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RT SC Repair Disassembly/Reassembly Procedures

1. wc_tx000419gb fm o 820 mm 442060 mm 32 22 wc gr000981 46 Maintenance 4 17 Battery The battery supplied on this machine is rated at 12V with 800 Amp cold cranking capacity It features a sealed ventless design and is constructed to resist vibration and provide longer service life NOT use automotive type batteries on this machine Automotive IX type batteries are not designed to withstand the heavy vibration CAUTION Produced by this machine The case on automotive type batteries could fail causing battery acid to leak Inspect battery periodically Keep battery terminals clean and connections tight Maintain the battery at full charge to improve
2. 560 _ 820 1826 22 32 72 B wc gr000232 wc td000077gb fm 1 8 RT Operation 3 Operation 31 Information Regarding Operation The information regarding the operation of the machine included in this manual is condensed Refer to the Operators Manual for complete operating instructions Always read understand and follow the procedures the Operators Manual when operating the machine wc_tx000518gb fm 1 9 Operation 3 2 Operation and Service Locations See Graphic wc_gr000234 and wc_gr000235 Description Ref Beserpon _ 5 DWecmelBug 0000 Drive case llevelpug EEC 00 Radiator drain plug 46 High water temperature switch Glow plug timer Hydraulic manifold 47 Hood hinge grease fitting 24 Battery wc_tx000518gb fm 2 0 Operation 39 31 wc gr000234 gb fm wc_tx000518 Operation RT CRet Description Ref Bescipton tei
3. 1230 48 ES IN
4. 100 102 7 Hydraulic Troubleshooting 105 7 1 No Vibration Flowchart 002220 1221 105 7 2 Checking Power to and Operation of Decoder Module 106 7 3 Replacing Decoder Modul amp aY 108 7 4 Checking Solenoid Lead 2 e ein et io ends 110 7 5 CHECKING SOLENOIDS 110 7 6 Replacing olenold atc Cot GO OU do 111 7 7 Checking Pressure at Gauge Port 1 G P1 112 7 8 Checking Function of Exciter Motors 113 7 9 No Steering Troubleshooting Flowchart 4A 114 7 10 No Travel Troubleshooting Flowchart 115 7 11 Checking Pressure at Gauge Port 2 G P2 116 7 12 Checking Function of Brake 2 116 7 13 Checking Function of Drive Motors 117 7 14 No High Speed Travel Troubleshooting Flowchart 118 wc br0160393en 004TOC fm 3 Table of Contents Table of Contents 8 RT SC Repair Disassembly Reassembly Procedures 119 8 1 119 8 2 Ordenng 119 8 3 Reference NUMDECNS 119 8 4 010 ditte cs 119 8 5 OIL A A 120 8 6 Drum Support Exploded View
5. Gradeability w o Vibration wc_td000077gb fm 1 6 RT Technical Data 2 3 Lubrication ltem No RT 56 SC RT 82 SC 0009026 0009025 Lubrication Engine Crankcase type SAE 15W40 Class CD rated qt 2 5 2 5 Hydraulic System type Premium grade anti wear hydraulic fluid SAE 10W30 gal AO 8 Exciter type SAE 10W30 ml oZ 950 32 Drum Drive Gearcase type SAE 10W30 ml oZ 370 12 5 Articulated Joint type Shell Alvania No 2 Grease gty as reguired Steering Cylinder type Shell Alvania No 2 Grease gty as reguired Radiator type Water Glycol qty 50 50 wc_td000077gb fm 1 7 Technical Data RT 2 4 Sound and Vibration Measurements Products are tested for sound pressure level in accordance with EN ISO 11204 Sound power level is tested in accordance with European Directive 2000 14 EC Noise Emission in the Environment by Equipment for use outdoors The sound pressure level at operator s location Lpa 83 dB A The guaranteed sound power level Lwa 109 dB A Because this machine is operated using remote control the operator is not exposed to vibration 2 5 Dimensions mm in
6. m 110193 N 98VH3 NODD DL 1 4350 2 2 272 5 WNDIS 038 AWLA lt MNDIS 351 4 a 5 3349 I BE 8104 59 9010 EE 5 HOSIn3d 1HD 1 INIHI e m ADLIANNOI on ala em 8 0 8 Liz Ou 8 4 asc Es 368 ER 8 8 So a a SITIS MOIS wo o n 1 1009 1033 S 9010 3 3 9NIA13239 RM 251130 Nid 30123NNDIJ Q yp 30187434 9 138 Ge 99 7 38 3504 02 16 31895 49311982 034 9 01 038 30v9 0D daa wc_gr001079 2503 06 56 gb fm wc tx000419 Maintenance annow9 ANG ND 378VN3 3313W 7 1150 ND dWV1 197005 ADI JTidsnd N3388 ND dAV1 dW3L 4319 AUTTJN3385 ND dWV1 431114 IV 3ONVSI N3385 ND TN T38 N3385 ND dAV1 AD 71350 ND dWV1 3ansS3ed ND NO Q3H2LIAS NID dWVT v 1381 LON 435 LON 2104 4541 9010 3 IDA 19510 1130 2 NELLO3NNUO 350 LON WNDIS 034 TWNOIS 3174 9339 2104 5 9010 PNIS 4 EOS EROR INI y 401 93NNO3 TWNOIS 30709 ANY 01 3185 0 40 0105 ANY NIC 13IHS 343 4 DNIT TJIHS 20109 AN
7. wc gr000980 4 2 Lifting Machine See Graphic 07000980 Lock front and rear machine halves together using the joint locking bar b at the articulated steering joint on the machine Use a lifting device with sufficient weight bearing capacity Lift machine from lifting eye c ALWAYS lock the articulated steering joint before lifting the machine wc tx000419gb fm 3 6 Maintenance 4 3 Job Site Storage See Graphic wc_gr000983 Never allow the roller to sit overnight in a ditch trench or other low lying area which might fill with water during a heavy rain Park the roller on a flat level surface out of the way of traffic patterns and congestion If the roller must be parked on an incline chock the drums to prevent any chance of movement If leaving the roller on the job site remember to remove the key and lock the control panel cover and engine hood to prevent tampering Both the front and rear hoods and access cover are equipped with locking ring a for use with a padlock for this purpose If desired the SmartControl M can be removed from the roller and stored separately wc_gr000983 wc_tx000419gb fm 37 Maintenance 4 4
8. Does wire check OK Repair replace wire Yes Replace repair wire Yes Check for 12V at pin 11 of ECM during cranking cycle Is there 12V on the pin See Section Testing ECM Yes Replace glow plug relay Confirming a malfunctioning relay Confirm relay fault by checking for 12V across contacts 30 and Call Wacker Service 87 during cranking If 12V is measured relay is OK wc_gr003243 wc_tx000430gb fm 73 Engine Starting Troubleshooting RT SC Repair 5 12 Checking Fuel Line at Fuel Rail Inlet See Graphic wc_gr002212 5 12 1 5 12 2 Have container ready to catch fuel Remove the fuel line a at the rail inlet With the keyswitch and the control box ON OFF switch in the ON positions press the engine crank button and observe the fuel line Fuel should flow from the fuel line If fuel does not flow from line check for a clogged fuel filter or fuel lines If air is in the fuel stream check fuel lines and clamps Then bleed the fuel system If you still have no flow refer to the Lombardini repair manual Wc 07002213 wc 01002212 5 13 Checking 50A Circuit Breaker See Graphic wc_gr002213 CAUTION wc_tx000430gb fm Burn hazard The 50A circuit breaker can be hot to the touch Allow the circuit breaker to cool before handling it The 50A circuit breaker b in the starter solenoid circuit is located in the front section of the machine m
9. b wc_gr000975 wc_tx000419gb fm 44 Maintenance 4 14 Scrapers See Graphic wc_gr000976 Scraper bars are provided on all four drums to prevent dirt from building up on the drum surfaces These scrapers should be inspected and adjusted as required to remove as much dirt from the drums as possible To adjust a scraper Loosen the three screws a holding each scraper to the drum casting Position the scraper 1 8 1 4 3 6 mm from the drum Tighten screws and run machine to check that the scraper does not rub against the drum surface 4 15 Shockmounts wc_tx000419gb fm See Graphic wc_gr000978 Inspect the drum shockmounts a every 300 hours for cracking splitting or tearing Replace shockmounts as needed CAUTION The shockmounts isolate the upper part of the machine from the heavy vibrations produced in the drums Operating the machine with damaged shockmounts for an extended period of time may eventually damage other machine parts a wc_gr000978 Maintenance RT 4 16 Changing Drums See Graphic wc_gr000981 4 16 1 4 16 2 4 16 3 4 16 4 4 16 5 4 16 6 4
10. 435 LON 425 LOND INdNI 9G8c GOcTH NVMOVd HILIMS AD 082 AIVdIALIN p 40193NNO9 NnLIND 1350 10N 135 10N 1504 dWV 681 20 21 3385 0338 3504 C81 2104 57 9010 1 251130 y 8 1123NNI2 6 AG 110 1131 43315 8 AG 110 1 1 43315 1 AG 100 3su3Aau 9 AG 100 03 4 AG 110 34 38 7303 143118 aNnow9 _ AG 100 431415 INdNI 2IAG 1 LAdNI 24 21 Df ld 371941 IL DW 3A WA OL 2 11 049 WVA 934 9 5 m c a m D ADTI34 038 JAA NDDRID 97003353 57 gb fm wc tx000419 Maintenance RT 4 28 Basic Troubleshooting Problem Symptom Reason Remedy ENGINE DOES NOT START Fuel tank empty Fill with No 2 diesel fuel and prime fuel lines Wrong type of fuel Old fuel Drain tank change fuel filter and fill with fresh fuel Fuel system not primed Fuel filter restricted or plugged Replace filter Battery connections loose or corroded Battery dead Engine oil level too low Air cleaner element plugged Starter motor defective Starter button on control box or transmitter defective Fuel valve solenoids on engine inoperative Starter relay inoperative Electrical connections loose or broken Machine out of infrared signal range ENGINE STOPS BY ITSELF Fuel t
11. Lift radiator up and out of machine If removing shroud Remove second hose 1 to overflow reservoir at the overflow reservoir Remove nut k securing shroud on top of engine and remove shroud If removing radiator shock mount Remove screw securing shock mount from underneath frame and remove the shock mount 160 Disassembly Reassembly Procedures RT SC Repair wc 01002375 161 gb fm wc_tx000410 Disassembly Reassembly Procedures RT SC Repair wc_tx000410gb fm Installation If replacing shock mount 8 30 15 Secure shock mount to frame using Loctite 243 or eguivalent on M10 screw Torque screw to 49 Nm 36 ft lbs If replacing shroud 8 30 16 Preassemble components of shroud if necessary 8 30 17 Secure shroud to top of engine with nut k 8 30 18 Attach hose to overflow reservoir 8 30 19 Insert radiator into machine frame Secure radiator to shock mounts with nuts 0 8 30 20 Connect green hose i to engine using hose clamp 8 30 21 Connect hose h to engine using hose clamp 8 30 22 Secure shroud f to radiator 8 30 23 Connect coolant level sensor at connector e 8 30 24 Connect input hose d using hose clamps 8 30 25 Connect overflow tube c and new wire ties b 8 30 26 Connect drain hose a 8 30 27 Fill radiator with coolant 162 Disassembly Reassembly Procedures RT SC Repair wc 01002375 163 gb fm wc_tx000410 Disassembly Reassembly Procedures RT SC
12. WEEDS Tee RF FF TIN HATT RPP A Bi iiias DHILEXEM NI wc_si000080gb fm 1 HEF mg me mnt 101 Use only breakaway neck strap provided by Wacker to avoid possible operator injury Nur den von Wacker ausgestatteten ausloeseschultergurt verwenden um moegliche verletzung der bedienungsperson zu vermeiden Solo use la correa al cuello proporcionada por Wacker para evitar posibles lesiones al operador Utiliser seulement la bretelle munie par Wacker pour eviter blessures eventuelles a L utilisateur FL LEIA eS LS LETHU LU A p E ain AEDE PALE 1 Le ee CT lu Lid LA Lu rg LE ere WRITE LP FEDES Pee SU Mr p Li EST ERIT i Tf 12 RT DANGER Engines emit carbon monoxide operate only in well ventilated area WARNING Read and understand the supplied Operator s Manual before operating this machine Failure to do so increases the risk of injury to yourself or others WARNING To prevent hearing loss wear hearing protection when operating this machine WARNING Infrared signal Always aim transmitter directly at receiving eye on machine 1 No forward reverse travel within 1 meter 2 Machine may receive stray signals if operated near solid objects CAU
13. a A 9 gt EL FN TE Wr 1 TT he Pr NE Cen ul E 4 0 E gt s 5 22 ES H P Gb eH 221 J 6 CN C LEE Ne H nL 7 SS F S Ts f S ks ra gi 25 m 4 Ss 1 a BOE m dio 2 0 A f Ii I e U a o i H 4 24 O yy y M 4 fcr wc 01002368 149 wc_tx000410gb fm Disassembly Reassembly Procedures RT SC Repair 8 25 Replacing Valve Block See Graphic wc_gr002369 8 25 1 8 25 2 8 25 3 8 25 4 8 25 5 8 25 6 8 25 7 8 25 8 8 25 9 Removal Note Shown with fuel tank removed for clarity Remove battery See Section Removing Battery Carefully mark all hydraulic hoses a and remove them from the valve Immediately plug all hydraulic hoses to prevent contamination of the hydraulic system Remove the green connector plug b from the decoder module All valve block solenoid wires run to this plug Remove the screw c securing the ground wires and remove the ground wires from the valve block Remove the four screws securing the bracket at i
14. b Powerrelay Glow plug wiring o pare KECO ed wc_tx000430gb fm 60 RT SC Repair Engine Starting Troubleshooting 5 2 Troubleshooting Flowcharts The troubleshooting flowcharts are designed to step you through the process of determining the source of a problem with starting the engine should a problem exist Many of the tests involve live voltages and therefore should only be attempted by qualified personnel The procedures for carrying out the tests are included in this manual Each flowchart includes references by section number to the location of the specific procedure s in the manual wc_tx000430gb fm 6 1 Engine Starting Troubleshooting RT SC Repair 5 3 Engine Does Not Crank Flowchart Check positions of keyswitch and control box ON OFF switch Are Switches in correct positions No Place switches in correct positions Yes Checking receiving eyes Check transmission of infrared signal from box to machine Checking 20A fuse Check condition of 20A fuse Is 20A fuse OK Yes Yellow LEDs should be flashing and green LED on back of eye should be lit Replace Is 20A fuse signal being transmitted Yes No Check charge of machine battery Y Checking NiCad battery charge Does battery measure 11 13V Recharge Check charge of control box replace battery battery Yes Check channel consistency betwee
15. 4 9 wc_tx000419gb fm RT Storage 4 4 1 4 4 2 4 4 3 4 4 4 If storing unit longer than 30 days the following steps are recommended Change the engine oil Clean or change air cleaner elements Drain any water that may have collected at the bottom of the fuel tank Replace the fuel filter Refill the tank with fresh No 2 diesel fuel Note Diesel fuel is subject to bacterial growth which can contaminate fuel lines Allowing the tank to sit dry for a long period of time helps promote such growth The addition of a biocide to the fuel is recommended to inhibit bacterial growth and protect the engine fuel system Store the unit indoors in a clean dry area If the unit must be stored outdoors cover it New Machines 4 5 1 4 5 2 Perform initial oil and filter changes as listed below Follow Periodic Maintenance Schedules thereafter Change engine oil and replace oil filter after first 50 hours Replace hydraulic return line filter after first month or 100 hours 38 Maintenance 4 6 Periodic Maintenance Schedules Daily Every Every Once Every before 100 500 A 2 starting hrs hrs Year Years Check hydraulic oil Fill to correct level Grease steering cylinder HED Change hydraulic system return line filter Change hydraulic fluid Change exciter oil The chart below lists basic engine maintenance Refer to the engine manufacturer s Operation Manual for additional
16. P2 51 52 4 2 3 1 wc gr002126 No Vibration wc tx000418gb fm 9 2 RT SC Repair Hydraulic System BOM 9026 SN 55461321 and lower BOM 9025 SN 5549417 and lower wc 01002127 wc 01002128 Low Vibration High Vibration wc_tx000418gb fm 93 Hydraulic System RT SC Repair BOM 9026 SN 55461322 and higher BOM 9025 SN 5549418 and higher P2 51 52 wc 9002786 No Vibration wc_tx000418gb fm 94 RT SC Repair Hydraulic System BOM 9026 SN 55461322 and higher BOM 9025 SN 5549418 and higher P wc_gr002787 wc_gr002788 Low Vibration High Vibration wc_tx000418gb fm 95 Hydraulic System RT SC Repair 6 8 Drive and Brake Circuit BOM 9026 SN 55461321 and lower BOM 9025 SN 5549417 and lower TA B 1 P2 5115200 4 2 a 3 1 wc_gr002129 No Movement wc_tx000418gb fm 9 6 RT SC Repair Hydraulic System BOM 9026 SN 55461321 and lower BOM 9025 SN 5549417 and lower wc 01002130 wc 01002131 Forward Reverse wc_tx000418gb fm 97 Hydraulic System RT SC Repair BOM 9026 SN 55461322 and higher BOM 9025 SN 5549418 and higher wc 01002783 Movement wc_tx000418gb fm 98 RT SC Repair Hydraulic System BOM 9026 SN 55461322 and higher BOM 9025 SN 5549418 and higher wc_gr002784 wc_gr002785 Forward Reverse wc_tx000418gb fm 99 Hydraulic System RT SC Repair 6 9 High Speed Drive and Brake Ci
17. RT SC Repair Hydraulic System Hydraulic Schematic Components See Graphic wc_gr000990 Rer Description s ommum _ Travel valve ES Exciter High speed travel valve wc_tx000418gb fm 87 Hydraulic System RT SC Repair BOM 9026 SN 55461322 and higher BOM 9025 SN 5549418 and higher 1 ok B 1 2 all PN a I 1 P2 51 52 A B b E AI UF a I 21 gt lt E 1 b 1 5 si E E a NO 14 9 002782 wc_tx000418gb fm 88 RT SC Repair Hydraulic System Hydraulic Schematic Components See Graphic wc_gr002782 Desonpion Description EI s ommum _ Travel valve ES Exciter High speed travel valve wc_tx000418gb fm 89 RT SC Repair Hydraulic System Hydraulic Diagram 6 5 wc_gr001693 90 gb fm wc 1 000418 RT SC Repair Hydraulic System 6 6 Hydraulic Diagram Components See Graphic wc_gr001693 Ret Description Description Parking brake Exciter pump Hydraulic tank Steering cylinder EB LLL wc_tx000418gb fm 91 Hydraulic System RT SC Repair 6 7 Exciter Circuit BOM 9026 SN 55461321 and lower BOM 9025 SN 5549417 and lower
