Manual - Servicio Ingles - Wacker Rd12a

 

0170797en 0309

Roller

RD 12 RD 12A

REPAIR MANUAL

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RD 12/RD 12A

Foreword   This manual covers machines with Item Number:

0620058, 0620320, 0620369, 0620059, 0620321

Operating / Parts Information You must be familiar with the operation of this machine before you attempt to troubleshoot or repair it. Basic operating and maintenance procedures are described in the Operator’s Manual supplied with the machine. Keep a copy of the Operator’s Manual with the machine at all times. Use the separate Parts Book supplied with the machine to order replacement parts. If you are missing either of the documents, please contact Wacker Neuson 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 Neuson model(s). For your y our 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 NEUSON CORPORATION RESERVES THE RIGHT TO CHANGE ANY PORTION OF THIS INFORMATION WITHOUT NOTICE.

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Foreword

RD 12/RD 12A

CALIFORNIA Propositi on 65 Warning Warning :

WARNING

Engine exhaust, some of its constituents, and certain vehicle components, contain or emit chemicals known to the State of  California to cause cancer and birth defects or other reproductive harm.

All rights, especially copying and distribution rights, are reserved. Copyright 2009 by Wacker Neuson 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 Neuson Corporation. Any type of reproduction or distribution not authorized by Wacker Neuson Corporation represents an infringement of valid copyrights, and violators will be prosecuted. We expressly reserve the right to make technical modifications, even without due notice, which aim at improving our machines or their safety standards.

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RD 12/RD 12A 1

Safety Information 1.1 1. 1.2 2 1.3 1.4 1.5

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Operati Operating ng Safety Safety ....... .......... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ..... .. 10 Opera Operato torr Safe Safety ty whil while e us usin ing g In Inte tern rnal al Comb Combus usti tion on Engin Engines es .... ...... .... .... .... .... .... .. 12 Service Service Safety Safety ........ ........... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 13 Label Label Locatio Locations ns ... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ..... .. 15 Safety Safety and Operati Operating ng Labels Labels ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 16

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Operati Operation on and Servic Service e Locati Locations ons ..... ........ ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... 22 Contro Controll Panel Panel ...... ......... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 24 Vibrat Vibration ion ... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 26 Water Water Spray Spray System System ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ..... .. 27 Starti Starting ng ... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ..... .. 28 Stoppi Stopping/ ng/Par Parkin king g ..... ........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ... 30 Auxili Auxiliary ary Batter Battery y Positiv Positive e Termina Terminall ..... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 31

Hon onda da Engin ngine e Sta tart rtin ing g Sys yste tem m 3.1 3.2 3.2 3.3 3.4 3.5 3.6

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Operation 2.1 2.2 2.3 2.4 2.5 2.6 2.7

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Table of Contents

32

Checki Checking ng the 20A 20A Main Main Fuse Fuse ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 33 Chec Checki king ng Wiri Wiring ng to the the Sta Start rter er Sole Soleno noid id & Ant Antii-ba back ckfi fire re Sole Soleno noid id .... ...... 34 Checki Checking ng the Key Switch Switch ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... 36 Checki Checking ng the Crank Crank Relay Relay .... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... 37 Checki Checking ng the Neutra Neutrall Switc Switch h ...... ......... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... 38 Checki Checking ng the Neutra Neutrall Rela Relay y ...... ......... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 39

Wacker Neuson Engine Starting System 4.1 4. 4.2 2 4.3 4.4 4.5 4.6

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Checki Checking ng the 20A Main Main Fuse Fuse ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 41 Chec Checki king ng th the e Wiri Wiring ng to th the e St Star arte terr Sole Soleno noid id & AntiAnti-ba backf ckfir ire e Sole Soleno noid id 42 Checki Checking ng the Key Switch Switch ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... 43 Checki Checking ng the Crank Crank Relay Relay ... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 44 Checki Checking ng the Neutra Neutrall Switch Switch ...... ......... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... 45 Checking the Neutral Relay ...................... ................................... ............................ ............................. .............. 46

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Table of Contents 5

6

Drive System

Checki Checking ng the the Tow Valve Valve .... ....... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....49 .49 Adjust Adjusting ing the Drive Drive Contro Controll Cable Cable ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... .....50 ..50 Chec Checki king ng the the Drive Drive Syst System em Oper Operat atin ing g Pressu Pressure re ..... ....... .... .... .... .... .... .... .... .... .... .... .... .... ....5 ..51 1 Chec Checki king ng the the Drive Drive Syst System em Reli Relief ef Pres Pressu sure re .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ...52 .52 Checki Checking ng Drive Drive Motors Motors for Bindin Binding g ...... ......... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ..... ..... ...... ...... .....53 ..53

