr002554
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RT Repair Disassembly/ReassemblyOlder Machines
5.44 Drive Pump and Coupling Assembly Components
wc_tx000473gb.fm 141
Disassembly/ReassemblyOlder Machines 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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RT Repair Disassembly/ReassemblyOlder Machines
1 7
2
3 6
8
4
9
29
28 a
27
26
12
25
16
24 20
21
23
22
wc_gr002555
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Disassembly/ReassemblyOlder Machines RT Repair
5.46 Removing Engine Cover
Cover Removal:
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.
wc_tx000473gb.fm 144
RT Repair Disassembly/ReassemblyOlder Machines
g
e
f
h
h wc_gr002556
wc_tx000473gb.fm 145
Disassembly/ReassemblyOlder Machines RT Repair
5.47 Removing Engine
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.
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.
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.
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
5.47.14 Remove drive pump, couplings and support from engine. See section
Drive Pump and Coupling.
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RT Repair Disassembly/ReassemblyOlder Machines
3
4
8
2
1 5
6
18 11
5 7
15 16 17
19
10
14
12
9 13
wc gr002557
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Disassembly/ReassemblyOlder Machines RT Repair
5.48 Installing Engine
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.
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
1
wc_gr002558
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Disassembly/ReassemblyOlder Machines RT Repair
5.49 Replacing Muffler
See Graphic: wc_gr002559
Removal:
Danger of burns! Muffler may be hotcare 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
11 16
wc_gr002559 wc_gr002560 17 15
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RT Repair Disassembly/ReassemblyOlder Machines
5.51 Engine Relays
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 anti-
restart module (7).
5.51.5 Line up mounting holes in air cleaner mounting plate (2) with studs (4)
in engine. Secure plate to engine using M8 locknuts (1).
Note: Install ground strap (3) on lower stud.
5
2
7
6
1 4
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:
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
wc_gr002562
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Disassembly/ReassemblyOlder Machines RT Repair
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
of the connector (3).
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
of the connector (8).
5.53.10 Insert red wire from harness (9) into position 3 of the connector (8).
5.53.11 Insert green/white wire from harness (9) into position 4 of 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 (AN).
wc_tx000473gb.fm 154
RT Repair Disassembly/ReassemblyOlder Machines
10.5"
(266.7 mm)
wc_gr002563
Continued
wc_tx000473gb.fm 155
Disassembly/ReassemblyOlder Machines RT Repair
(Engine wiring continued)
0111879 0111878
8 Cap-retainer Cap-retainer 3
0111872 0111871
Connector 5 10 Connector
8
3 C
B
M
A H
E N
M
D L
F 9
J wc_gr002564
G
I
wc_tx000473gb.fm 156
RT Repair Disassembly/ReassemblyNewer Machines
6. Disassembly/ReassemblyNewer Machines
6.1 Tools
250 kg
(550 lbs.)
wc_gr000843
wc_tx000474gb.fm 157
Disassembly/ReassemblyNewer Machines RT Repair
6.5 Drum Support Exploded View
30
47 31
32
33
34
46
45 35
43 36
1 2 3 4
42
5 38
41
40
39
6
26 7
9 10 11
27 12
28 13
14
15
16
23
22 17
21
20
19
16
24
7
6
6
4
29
25
3
28
27
wc_gr002097 2
26
1
wc_tx000474gb.fm 158
RT Repair Disassembly/ReassemblyNewer Machines
6.6 Drum Support Components
wc_tx000474gb.fm 159