18. gt Tel 49 0 89 3 5402 0 Fax 49 0 89 3 54 02 3 90 Wacker Corporation Box 9007 Menomonee Falls WI 53052 9007 Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Wacker Asia Pacific Operations Skyline Tower Suite 2303 23 F 39 Wang Kwong Road Kowloon Bay Hong Kong Tel 852 2406 60 32 Fax 852 2406 60 21
19. 2 5 DIC OD Ga TODOS 18 3 Operation 19 3 1 Information Regarding Operation 19 9 2 Operation and Service Locations 20 3 3 24 3 4 omartGontrol Transmitter 26 3 5 Infra red System and Control Channels 30 3 6 1410 vessel scene O O O Oe OTS 32 3 7 REC ET 33 3 8 SLOP DING 34 3 9 en EN _ 35 4 Maintenance 36 4 1 36 4 2 MAC MING wuss 36 4 3 Job Site Storage 37 4 4 ile g215 Mm Re 38 4 5 ebur avid tado osa Dodo Wd O DU GG Gudd Oo LD 38 4 6 Periodic Maintenance Schedules 39 4 7 Hydraulic Oil ee Sende n deas 40 wc br0160393en 004TOC fm 1 Table of Contents RT SC Repair 4 8 Hydraulic 40 4 9 Changing Hydraulic Oil amp Filter 2 008 41 4 10 Articulated Joint Steering Cylinder and Hood Hinges 42 4 11 Cleaning SmartControl Transmitter 42 4 12 DrWVeGeamcdse
20. Removing amp testing control Does LED button circuit board i flash when button mE utton is pressed Check function of vibration properly button Yes Yes Check incoming signal to decoder Replace decoder module Call Wacker Service Replace button card flash when button is pressed Yes Contr le des Check incoming signal to vibration solenoid Does Checking solenoid lead Does wire solenoid LED No Check continuity of have continuity illuminate solenoid lead Yes Yes Replace wire Does solenoid function properly Replace solenoid Yes Checking pressure at gauge port 1 G P1 exciter motors Check Check function of at gauge port 1 exciter motor wc_tx000418gb fm 1 o5 Checking function of Check exciter bearings wc_gr003244 Hydraulic Troubleshooting RT SC Repair 7 2 Checking Power to and Operation of Decoder Module See Graphic wc_gr002196 wc_gr0002340 wc_gr002335 When the machine and control box are ON for every command sent by the control box the signal transmission indicator LED a illuminates A corresponding LED b the decoder module flashes three times for each signal received An LED on the appropriate solenoid c also illuminates when power is sent to it By observing these LEDs one can d
21. Torque the hub nut to 816 Nm 600 ft Ibs Connect the drive motor and brake hydraulic lines On the exciter side of the drum support position the slave hub on the drum support Secure the assembly to the drum support using twelve M10 x 20 screws Use Loctite 243 or equivalent on the screws and torque them to 49 Nm 36 ft Ibs Tighten the hub nut Torque the nut to 816 Nm 600 ft lbs 127 Disassembly Reassembly Procedures RT SC Repair 8 13 Disassembling Drive Hub See Graphic wc_gr002352 wc_gr002097 8 13 1 8 13 2 8 13 3 8 13 4 8 13 5 8 13 6 8 13 7 8 13 8 8 13 9 8 13 10 8 13 11 8 13 12 8 13 13 wc_tx000410gb fm Remove drum See Section Removing Drum Open drum See Section Opening Drum Remove drive motor a and brake b on rear hubs Remove oil from drive hub Dispose of oil properly Remove five screws c securing gear cover d and remove the gear cover Note Because gasket eliminator is applied to the mating surfaces of the hub and the gear cover during assembly it may be necessary to tap the gear cover to break it loose Press the shaft seal from the gear cover Remove the retaining ring f Leave the hub nut g on the shaft and using three pusher bolts h pull the gear off the shaft Pull the lip seal off the shaft With the hub nut loose but still on the shaft tap the hub from the opposite side to break the hub loose from the taper on the shaft Note Leaving t
22. 00 729 5 ane _ ECH LL 9 _ 0 Desmeolwepug 9 bdepm 000158 Wem 0000 Sterng oyinder 000 95 _ Decodermedile 000 Engine contolmodkle _ or fen 99 manuan 0 EE CH 0 Soessing creat breaker 50A EN EN EA NENNEN EN m Articulated joint grease fitting Oil PSI switch Air filter restriction switch High water temperature switch Glow plug timer Hood hinge grease fitting Steering cylinder grease fittings Fuel tank Radiator drain plug Hydraulic manifold 24 Battery 18 Hydraulic tank drain plug Charge cord Service box recepta cle wc tx000518gb fm 22 Operation 5 7 X NS d 09 WI aS 8 gt Al Y mse de 141 2 A Q J 9 M px C t 23 gb fm wc_tx000518 Operation 3 3 wc_tx000518gb fm RT Control Panel See Graphic wc_gr001728 3 3 1 CAUTION 3 3 2 3 3 3 3 3 4 The control panel is mounted to the dash under the back hood access cover of the machine It contains the following features 01001728 Charging System Light a The engine is equipped with an alternator and voltage regulator to maintain the battery charge The charging syste
23. 07002196 7 wc 7002340 WC gr002335 wc tx000418gb fm 1 07 Hydraulic Troubleshooting RT SC Repair 7 3 wc_tx000418gb fm Replacing Decoder Module See Graphic wc_gr002342 7 3 1 7 3 2 7 3 3 7 3 4 7 3 5 7 3 6 7 3 7 7 3 8 7 3 9 7 3 10 7 3 11 7 3 12 7 3 13 Removal Remove the four screws securing the decoder module to the machine frame Rotate the decoder module to aid in removal of the brown connector plug and remove the brown connector plug a Cut the two wire ties b securing the wiring harness Remove the green c and the grey d connector plugs Remove the two screws e one also includes ground from the valve block securing the block to the block bracket Remove the connectors f from the left and right turn solenoid valves Pull the decoder module g from the machine Installation Slide the decoder module back into position and connect the green c and grey connectors 0 Re install the two screws securing the valve block to its bracket e Reconnect the brown connector a Secure the decoder module to the machine frame with four screws Secure the wiring harness with two new wire ties b Reinstall the left and right solenoid valve connectors f 108 RT SC Repair Hydraulic Troubleshooting mw wc 002342 wc_tx000418gb fm 1 09 Hydraulic Troubleshooting RT SC Repair 7 4 Checking Solenoid Lead See Graphic wc gr002197 7 4 1 7 4 2 7 4
24. 142 RT SC Repair Disassembly Reassembly Procedures wc 01002350 wc_tx000410gb fm 1 43 Disassembly Reassembly Procedures RT SC Repair 8 22 Removing Drum Support wc_tx000410gb fm See Graphic wc_gr002348 9 22 1 9 22 2 9 22 3 9 22 4 9 22 5 9 22 6 8 22 7 8 22 8 8 22 9 8 22 10 8 22 11 8 22 12 8 22 13 8 22 14 Open the drum See Section Opening the Drum Disconnect the hydraulic lines a at the exciter motor Plug hydraulic lines immediately after disconnecting to prevent contamination of the hydraulic system Remove the exciter components weights shafts covers See Section Rebuilding Exciters Empty the drum support of oil Label positions of all the hoses b Cut the wire tie c Using an appropriate hoist or crane raise the machine approximately six inches off the ground Using an appropriate hoist or crane secure the drum support in the raised position d Using jack stands e or screw jacks secure the machine frame in position Secure the machine frame and the drum support using separate devices You will be required to lower the drum support in upcoming steps while retaining the position of the machine frame Remove the shock mount screws f at the outer and the upper inner locations Lower the drum support to gain access to the upper hose clamp Loosen the nuts g of the hose clamps Remove the screws h securing the hose clamps to the drum support Remove the brake
25. 2 2 122 8 7 Drum Support 123 8 8 Identifying Drum Supports 22 GWY Ln NR YNAD 124 8 9 RemMOvVINO d Bg ao M 125 8 10 191 1 1 1819 DOUN S HO NR HN 126 8 11 Opening DT CII ice 126 9 12 Closing Drum ae wm 127 8 13 I21Sassembllng Drive FIUD 128 8 14 Reassembling Drive Hub 2 000000 nennen 130 8 15 Disassembling Slave Hub 2 132 8 16 _Reassembling Slave Hub 134 8 17 ACDUNGIDIO ce 136 8 18 Exciter Exploded VIEW tints 138 8 19 EXCIIEF ag DAU 139 8 20 DISASSEMDIING 140 8 21 Heassernblirig EXCIIG esos en reip ayn 142 8 22 Removing Drum SUD DOM 22 ioco iet o et ei a ce 144 8 23 Installing Drum EDDOL GG yu CO ROL 146 8 24 Replacing Steering Cylinder 2 148 8 25 Replacing VaVe BIOCK FY 150 8 26 Heplacing Fuel TANK 152 8 27 Replacing Hydraulic TanK a inito peo drea 154 8 28 FlIVdraull ODRO WR 156 8 29 Replacing Hydraulic Oil Cooler 2 158 8 30 Replacing Radiator and 1
26. 3 check any solenoid lead for continuity Disconnect the solenoid lead connector a green connector from the decoder module Remove the screw securing the LED end b of the solenoid lead to the solenoid valve Trace the wires back through the solenoid lead and test the appropriate wires between the connector and the LED end of the solenoid lead wc 1002197 7 5 Checking Solenoids 75927 159 2 wc tx000418gb fm To test the hydraulic valve solenoids high and low vibration solenoids as well as the reverse and forward solenoids are identical Replace a suspect coil with a known to be working coil If the circuit being tested then works replace the suspect coil Note The same test can be carried out between the left and right steering coils because they are identical Measure resistance in the coils All solenoid coils should measure between 6 5 and 6 7 Ohms cold 7 0 7 5 Ohms warm 110 RT SC Repair Hydraulic Troubleshooting 7 6 Replacing Solenoid See Graphic wc_gr002199 When replacing a valve always have the replacement valve ready to install as soon as the failed valve is removed This will minimize the time the hydraulic system is open to contamination Removal 7 6 1 Remove the screw a securing the LED connector lead and remove the lead 7 6 2 Remove the retaining nut b and washer 7 63 Remove the c from the valve 7 6 4 Remove the valve d from the manifold block
27. 4 1 1 4 2 1 4 3 1 4 4 Poorly maintained equipment can become a safety hazard In order for the equipment to operate safely and properly over a long period of time periodic maintenance and occasional repairs are necessary ALWAYS replace the safety devices and guards after repairs and maintenance ALWAYS turn engine off and remove key from machine before performing maintenance or making repairs This is required to prevent unintentional remote starting 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 ALWAYS replace missing and hard to read labels See Parts Manual for ordering information wc_si000080gb fm 1 4 5 1 4 6 1 4 7 1 4 8 1 4 9 1 4 10 1 4 11 1 4 12 1 4 13 1 4 14 Safety Information 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 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 ALWAYS replace worn or damaged components with spare parts designed and recommended by Wacker Corporation ALWAYS keep the machine clean
28. 5 8 Checking Power to Starter Solenoid 68 5 9 a 70 5 10 Checking NiCad Battery Charge 71 5 11 Engine Cranks But Does Not Start Flowchart 2A 72 5 12 Checking Fuel Line at Fuel Rail 74 5 13 Checking 50A Circuit Breaker 74 5 14 Checking Power to Glow Plugs 75 5 15 Checking GIOW PIUOS oed Eon 75 5 16 CHECKING Relay An Ute e te to 76 5 17 Confirming a Malfunctioning Relay 77 2 RT SC Repair 519 RESTING m 78 519 Checking Fuel oolenold te ui 79 5 20 ROPACH 80 5 21 Replacing SAN un DA Y 81 6 Hydraulic System 83 6 1 Ay OFAUNG eme 84 6 2 Hydraul VV alVeS asu Gu pte s 85 6 3 Hydraulic System Pressures 85 6 4 Hydraulic SCMEMAUCS 86 6 5 90 6 6 Hydraulic Diagram Components 91 6 7 ele SER FED E 92 6 8 Drive and Brake Y ouo FN deua o Uyw 96 6 9 High Speed Drive and Brake Circuit
29. 7 8 4 If you observe more flow from one of the case drain lines than the other the motor with the greatest flow is bad replace it If you observe a substantial flow from both case drain lines both motors are bad Replace both motors wc 235 17 wc_tx000418gb fm 1 1 3 Hydraulic Troubleshooting RT SC Repair 7 9 No Steering Troubleshooting Flowchart 4A With engine ON check operation of travel circuit travel circuit function No gt See Flowchart 5A Checking power to and function of decoder module Yes gt Check outgoing signal from control box Does LED flash when attempting to steer No Check condition of joystick brushes Replace brushes Yes Yes Rebuild replace control box Call Wacker Service Check incoming signal to decoder Does LED flash when attempting to steer Replace decoder module Call Wacker Service Yes Checking solenoids Check incoming signal to steering solenoid Does Checking solenoid lead Does wire solenoid LED No Check continuity of have continuity ne illuminate solenoid lead Yes Yes Replace wire Does solenoid function properly Replace solenoid Rebuild replace rin linder wc 1003245 wc_tx000418gb fm 1 1 4 RT SC Repair Hydraulic Troubleshooting 7 10 No Travel Troubleshooting Flowchart 5A Checking power to and function of
30. 9 2 2 9 2 3 9 2 4 9 2 5 9 2 6 9 2 7 9 2 8 9 2 9 9 2 10 9 2 11 9 2 12 9 2 13 Disassembly Remove the four T16 Torx screws and separate the control into its two halves Label the positions of the red a brown b and blue c wires and disconnect them Also disconnect the charge plug connector d Remove the four T10 Torx screws e and lift off the primary card f Disconnect the joystick connectors 0 Remove the four T10 Torx screws h securing the secondary card i and lift off the secondary card Remove the retaining nut j and washer securing the ON OFF switch k Push the switch body through the control box cover The primary secondary card assembly 1 should now be free from the control box Reassembly Place the ON Off switch into the control box cover Secure the switch to the cover with washer and retaining nut Secure the secondary card to the control box Reconnect the joystick connectors Secure the primary card to the control box Reconnect the red brown and blue wires Reassemble the two halves of the control box Re install the control box battery if removed 172 RT SC Repair Rebuilding Control Box wc gr 2182 wc tx000410gb fm 1 73 Rebuilding Control Box RT SC Repair 9 3 Removing amp Testing Control Button Circuit Board See Graphic wc_gr002188 9 3 1 Remove primary secondary card assembly 9 3 2 Remove the six T10 Torx screws a The button circuit bo
31. During glow plug timer cycle immediately after machine is switched on Throttle relay pull pink green wire Momentarily whenever the throttle switch is placed in the fast position Starter solenoid black wire Only when the engine crank button is pressed wc tx000430gb fm 78 RT SC Repair Engine Starting Troubleshooting 5 19 Checking Fuel Solenoid See Graphic wc_gr002343 To check the condition of the fuel solenoid remove the wire a from the fuel solenoid and check its resistance A functioning solenoid should measure 17 8 Ohms The solenoid will draw 0 5 Amps 17 8 Ohms wc wc_tx000430gb fm 79 Engine Starting Troubleshooting RT SC Repair 5 20 Replacing Battery wc_tx000430gb fm See Graphic wc_gr002367 5 20 1 5 20 2 5 20 3 5 20 4 5 20 5 5 20 6 Removal Remove the nut a securing the air cylinder to the hood This allows enough room to lift the battery up and out of the compartment Remove the two clamp nuts b from the rods c Remove the clamp d and pull the battery from the frame Installation Note Do not connect the battery until all installation steps are complete Place the battery into the machine Secure the battery to the frame using clamp d rods c and clamp nuts b Reconnect the air piston with nut a Reconnect the battery CAUTION Be certain to connect the battery leads to the correct terminals of the battery Incorrect connect
32. Installation 7 6 5 Install the valve d into the manifold block Do not overtighten the valve 7 6 6 Slide the coil c over the valve 7 6 7 Position the coil so that the LED connector can be attached and secure the LED connector to the coil 7 6 8 Secure the coil with the washer and retaining nut 6 wc gmn e8 wc_tx000418gb fm 1 1 1 Hydraulic Troubleshooting RT SC Repair 7 7 Checking Pressure at Gauge Port 1 G P1 See Graphic wc_gr002358 7 7 1 Using a 5000 psi rated gauge check pressure at G P1 top fitting angled upward on back side of valve block The pressure should spike at 3500 psi upon startup of the exciter motors then settle in at normal operating pressure of 1200 psi for low vibration and 1500 psi for high vibration wc cg id wc_tx000418gb fm 1 1 2 RT SC Repair Hydraulic Troubleshooting 7 8 Checking Function of Exciter Motors See Graphic wc_gr002357 7 8 1 Have at the ready two 5 gallon pails Remove exciter motor drain lines a amp b at tank Plug tank fittings as soon as drain lines are disconnected to avoid contaminating the hydraulic system Place the exciter motor case drain lines one each into the 5 gallon pails 7 8 2 Start the engine and allow the hydraulic oil to warm up for several minutes 7 8 3 _ Turn on low vibration and observe the flow from the exciter motor case drain lines Turn on high vibration and observe the flow from the exciter motor case drain lines