5. 5.6 6

Check Checkin ing g Oil Flo Flow w throu through gh the the Drive Drive Moto Motors rs ...... ........ .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ...55 .55

Vibration System and Steering

Chec Checki king ng the the Eng Engin ine e Spee Speed d and and Vibra Vibrati tion on Spe Speed ed .... ...... .... .... .... .... .... .... .... .... .... .... .... ....5 ..57 7 Troub Trouble lesh shoot ootin ing g a Syste System m that that Vib Vibrat rates es Poorl Poorly y .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... ....5 ..58 8 Checki Checking ng the Vibrat Vibration ion Soleno Solenoid id Valve Valve ....... .......... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... .....60 ..60 Checki Checking ng the the Vibr Vibrati ation on Switch Switch ... ...... ...... ...... ..... ..... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ..... ..... ...... ...... ...... ....61 .61

62

Checki Checking ng the Steeri Steering ng System System Hydrau Hydraulic lic Pre Press ssure ure ...... ......... ...... ...... ..... ..... ...... ...... ......6 ...62 2 Troub Troubles lesho hooti oting ng th the e Steer Steering ing System System ........ .......... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... .....63 ..63

Sp r ay Sy s t em 8.1 8.2 8.3 8.4

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St eer i n g Sy s t em 7.1 7.2

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5.1 5.2 5. 5.3 3 5. 5.4 4 5.5

6. 6.1 1 6. 6.2 2 6.3 6.4

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RD 12/RD 12A

64

Troub Troubles leshoo hootin ting g th the e Spray Spray System System ........ ........... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... .....64 ..64 Checki Checking ng Power Power to the Spray Spray Bar Pump Pump ...... ........ ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ......6 ...65 5 Checki Checking ng the Pump Pump Time Timerr Mod Module ule ...... ......... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ..... ..... ...... ...... .....66 ..66 Checki Checking ng the Spray Spray System System Switch Switch ...... ........ ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .....67 ..67

Disassembly & Assembly

68

9. 9.1 1 9.2 9. 9.3 3 9. 9.4 4

Tools Tools Requ Requir ired ed fo forr Di Disa sass ssem embl bly/ y/As Asse semb mbly ly Proce Procedur dures es .... ...... .... .... .... .... .... .... .... ...68 .68 Informa Informatio tion n Regard Regarding ing Replac Replaceme ement nt Parts Parts ...... ......... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ......6 ...68 8 In Info form rmat atio ion n Rega Regard rdin ing g Refe Referen rence ce Num Numbe bers rs ( ) .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ...68 .68 In Info form rmat atio ion n Regar Regardi ding ng Threa Threadl dlock ockin ing g Compo Compound unds s .... ...... .... .... .... .... .... .... .... .... .... .... .... ...68 .68

9.5 9.6

Removi Removing ng the Articu Articulat lating ing Joint Joint ..... ........ ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....69 .69 Installing the Articulating Joint ............................ ......................................... ............................ ....................70 .....70

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RD 12/RD 12A

Table of Contents

9.7 9.8 9. 9.9 9 9.10 9.1 0 9.11 9.1 1 9.12 9.1 2 9.13 9.1 3

Removi Removing ng the Rear Rear Drum Drum .... ....... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ... 71 Instal Installin ling g the Rear Rear Drum Drum ..... ........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ..... ..... ...... ...... ... 73 Remo Removi ving ng the the Bra Brake ke and and Brak Brake e Cabl Cable e .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 75 Instal Installin ling g the the Brak Brake e and and Brake Brake Cable Cable ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ..... .. 77 Removi Removing ng Rear Rear Drive Drive Motor Motor ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ..... .. 79 Instal Installin ling g the Rear Rear Drive Drive Motor Motor ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ... 81 Removi Removing ng the the Front Front Drum ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ..... .. 83

9.14 9.14 9.15 9.1 5 9.16 9.1 6 9.17 9.1 7 9.18 9.1 8 9.19 9.1 9 9.20 9.2 0 9.21 9.2 1 9.22 9.2 2 9.23 9.2 3 9.24 9.2 4