Disassembly/ReassemblyNewer Machines RT Repair
6.7 Identifying Drum Supports
wc_tx000474gb.fm 160
RT Repair Disassembly/ReassemblyNewer Machines
6.8 Removing Drums
e wc_gr002052
c
wc_tx000474gb.fm 161
Disassembly/ReassemblyNewer Machines RT Repair
6.9 Installing Drums
wc_tx000474gb.fm 162
RT Repair Disassembly/ReassemblyNewer Machines
wc_tx000474gb.fm 163
Disassembly/ReassemblyNewer Machines RT Repair
6.12 Disassembling Drive Hub
wc_tx000474gb.fm 164
RT Repair Disassembly/ReassemblyNewer Machines
wc_tx000474gb.fm 165
Disassembly/ReassemblyNewer Machines RT Repair
6.13 Reassembling Drive Hub
wc_tx000474gb.fm 166
RT Repair Disassembly/ReassemblyNewer Machines
8
10 12
2 23 13
1 14
4 9
3 11
22 16
15
c 17
26
27 21
28 20
6 19 18
5 7
b
d e
e
f
wc_gr002355
wc_tx000474gb.fm 167
Disassembly/ReassemblyNewer Machines RT Repair
6.14 Disassembling Slave Hub
wc_tx000474gb.fm 168
RT Repair Disassembly/ReassemblyNewer Machines
62
64
59
57
758
60
53
52
70
71 672
671
c
b
a
wc_gr002353
wc_tx000474gb.fm 169
Disassembly/ReassemblyNewer Machines RT Repair
6.15 Reassembling Slave Hub
wc_tx000474gb.fm 170
RT Repair Disassembly/ReassemblyNewer Machines
62
64
59
57
758
60
53
52
70
71 672
671
b
a
e
c
d f
wc_gr002356
wc_tx000474gb.fm 171
Disassembly/ReassemblyNewer Machines RT Repair
6.16 Rebuilding Brake
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).
wc_tx000474gb.fm 172
RT Repair Disassembly/ReassemblyNewer Machines
90 698
56
91
86
88
80
92 89
84
87
85
82 69
693
69
83
81
b c
wc gr002354
wc_tx000474gb.fm 173
Disassembly/ReassemblyNewer Machines RT Repair
6.17 Exciter Exploded View
4
13
5
12
9
692
702 11
14
12
692
720
695
10 13
12
8
5
70
1 71
12
14
702
wc_tx000474gb.fm 174
RT Repair Disassembly/ReassemblyNewer Machines
6.18 Exciter Parts List
Measurem./Abm. Norm
Ref. Part No. Qty. Description Descripcin
Pos. Artikel Nr. St. Beschreibung Description Sealant
Torque/Drehm.
Schmierstoff
wc_gr002351
wc_tx000474gb.fm 175
Disassembly/ReassemblyNewer Machines RT Repair
6.19 Disassembling Exciter
wc_tx000474gb.fm 176
RT Repair Disassembly/ReassemblyNewer Machines
wc_tx000474gb.fm 177
Disassembly/ReassemblyNewer Machines RT Repair
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.).
wc_tx000474gb.fm 178
RT Repair Disassembly/ReassemblyNewer Machines
d
b
a c
e
f g
i
j
wc_gr002350
wc_tx000474gb.fm 179
Disassembly/ReassemblyNewer Machines RT Repair
6.21 Removing Drum Support
wc_tx000474gb.fm 180
RT Repair Disassembly/ReassemblyNewer Machines
f
i
b d
c
j
a e
6" (15 cm)
g h h
wc_gr002706
wc_tx000474gb.fm 181
Disassembly/ReassemblyNewer Machines RT Repair
6.22 Installing Drum Support
wc_tx000474gb.fm 182
RT Repair Disassembly/ReassemblyNewer Machines
685
682
15
694 685
682
777
719 46
702
47
680 16
371
3
709
718
704
718 72
48
685
777
49
682
wc_gr002359
wc_tx000474gb.fm 183
CombiControl/Electrical System RT Repair
7. CombiControl/Electrical System
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.
wc_tx000475gb.fm 184
RT Repair CombiControl/Electrical System
wc_gr002567
wc_gr002568
wc_tx000475gb.fm 185
CombiControl/Electrical System RT Repair
7.3 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.
The LED's (green and red) are there for diagnostic aiding. They are:
The green LED (f) will light when the decoder is receiving a con-
trol signal (joystick movement).
The red LED (g) will be constantly on for machines 9000 & 9002.
wc_tx000475gb.fm 186
RT Repair CombiControl/Electrical System
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
wc_tx000475gb.fm 187
CombiControl/Electrical System RT Repair
7.5 CombiControl Control Cable
Removal:
Stop and switch off the machine and disconnect the battery.