33. Pressing this button causes the vibration to come on in HIGH Vibration pushbuttons k or m Pressing either vibration pushbutton will cause the roller to drop out of high speed travel conversely when vibration is on the roller cannot go to high speed 28 wc_tx000518gb fm 3 4 13 3 4 14 Operation When shifting from one vibration mode to the other the exciter weights must come to a complete stop and reverse direction Therefore a 7 second delay has been built into the control circuit No vibration pushbutton l Pressing this button causes all vibration to stop Signal transmission indicator n To aid in diagnostics this LED blinks any time a signal is sent to the roller 29 Operation 3 5 wc_tx000518gb fm RT Infra red System and Control Channels 3 5 1 3 9 2 See Graphic wc_gr003061 The infra red IR system consists of three main components the SmartControl transmitter a the receiving eyes b and the decoder module The receiving eyes are positioned on the top of the machine enclosed within protective lenses They receive filter and amplify the infra red transmission They include e An integrated pre amp to strengthen signal input correction to filter outside light interference e lt A frequency range of 500 kHz There is a green LED d on the base bottom of each eye When illuminated the green LED indicates e That electric power is be
34. RT SC Repair 8 5 wc_tx000410gb fm Articulated Joint See Graphic wc_gr002346 8 5 1 8 5 2 8 5 3 8 5 4 8 5 5 8 5 6 8 5 7 8 5 8 8 5 9 8 5 10 8 5 11 8 5 12 8 5 13 8 5 14 Disassembly Position the machine so that the two halves are not straight in line with each other but rather are off center by approximately 5 Support the two machine halves with jack screws a Remove the nut scuring the pivot and remove the pivot pin Remove the four screws d securing the bearing bracket e and remove the bearing bracket Using an Arbor press press the bearing f from the bearing bracket If replacing only the bearing continue with step 10 If replacing the entire articulated joint remove the four screws g securing the pivot block h and remove the pivot block If replacing screws place a floor jack or third screw jack underneath the drum support Remove the four screws i securing the inside shockmounts there are two on the left and two on the right hand side of the machine Using the jack jack up the drum support just enough to lift the shockmount boss out of the way to remove the screws Reassembly Using blue Loctite 243 or equivalent on the four screws i secure the shockmounts to the frame Torgue screws to 120 Nm 88 ft lbs Slide the pivot block h into the frame and secure it with four screws g Use blue Loctite 243 or eguivalent on screws and torgue to 12
35. With the aid of an assistant or appropriate crane position the drive hub assembly so that the shaft is approximately halfway in to the drum support Connect the hydraulic line leading to the hydraulic fitting b on the drive motor that is closest to the drive hub Using the pin as a guide slide the drive hub assembly the rest of the way into the drum support Use Loctite 243 or equivalent on twelve M10x20 screws and secure the drive hub assembly to the drum support Torque the screws to 49 Nm 36 ft Ibs Attach the rest of the hydraulic lines and add wire tie Tighten hose clamps around hoses Grease inner seal c with white lithium grease and place it approximately halfway on the taper portion of the drive shaft Install the key on drive shaft and install the hub with hub nut Torque hub nut to 816 Nm 600 ft lbs Also torque drive side hub nut Install drums and scrapers See Section nstalling Drums 146 RT SC Repair Disassembly Reassembly Procedures 9002359 wc_tx000410gb fm 1 47 Disassembly Reassembly Procedures RT SC Repair 8 24 Replacing Steering Cylinder wc_tx000410gb fm See Graphic wc_gr002368 9 24 1 9 24 2 9 24 3 9 24 4 9 24 5 9 24 6 9 24 7 9 24 8 9 24 9 8 24 10 8 24 11 8 24 12 8 24 13 Removal Position the roller as shown 1 so that you have adequate access to the piston head screw a If the steering cylinder is not allowing you to position the roller in this m
36. and labels legible Replace all missing and hard to read labels Labels provide important operating instructions and warn of dangers and hazards 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 DO NOT attempt to clean or service the machine while it is running Rotating parts can cause severe injury 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 DO NOT modify the equipment without the express written approval of the manufacturer DO NOT leave SmartControl transmitter unattended while servicing machine ALWAYS turn the engine off before servicing the machine the engine has electric start disconnect the negative terminal on the battery before servicing the machine Safety Information RT 1 5 Label Locations 2 L c A m gt D O 52425 2 R J E jg 2 KA NUTS 7 1 a d 1 C v X BW T ff S M K B wc 9 000233 wc si000080gb fm 1 0 RT Safety Information 1 6 Warning and Informational Labels Wacker machines use international pict
37. and sealants are specified throughout this manual by a notation of S plus a number S and should be used where indicated Threadlocking compounds normally break down at temperatures above 175 C 350 F If a screw or bolt is hard to remove heat it using a small propane torch to break down the sealant When applying sealants follow instructions on container The sealants listed are recommended for use on Wacker equipment PART NO COLOR SIZE Clear Instant adhesive for bonding rubber metal 52676 102 and plastics general purpose Omnifit Sicomet 7000 For gaps up to 0 15 mm 0 006 Read caution instructions before using Loctite Primer T Hernon Primer 10 Omnifit VC Activator Temp range 54 to 82 C 65 to 180 F Fast curing primer for threadlocking 2006124 6 oz retaining and sealing compounds Must be used with stainless steel hardware Recommended for use with gasket sealants Torque Values Torque Values Metric Fasteners DIN TORQUE VALUES Based on Bolt Size and Hardness WRENCH SIZE 1 ft lb 1 357 Nm 1 inch 25 4 mm eee Cm Torque Values Torque Values continued Inch Fasteners SAE 1 ft lb 1 357 Nm in Ib 1 inch 25 4 mm Wacker Construction Equipment AG PreuBenstraBe 41 D 80809 M nchen
38. b to the drum Support and remove the exciter motor Remove the screws securing the exciter housing cover Use two of the longer screws as pushers to push off the exciter housing cover 0 Pull the exciter shaft e and drive gear from the exciter housing Remove the screws securing the bearing cover f to the exciter housing Remove the bearing cover by tapping it from inside the exciter housing On the opposite side of the machine remove the exciter housing cover and the bearing cover as stated above Pull the second exciter shaft and drive gear from the exciter housing Using a properly sized adapter plug g tap the bearing from the exciter housing Using an Arbor press press the bearing from the exciter housing cover h that the exciter motor mounts to Using an inside style puller pull the bearing from the other exciter housing cover i Tap on the small eccentric weight j to remove the bearing race from the exciter shaft Using a gear puller K pull the gear and the inner bearing race off the exciter shaft 140 RT SC Repair Disassembly Reassembly Procedures wc 07002349 wc_tx000410gb fm 1 4 1 Disassembly Reassembly Procedures RT SC Repair 8 21 Reassembling Exciter wc_tx000410gb fm See Graphic wc_gr002350 9 21 1 9 21 2 9 21 3 9 21 4 9 21 5 9 21 6 8 21 7 8 21 8 8 21 9 Using an Arbor press press new outer bearing races a into the exciter housing covers Inst
39. cold weather starting CAUTION Observe the following to prevent serious damage to the machine s electrical system e Never disconnect the battery with the machine running e Never attempt to run the machine without a battery e Never attempt to jump start a machine e Inthe event that the machine has a dead battery either replace the battery with a fully charged battery or charge the battery using an appropriate battery charger 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 Explosion hazard Batteries can emit explosive hydrogen gas Keep all wc tx000419gb fm 47 Maintenance RT 4 18 Engine Oil System See Graphic wc_gr000971 Check the engine oil level daily Add oil as required To check oil Place the machine on a level surface remove the dipstick and check that the oil level is at the top mark Add oil through the oil filler cap a on top of engine checking occasionally with dipstick DO NOT overfill Suggested oil grades Use only diesel engine oil API service rating CD or equivalent wc 9 000971 wc_tx000419gb fm 48 Maintenance 4 19 Engine Oil and Filter wc_tx000419gb fm See Graphic wc_gr000971 4 19 1 4 19 2 4 19 3 4 19 4 4 19 5 Change oil and oil filter b every 125 hours On new machines change oil afte
40. decoder module Check outgoing signal from control box Does LED flash when No Check condition of joystick brushes attempting to travel Are brushes OK Yes Replace brushes Yes Rebuild replace control box Call Wacker Service Check incoming signal to decoder Does Replace LED flash when No decoder module attempting to Call Wacker steer Service Yes Checking solenoids Check incoming signal to travel solenoid Does Checking solenoid lead Does wire solenoid LED No Check continuity of have continuity illuminate solenoid lead Yes Yes Replace wire Does solenoid function properly Replace solenoid Yes Checking pressure Checking function of at gauge port 2 G P2 drive motors Check function of drive motor Replace drive motor Check hydraulic pressure at gauge port 2 wc_gr003246 wc_tx000418gb fm 1 1 5 Hydraulic Troubleshooting RT SC Repair 7 11 Checking Pressure at Gauge Port 2 G P2 See Graphic wc_gr002358 7 11 1 Using a 5000 psi rated gauge check pressure at G P2 bottom fitting on back side of valve block The pressure should spike at 3000 psi upon startup of the drive motors then settle in at normal operating pressure of 1200 psi for low speed travel and 1500 psi for high speed travel 7 12 Checking Function of Brake wc
41. on the opposite side of machine from that shown in graphic wc_gr000479 Change the oil in the drive gearcase once a year or every 500 hours of operation Note the interests of environmental protection place plastic sheeting and a container under the machine to collect the liguid which drains off Dispose of this liguid properly To change the oil 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 Open fill plug c for venting and then remove drain plug b from bottom of drum assembly Install drain plug and remove level plug a from gearcase Add SAE 10W30 oil through fill plug opening until oil flows out of level plug opening approximately 12 5 oz 370 ml Replace plugs and install drum wc_gr000479 43 Maintenance RT 4 13 Exciter Lubrication See Graphic wc_gr000975 The exciter is a sealed unit and under normal conditions should not require any periodic maintenance however an oil change once every two years is recommended to ensure bearing life Exciter maintenance should be done on the right front drum and left rear drum only CAUTION Changing the exciter oil requires special tools and should be performed by an experienced mechanic EN Oil fill plug Oil drain plug Oil level plug Maintain oil at this level
42. to the electrical signals being transmitted by the operator from the control box There are four relief valves in the control block the exciter relief valve limits pressure to 3500 psi 24 mPa the brake relief valve is set at 90 psi 620 kPa drive pressure relief valve is set at 3000 psi 21 mPa and the steering circuit relief is set at 1000 psi 7 mPa Oil from the hydraulic tank flows through a suction strainer 13 before it is drawn into the pump suction ports The suction strainer is mounted in the tank and is magnetic for removing metal particles Hoses connect the output ports of the pumps to the main block on the control manifold The main manifold directs oil flow into the vibration and travel valves These valves in turn supply hydraulic pressure to operate the exciter and drive motors When operating in low speed travel the exciter pump is used to operate the exciter motors 5 and the drive pump is used to operate the drive motors 3 When operating in high speed travel the vibration valve and high speed valve redirect exciter pump oil flow away from the exciter motors to the drive motors During high speed travel the exciter motors do not operate The machine may travel in high speed both forward and reverse Return oil from the drive circuit flows to the steering valve 12 which directs it to the steering cylinder 11 The hydraulic system is protected by an oil cooler 9 and return line filter 10 The return line
43. wire a to the starter solenoid Press the crank button on the control box and check the wire for 12V If 12V is measured on the black wire check function of starter solenoid Refer to Lombardini repair manual for starter replacement procedures lf 12V is not measured check the wire for continuity If the wire has continuity continue Check the pink wire b from the keyswitch to the ECM for 12V lf 12V is measured on the pink wire at the ECM and not on the black wire the problem is in the ECM See Section Testing ECM Call Wacker Service before replacing the ECM lf 12V is not measured on the pink wire check the wire for continuity If the wire has continuity continue Check function of keyswitch Remove screws c remove connector d place the switch in the ON position and test the switch for continuity If the Keyswitch is not functioning properly replace it If the keyswitch is functioning properly call Wacker Service 68 RT SC Repair Engine Starting Troubleshooting ha dra Lm E Em m 8 1 T m i Lo F wc 07002180 wc_tx000430gb fm 69 Engine Starting Troubleshooting RT SC Repair 5 9 Replacing Keyswitch See Graphic wc_gr002210 5 9 1 5 9 2 5 9 3 5 9 4 5 9 5 5 9 6 5 9 7 wc_tx000430gb fm Removal Turn machine OFF and disconnec
44. 0 Nm 88 ft lbs Using an Arbor press press the replacement bearing f into the bearing bracket e marking side in first Press the bearing down until it seats on the shoulder of the bearing bracket Slide the bearing bracket and washer j into the frame and secure the bearing bracket to the frame with four screws d Use blue Loctite 243 or equivalent on screws and torque to 120 Nm 88 ft lbs Insert pivot pin c through pivot block h and bearing bracket Secure the pin with M24 nut b Grease bearing with Shell Alvania 2 or UNIREX 2 grease or equivalent Repeat procedure for upper portion of joint 120 RT SC Repair Disassembly Reassembly Procedures 9 91002346 wc_tx000410gb fm 1 2 1 Disassembly Reassembly Procedures RT SC Repair 8 6 Drum Support Exploded View wc_gr002097 wc_tx000410gb fm 1 2 2 RT SC Repair Disassembly Reassembly Procedures 8 7 Drum Support Components See graphic wc_gr002097 Ret Description SSS 6 Reed _ 0 0 weisse Ret
45. 001 4 2 E 2 238802 2 AD133NND2 m 2 E 21 5 lt o gt E S 5 11 s lt 70 gt e P m ia 2 2 lt 2 Oo FE os 2 2 AH VO 32V 18 038 ADTISA NVL 387 Nid 99 vD 9D 4 JLIHA N338D del id N JAY PUTT3A NT38D 39 7307 3380 03974338 WL M PP TN LG U VS2I 901W0 HISLNIT Nid Cava 3D123NND3 anno NIINI AIV N nm 3108 1304 CLAD Av 133 Onld ADD QIDN3TDS 8318715 ng 311 104HL nm 3111 CLOD 318 3 831384 100 4 1 13 31 INV1009 1 0 gt BLVA CLOD 231714 CLOD 33AD 7704 110 dWv ADD CLNO gt 4 1 3 0553 4 10 ND MUSN3S 13A31 18910103 3IIHA NVI XNIa N3385 ND 805835 331714 a 3TW NI ND aUSN3S JILVA m NOV E 8 ND DSN3S dW3L 32078 a NY L ND 05 34055384 71 1 9 ND uini 5 S ND ND iS 5 1HDI1 033 5 98 ADA 95 vD 8521 90100 INOW 105109 m HJS1n30 el ll 33W78 0193 02 2
46. 16 7 4 16 8 The drums can be changed to adjust the working width of the machine Drums are available in two standard sizes that provide a working width of 560 mm 22 in or 820 mm 82 in To change drum Lock the articulated joint Remove scraper bars Use a screw jack hoist or other type of lifting device to lift drums 25 50 mm 1 2 inches off the ground Lift only one end of the machine Keep the other end in contact with the ground for stability Use a 22 mm wrench and remove the six screws which hold the drum to the drum support Remove the three plugs a covering the pusher holes Insert three of the mounting screws into the pusher holes and thread them in evenly to push drum off Install new drum and fasten to support Secure mounting screws with a medium strength threadlocking adhesive Replace pusher hole plugs Install the correct size scraper bars
47. 60 8 31 FASO ENGINE TE 164 8 32 168 Rebuilding Control Box 170 9 1 Removing Rebuilding Joysticks 170 9 2 Removing and Installing Circuit Boards 172 9 3 Removing amp Testing Control Button Circuit Board 174 Safety Information 1 Safety Information 1 1 wc_si000080gb fm This manual contains DANGER WARNING CAUTION and NOTE callouts which must be followed to reduce the possibility of personal injury damage to the eguipment or improper service This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death gt DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury 4 DANGER WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury gt WARNING CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury gt CAUTION CAUTION Used without the safety alert symbol CAUTION indicates a potentially hazardous situation which if not avoided may result in property damage Note Contains additional information important to a procedure Laws Pertaining to Spark Arr