Instal Installin ling g the Front Drum Drum ... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ..... .. 85 Removi Removing ng the the Front Front Drive Drive Moto Motorr ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 87 Instal Installin ling g the the Front Front Drive Drive Moto Motorr ... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ... 88 Removi Removing ng the Exciter Exciter ... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ... 89 Instal Installin ling g the Exciter Exciter ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ..... .. 91 Disass Disassemb emblin ling g the the Excite Exciterr Bearin Bearings gs ...... ......... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ..... .. 93 Assembl Assembling ing the the Excite Exciterr Bearing Bearings s ........ ........... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ..... .. 95 Removi Removing ng the Contro Controll Cable Cable and Contro Controll Lever Lever ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ... 97 Instal Installin ling g the the Cont Control rol Cable Cable and and Contr Control ol Lever Lever ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 99 Removi Removing ng the the Exciter Exciter Pump Pump ... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 100 Instal Installin ling g the Exciter Exciter Pump Pump ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ..... 101

9.25 9.25 9.26 9.2 6 9.27 9.2 7 9.28 9.2 8 9.29 9.2 9 9.30 9.3 0 9.31 9.3 1 9.32 9.3 2 9.33 9.3 3 9.34 9.3 4

Removi Removing ng the Drive Drive Pump Pump ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ..... ..... ...... ...... ..... .. 102 Instal Installin ling g the Driv Drive e Pump Pump ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ..... ..... ...... ..... 103 Removi Removing ng the Engine Engine ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 104 Instal Installin ling g the Engine Engine ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ... 106 Removi Removing ng the the Steerin Steering g Valve Valve ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ..... ..... ...... ..... 108 Instal Installin ling g the Steerin Steering g Valve ... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 110 Removi Removing ng the Hydraul Hydraulic ic Tank Tank ... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 112 Instal Installin ling g the Hydra Hydrauli ulic c Tank Tank ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ..... 114 Removi Removing ng the the Fuel Fuel Tank Tank ... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ..... 116 Instal Installin ling g the Fuel Fuel Tank ... ...... ...... ...... ..... ..... ...... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ... 118

10 Schematics

120

10.1 10.1 10.2 10. 2 10.3 10. 3 10.4 10. 4 10.5 10. 5 10.6 10. 6 10.7 10. 7

Hydraul Hydraulic ic Schema Schematic tic ... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ... 120 Hydraul Hydraulic ic Schema Schematic tic Compon Component ents s ...... ......... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ... 121 Electr Electrica icall Schem Schemati atic c Ident Identifi ificat cation ion—RD —RD 12A .... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 121 Electr Electrica icall Schem Schemati atic c “A”—R “A”—RD D 12A 12A ...... ......... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ... 122 Electr Electrica icall Schemat Schematic ic “A” Compone Components nts—RD —RD 12A ...... ......... ...... ..... ..... ...... ...... ...... ...... ..... 123 Electr Electrica icall Schem Schemati atic c “B”—R “B”—RD D 12A 12A ...... ......... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ...... ..... ..... ...... ...... ... 124 Electr Electrica icall Schemat Schematic ic “B” Compone Components nts—RD —RD 12A ...... ......... ...... ..... ..... ...... ...... ...... ...... ..... 125

10. 10.8 8 10.9

Electr Electrica icall Schem Sc hemati atic—R c—RD D 12 ... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 126 Electrical Schematic Components—RD 12 ............................... .................. .................... ....... 127

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Table of Contents

RD 12/RD 12A

11 Technical Data

128

11.1 11.2 11.3 11.4 11.5

Engine ........ ............. ......... ........ ......... .......... ......... ......... .......... .......... ......... ......... .......... ......... ........ ......... ......... ........ ........ ......... ......128 .128 Roller Roller ........ ............ ......... .......... .......... ......... ......... .......... ......... ......... .......... ......... ......... .......... ......... ......... .......... ......... ......... ..........12 .....129 9 Lubrication Lubrication ......... ............. ........ ......... ......... ........ ........ ......... .......... ......... ......... .......... ......... ........ ......... ......... ........ ........ ......... ......129 .129 Dimensions Dimensions ......... .............. .......... ......... ......... .......... ......... ......... .......... ......... ......... .......... ......... ......... .......... ......... ......... .........130 ....130 Sound Measurements Measurements ......... ............. ......... .......... ......... ......... .......... ......... ........ ........ ......... .......... ......... ......... ........131 ...131

11.6 11.6 11.7

Measure Measuremen ments ts of Operat Operator or Exposur Exposure e to to Vibr Vibrati ation on ........ ........... ...... ...... ..... ..... ...... ......1 ...131 31 Hydraulic Pressures Pr essures ............................ .......................................... ............................ ............................. ..................132 ...132

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RD 12/RD 12A 1

Saf et y In f o r m at i o n

Saf et y IIn n f o r m at i o n This manual contains DANGER, WARNING, CAUTION, NOTICE and NOTE callouts which must be followed to reduce the possibility of  personal injury, damage to the equipment, or improper service.