7.5.1 Remove six M8 screws (1) mounting rear cover (2) to rear frame.
7.5.2 Unscrew connector end of cable (3) from decoder module (4).
7.5.3 Remove two M5 screws (5) and nuts (6) holding nylon clamp (7)
around cable (8).
Note: You may need to unscrew strain relief from swivel mount to 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).
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING
tightened.
wc_tx000475gb.fm 188
RT Repair CombiControl/Electrical System
10
11
12
8
6
7
5 3
2
5
wc_gr002570
wc_tx000475gb.fm 189
CombiControl/Electrical System RT Repair
7.6 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).
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
tightened.
WARNING
wc_tx000475gb.fm 190
RT Repair CombiControl/Electrical System
NEGATIVE, GND
1 4 #1 GREEN GREEN "A"
1
SIGNAL, I.R. 2
#2 RED BLACK "B"
3 C A
+ POSITIVE, 12VDC 4 #4 WHITE WHITE "C" B
2 3
wc_gr002572
15 13
19
21
18
16
21
21
14
23 17
22
wc_gr002571
wc_tx000475gb.fm 191
CombiControl/Electrical System RT Repair
7.7 CombiControl Wiring
P
G/B-W
R
P
W
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 192
RT Repair CombiControl/Electrical System
7.8 CombiControl Transmitter Module
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.
A Red
Brown
Blue
2
wc_gr002574
1
wc_tx000475gb.fm 193
CombiControl/Electrical System RT Repair
7.9 Wiring SchematicDecoder Module, Control Panel & Engine
"A"
BROWN "B" INFRA-RED EYE MODULE WIRE COLORS
A C
B
WHITE "C" PANEL MOUNT
B- BLACK Br - BROWN
G- GREEN Gr - GRAY
L- BLUE Or - ORANGE
P- PINK Pr - PURPLE
DECODER MODULE RECEPTACLE R- RED
1 4 #1 GREEN GREEN "A" T- TAN
NEGATIVE, GND. 1
SIGNAL,I.R. 2 #2 RED BLACK "B" CONTROL CORD W- WHITE
C A
3
B CONNECTOR END Y- YELLOW
4 #4 WHITE WHITE "C"
+ POSITIVE, 12VDC 2 3
HYDRAULIC VALVES
Or/W
REVERSE
DECODER HAS 10 SEC FORWARD
VIBRATION HIGH
SWITCHOVER DELAY
VIBRATION LOW
FOR EXCITER OUTPUTS BRAKE
STEERING LEFT
A STEERING RIGHT
BACKUP HIGH SPEED
SAFETY ENGINE
B CONNECTOR
Or P
REVERSE 32
Y A
FORWARD 30
CONTROL LIGHT 28
G GLOW PLUG SWITCH
VIBRATION-HIGH 26
W B
B
VIBRATION-LOW 24
Gr
TILT
(NOT USED) 22
BRAKE 20
T/B
STEERING-LEFT 18
Pr A B C
L T/R
STEERING-RIGHT 16 C
HIGH SPEED 14 Y/Or
FUEL VALVES 12 T
B W
STARTER 10 D
(NOT USED) 8 82 Resistor
12 V (POSITIVE) 6 B P G/W
Br E
GROUND 4
OFF
A B ON HOUR ALT
KEYSWITCH
G/B G/R
CONTROL OIL F
W
TO
R R STARTER
Br Br
REVERSE POLARITY 30
MODULE BATTERY
Br
R P 12 VDC
B
ENGINE
CONNECTOR
Pi
A
B
B B
STARTER
RELAY
T R
C
W
D
G/W T GLOW
E PLUG
ANTI-RESTART RELAY
MODULE
G/R
F
ENGINE
OIL
PRESSURE
FROM R R
BATTERY
GLOW
30 QSD FUEL PLUG Br
G G B L C VALVE
50 STARTER ALT. VOLTAGE
REGULATOR
wc_gr002575
wc_tx000475gb.fm 194
Threadlockers and Sealants
Threadlockers and Sealants