48. 9 Exciter Parts List Measurem Abm Part No Artikel Nr Description Descripcion Drum support Basa del tambor Bandagentrager Support de tambour a ae Exciter shaft Eje del excitador SHE Erregerwelle Arbre de l excitatrice Exciter shaft Eje del excitador Erregerwelle Arbre de l excitatrice BEEN Eccentric weight Masa exc ntrica Eccentric weight Masa exc ntrica Gear Engranaje Cover Tapa 116959 1 Bearing cover Tapa del rodamiento Lagerdeckel Couvercle du roulement 119314 1 Exciter motor Motor excitador Erregermotor Moteur d excitatrice Roller bearing Rodamiento de rodillos Rollenlager Roulement a rouleaux Square Chaveta 14 9 50 DIN6885 O Ring Anillo O 12x2 Plug threaded Tap n roscado 9 16 18in Screw Tornillo M8 x 25 DIN933 M8 x 20 DIN912 0115431 2 Screw Tornillo X Schraube Vis 41Nm 30ft lbs 0029311 Screw Tornillo M8 x 16 Lockwasher Arandela el stica 10 wc 01002351 2 3 4 o o 10 o 11 o 12 14 o Ref Pos i O 92 o 695 o 702 720 wc_tx000410gb fm 1 39 Disassembly Reassembly Procedures RT SC Repair 8 20 Disassembling Exciter wc_tx000410gb fm See graphic wc_gr002349 9 20 1 8 20 2 8 20 3 8 20 4 8 20 5 8 20 6 8 20 7 8 20 8 8 20 9 8 20 10 8 20 11 8 20 12 Open the drum See Section Opening the Drum Remove the two screws a securing the exciter motor
49. 90 Loctite 515 Hernon 910 Omnifit 10 Green Medium to high strength for locking preassembled threads and for sealing Omnifit 1710 230LL weld porosity wicking Purple Low strength for locking threads smaller 73287 10 ml than 6 mm 1 4 Hand tool removable Temp range 54 to 149 C 65 to 300 F Blue Medium strength for locking threads 29311 5 ml larger than 6 mm 1 47 Hand tool removable Temp range 54 to 149 C 65 to 300 F 17380 50 ml High strength for all threads up to 25 mm 1 Heat parts before disassembly Temp range 54 to 149 C 65 to 3007F 29312 5 ml 26685 10 ml 73285 50 ml 28824 5 ml 25316 10 ml Gaps up to 0 13 mm 0 005 Temp range 54 to 149 C 65 to 3007F Green Medium strength retaining compound 29314 5 ml slip or press fit of shafts bearings gears pulleys etc Gaps up to 0 13 mm 0 005 Temp range 54 to 149 C 65 to 3007F Brown Hydraulic sealant 79356 50 ml Temp range 54 to 149 C 65 to 300 F White _ Pipe sealant with Teflon for moderate pressures Temp range 54 to 149 C 65 to 3007F Purple Form in place gasket for flexible joints 70735 50 ml Fills gaps up to 1 3 mm 0 05 Temp range 54 to 149 C 65 to 300 F 26695 6 ml 73289 50 ml Threadlockers and Sealants Threadlockers and Sealants continued TYPE Europe Loctite 496 Hernon 110 Threadlocking adhesives
50. CAUTION Do not stand within 1m 3ft of the machine when the amber control lights are flashing The roller will respond to remote signals when the light is flash ing Hydraulic oil drain Technical Data 2 Technical Data 2 1 Engine Item No RT 56 SC 0009026 RT 56 SC 0009026 RT 82 SC 0009025 RT 82 SC 0009025 Revisions 108 and Revisions 109 and lower higher Engine Type 3 cylinder 4 cycle liquid cooled diesel engine Lombardini Engine Model LDW 903 LDW 1003 Rated Power kW Hp 15 6 21 2 3600 15 5 20 8 2600 Engine Make Alternator Amp V 3 3 23 8 16 5 amp 2600 rpm Engine Speed full load rpm 2600 Engine Speed idle rpm 1300 Valve Clearance cold intake mm in 0 15 0 006 exhaust 0 20 0 008 Air Cleaner type Battery V CCA Dry pleated paper elements 12V Sealed 800 Fuel type No 2 Diesel Fuel Tank Capacity I gal 18 9 6 3 Fuel Consumption gal hr 5 64 0 67 Radiator Capacity I gal 4 75 1 25 wc_td000077gb fm 1 5 Technical Data RT 2 2 Roller No RT 56 SC 0009026 RT 82 SC 0009025 Roller Operating Weight kg Ib 1391 3068 1473 3247 Area Capacity ft hr 668 7260 972 10560 Inside Turning Radius m in 1 9 73 1 6 63 5 Travel Speed m ft min 41 66 136 7 High 20 65 6 Low Vibration Frequency Hz vpm 41 7 2500 Gradeability with Vibration r r A O
51. Operation Starting See Graphic wc_gr0001662 01001727 3 7 1 3 7 2 3 7 3 3 7 4 3 7 5 3 7 6 3 7 7 Place the throttle switch b in the idle slow positon Turn the key switch a to the 1 ON position All lights on the display control panel and light ring will illuminate for a 5 second LED test After 5 seconds the power ON indicator h charge indicator i and engine oil pressure indicator 1 will remain illuminated The light ring 8 will have a steady amber color Place the SmartControl transmitter ON OFF toggle switch d in the ON position Make sure the amber indicator lights in the light rings q are flashing at a slow rate This indicates infra red reception and that the transmitter is at the correct distance from the machine If they are not flashing or they are flashing at a fast rate reposition the SmartControl transmitter so that they do flash at a slow and steady rate If you are operating multiple rollers check to make certain each roller and its accompanying transmitter are set to a different control channel After approximately 2 seconds if engine conditions dictate coolant temperature too cool the glow plug indicator j will illuminate signifying the glow plugs are on The colder the engine coolant temperature the longer the glow plugs and thus the glow plug indicator will stay on approximately 30 seconds at 0 C 32 F Do not start the engine until the indic
52. Repair 8 31 Replacing Engine wc_tx000410gb fm See Graphic wc_gr002376 8 31 1 8 31 2 8 31 3 8 31 4 8 31 5 8 31 6 8 31 7 8 31 8 8 31 9 8 31 10 8 31 11 8 31 12 8 31 13 8 31 14 8 31 15 8 31 16 Removal Drain engine coolant Drain hydraulic oil Drain engine oil Remove hydraulic oil cooler See section Removing Hydraulic Cooler Remove radiator and shroud See section Replacing Radiator and Shroud Remove hydraulic pumps See section Replacing Hydraulic Pumps Remove the hardware a securing the air cleaner bracket The lower hardware also secures the muffler Loosen the hose clamp b securing the air cleaner and remove the air cleaner and bracket as an assembly Remove the screw c securing the dipstick and remove the dipstick Remove the screws d securing the muffler to the engine Rotate the muffler toward the engine so tab clears bell housing Then push the muffler down and towards rear of machine until it can be lifted out of the machine Remove the oil drain tube e at the engine Disconnect the wiring harness at the oil pressure sensor f throttle solenoid g glow plugs h starter 1 voltage regulator 1 and fuel solenoid k On the opposite side of the engine disconnect the coolant temperature sensor 1 Remove the ground wires at the starter mounting flange Remove the fuel hoses n at the fuel inlet Also remove hoses at fuel filter Discon
53. See Graphic wc_gr000979 wc_tx000419gb fm A hydraulic oil level sight gauge c is located on the hydraulic tank inside the rear section of the machine Check that the oil level is within 25 mm one inch of the top of the sight gauge Add oil as reguired through the filter housing on top of hydraulic tank If hydraulic oil continually needs to be added inspect hoses and connections for possible leaks Repair hydraulic leaks immediately to prevent damage to hydraulic components 40 4 9 wc_tx000419gb fm Maintenance Changing Hydraulic Oil amp Filter See Graphic wc_gr000979 4 9 1 4 9 2 CAUTION 4 9 3 4 9 4 4 9 5 Note 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 To change hydraulic oil Remove drain plug from bottom of frame and allow hydraulic fluid to drain Clean filter housing cover Remove cover from the filter housing and remove the filter element a Be extremely careful to avoid dropping anything into the filter housing while cover is off Install drain plug Fill hydraulic tank through filter housing b using clean hydraulic fluid Install new filter element a as shown in illustration Replace housing cover wc_gr000979 41 Maintenance RT 4 10 Articulated Joint Steering Cylinder and Hood Hinges See Gra
54. TION Clean transmitter and receiving ele ments prior to operation Use only breakaway neck strap pro vided by Wacker to avoid possible oper ator injury Operator s Manual must be stored on machine Replacement Operator s Man ual can be ordered through your local Wacker distributor RT Safety Information NNNM WARNING Disconnect battery before servicing Read the Operator s Manual Tie down point CAUTION Lifting point A nameplate listing the model number item number revision number and serial number is attached to each unit Please record the information found on this plate so it will be available should the nameplate become lost or dam aged When ordering parts or request ing service information you will always be asked to specify the model number item number revision number and serial number of the unit This machine may be covered by one or more patents U S PAT Nos OTHER U S AND FOREIGN PATENTS PENDING M wc si000080gb fm 1 3 Safety Information ep p CAUTION PRECAUTION VORSICHT PRECAUC TON HYDRAULIC OIL HYDRAULIKOL ACEITE HIDRAULICO HUILE HYDRAULIQUE wc_si000080gb fm Torque battery hold down nuts to 3 5 Nm 2 5 ft lbs max CAUTION Engine oil may enter the cylinders if machine tips over causing possible engine damage Guaranteed sound power level in dB A WARNING Pinching hazard Rotating machinery
55. V 21 2 343 ayaa VINO INDJ 0102 INOA 24 2 343 1H9I1 708109 195171 704109 3079 3350 SIAWA 1304 51114100 3119 3 04 130 211 5 4314915 LNdNI 01335 0 SVH 300934 NRI 1009 8003 521 9010 HISLNAG Nid 2I CAVA ADLIINNOD 190 BARE Mad 1009 NISHS 1033 56 9010 35 1034 DNIAI3233 8 3349 ADT T3A 30V 1 5 n n HOLIMS 435 LON 19300511 4431198 OL 4350 LON 011 41 AS ND 2NVND CAG ND 1431 43215 3S383A 33 CAG ND 1 914 43315 Gay Aaa AG ND 3 83A 3a HDIH NUI 1V 38 A AG ND AUT NUILVNGIA AS ND and aad annow9 1431 5NIN331S AG ND 4314918 1 914 0 143315 109110 IMAG 03345 HDIH 3S83 38 AN ASID HOIH NOILVaaIA AUT NUILVNEIA 1411 9 213315 1HDI8 DNT4331S 13345 9 NIG 1009 SAA WA 21 sumi23NNUD 032 2581 9014 251130 Nid 21 3349 gt 0193 05 BESA SNVE AL 32V 19 034 1009 032 0521 9010 351034 Nid NADAa 019309 3HOLIAS 20 21 39V 18 OINId IDA HOLIAS 3T1LLHMHL HOLIASDNITMV2 0 YOLI3NNO9 GSHILIAS WD
56. _tx000418gb fm See Graphic wc_gr002379 and wc_gr002358 7 12 1 7 12 2 7 12 3 On item 9025 serial number 5549418 and above also on item 9026 serial number 5546132 and above disconnect the brake solenoid b On all other machines disconnect the brake hose a at the manifold Plug the fitting at the manifold and the hose to prevent contamination of the hydraulic system Start the machine and attempt to drive forward then reverse A working brake will prevent movement of the machine in either direction If the machine drives through the brake the mechanical activation of the brake is faulty rebuild the brake See Section Rebuilding Brake 116 RT SC Repair Hydraulic Troubleshooting 7 13 Checking Function of Drive Motors See Graphic wc_gr002357 7 13 1 Remove brake hose at manifold and plug it See Section Checking Function of Brake 7 13 2 Have at the ready two 5 gallon pails Remove drive motor drain lines c 8 d at tank Plug tank fittings as soon as drain lines are disconnected to avoid contaminating the hydraulic system Place the drive motor case drain lines one each into the 5 gallon pails 7 13 3 Start the engine and allow the hydraulic oil to warm up for several minutes 7 13 4 Turn on forward travel and observe the flow from the drive motor case drain lines Turn on reverse travel and observe the flow from the drive motor case drain lines 7 13 5 f you observe more flow from one of the case drain line
57. all 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 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 Insert the bearing outer race h into the follower side of the exciter housing Insert the follower side exciter shaft assembly into the exciter housing Apply Loctite 515 gasket eliminator or equivalent to the bearing cover 1 and secure the follower side bearing cover to the exciter housing with six screws Torque screws to 25 Nm 18 ft lbs 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 Fill exciter housing with oil Insert driven exciter assembly into the exciter housing so that weights are even and level with each other j 8 21 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 8 21 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 25 Nm 18 ft lbs
58. and remove the slave hub assembly d from the drum support 8 11 7 If working on the rear drum support disconnect the hydraulic line to the brake Cap the line immediately after disconnecting it to prevent contamination of the hydraulic system 8 11 8 Disconnect the hydraulic lines to the drive motor f Cap all lines immediately after disconnecting them to prevent contamination of the hydraulic system 8 11 9 On the opposite side of the drum support remove the outer ring of bolts securing the drive hub assembly onto the drum support 8 11 10 Using three pusher bolts gradually push the drive hub assembly off the drum support With the help of an assistant pull the drive hub assembly completely from the drum support The assembly will include the shaft drive motor g and the brake h on rear drum supports 126 RT SC Repair Disassembly Reassembly Procedures wc gr d234 8 12 Closing Drum wc tx000410gb fm See Graphic gr002347 and wc gr002097 8 12 1 8 12 2 8 12 3 8 12 4 8 12 5 8 12 6 Heassemble drive and slave hubs See sections Heassembling Drive Hub and Reassembling Slave Hub With the aid of an assistant position the drive hub assembly shaft drive hub drive motor and brake on rear drums into the drum support Secure the assembly to the drum support using twelve M10 x 20 screws Use Loctite 243 or equivalent on the screws and torque them to 49 Nm 36 ft lbs Tighten the hub nut
59. ank empty Fuel filter plugged Fuel lines broken or loose Machine out of infra red range NO VIBRATION e Machine in high speed travel mode Defective switch or poor connection in control box or transmitter Solenoid on vibration valve inoperative e Exciter assembly damaged e Exciter motor coupling damaged e Exciter motor damaged e Exciter pump damaged wc_tx000419gb fm 58 Maintenance Problem Symptom Reason Remedy NO TRAVEL or TRAVEL ONLY IN ONE DIRECTION NO HIGH SPEED TRAVEL NO STEERING wc_tx000419gb fm Defective switch or poor connection in control box or transmitter Solenoid on travel valve inoperative Drive gearcase assembly damaged Loose broken or corroded wire connections Drive motor damaged Drive pump damaged 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 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 59 Engine Starting Troubleshooting RT SC Repair 5 Engine Starting Troubleshooting 51 Component Locations wc 002178 Ref Description Ref Description lt Fuel rail input line Self resetting 50A circuit breaker
60. anner remove the steering hydraulic hoses b amp at the valve Then manually position the roller Loosen but do not remove the screw securing the piston head Reposition the roller in the opposite manner as shown 2 This retracts the piston and allows the cylinder to be removed more readily Remove the steering hydraulic hoses b amp c at the valve Remove the drive hydraulic hoses d amp e at the valve Remove the piston head screw a and the cylinder head screw Pull the cylinder head up and off the mounting stud Do likewise for the piston head If necessary jack up the machine slightly at the articulated joint to increase access Maneuver the cylinder f until you can pull it up and out of the machine If necessary adjust the angle of the machine halves closer or farther apart Once removed remove the hydraulic hoses from the cylinder Installation Insert the cylinder f with hoses attached into the machine frame and place over mounting studs Remove the hydraulic oil cooler and guard for improved access See Section Replacing Hydraulic Oil Cooler Using Loctite 243 or equivlaent on M12 screws secure the cylinder to the mounting studs Torque screws to 86 Nm 63 ft lbs Attach the hydraulic hoses d amp e at the valve Attach the steering hydraulic hoses b amp c at the valve 148 RT SC Repair Disassembly Reassembly Procedures 2 4 2 X N 3 FF ba 2
61. ard b is sealed with silicon and may require a small amount of force to break it loose from the silicon seal To do so Replace three or four of the screws back into the control box cover approximately one revolution Tap on the screw heads to break the card from the silicon seal 9 3 3 Totestthe card check for continuity between the button c in question and common d while the button is being pressed In the graphic the engine crank button is being tested If no continuity is measured replace the button circuit board wc_tx000410gb fm am wc gro2x1 BB 174 Threadlockers and Sealants Threadlockers and Sealants Threadlocking adhesives and sealants are specified throughout this manual by a notation of S plus a number S and should be used where indicated Threadlocking compounds normally break down at temperatures above 175 C 350 F If a screw or bolt is hard to remove heat it using a small propane torch to break down the sealant When applying sealants follow instructions on container The sealants listed are recommended for use on Wacker equipment TYPE PART NO Europe COLOR SIZE Loctite 222 Hernon 420 Omnifit 1150 50M Loctite 243 Hernon 423 Omnifit 1350 100M Loctite 271 277 Hernon 427 Omnifit 1550 220M Loctite 290 Hernon 431 Loctite 609 Hernon 822 Omnifit 1730 230L Loctite 545 Hernon 947 Omnifit 1150 50M Loctite 592 Hernon 920 Omnifit 7