This is the safety alert symbol. It safety is usedmessages to alert you potential personal injury hazards. Obey all thattofollow this symbol to avoid possible injury or death.

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. DANGER

WARNING indicates indica tes a hazardous situation which, if not avoided, could result in death or serious injury. WARNING

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION

NOTICE:   Used

without the safety alert symbol, NOTICE  indicates a situation which, if not avoided, could result in property damage.

Note:   Contains additional information important to a procedure. Note:  

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Safety Information 1.1

RD 12/RD 12A

Op er at i n g Sa Saf et y Notice:  State Health Safety Codes and Public Resources Codes Notice:  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.

WARNING

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Familiarity and proper training tr aining are required for the safe operation of the machine. Machines operated improperly or by untrained personnel can be hazardous. Read the operating instructions contained in this manual and the engine manual, and familiarize yourself with the location and proper use of all controls. Inexperienced Inexper ienced operators should receive instruction from someone familiar with the machine before being allowed to operate it.

1. 1.1.1 1.1

DO NOT NOT drive drive over over curbs curbs or or othe otherr une uneve ven n obje objects cts tha thatt wil willl resu result lt in tthe he machine and operator being shaken.

1. 1.1.2 1.2

DO NOT NOT atte attempt mpt to star startt the the mach machine ine when when stand standin ing g alon alongsi gside de it. it. Only Only start the engine when seated in the driver's seat and with the forward/ reverse control in the neutral position.

1.1.3 1.1 .3

Do not allow allow anyon anyone e to operate operate this equipme equipment nt witho without ut proper proper training training.. People operating this equipment must be familiar with the risks and hazards associated with it.

1. 1.1.4 1.4

Do not not tou touch ch the the eng engine ine or muf muffle flerr while while the engin engine e is on or  or  immediately after it has been turned off. These areas get hot and may cause burns.

1. 1.1.5 1.5

Do not not use use acce accesso ssorie ries s or atta attachm chment ents s that that ar are e not not recom recommen mende ded d by Wacker Neuson. Damage to equipment and injury to the user may

1.1. 1.1.6 6

result. NEVE NEVER R leav leave e the the mach machin ine e runn runnin ing g un unat atte tend nded ed..

1. 1.1.7 1.7

NEVER NEVER ope operat rate e the the mach machine ine with with th the e fuel fuel cap cap loos loose e or m miss issing ing..

1. 1.1.8 1.8

NEVER NEVER car carry ry pas passen senger gers s on the machin machine. e. Danger Danger of cru crush shing ing—ke —keep ep clear of the articulated steering joint joi nt between the front and rear frames.

1. 1.1.9 1.9

NEVER NEVER use use or or attem attempt pt to to repa repair ir d dama amage ged d sa safe fety ty belt belts s or ROPS. ROPS. Replace only with Wacker Neuson spare parts.

1.1.10 1.1 .10

ALWAYS ALWAYS diseng disengage age and and stow stow the locki locking ng bar bar for the the articu articulate lated d steering joint before operating the machine. The machine cannot be steered when the locking bar is engaged.

1.1.11 1.1 .11

ALWAYS ALWA YS check chec k that alloperate control controls s are functi functionin oning g properly prop immed immediate iately ly after start-up! DO NOTall the machine unless all erly control controls s operate correctly.

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RD 12/RD 12A

Saf et y In f o r m at i o n

1.1.12 1.1. 12

ALWAYS ALWAYS remain remain aware aware of chan changing ging posit positions ions and and the the movemen movementt of  other equipment and personnel on the job site.

1.1.13 1.1. 13

ALWAYS ALWAYS remain remain seated seated and wear the seat seat belt belt at at all times times while while operating the machine.

1.1.14 1.1. 14

ALWAYS ALWAYS remain remain aware aware of chang changing ing surfa surface ce conditi conditions ons and and use extra extra care when operating over uneven ground, on hills, or over soft or  coarse material. The machine could shift or slide unexpectedly.

1.1.15 1.1. 15

ALWAYS ALWAYS use cautio caution n when oper operatin ating g the ma machin chine e near the the edges edges of  pits, trenches or platforms. Check to be sure that ground surface is stable enough to support the weight of the machine with operator and that there is no danger of the roller sliding, falling or tipping.

1.1.16 1.1. 16

ALWAYS ALWAYS wear prote protectiv ctive e clothin clothing g app approp ropriat riate e to the job job site site when when operating the machine.