62. ator light goes out Note A red flashing ring of lights will also come on in the light ring q to indicate the glow plugs are on Immediately after the glow plug light j and red LED rings q go out press the engine start button g and hold it down until the engine starts If the unit fails to start within 20 seconds of cranking place the ON OFF toggle switch in the O OFF position Wait 30 seconds before going through the start procedure again Note A 30 second wait time is required so the anti restart cycle can reset Once started and sufficient oil pressure is sensed the oil pressure indicator will go out Allow the unit to warm up a minimum of 5 minutes before engaging the throttle switch b to the high fast position 33 Operation RT 3 8 Stopping See Graphic wc_gr001662 wc_gr001727 3 8 1 Using the vibration off pushbutton f turn vibration off 3 8 2 Place the throttle switch b in the idle slow positon Note 7he engine cannot be shut down using the throttle control alone The throttle switch only changes the engine speed from high fast to idle slow 3 8 8 Place the transmitter ON OFF switch d in the O OFF position to stop the engine 3 8 4 Turn the key switch a to the O OFF position wc tx000518gb fm Note he key switch has a built in shutoff timer If left in the ON position when the engine is not running after one hour the timer will shut off the power to the control pane
63. ck function of keyswitch Is keyswitch functioning properly Repair replace keyswitch Yes Call Wacker wc_gr003244 Service wc_tx000430gb fm 63 Engine Starting Troubleshooting RT SC Repair 5 4 Checking 20A Fuse See Graphic wc gr00221 1 The 20A fuse b in the keyswitch circuit is located in the front section of the machine as shown lt is enclosed in a plastic protective enclosure Remove the enclosure cover to access the fuse wc 2211 wc gr002335 5 5 Checking Starter Circuit at Trailer Plug See Graphic wc 07002335 The functions of the decoder and ECM can be tested at the trailer plug Testing at the trailer plug by passes the control box and aids in determining if the control box is functioning properly To test the crank circuit 5 5 1 Place the keyswitch in the ON position 5 5 2 Attach a jumper wire across pins 1 and for two seconds If the engine cranks with the jumper wire but not through the control box the problem lies within the control box If the engine does not crank with the jumper wire the problem could be in the decoder module or its wiring Check power to and from decoder module then continue testing the start circuit if necessary wc tx000430gb fm 64 RT SC Repair Engine Starting Troubleshooting 5 6 Checking Receiving Eyes See Graphic wc_gr002179 To check infrared transmission between receiving eyes and control Dox 5 6 1 Turn both t
64. coire tetra teo et deme 43 4 13 MEER DOO 44 1 14 SCVAD SNS 45 415 Sede 45 2 16 changing DIUS ae 46 4 17 zat 47 ANG Endine Oil Stena 48 4 19 ENONSE Oland FIO sso dn FORD CRYNO ong aii 49 1220 UN A 50 4 21 Engine Fuel Delivery System Maintenance 51 4 22 i 51 4 23 Priming the Fuel System 52 4 24 ENGINE Coolant 52 425 ValveCleamnceS 53 4 26 Adjusting Engine Fan Belt 2 54 427 WiMilindSchemau6 56 4 28 BASIC 9108 521880 58 5 Engine Starting Troubleshooting 60 5 1 Component Location datu dus 60 5 2 Troubleshooting Flowcharts 2 61 5 3 Engine Does Not Crank Flowchart 1 62 5 4 Checking 20A FUS amp 64 5 5 Checking Starter Circuit at Trailer 64 5 6 Checking Receiving Eyes 65 5 7 Replacing Receiving Eye Light 66
65. e Control System will only charge the transmitter battery if the control cable is connected to the transmitter receptacle b and plugged into the port a in the back of the roller Multiple rollers are not to be operated within 45 feet 14 meters of one another unless you are certain you have each roller and its accompanying transmitter set to a different control channel than the other rollers transmitters being used within the area Refer to section Setting Control Channels for additional information Failure to assign different control channels can in certain circumstances cause one transmitter to inadvertently take control of multiple rollers Always use the SmartControl transmitter neck strap provided by Wacker while operating with the control cable connected This neck strap is designed to break away so that the operator will not be dragged by the machine should the machine slide tip or fall wc_gr000959 Maintenance RT 4 Maintenance 41 Transporting Machine See Graphic wc_gr000980 When transporting the machine place blocks in front of and behind each drum and use the tie down lugs a provided to securely fasten the machine to the trailer Make sure that the joint locking bar b is engaged
66. e hub as shown and using a propane torch heat the bearing inner race quickly When heated to the proper temperature the bearing race will slide off the hub Pull it from the shaft if necessary 132 RT SC Repair Disassembly Reassembly Procedures wc 1002353 wc_tx000410gb fm 1 33 Disassembly Reassembly Procedures RT SC Repair 8 16 wc_tx000410gb fm Reassembling Slave Hub See Graphic wc_gr002356 and wc_gr002097 8 16 1 Press new seal a into cover 8 16 2 Apply a liberal amount of EMB lubriplate white grease or equivalent to the replacement bearing outer race b and insert it into the gear cover Secure it with the disc c and retaining ring d 8 16 3 Press the inner bearing race onto the hub and add new replacement seal f 134 RT SC Repair Disassembly Reassembly Procedures wc 01002356 wc_tx000410gb fm 1 35 Disassembly Reassembly Procedures RT SC Repair 8 17 wc_tx000410gb fm Rebuilding Brake See Graphic wc_gr002354 Disassembly 8 17 1 Open the drum See Section Opening the Drum 8 17 2 Remove drive hub See Section Disassembling Drive Hub 8 17 3 Remove the three screws 698 securing the brake to the hub and remove the brake Note Gasket eliminator is applied to the mating surfaces of the hub and the brake during assembly it may be necessary to tap the brake cover to break it loose from the hub 8 17 4 Remove fitting and drain hydraulic oil from casing dispose of hydraulic oi
67. e hydraulic lines e from the guard to the cooler Remove the two screws f securing the cooler to the guard and remove the cooler Installation Install the cooler to the guard using two screws f Connect the hydraulic lines e from the guard to the cooler Secure the guard cooler assembly to the machine using four screws d Torque the screws to 25 Nm 18 ft lbs 8 29 10 Connect the two hydraulic hoses c running to the cooler 8 29 11 Connect the air intake hose b using two hose clamps a 158 RT SC Repair Disassembly Reassembly Procedures wc 574 wc_tx000410gb fm 1 59 Disassembly Reassembly Procedures RT SC Repair 8 30 Replacing Radiator and Shroud wc_tx000410gb fm See Graphic wc_gr002375 8 30 1 8 30 2 8 30 3 8 30 4 8 30 5 8 30 6 8 30 8 30 8 8 30 9 8 30 10 8 30 11 8 30 12 8 30 13 8 30 14 Removal Drain coolant Remove hydraulic oil cooler See Section Removing Hydraulic Oil Cooler Remove drain hose a from radiator Snip wire ties b securing overflow tube c and disconnect overflow tube from radiator Disconnect input hose d from radiator Disconnect coolant level sensor at connector e Remove screws securing shroud f Remove the two nuts securing the radiator to the shock mounts g Loosen the hose clamp and remove the hose h running to the engine at the engine Remove the hose clamps on green hose i and remove green hose from engine
68. e operating the machine The machine cannot be steered when the locking bar is engaged ALWAYS check that all controls are functioning properly immediately after start up DO NOT operate machine unless all controls operate correctly ALWAYS remain aware of changing positions and the movement of other equipment and personnel on the job site ALWAYS remain in visual contact with machine at all times while operating controls 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 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 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 ALWAYS use the SmartControl transmitter neck strap provided by Wacker while operating with the control cable connected This neck strap is designed to break away so that the operator will not be dragged by the machine should the machine slide tip or fall ALWAYS wear protective clothing appropriate to the job site when operating equipment ALWAYS
69. e shaft into the gear Allow the gear and shaft to cool Slide the shaft assembly through the gear cover Apply Loctite flexible anaerobic gasket or equivalent on the gear cover and connect the gear casing cover 21 to the gear cover using five 8 20 screws 4 Use Loctite 243 or equivalent on the screws and torque the screws to 41 Nm 30 ft lbs Add key d and seal e to shaft Place the hub 3 onto the shaft and secure it with washer 2 and hub nut 1 Fill hub with 12 5 oz of 10W30 See specification chart Apply Loctite flexible anaerobic gasket f or equivalent between face of gear casing cover and the drive motor Install the drive motor g using three M12 screws Use Loctite 243 or equivalent on the screws and torque the screws to 85 Nm 62 ft lbs 8 14 10 Apply Loctite flexible anaerobic gasket or equivalent between face of gear casing cover and the brake Install the brake h using three M8 screws Use Loctite 243 or equivalent on the screws and torque them to 41 Nm 30 ft lbs 130 Disassembly Reassembly Procedures RT SC Repair 01002355 131 gb fm wc_tx000410 Disassembly Reassembly Procedures RT SC Repair 8 15 Disassembling Slave Hub wc_tx000410gb fm See Graphic wc_gr002353 and wc_gr002097 9 15 1 8 15 2 8 15 3 8 15 4 Remove the retaining ring a and remove the disc b Remove the bearing outer race c from the cover Press the seal d from the cover Invert th
70. ecure the dipstick with screw c 8 31 24 Using hardware a secure the air cleaner bracket The lower hardware also secures the muffler 8 31 25 Connect the hose clamp b 8 31 26 Secure the front hood cable at the lifting eye 8 31 27 Remount the hydraulic pumps See section Heplacing Hyaraulic Pumps 8 31 28 Remount the radiator and shroud See section Replacing Radiator and Shroud 8 31 29 Fill engine with coolant 8 31 30 Fill tank with hydraulic oil 8 31 31 Fill engine with oil 166 RT SC Repair Disassembly Reassembly Procedures 01002376 wc_tx000410gb fm 1 67 Disassembly Reassembly Procedures RT SC Repair 8 32 Engine Alternator wc_tx000410gb fm See Graphic wc_gr002378 8 32 1 8 32 2 8 32 3 8 32 4 8 32 5 8 32 6 8 32 7 8 32 8 Removal Remove the exciter pump See Section Replacing Hydraulic Pumps Remove the five screws a securing the flywheel to the engine and remove the flywheel Remove the six screws b securing the alternator assembly to the engine Also remove the screw c securing the connector wire Remove the connector from the wire Slide the wire through the access hole and pull the alternator assembly from the engine Installation Position the alternator assembly on the engine Feed the connector wire through the access hole and secure it with screw c Remount the connector end on the wire Secure alternator assembly to engine using six screws b Secu
71. el and condition of air filter Fill fuel tank with fresh fuel add oil and change air filter as needed Checking fuel flow at fuel rail inlet Remove fuel line at fuel rail and check for flow Check condition of fuel filter replace if necessary If air is present in fuel check condition of fuel hoses and clamps Then bleed Yes the fuel system squirt out during Refer to Lombardini repair manual for fuel system repairs Checking 50A circuit breaker Check condition of the 50A circuit breaker Heplace circuit breaker Checking glow plugs Check condition of glow plug Checking power to glow plugs 5 glow plug OK Check pink wire at glow plugs for 12V during cranking Replace glowplug Refer to Lombardini repair manual No Investigate the following Fuel Injectors Valves Is there 12V on wire Yes Yes Injection timing Piston Governor linkage Cylinder head gasket See Flowchart 2B Cylinder and piston wc_gr003242 wc_tx000430gb fm 72 RT SC Repair Engine Starting Troubleshooting Flowchart 2B Continued from Flowchart 2A Checking relay wiring Check pink red wire at glow plug relay for 12V Is there 12V on the wire Check connection and continuity of brown wire to engine ground Yes No Check continuity of pink red wire between ECM and glow plug relay Is there 12V on the wire
72. esters Notice State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters be used on internal combustion engines that use hydrocarbon fuels A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust Spark arresters are qualified and rated by the United States Forest Service for this purpose In order to comply with local laws regarding spark arresters consult the engine distributor or the local Health and Safety Administrator Safety Information RT 1 2 wc_si000080gb fm Operating Safety WARNING 1 2 1 1 2 2 1 2 3 1 2 4 1 2 5 1 2 6 1 2 7 1 2 8 1 2 9 1 2 10 1 2 11 Familiarity and proper training are required for the safe operation of equipment Equipment operated improperly or by untrained personnel can be dangerous Read the operating instructions contained in both this manual and the engine manual and familiarize yourself with the location and proper use of all controls Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate the machine 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 ALWAYS disengage and stow the locking bar for the articulated steering joint befor
73. etermine if an infrared signal is being sent by the control box received by the decoder module and applied to the corresponding component solenoid The decoder module is fed electric power by the power relay through the pink yellow wire within the gray connector If the decoder module is receiving power its green LED will illuminate when receiving a signal If the green LED does not illuminate the decoder module is malfunctioning or it is not receiving power To determine if the decoder module is receiving power disconnect the grey connector from the decoder module and with the key switch in the ON position check pin 2A d for 12V battery voltage If 12V is not measured the decoder module is not receiving electric power Trace the wiring to the module and repair as needed lf 12V is measured at pin 2A reconnect the grey connector Check connection of brown connector on the opposite side of the decoder module Check the operation of decoder module by connecting a jumper wire between the power pin 2 and each of the pins at the trailer plug one at a time As you connect the jumper observe the LED on the corresponding solenoid connector If the LED illuminates the decoder module is functioning If LEDs on two or more of the solenoids do not illuminate the decoder module is malfunctioning Replace the decoder module 5Vdc input Fuel brake Steer right wc_tx000418gb fm 1 06 RT SC Repair Hydraulic Troubleshooting wc
74. f the filter to ensure a good seal the filter housing neck or inlet pipe are crushed or damaged replace them immediately wc_gr000968 50 RT Maintenance 4 21 Engine Fuel Delivery System Maintenance Maintenance to the engine fuel delivery system should be performed by an experienced mechanic familiar with diesel engines For detailed maintenance procedures on the engine fuel system refer to the engine manual supplied with the machine at the time of shipment 4 22 Fuel Filter See Graphic wc_gr000973 Change engine fuel filter every 300 hours of operation To change fuel filter 4 22 1 Remove filter a from engine block 4 22 2 Install new filter If necessary prime fuel lines as described in next section amp we gro000073 wc_tx000419gb fm 51 Maintenance RT 4 23 Priming the Fuel System See Graphic wc_gr000973 If the fuel tank has been run completely dry or drained for service it will be necessary to manually prime the fuel system To prime the fuel system 4 23 1 both the key switch on the machine and on off switch on control box on This will open the fuel valve 4 23 2 Loosen the bleed screw on the fuel filter and pump the lever on the fuel pump b until fuel flows freely from the bleed screw Tighten the bleed screw 4 23 3 Repeat this procedure for the fuel line bleed screw 4 24 Engine Coolant Check the coolant level of t
75. filter removes particles down to 10 microns and includes a by pass in case the filter should plug A parking brake 1 is located in the rear drum The brake is connected to the hydraulic system through the brake valve of the control manifold The brake is spring activated and hydraulically disengaged Hydraulic oil flow to the brake is enabled as soon as the engine starts Thus when the engine is running the brake is disengaged when the engine is not running the brake is engaged Refer to the circuit diagrams included in this chapter wc_tx000418gb fm 93 Hydraulic System RT SC Repair 6 1 Hydraulic Manifold 69 bar 1000 psi 4 14 12 11 10 9 241 6 2bar 207 bar 3500 psi 90 psi 3000 psi wc_gr003248 wc_tx000418gb fm 84 RT SC Repair Hydraulic System 6 2 Hydraulic Valves See Graphic wc_gr003248 eee Te cameras 4 Steering relief 69 bar 1000 psi Check valve Counter balance relief B Exciter relief 241 bar 3500 psi High vibration 6 3 Hydraulic System Pressures Operating Pressure Relief Pressure bar psi bar psi 83 1200 207 3000 103 1500 207 3000 83 1200 241 3500 103 1500 241 3500 69 1000 69 1000 Brake 6 2 90 6 2 90 wc tx000418gb fm 85 Hydraulic System RT SC Repair 6 4 Hydraulic Schematics BOM 9026 SN 55461321 and lower BOM 9025 SN 5549417 and lower wc_gr000990 wc_tx000418gb fm 86
76. four screws d securing the light ring to the cover Take note that the left hand side screws are longer and with two lock nuts e are used to secure the latch After the screws are removed the receiving eye light ring assembly may be removed from the machine To separate the receiving eye f from the light ring 0 Lift off the outer securing ring h and the globe i Remove the plastic nut j and the two components may be separated Installation Insert the receiving eye f through the light ring g and secure them together using the plastic nut j Add the globe i and the securing ring h Insert the wiring through the cover and secure the assembly with the four screws d Use the longer screws on the left hand side the shorter on the right Open the cover and reconnect the wiring b amp c Secure the hood latch with the two lock nuts e Secure the wiring with a wire tie a Note The LED light ring does not have to be connected for the receiving eye to function The LED light ring is merely an indicator 66 RT SC Repair Engine Starting Troubleshooting wc 002344 wc_tx000430gb fm 67 Engine Starting Troubleshooting RT SC Repair 5 8 Checking Power to Starter Solenoid wc_tx000430gb fm See Graphic wc_gr002180 5 8 1 5 8 2 5 8 3 5 8 4 5 8 5 To check power to starter solenoid Turn keyswitch to ON position Place control box ON OFF switch to the ON position Disconnect the black
77. functions and the air filter restriction circuit have built in circuitry to detect a possible bad sensor unplugged sensor or a cut or damaged wire to the sensor Whenever any of these sensor faults occur the corresponding control panel light will flash on and off 25 Operation 3 4 SmartControl Transmitter See Graphic wc_gr001660 e Wireless control _ Line of sight operation e 3 control channels e Clear transmissions into direct sunlight up to 100 000 LUX e Maximum Range 14 m 45 ft e Transmitting time 8 hours e Recharge time lt 40 minutes e Batteries Ni Cad battery pack The standard operating controls include Ret Description 0 Cable connector Engine START pushbutton Infra red emitting diodes ON OFF toggle switch c Joysiks k LOW vibration LOW vibration pushbutton ERE E charge indicator EA pushbutton green LED e Battery failure indicator red LED j HIGH vibration pushbutton Power ON indicator green LED indicator green LED Power ON indicator green LED Signal transmission indicator EA reguired indicator red LED wc_tx000518gb fm 2 6 wc_tx000518gb fm 3 4 1 3 4 2 3 4 3 3 4 4 3 4 5 Operation Cable connector a The cable connector provides battery charging capabilities Transmitter batteries can be recharged using the cord while the engine is running or during non work
78. he four screws c on the under side of the frame and the two screws b on the upper side Reattach the fuel hoses to the tank at the cocks a Reinstall the air cylinder d and bracket 152 RT SC Repair Disassembly Reassembly Procedures 07002370 wc_tx000410gb fm 1 53 Disassembly Reassembly Procedures RT SC Repair 8 27 Replacing Hydraulic Tank wc_tx000410gb fm See Graphic wc_gr002371 8 27 1 9 27 2 9 27 3 9 27 4 8 27 5 8 27 6 8 27 7 8 27 8 8 27 9 8 27 10 8 27 11 Removal Drain hydraulic oil tank Remove fuel tank See Section Replacing Fuel Tank Label then remove the five hydraulic hoses a leading into the tank The hose d from the valve block can remain attached and be removed after the tank is free Remove the hardware b securing the hood cable Remove the two screws 690 at the top of the hydraulic tank Remove the two screws 797 securing the tank to the machine frame Remove the hoses c connected to the under side of the tank If the tank is not drained well there will be significant spillage Be sure tank is well drained Work quickly to avoid oil spillage When underside hoses are free remove tank from machine Installation Position tank on machine frame Connect hydraulic hoses c on under side of tank Secure tank to frame with the two upper screws 690 and the two lower screws 797 Attach hydraulic hoses a to appropriate ports 154 RT SC Repair Disa
79. he hub nut threaded on the shaft prevents the hub from popping off the shaft when the hub releases from taper on the shaft Pull the Key from the shaft Invert the hub as shown and using a propane torch heat the bearing inner race quickly When heated to the proper temperature the bearing race will slide off the hub Pull it from the shaft if necessary Remove the retaining ring from the gear cover and remove the outer bearing race 128 RT SC Repair Disassembly Reassembly Procedures wc 6002152 wc_tx000410gb fm 1 29 Disassembly Reassembly Procedures RT SC Repair 8 14 Reassembling Drive Hub wc_tx000410gb fm See Graphic wc_gr002355 and wc_gr002097 9 14 1 9 14 2 9 14 3 9 14 4 9 14 5 9 14 6 8 14 7 8 14 8 8 14 9 Insert the replacement bearing outer race 6 markings side in first into the gear cover 5 and secure it with the retaining ring 7 Press the inner bearing race a onto the hub and add a new Seal b to the hub When hub nut is tightened the seal seats into gear cover 5 Insert the key 16 and the retaining ring 19 on the shaft 17 Cool the shaft with cold water and apply a thin film of oil to the shoulder of the shaft c where the gear will rest Heat the gear to 400 F use a hot plate or similar source Then slide or press the shaft into the gear 23 up to the retaining ring Note When heated to the correct temperature very little pressure is required to press th
80. he machine and the control box ON 5 6 2 Position the control box within 20 65 feet of the machine The amber LEDs of the light ring should flash on and off They will flash rapidly when the control box is held too close to the machine The amber LEDs will not flash when the control box is held further away than 20 m 65 feet instead the amber LEDs will remain illuminated 5 6 3 If the amber LEDs do not flash try several different positions until they do flash Also check the charge of the NiCAD battery and the function of the starter button If the amber LEDs still don t flash open the hood and check the green LED a on the back of the light ring If the receiving eye is receiving a signal the green LED will illuminate 5 6 4 If the green LED is not illuminated check the wiring between the receiving eye and the decoder module for continuity Replace the wiring if no continuity is measured If neither receiving eye is functioning disconnect one of the receiving eyes and check if the other now operates If it does replace the non functioning eye Check each eye in this manner wc_gro0e1 79 wc_tx000430gb fm 65 Engine Starting Troubleshooting RT SC Repair 5 7 wc_tx000430gb fm Replacing Receiving Eye Light Ring See Graphic wc_gr002344 5 7 1 5 7 2 5 7 3 5 7 4 5 7 5 5 7 6 5 7 7 5 7 8 5 7 9 5 7 10 5 7 11 Removal Cut the wire tie a Disconnect the wiring connectors b 8 Remove the
81. he radiator daily while the engine is cold The coolant level should be at the cold level mark lower line on the overflow bottle Add coolant in a 50 water 50 glycol mixture if required NEVER remove the radiator cap or drain plug while the engine is hot Pressurized coolant can cause serious burns WARNING If it is necessary to open the radiator only do so with the engine off and only when coolant is cool enough to touch with bare hands Slowly loosen cap to relieve pressure first before removing it completely wc tx000419gb fm 5 2 Maintenance 4 25 Valve Clearances wc_tx000419gb fm See Graphic wc_gr002366 4 25 1 4 25 2 4 25 3 4 25 4 4 25 5 4 25 6 Check and adjust valve clearance every 500 hours Set clearance with engine cold Replace the valve rocker arm cover gasket when checking the valve clearances Refer to the engine manufacturer s service manual for detailed information To adjust valve clearances Remove valve rocker arm cover Bring each cylinder piston to top dead center on the compression stroke and set clearance Valve clearance A 0 20mm 0 008 in Valve clearance B 0 15mm 0 006 in Clean gasket material from cylinder head Place a small bead of RTV Silicone on cylinder head to secure ends of new gasket Gently place gasket on cylinder head Replace valve rocker arm cover Torque bolts to 9 Nm 7 ft lbs wc 002366 53 Maintenance 4 26 Adjust
82. information on engine maintenance before 100 125 250 300 500 starting hrs hrs hrs hrs hrs Geg Replace ater Check condtonandterson onfenbeR engrenead and inderins Ommesnewwecmme Replace engine offer 1 5 Replace Clean injectors and check injector pres sure mmm Check valve clearance wc_tx000419gb fm 39 Maintenance RT 4 7 Hydraulic Oil Requirements Wacker recommends the use of a good petroleum based anti wear hydraulic oil in the hydraulic system of this equipment Good anti wear hydraulic oils contain special additives to reduce oxidation prevent foaming and provide for good water separation When selecting hydraulic oil for your machine be sure to specify anti wear properties Most hydraulic oil suppliers will provide assistance in finding the correct hydraulic oil for your machine Avoid mixing different brands and grades of hydraulic oils Most hydraulic oils are available in different viscosities The SAE number for an oil is used strictly to identify viscosity it does not indicate the type of oil engine hydraulic gear etc When selecting a hydraulic oil be sure it matches the specified SAE viscosity rating and is intended to be used as a hydraulic oil See Technical Data Lubrication 4 8 Hydraulic Oil Level
83. ing Engine Fan Belt wc_tx000419gb fm See Graphic 07002377 4 26 1 4 26 2 4 26 3 4 26 4 4 26 5 4 26 6 Remove the hydraulic oil cooler See Section Replacing Hydraulic Oil Cooler Remove radiator and shroud See Section Replacing Radiator and Shroud Remove the four screws a securing the fan to the engine and remove the fan Remove the outer pulley plate b Insert the appropriate amount of shims c to give you the required tension on the belt The fewer the number of shims the tighter the belt will be Approximately 6 12 mm 1 4 1 2 in deflection is recommended Place unused shims between outer pulley plate and fan when reinstalling the fan Secure the fan to the engine with the four screws a 54 Maintenance wc 0 wc_tx000419gb fm 55 Maintenance 4 27 Wiring Schematic 66 0 N d 082 XJVd S4l3W 2 WNDIS dW3L KE scans 01043105 R 11 0719 37 IN ON H21IAS an 38055334 HOLIAS dW3l 121415384 T3A31 LNI T 10 WNO aly INV 1009 INI Q wa We 5 2104 56 9010 e E am SAN E w 5 bs SS 2 2 5 2104 57 9010 Nid 204 56 90 1 5 HJSIn3d Nid
84. ing hours using the docking port Infra red emitting diodes b The diodes are used to transmit the coded infra red signal to the receiving eye on the machine Keep the window in front of the diodes clean to ensure maximum signal strength Joysticks c Two joysticks control low and high speed directional motion of the roller The left joystick controls left right motion The right joystick controls forward reverse motion Move the joysticks in the direction desired The roller will change to high speed whenever the right joystick is placed fully in the forward or fully in the reverse position Battery charge indicator green LED d When this light is OFF and transmitter is in use it indicates that the batteries are charged If this light is blinking it indicates that there is no battery present that there is an internal failure Temp sensor or that the battery is too hot When the light is ON steady it means the batteries are being charged through the charging cable or docking port Battery failure LED red e This LED illuminates when the battery has failed due to discharge damage or breakdown 27 Operation wc_tx000518gb fm 3 4 6 3 4 7 3 4 8 3 4 9 3 4 10 3 4 11 3 4 12 RT Power ON indicator green LED f When the ON OFF toggle switch is in the ON position this light blinks indicating that the SmartControl transmitter is ON and ready for operation Charging re
85. ing supplied to the eye The LED illuminates for the first 1 2 seconds after power has been applied Key switch is turned on e Thatthe eye is receiving a signal from the SmartControl transmitter module The LED will remain on during operation The decoder module is positioned behind the hydraulic manifold at the back of the machine It receives decodes and outputs the signal from the transmitter module It is also the electric power supply for all hydraulic solenoids The IR system can be set to one of three different control channels Using different channels allows multiple rollers to operate in the same area without interference Whenever multiple rollers are operated within 45 feet 14 meters of one another make certain each roller and its accompanying transmitter is set to a different control channel than the other rollers transmitters being used within the area Channel selection microswitches and are included on both the transmitter module and on the decoder module The microswitches come from the factory set randomly For proper operation BOTH microswitches must be set to the SAME channel The channel is determined by the position of the microswitch To change the control channel Remove the four screws holding the transmitter module together and carefully pull it apart Place the microswitch on the transmitter module in any of the three positions Close the box and secure with four screws Place the microswi
86. ing the eguipment cannot be anticipated it is up to the mechanic to use common sense and good judgement in tool selection The use of any special tools is recommended only for those operations where the use of conventional tools proves inadeguate Before substituting another tool or procedure you should be satisfied that neither personal injury nor damage to the component will result Ordering Parts The repair procedures contained in this manual do not include part numbers For parts replacement information refer to the Parts Book originally supplied with the unit If the original Parts Book has been lost a replacement may be ordered from Wacker Corporation When ordering a replacement Parts Book please list the model number item number revision level and serial number of the machine Parts Books are also available on the Wacker Corporation Web site See www wackergroup com Enter the site as a visitor Reference Numbers Repair procedures contain reference numbers enclosed parentheses These numbers refer to the item numbers shown on the assembly drawings and other detailed drawings They are included to aid the mechanic in identifying parts and assembling components Weight Block See Graphic wc_gr000843 The weight block symbol gives an approximate weight measurement to aid the mechanic when lifting hoisting larger components 250 kg 550 Ibs wc_gr000843 119 Disassembly Reassembly Procedures
87. ions may damage the ECM and other electrical components wc 017002367 80 RT SC Repair Engine Starting Troubleshooting 5 21 Replacing Trailer Plug See Graphic wc_gr002345 Removal 5 21 1 Disconnect and remove the battery 5 21 2 Remove the four screws a and lock nuts b securing the trailer plug c to the frame 5 21 3 Disconnect the wiring harness from the decoder module at the brown connector Installation 5 21 4 Secure the trailer plug c to the frame with the four screws a and lock nuts b 5 21 5 Connect the wiring harness to the decoder module 5 21 6 Re install the battery wc 002345 wc_tx000430gb fm 9 1 Engine Starting Troubleshooting RT SC Repair Notes wc_tx000430gb fm 82 RT SC Repair Hydraulic System 6 Hydraulic System See Graphic wc_gr000990 Pressure in the hydraulic system is generated by two gear pumps the drive pump 4 and the exciter pump 6 Both pumps provide 6 24 lom The exciter pump is driven by the engine s crankshaft while the drive pump is driven by the engine s camshaft A control manifold 8 directs oil flow from the pumps to the motors and steering cylinder The control manifold is mounted beneath the control panel at the rear of the machine It consists of the main block exciter vibration 7 travel 14 high speed travel 15 brake 2 and steering 12 valves All valves are solenoid operated During operation the solenoids respond