1.1.17 1.1. 17

ALWAYS ALWAYS keep hand hands, s, feet, feet, and loose loose cloth clothing ing aw away ay from from moving moving parts parts of the machine.

1.1.18 1.1. 18

Read, Read, understa understand, nd, and and follow follow procedu procedures res in the the Operato Operator’s r’s Manual Manual before attempting to operate the machine.

1.1.19 1.1. 19

Store Store the machi machine ne proper properly ly when when it is not not being being used. used. The The machine machine should be stored in a clean, dry location out of the reach of children. Always Always operate operate the machin machine e with all all safety safety devic devices es and and guards guards in place and in working order.

1.1.20 1.1. 20 1.1.21 1.1. 21

ALWAYS ALWAYS be sure sure that that all other other pers persons ons are are at a safe safe distan distance ce from from the machine. Stop the machine if people step into the working area of the machine.  

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Safety Information 1.2

RD 12/RD 12A

Ope pera rator tor S Sa afe fety ty whi while le using Inte nterna rnall C Combus ombustion tion E Engine ngines s

WARNING

Internal combustion engines present special hazards during operation and fueling. Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. Failure to follow the warnings and safety standards could result in severe injury or death.

1.2. 1.2.1 1

Do not not s smo moke ke whil while e ope opera rati ting ng the the mach machin ine. e.

1.2. 1.2.2 2

Do not not s smo moke ke when when refu refuel elin ing g the the engi engine ne..

1.2. 1.2.3 3

Do not not ref refue uell a hot hot or or rrun unni ning ng engi engine ne..

1.2. 1.2.4 4

Do not not ref refue uell the the eng engin ine e nea nearr an open open flam flame. e.

1.2. 1.2.5 5

Do not not spi spill ll ffue uell when when refu refuel elin ing g the the eng engin ine. e.

1.2. 1.2.6 6

Do not not run run the the eng engin ine e nea nearr ope open n ffla lame mes. s.

1. 1.2.7 2.7

Do not not run run the the mac machin hine e indoo indoors rs or or in an an enclo enclose sed d area area suc such h as a deep deep trench unless adequate ventilation, through such items as exhaust fans or hoses, is provided. Engine exhaust contains conta ins carbon monoxide. This is a poison you cannot see or smell. Exposure to carbon monoxide can cause loss of consciousness and CAN KILL YOU IN

1.2. 1.2.8 8

MINUTES. Refi Refill ll the the fue fuell tank tank in in a well well-v -ven enti tila late ted d area area..

1.2. 1.2.9 9

Repl Replac ace e the the fuel fuel tan tank k cap cap afte afterr refu refuel elin ing. g.

1.2.10 1.2 .10

ALWAYS ALWAYS keep the the area area around around a hot hot exhaus exhaustt pipe ffree ree of of debr debris is to reduce the chance of an accidental fire.

1.2.11 1.2 .11

ALWAYS ALWAYS check check the fuel fuel lines lines and and the fuel fuel tank tank for leaks leaks and crack cracks s before starting the engine. Do not run the machine if fuel leaks are present or the fuel lines are loose.  

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12

 

RD 12/RD 12A 1.3

Saf et y In f o r m at i o n

Ser v vii c e Saf et y  A poorly maintained maintained machine can become a safety hazard! In order  for the machine to operate safely and properly over a long period of  time, periodic maintenance and occasional repairs are necessary. WARNING

1.3.1 1.3 .1

Some Some serv service ice proce procedur dures es requ require ire that that the machin machine’s e’s batt battery ery be disconnected. To reduce the risk of personal injury, read and understand the service procedures before performing any service to the machine.

1.3.2 1.3 .2

All ad adjus justme tment nts s and and repai repairs rs MUST MUST be be compl complete eted d befor before e oper operati ation on.. Do not operate the machine with a known problem or deficiency! All repairs and adjustments should be completed by a qualified technician.

1. 1.3.3 3.3

Do not not atte attempt mpt to clea clean n or ser servic vice e th the e mach machine ine while while itit is runn runnin ing. g. Rotating parts can cause severe injury.

1.3.4 1.3 .4

Do not not cra crank nk a flood flooded ed eng engine ine with with th the e spark spark plug plug remov removed ed on on gasoline-powered engines. Fuel trapped in the cylinder will squirt out

1. 1.3.5 3.5

1. 1.3.6 3.6

Do not not use use gas gasoli oline ne or or other other typ types es of of fuels fuels or flam flamma mable ble solven solvents ts tto o clean parts, especially in enclosed areas. Fumes from fuels and solvents can become explosive.

1. 1.3.7 3.7

Do not not modify modify the the mach machine ine with without out the the expr express ess writ writte ten n appro approval val of of the manufacturer.

1. 1.3.8 3.8

DO NOT NOT stan stand d under under the machin machine e while while it is being being hoi hoiste sted d or move moved. d.

1. 1.3.9 3.9

DO NOT NOT get get onto onto the the mach machin ine e while while it is is be being ing ho hoist isted ed or or move moved. d.

1.3.10 1.3. 10

DO NOT use use the machin machine e as a ladde ladder. r. Use safe safe ladder ladders s and platf platforms orms designed for this purpose.

1.3.11 1.3. 11

DO NOT modify, modify, weld, weld, or or drill drill safety safety frames frames (ROPS) (ROPS) fitted fitted as as original original equipment. DO NOT loosen or remove bolts. DO NOT weld, drill or  modify a broken safety frame.

1.3.12 1.3. 12

DO NOT open open the hydrau hydraulic lic lines lines or loosen loosen the the hydraul hydraulic ic connect connections ions while the engine is running! Before dismantling the hydraulic connectors or hoses, ensure that all pressure has been bled from the circuit. Hydraulic fluid under pressure can penetrate the skin, cause burns, blind, or create other personal injury hazards. Set all controls in neutral, turn engine off, and allow the fluids to cool before loosening

1.3.13 1.3. 13

wc_si000302gb.fm

the spark plug opening. Do not not test test for spa spark rk on gas gasoli oline ne-po -power wered ed en engi gines nes ifif the eng engine ine iis s flooded or the smell of gasoline is present. A stray spark could ignite the fumes.

hydraulic fittings or attaching test gauges. ALWAYS ALWAYS check check all all externa externall fastene fasteners rs at regul regular ar interv intervals. als.

13

 

Safety Information 1.3.14 1.3 .14

Keep the the area area around around the muffl muffler er free free of debris debris such such as le leaves aves,, pape paper, r, cartons, etc. A hot muffler could ignite the debris and start a fire.

1.3.15 1.3 .15

Replace Replace worn worn or damage damaged d componen components ts with spare spare parts parts desig designed ned and and recommended by Wacker Neuson Corporation.

1.3.16 1.3 .16

Disconn Disconnect ect the the spark spark plug on on machines machines equip equipped ped with with gasoli gasoline ne engines, before servicing, to avoid accidental start-up.

1.3.17 1.3 .17

Keep the the machine machine clean clean and and labels labels legibl legible. e. Replace Replace all all missing missing and and hard-to-read labels. Labels provide important operating instructions and warn of dangers and hazards.

1.3.18 1.3 .18

ALWAYS ALWAYS do periodi periodic c maintenan maintenance ce as recomm recommende ended d in the Operat Operator’s or’s Manual.

1.3.19 1.3 .19

ALWAYS ALWAYS turn the the engine engine off before before perfo performin rming g mainten maintenance ance or or making making repairs.

1.3.20 1.3 .20

ALWAYS ALWAYS keep keep hands, hands, feet feet and loose loose clothi clothing ng awa away y from movin moving g parts. parts.

1.3.21 1.3 .21

ALWAYS ALWAYS make sure sure sling slings, s, chains, chains, hook hooks, s, ram ramps, ps, jacks jacks and and other  other  types of lifting devices are attached securely and have enough weightweight bearing capacity to lift or hold the machine safely. Always remain aware of the location of other people in the area when lifting the machine.

1.3.22 1.3. 22

ALWAYS ALWAYS make sure hose connecti connections ons have have been been rrecon econnec nected ted ba back ck to the correct fitting. Failure to do so may result in damage to the machine and/or injury to person on or near the machine.

1.3.23 1.3 .23

ALWAYS ALWAYS secure secure the articu articulate lated d stee steering ring joint joint using using the the locking locking bar  bar  before lifting, jacking, and servicing the machine. The machine halves could swing together unexpectedly and cause a serious injury.

1.3.24 1.3 .24

ALWAYS ALWAYS lock the the lifting lifting cylinde cylinders rs in the the open posit position ion when when the seat seat pedestal is raised.

1.3.25 1.3 .25

Before Before you start start the the machine, machine, ensu ensure re tha thatt all tools tools have have been remov removed ed from the machine and that replacement parts and adjusters are firmly tightened. Fluid Fluid leaks leaks from small small holes holes are are often often practic practically ally in invisi visible. ble. DO DO NOT use your bare hands to check for leaks. Check for leaks using a piece of  cardboard or wood.