88. iring ing _ Retaining 00000000 9 _ Ring _ 9 feo 4 fpe 4 ON Sub Seng n EN EN EE Don EU _ 2 wc_tx000410gb fm 1 23 Disassembly Reassembly Procedures RT SC Repair 8 8 wc_tx000410gb fm Identifying Drum Supports See graphic wc_gr002053 8 8 1 The rear drum 1 contains a brake a a drive motor b an exciter assembly c with exciter motor d 8 8 2 _ The front drum 2 contains a drive motor b and an exciter assembly c with exciter motor d 8 8 3 When disassembling the drum support always start on the exciter side of the drum it can be identified by the bulge e in the casting wc 97002053 124 RT SC Repair Disassembly Reassembly Procedures 8 9 Removing Drums See graphic 9002052 8 9 1 Lock articulated joint 8 9 2 Lift one end of the machine using an appropriate crane or hoist Insert jack stands x to support machine from underneath 8 93 Remove the M12 screws and washers and remove the scrapers b 8 9 4 Remove the six M16x55 screws d securing the drum to the drum support f 8 9 5 Remove the three M16 screws c and washers acting as plugs In their place insert three of the M16x55 removed in the previous step Use these screws as pushers to push the drum off the drive housing wc_tx000410gb fm wc_gr002052 Disassembly Reas
89. l A parking brake is located in the rear drum The brake is connected to the hydraulic system through the brake valve of the control manifold The brake is spring activated and hydraulically disengaged Hydraulic oil flow to the brake is enabled as soon as the engine starts Thus when the engine is running the brake is disengaged when the engine is not running the brake is engaged wc 91001662 ho AF es eed wc 07001727 34 RT 3 9 wc_tx000518gb fm Operation Operation See Graphic wc_gr000959 CAUTION WARNIN Keep the transmitter pointed at either of the receiving eyes on the machine to continue operation The light ring amber LEDs will blink to show that the machine is receiving signals from the transmitter Note Clean transmitter and receiver eyes prior to operation infra red system is equipped with an operator distance sensing system If the operator is standing within 1 3 3 ft of the machine the amber light ring will flash rapidly The machine will not travel forward reverse or vibrate until the operator moves outside this distance The amber lights will flash slowly to indicate the machine can be operated Note 7he control cable is not needed for using the infra red system The SmartControl transmitter battery can be recharged at the end of operation by connecting the transmitter receptacle b to the battery docking port c See Charging Transmitter Batteries The Cabl
90. l properly 8 17 5 Remove the retaining ring 90 and remove gear 56 8 17 6 Remove the six screws 693 securing the cover 81 and remove the cover 8 17 7 Remove O ring a from cover 8 17 8 Remove the plate 83 and inner O ring 94 from housing 80 8 17 9 Remove the retaining ring 89 and pull bearing 87 from cover 8 17 10 Pull the shaft 82 from inside the housing 8 17 11 Remove the ring spacer 84 and spring 85 8 17 12 Remove the retaining ring 88 and pry bearing b out of housing 8 17 13 Pull seal c from housing Reassembly 8 17 14 Insert the seal c into housing 8 17 15 Insert bearing 86 into housing 80 and secure with retaining ring 88 8 17 16 Dip O ring 94 in hydraulic oil and position on face of housing 8 17 17 Insert bearing 87 into cover 81 and secure with retaining ring 89 8 17 18 Align holes in plate 83 with pins and place plate on housing 8 17 19 Add spring 85 and gear to shaft and insert shaft assembly into housing 8 17 20 Apply Loctite 243 or equivalent to six screws 693 and secure cover 81 to housing 8 17 21 Add gear 56 to shaft and secure with retaining ring 90 136 RT SC Repair Disassembly Reassembly Procedures wc 1002354 wc_tx000410gb fm 1 37 RT SC Repair Disassembly Reassembly Procedures 8 18 Exciter Exploded View 0009025100 14 138 gb fm wc_tx000410 RT SC Repair Disassembly Reassembly Procedures 8 1
91. line i from the valve block and pull the brake line from the drum support Lower the drum support to the floor Guide the hoses through it as it is being lowered Remove the screw j securing the lower inner shock mount Continue guiding the hoses through the drum support and pull the drum support completely away from the frame 144 RT SC Repair Disassembly Reassembly Procedures wc gr o2348 wc tx000410gb fm 1 45 Disassembly Reassembly Procedures RT SC Repair 8 23 wc_tx000410gb fm Installing Drum Support See Graphic wc_gr002348 and wc_gr002359 8 23 1 8 23 2 8 23 3 8 23 4 8 23 5 8 23 6 8 23 7 8 23 8 8 23 9 8 23 10 8 23 11 With shock mounts attached to drum support position drum support on the floor and under frame of machine As you position it guide the hydraulic hoses into the drum support Attach upper and lower hose clamps to drum support During mounting of hose clamps on rear drums attach hose guard 15 Do not tighten hose clamps around hoses at this time Lower the machine frame so that the outer shock mounts can be secured Use Loctite 243 or equivalent on the screws and torque them to 86 Nm 63 t lbs Continue lowering machine until innermost shock mounts can be secured Use Loctite 243 or equivalent on the screws and torque them to 86 Nm 63 t lbs Cut the head off an M10 screw Insert it into the drum support in an upper location and use it as a guide pin
92. m warning light illuminates when there is a malfunction of the system Although the machine will run with the light on for a short period of time continued operation will drain the battery and eventually cause the machine to lose all operating functions If the system warning light illuminates while operating the machine a narrow trench or other confined area drive machine into a safer area as soon as possible to avoid stranding it in a hazardous or inaccessible location Glow Plug Light b The engine is equipped with an automatic glow plug system that pre heats the combustion chambers to improve normal and cold weather starts The glow plug light illuminates when the keyswitch and the transmitter ON OFF switch are placed in the ON positions It will go off when the combustion chambers are pre heated Note Allow 5 minutes for the engine to warm up before operating the roller Air Cleaner Light c The air cleaner warning light illuminates when the air filter cartridge needs to be replaced Hour Meter d The hour meter records the actual running time of the engine Use the hour meter when planning scheduled maintenance 24 wc_tx000518gb fm 3 3 5 3 3 6 3 3 7 3 3 8 3 3 9 Operation Engine Oil Pressure Light e The oil pressure warning light illuminates when oil pressure falls below the engine manufacturers recommended value During such condition the engine will automatically shu
93. n RT 1 3 1 4 wc_si000080gb fm Operator Safety while using Internal Combustion Engines DANGE ER 1 3 1 1 3 2 1 3 3 1 3 4 1 3 5 1 3 6 1 3 7 1 3 8 1 3 9 1 3 10 1 3 11 Internal combustion engines present special hazards during operation and fueling Read and follow the warning instructions in the engine manual and the safety guidelines below Failure to follow the warnings and safety guidelines could result in severe injury or death DO NOT run the machine indoors or in an enclosed area such as a deep trench unless adequate ventilation through such items as exhaust fans or hoses is provided Exhaust gas from the engine contains poisonous carbon monoxide gas exposure to carbon monoxide can cause loss of consciousness and may lead to death DO NOT smoke while operating the machine DO NOT smoke when refueling the engine DO NOT refuel a hot or running engine DO NOT refuel the engine near an open flame DO NOT spill fuel when refueling the engine DO NOT run the engine near open flames ALWAYS refill the fuel tank in a well ventilated area ALWAYS replace the fuel tank cap after refueling ALWAYS check the fuel lines and the fuel tank for leaks and cracks before starting the engine Do not run the machine if fuel leaks are present or the fuel lines are loose ALWAYS keep the area around a hot exhaust pipe free of debris to reduce the chance of an accidental fire Service Safety WARNING 1
94. n control box and machine Are both set to the same channel Recharge control box battery Synchronize channels Removing amp testing control button circuit board Yes Check function of starter button Checking starter circuit at trailer plug Check function of starter circuit with jumper at trailer plug Does machine crank 5 button functioning properly No Replace rebuild control button card Yes No Y See Flowchart 1B wc 01003240 wc tx000430gb fm 62 RT SC Repair Engine Starting Troubleshooting Flowchart 1B Continued from Flowchart 1A Checking power to starter solenoid Place key switch in ON position Remove black wire from starter solenoid Check for 12V on wire when start button is pressed Is there 12V on black wire Yes Check function of starter solenoid Is No Refer to Lombardini repair manual for starter motor repair replace procedures Replace Call Wacker Service starter Check continuity of black wire to starter solenoid Does wire have continuity Check for 12V on pink wire from keyswitch to ECM Is there 12V on pink wire Yes Replace the ECM Call Wacker Service No Y CE DU Check continuity of pink wire No from keyswitch to ECM Repair replace wire Does wire have continuity gt NO Yes Che
95. nect the screw at the lifting eye and remove the front hood cable Reinstall the lifting eye Support the engine by the lifting eyes with an appropriate lift or hoist Remove the screws p securing the engine to the mounting brackets and lift the engine off the frame enough to disconnect the ground wire q from the voltage regulator After the ground wire is disconnected lift the engine up and out of the machine 164 RT SC Repair Disassembly Reassembly Procedures 01002376 wc_tx000410gb fm 1 65 Disassembly Reassembly Procedures RT SC Repair wc_tx000410gb fm Installation 8 31 17 Support the engine by the lifting eyes with an appropriate lift or hoist and position the engine over the machine frame Connect the ground wire leading to the voltage regulator Lower the engine into the frame and secure it to the mounting brackets using four screws p 8 31 18 Connect the oil drain tube e at the engine 8 31 19 Connect the fuel hoses n at the fuel inlet Also connect hoses at fuel filter 8 31 20 Connect the ground wires m at the starter mounting flange 8 31 21 Connect the wiring harness at the oil pressure sensor f throttle solenoid g glow plugs h starter 1 voltage regulator 1 and fuel solenoid k On the opposite side of the engine connect the coolant temperature sensor lI 8 31 22 Position the muffler inside the frame and secure it to the engine with two screws d 8 31 23 S
96. o the State of WARNING California to cause cancer and birth defects or other reproductive wc_tx000397gb fm harm All rights especially copying and distribution rights are reserved Copyright 2006 by Wacker Corporation No part of this publication may be reproduced in any form or by any means electronic or mechanical including photocopying without express written permission from Wacker Corporation Any type of reproduction or distribution not authorized by Wacker Corporation represents an infringement of valid copyrights and violators will be prosecuted We expressly reserve the right to make technical modifications even without due notice which aim at improving our machines or their safety standards RT SC Repair Table of Contents 1 Safety Information 5 1 1 Laws Pertaining to Spark Arresters 5 1 2 ODperaung SalelV 6 1 3 Operator Safety while using Internal Combustion Engines 8 1 4 SPME all dmm NT 8 1 5 LAD Gl WOCANOINS EE 10 1 6 Warning and Informational Labels 11 2 Technical Data 15 2 1 ENGINE T y 15 2 2 KONOR SW 16 2 3 PUIG ANON 17 2 4 Sound and Vibration Measurements 18
97. orial labels where needed These labels are described below WARNING Pressurized contents Do not open when hot WARNING Hot surface WARNING Pinch point Hydraulic oil reservoir fill tube WORBICHT PRECAUCION PHECALITICHM Radiator Engine RADIATOR ENGINE OIL KUEHLER MOTOROEL RADIADOR ACEITE DE MOTOR RADIATEUR JL HUILE 5 0154325 wc_si000080gb fm 1 1 Safety Information umm O O Ei HAU TH FPA rn Ye 1 i BD LIRE LL Tau Pu md S a E mE nm CLA a r 5 Budd 11 Cpu oe HLEEFZ E ALMBNTAR UL DX UR PF umm E EE LA ut aea 4 Ten Lit s L T1 HE Clean transmitter and receivin elements prior to operation Vor MU un nd nigen Limpie el aparato emisor receptor s del funcionamiento pom retle ecepteur e avant op ration OPEPhACO FF ETIPAPI Ue HE eH ir DAm UL CHIWIDSETI 1
98. ounted on the left side of the engine It is a self resetting type circuit breaker and is enclosed by a red rubber boot The circuit breaker is tripped by heat and automatically resets itself once cool When cool a working 50A circuit breaker will have 12V incoming and 12V outgoing If you measure less than 12V outgoing replace the 50A circuit breaker 74 RT SC Repair Engine Starting Troubleshooting 5 14 Checking Power to Glow Plugs See Graphic wc_gr002214 The pink power wire a runs to the glow plugs as shown Check the wire for 12V If 12V is not measured check the continuity of the wire and replace or repair the wire as needed al a 2 ji m 7 y RAI T Y wc 97002033 wc gnel el 4 5 15 Checking Glow Plugs See Graphic wc_gr002033 5 15 1 Remove the glow plug from the engine Burn hazard Glow plugs can reach temperatures up to 1200 F 6499 Do not touch the element of the glow plug Be extremely careful when testing the glow plug WARNING 5 15 2 Using 10 gauge wire apply 12VDC to the glow plug positive on the upper portion and ground the base If the glow plug does not heat glow within five seconds replace the glow plug Note f any one of the glow plugs needs replacing replace all of them wc_tx000430gb fm 75 Engine Starting Troubleshooting RT SC Repair 5 16 Checking Relay Wiring See Graphic wc_gr002215 5 16 1 Tu
99. own to be working throttle or glow plug Do not disconnect the power relay and use it as a test relay The power relay is required for all functions 5 17 2 Place the keyswitch and the control box ON OFF switch in the ON positions If testing the throttle relay press the throttle switch If the function glow plug throttle or power works with a known to be working relay the suspect relay is bad replace it Alternative method 5 17 3 Disconnect the relay in question 5 17 4 Place a jumper d across the connector as shown and check if the function works power throttle or glow plugs If the function works with the jumper in place the relay is bad replace it Power to the throttle relay is only momentary Repeat test if necessary Note Simply listening for the relay to click when power is supplied to it is not an adequate test wt 0002330 wc_tx000430gb fm 77 Engine Starting Troubleshooting RT SC Repair 5 18 Testing ECM An overall test of the ECM can be made by checking for battery voltage to the following components during the conditions listed If battery voltage is not found the ECM is faulty Note These tests assume that there is power to the ECM key switch and control box ON OFF switch in the ON positions that all wire connections are tight and that all wires have continuity Check all connections and wiring before conducting these tests Table 1 Glow plug relay connector pink red wire
100. phic wc_gr001665 ss i C C 2 Lubricate top and bottom bearing blocks a cylinder knuckles b and hood hinges d every 100 hours using a hand held grease gun Cylinder knuckles can be accessed through holes on side of machine c Use Shell Alvania No 2 or an equivalent No 2 general purpose grease CG EN SSSSSSS CAL m Enc CD wc 41001665 4 11 Cleaning SmartControl Transmitter wc_tx000419gb fm 4 11 1 4 11 2 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 the transmitter using a damp cloth Allow it to air dry To remove dirt and dust trapped around switches use low pressure compressed air 42 Maintenance 4 12 Drive Gearcase wc_tx000419gb fm See Graphic wc_gr000479 CAUTION 4 12 1 4 12 2 4 12 3 4 12 4 4 12 5 Any disassembly of the drive gearcase should be done
101. quired indicator red LED g This red LED is used to indicate the capacity of the battery in the SmartControl transmitter module When the battery capacity falls to 20 of full charge the LED will begin to blink indicating that the battery needs recharging At this stage transmission distance may begin to diminish If the battery charge falls to 10 or less the red LED changes from blinking light to a continuously on light and transmission is shut off This avoids possible malfunctions caused by weak signals e Light Off Battery charged e Light Blinks Battery charge at 20 e Light On Battery at 10 machine shuts down When the control cable is connected to the SmartControl transmitter the battery will automatically charge as needed Note f the transmitter battery is completely discharged neither the red LED nor green LED will illuminate Engine START pushbutton h Pushing this button causes the engine to crank An override prevents the engine from cranking if it is already running ON OFF toggle switch j Placing this switch in the O forward position causes the roller to stop all motion and the engine to shut down Placing this switch in the backward position supplies power to the SmartControl transmitter In this position the Power ON indicator green LED f illuminates Low vibration pushbutton k Pressing this button causes the vibration to come on in LOW High vibration pushbutton m