1.3.26 1.3 .26

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RD 12/RD 12A

14

 

RD 12/RD 12A 1.4

Saf et y In f o r m at i o n

L ab el L o c at i o n s

FF

X

wc_si000302gb.fm

15

 

Safety Information 1.5

RD 12/RD 12A

Safe fety ty and Ope pera rati ting ng L La abels bels Wacker Neuson machines use international pictorial labels where needed. These labels are described below:

Ref.

Label

Meaning

A

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

B

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

C

Tie-down point

E

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

F

wc_si000302gb.fm

WARNING! Pinch point.

16

 

RD 12/RD 12A Ref.

Saf et y In f o r m at i o n

Label

Meaning

G

WARNING! Hot surface!

H

WARNING! Hot surface!

I

Hydraulic oil reservoir fill tube. Torque nuts to 13.6-14.7 Nm (120-130 in.lbs.) maximum.

J

CAUTION Lifting point.

K

WARNING! To prevent hearing loss, wear hearing protection when operating this machine.

M

WARNING! Disconnect battery before servicing. Read Repair Manual for instructions. Battery contains caustic acid and potentially explosive hydrogen gas.

WARNING

N

wc_si000302gb.fm

WARNING!  Always wear seat belt belt when operating operating roller.

17

 

Safety Information Ref.

RD 12/RD 12A

Label

Meaning Choke: 0 = Open

T

l = Closed

U

Grease points: Inspect and lubricate every 100 hours of operation.

V

WARNING!  Avoid crushing crushing area. area.  Articulated  Articulate d steering steering joint joint locking locking location. location. Lock the articulated steering joint before servicing the machine. Read Repair Manual.

W

Engine will stop without operator seated.

X

Guaranteed sound power level in dB(A).

wc_si000302gb.fm

18

 

RD 12/RD 12A Ref.

Saf et y In f o r m at i o n

Label

Meaning

Y

 A nameplate nameplate listing the model model number, number, item number, revision number, and serial number is attached to each unit. Please record the information found on this plate so it will be available should the nameplate become lost or damaged. When ordering parts or requesting service information, you will always be asked to specify the model number, item number, revision number, and serial number of the unit.

Z

No lift point.

CC

CAUTION! Electric shock hazard at auxiliary battery positive terminal. Never touch this terminal and a metal portion of the machine simultaneously.

DD

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

EE

wc_si000302gb.fm

Water tank

19

 

Safety Information Ref.

RD 12/RD 12A

Label

Meaning

FF

wc_si000302gb.fm

This machine may be covered by one or more patents.

20

 

RD 12/RD 12A

Saf et y In f o r m at i o n

Notes

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21

 

Operation 2

RD 12/RD 12A

Operation 2. 2.1 1

Opera perattio ion na and nd Se Serv rvic ice eL Loc oca atio ions ns See Graphic: wc_gr002946

Ref.

Description

Ref.

Description

1

Air cleaner

24

Operator’s platform

2

Articulated joint

25

Engine oil filter

3

Hand holds

26

Rear drum fill/drain plug

4

Control panel

27

Rear drum—static

5

Dipstick

28

Scraper bar (4 places)

6

Drain hose—hydraulic tank

29

Sightglass—hydraulic tank

7

Drive motor

30

Sprinkler tube (2)

8

Drive pump

31

Steering wheel

9

Engine hood

32

Steering cylinder (under floor panel)

10

Vibration control button

33

Tiedown (2 places)

11

Exciter motor

34

Beacon light (optional)

12

Exciter/Steering pump

35

Battery (under floor panel)

13

Hydraulic filter—return line

36

Hydraulic suction line

14

Hydr Hydrau auli lic c st stra raiiner— ner—su suct ctio ion n lin ine e

37

Grea Grease se fitt fittiing—e ng—exc xcit iter er (2 pl plac aces es))

15

Forward / Reverse control

38

Lifting eye (4 places)

16

Front drum—vibratory

39

ROPS

17

Fuel tank fill cap

40

Seat with seatbelt

18

Fuel filter

41

Water drain

19

Grea Grease se fit fitti ting ngs— s—ar arti ticu cula late ted d join jointt (4 places)

42

Parking brake

20

Hydraulic tank fill port

43

Tow valve

21

Hydraulic manifold block

44

Choke lever

22

Water tank fill cap

45

Auxiliary battery positive terminal

23

Lockarm

wc_tx000865gb.fm

-

22

---

 