102. r first 50 hours of operation Drain oil while engine is still warm Note the interests of environmental protection place plastic sheeting and a container under the machine to collect the liguid which drains off Dispose of this liguid properly To change Remove oil filler cap a and oil drain plug c Drain oil into a suitable container Reinstall the drain plug and tighten Remove and replace oil filter b Remove oil filler cap a and fill engine crankcase with recommended oil See Technical Data for oil quantity and type Install oil filler cap 49 Maintenance 4 20 Air Cleaner wc_tx000419gb fm RT See Graphic wc_gr000968 4 20 1 4 20 2 4 20 3 Replace the air filter cartridge when the air filter warning light illuminates See Section Control Panel Features The air cleaner assembly contains a one piece single element air filter cartridge a To replace the air filter cartridge Remove the end cover b then discard the entire air filter cartridge Insert a new air filter cartridge then Re install the end cover making sure that the dust is clean and is pointing downward Periodically make sure the inlet pipe d is free from obstructions Check all connections and make sure they are snug An air leak at the neck clamp or intake pipe can quickly lead to expensive engine CAUTION ebalrs e sure that the intake piping e is fully engaged over the neck o
103. rcuit BOM 9026 SN 55461321 and lower BOM 9025 SN 5549417 and lower ra hull 2111 1 3000 PSI 1002132 wc_tx000418gb fm 1 00 RT SC Repair Hydraulic System BOM 9026 SN 55461322 and higher BOM 9025 SN 5549418 and higher P2 S1 S2 b rne OT a 3000 PSI m 01002789 wc_tx000418gb fm 1 0 1 Hydraulic System RT SC Repair 6 10 Steering Circuit BOM 9026 SN 55461321 and lower BOM 9025 SN 5549417 and lower 2 P2 S1 S2 3000 PSI 1 HEIN Fil a T 4 3500 PSI a a b 90 ml S wc_gr002133 wc_gr002134 wc 01002135 wc_tx000418gb fm 1 02 RT SC Repair Hydraulic System BOM 9026 SN 55461322 and higher BOM 9025 SN 5549418 and higher 01002790 01002791 wc 1002792 wc_tx000418gb fm 1 03 Hydraulic System RT SC Repair Notes wc_tx000418gb fm 1 04 RT SC Repair Hydraulic Troubleshooting 7 Hydraulic Troubleshooting 7 1 No Vibration Flowchart Checking power to and function of Does the machine operate in No high See Flowchart 6A With engine ON check operation of hydraulic high speed drive circuit Check outgoing signal from control box
104. re the flywheel to the engine using five screws Torque screws to 82 Nm 60 105 Remount exciter pump 168 RT SC Repair Disassembly Reassembly Procedures wc_tx000410gb fm 1 69 Rebuilding Control Box RT SC Repair 9 Rebuilding Control Box 9 1 wc_tx000410gb fm Removing Rebuilding Joysticks See Graphic wc_gr002189 9 1 1 9 1 2 9 1 3 9 1 4 9 1 5 9 1 6 9 1 7 9 1 8 9 1 9 9 1 10 9 1 11 9 1 12 Disassembly Remove the four T10 Torx screws a and pull the joystick from control box Disconnect the connector b Unscrew the cap c Remove the holding ring d and boot e Hemove the two T8 Torx screws f and remove the housing bottom cover with circuit board g Remove T6 Torx screws k and separate the circuit board from the housing bottom cover Remove the three T8 Torx screws h and remove the housing i Remove the brush assembly Reassembly Position the brush assembly into the indent 1 of the joystick Secure the housing to the joystick Secure the circuit board to the housing bottom cover and secure the assembly to the housing Attach the boot boot ring and cap to the joystick Connect the connector Secure the joystick to the control box 170 RT SC Repair Rebuilding Control Box wc gr 2188 wc tx000410gb fm 1 7 1 Rebuilding Control Box RT SC Repair 9 2 wc_tx000410gb fm Removing and Installing Circuit Boards See graphic wc_gr002182 9 2 1
105. remain aware of moving parts and keep hands feet and loose clothing away from the moving parts of the equipment 6 wc_si000080gb fm 1 2 12 1 2 13 1 2 14 1 2 15 1 2 16 1 2 17 1 2 18 1 2 19 1 2 20 Safety Information ALWAYS read understand and follow procedures in the Operator s Manual before attempting to operate the equipment 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 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 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 NEVER use accessories or attachments that are not recommended by Wacker Damage to equipment and injury to the user may result NEVER leave machine running unattended NEVER start a defective unit in need of service or repair NEVER operate the machine with the fuel cap loose or missing NEVER operate multiple rollers within 45 feet 14 meters of one another unless you are certain that each roller and its accompanying transmitter have been set to a different control channel than the other rollers transmitters being used within the area Refer to section Setting Control Channels for additional information Safety Informatio
106. rn the keyswitch and the control box ON OFF switch to the ON positions When checking the glow plug relay do so immediately after turning the ON OFF switch to the ON position during the glow plug warm up period 5 16 2 Slide the connector a down the spade of the relay just enough to allow a multimeter probe to contact the spades Or remove the connector completely 5 16 3 Check for 12V between the connector power lead and ground The power lead will be the pink wire with striping pink red on glow plug relay pink green on throttle relay and pink gray on power relay lf 12V is not measured check the wire for continuity and repair or replace the wire as needed Also check that the brown wire s provide a good ground for the relay Check the brown wire s for continuity Repair or replace the wires as needed 5 16 4 If the wire continuity is OK and 12V is still not measured the problem lies within the ECM engine control module or the wiring to the ECM Check the power into the ECM wc 7002215 wc tx000430gb fm 76 RT SC Repair Engine Starting Troubleshooting 5 17 Confirming a Malfunctioning Relay See Graphic wc_gr002330 If the power lead to the relay measures 12 Volts and the brown wire to the relay supplies a good ground confirm the relay is malfunctioning by 5 17 1 The power a throttle b and glow plug relays are identical Temporarily exchange the suspect relay power throttle or glow plug with one kn
107. s than the other the motor with the greatest flow is bad replace it If you observe a substantial flow from both case drain lines both motors are bad both motors wc 235 7 wc_tx000418gb fm 1 1 7 Hydraulic Troubleshooting RT SC Repair 7 14 No High Speed Travel Troubleshooting Flowchart 6A Checking power to and function of decoder module With machine ON and moving check outgoing signal from control box Does LED flash when attempting high speed travel Check condition of joystick brushes Are brushes OK Yes Replace brushes Yes Rebuild replace control box Call Wacker Service Replace button card Does button function gt No Check function of vibration properly button Removing amp testing control button circuit board exciter function Yes Yes Heplace exciter pump Call Wacker Service Checking solenoid lead Does solenoid LED illuminate Does wire No No Check continuity of have continuity solenoid lead Yes Yes Does solenoid function properly Replace solenoid Yes Replace drive motor Call Wacker Service wc_gr003247 wc_tx000418gb fm 1 1 9 RT SC Repair 8 Disassembly Reassembly Procedures 8 1 8 2 8 3 8 4 wc_tx000410gb fm Tools Disassembly Reassembly Procedures Because all possible problems encountered while repair
108. sembly Procedures RT SC Repair 8 10 8 11 wc_tx000410gb fm Installing Drums See graphic wc_gr002052 8 10 1 Lock articulated joint 8 10 2 Lift one end of the machine using an appropriate crane or hoist Insert jack stands x to support machine from underneath 8 10 3 Place the drum e on the drum support f and secure it to hub using six M16x55 screws d and washers Use Loctite 243 or equivalent on the screws and torque them to 210 Nm 154 ft lbs 8 10 4 Install the scrapers using M12 screws a Use Loctite 243 or equivalent on the screws and torque them to 120 Nm 88 t lbs Opening Drum See graphic wc_gr002347 8 11 1 Loosen the center hub nut a so that it is nearly off 2 3 threads remaining on Do so for both sides of the drum 8 11 2 Remove the scrapers and the drums See Section Removing Drums 8 11 3 Position the drum support slightly off the floor and support it with jack stands 8 11 4 Starting with the exciter side remove the outer ring of bolts b securing the slave hub assembly onto the drum support 8 11 5 Using three pusher bolts in position c gradually push the slave hub assembly off the drum support When the hub releases from the taper of the drive shaft a distinct pop will be heard Be sure to leave the center hub nut on the shaft 2 3 threads to prevent the hub assembly from popping off the drum 8 11 6 Once the slave hub assembly is free remove the hub nut
109. ssembly Reassembly Procedures 07002371 wc_tx000410gb fm 1 55 Disassembly Reassembly Procedures RT SC Repair 8 28 Replacing Hydraulic Pumps wc_tx000410gb fm See Graphic wc_gr002373 8 28 1 8 28 2 8 28 3 8 28 4 8 28 5 8 28 6 8 28 7 8 28 8 Removal Drain Hydraulic oil Remove hydraulic hoses a or b On drive pump remove nut and screws securing relay bracket Remove the four screws securing the pump to the engine and remove the pump Installation Secure pump to engine using four screws apply Loctite 243 or equivalent to screws and torque to 41 Nm 30 ft Ibs On drive pump secure relay bracket c Attach hydraulic hoses a or Fill hydraulic tank with oil 156 Disassembly Reassembly Procedures RT SC Repair wc 01002373 157 gb fm 1 000410 Disassembly Reassembly Procedures RT SC Repair 8 29 Replacing Hydraulic Oil Cooler wc_tx000410gb fm See Graphic wc_gr002374 8 29 1 9 29 2 8 29 3 8 29 4 8 29 5 8 29 6 8 29 7 8 29 8 8 29 9 Removal Drain hydraulic oil tank Disconnect the two hose clamps a securing the air intake hose b and remove the hose Disconnect the two hydraulic hoses c running to the cooler Plug the hoses immediately after disconnecting to prevent contamination of the hydraulic system Remove the four screws d securing the guard and remove the guard and hydraulic oil cooler as an assembly Disconnect th
110. t battery Remove screws securing faceplate and pull faceplate from machine Disconnect plug a from back of keyswitch b Remove retaining nut c and spacer and remove keyswitch Installation Secure keyswitch b to faceplate with spacer and retaining nut c Connect plug a to keyswitch Secure faceplate to machine 70 RT SC Repair Engine Starting Troubleshooting 5 10 Checking NiCad Battery Charge See Graphic 07002336 To check the charge of the NiCad battery remove the battery and check for voltage as shown A fully charged battery will have a minimum of 7 2 Volts To charge the battery 5 10 1 Plug the transmitter box into the charging jack on the machine for a minimum of 40 minutes When doing so check that the green charging LED illuminates indicating that a good connection has been made Note The charge connector is always on and connected to the machine s 12V battery 5 10 2 The low battery charge LED will flash red when the battery needs to be recharged A battery will need to be recharged when it reaches approximately 6 5Vdc 5 10 3 Replace the battery when it is only able to operate for three or four hours Do not allow a discharged battery to sit in the transmitter box Discard the battery if it shows signs of leaking gne do wc_tx000430gb fm 7 1 Engine Starting Troubleshooting RT SC Repair 5 11 Engine Cranks But Does Not Start Flowchart 2A Check fuel level engine oil lev
111. t down Coolant Temperature Light f The cooling temperature warning light illuminates when engine coolant temperature exceeds 230 F 110 C During such a condition the engine will automatically shut down Note Allow temperature to drop below 212 F 100 before attempting to restart Coolant Level Light g The cooling level warning light illuminates when coolant level is too low During such a condition the engine will automatically shut down Stability Light h The stability warning light illuminates when the pitch of the roller exceeds 45 The machine is equipped with safety switches that shut down the engine during such a condition Keyswitch j Turning the keyswitch to the ON position supplies power to the machine The green power on indicator k illuminates indicating power is on The keyswitch has an automatic shutoff feature that after 1 hour of non engine run time the electronics will power off To reset the machine turn the keyswitch to the O OFF position and then back to the I ON position Note The machine can be restarted within this 1 hour period if the transmitter is turned off and then on The glow plugs will be activated if needed All shutdown functions have the feature that when a fault is detected the warning light and red LED light rings will remain on after the machine shuts down until the fault is corrected and the keyswitch is turned to the O OFF position All shutdown
112. tch on the decoder module in the same position as that of the microswitch on the transmitter module 30 wc_tx000518gb fm 3 5 3 3 5 4 Operation To determine if the decoder module and the transmitter module are set to the same channel turn the key switch to the ON position and place the transmitter module s ON OFF toggle switch in the ON position The amber lights on the machine s light ring should blink at a slow rate indicating that the machine is receiving signals from the transmitter module If the amber lights illuminate but do not blink the transmitter module and the decoder module are not set to the same channel Try another position until the LEDs do blink Once set label the control channel setting on both the roller and its accompanying transmitter wc_gr003061 31 Operation 3 6 wc_tx000518gb fm Before Starting See Graphic wc_gr0003062 Before starting the machine check the following Engine oil level Hydraulic fluid level Condition of fuel lines Condition of air cleaner Fuel level Water level Scraper bars are clean and properly adjusted Check that the SmartControl transmitter module and the machine s decoder module are set to the same control channel Note All fluid levels should be checked with the machine a level surface Ensure that regular maintenance has been carried out wc_gr003062 32 RT 3 7 wc_tx000518gb fm
113. ts base and remove the valve and bracket as an assembly d Remove the valve block from the mounting bracket Installation Secure the valve block to the mounting bracket Position the valve block assembly d into the machine frame and secure it with four M12 screws and nuts Torque the screws to 86 Nm 63 ft lbs Secure the ground wires with screw c 8 25 10 Connect the green connector plug b to the decoder module 8 25 11 Replace all the hydraulic hoses a wc_tx000410gb fm 150 Disassembly Reassembly Procedures RT SC Repair 91002369 151 gb fm wc_tx000410 Disassembly Reassembly Procedures RT SC Repair 8 26 Replacing Fuel Tank wc_tx000410gb fm See Graphic wc_gr002370 9 26 1 9 26 2 9 26 3 9 26 4 9 26 5 9 26 6 8 26 7 8 26 8 8 26 9 8 26 10 8 26 11 Remove battery See Section Removing Battery Drain fuel tank Close cocks a on inlet and outlet lines at tank Remove inlet and outlet hoses at cocks Remove the two screws b on the upper side and the four screws c on the under side of the frame securing the tank Note Access to screws securing tank to frame is substantially improved by removing the drum Remove the screws securing the air cylinder d and remove the cylinder and the bracket Pull the fuel tank from the machine Installation Position the fuel tank into the machine under the hydraulic tank Secure the fuel tank with t
114. www wackergroup com 0160393en 004 Trench Roller RT 56 SC RT 82 SC REPAIR MANUAL 0 1 6 0 3 9 3 E N Foreword This manual covers machines with Item Number 0009025 0009026 Operating Parts Information You must be familiar with the operation of this machine before you attempt to troubleshoot or repair it Basic operating and maintenance procedures are described in the Operators Manual supplied with the machine Keep copy of the Operator s Manual with the machine at all times Use the separate Parts Book supplied with the machine to order replacement parts If you are missing either of the documents please contact Wacker Corporation to order a replacement Damage caused by misuse or neglect of the unit should be brought to the attention of the operator to prevent similar occurrences from happening in the future This manual provides information and procedures to safely repair and maintain the above Wacker model s For your own safety and protection from injury carefully read understand and observe all instructions described in this manual THE INFORMATION CONTAINED IN THIS MANUAL IS BASED ON MACHINES MANUFACTURED UP TO THE TIME OF PUBLICATION WACKER CORPORATION RESERVES THE RIGHT TO CHANGE ANY PORTION OF THIS INFORMATION WITHOUT NOTICE wc_tx000397gb fm Foreword CALIFORNIA Proposition 65 Warning Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known t

RT SC Repair Disassembly/Reassembly Procedures

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