Operation 2.2

RD 12/RD 12A

Control Panel See Graphic: wc_gr004114

  Ref. Description

Ref. Description

47

Hour meter

55

Ignition switch

50

Vibration ON indicator

56

Low fuel indicator

53

Li Ligh ghts ts swit switch ch - ON ON and and OFF OFF (if equipped)

61

Wate Waterr spr spray ay swit switch ch - ON ON and and OFF OFF

54

Throttle switch - HIGH and LOW

62

Water spray dial

wc_tx000865gb.fm

24

 

RD 12/RD 12A

Operation

50

56 47

62

54

53

61

55

wc_gr004114

wc_tx000865gb.fm

25

 

Operation 2.3

RD 12/RD 12A

Vibration See Graphic: wc_gr002955

The vibration is turned ON or OFF by a push button (10) located on the forward/reverse control (15) (15).. Press the button to turn vibration ON; press it again to turn it OFF. The vibration ON indicator (50)  will light (50) will when vibration is on. The vibration can be turned on while operating in either forward or reverse and will remain on until it is turned off. On the RD 16, select either the front drum vibration or dual drum vibration by pressing the vibration switch (63)  on the control panel. (63) on CAUTION: If the machine has been turned off with the vibration on, the CAUTION: If vibration will come on as soon as the machine is restarted. Therefore, for easier starting and to keep the surface finish smooth, be ready to switch vibration off should it come on while cranking the engine. Note: The vibration will remain on even when the forward/reverse control (15) is in NEUTRAL. When operating on asphalt and in order  to keep the surface finish smooth, turn the vibration off before stopping the roller.

F

N

R

10 50 15

63 wc_gr002955

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26

 

RD 12/RD 12A 2.4

Operation

Water Spray System See Graphic: wc_gr002946, wc_gr003638

Water from the tank is fed to the spray bars by an electric pump. The flow of the water is controlled by a switch and a rotary dial. Press the upper half of the water spray switch (61) switch (61) to  to turn the water pump on. Turn the water spray dial  dial  (62)  (62)  clockwise to increase the spray frequency. Turn the water spray dial counter-clockwise to decrease the spray frequency. Press the lower half of the water spray switch (61) switch  to turn the water pump off.  (61) to Only use clean water. Dirty water, even when filtered, will rapidly clog the tubes of the spraying equipment. During winter, or when temperatures drop to below 0°C (32°F), drain the water tank and spraying equipment. Run the water pump to remove excess water from the system. Drain the water through the water drain plug (41) (41)   located near the bottom of the rear frame, through the sprayer end plugs, and the water filter. Freezing water may cause broken hoses, filters and water pumps and may deform the water tank.

62

61

wc_gr003638

wc_tx000865gb.fm

27

 

Operation 2.5

RD 12/RD 12A

Starting See Graphic: wc_gr002951

Exhaust gases are toxic. Do not start the engine in an enclosed space. WARNING

2. 2.5. 5.1 1 2.5. 2. 5.2 2

Si Sitt down down in in the the opera operato tor’ r’s s seat seat and and fast fasten en the the sea seatt belt belt.. Set Set th the e fo forw rwar ard/ d/re reve vers rse e cont contro roll (15)  in the neutral position.  (15) in

2. 2.5. 5.3 3

If th the e eng engin ine e is is col cold, d, move move th the e chok choke e lev lever er (44) (44)   to the left into the CLOSED position. If the engine is warm, move the choke control to the right in the OPEN position. Note:  The roller will not start unless the forward/reverse control is in Note:  the NEUTRAL position.

2. 2.5. 5.4 4

Chec Check k tha thatt the the park parkin ing g bra brake ke (42) (42)   is set. To set the brake, pull the brake lever up until the brake pad engages the drum. To release the brake lever, lower the lever. Always set the parking brake before leaving the machine.

2. 2.5. 5.5 5

Turn Turn the igni gniti tion on swit switch ch (55)  to start the engine. If the vibration indicator (55) to light (50)  is on, turn the vibration off by pressing the vibration control (50) is button (10). NOTICE : Do

not crank the engine starter for more than 15 seconds at one time. Longer cranking cycles could lead to starter damage.

Note: The ignition switch has an anti-restart an ti-restart feature. If the engine does not start, the switch will need to be turned to the OFF position before it  will allow the engine to be cranked again. 2.5.6 2.5 .6

Gradual Gradually ly place place the the choke choke lever lever in in the the OPEN OPEN positi position on as as the the engin engine e warms up. Allow the engine to warm up for a few minutes before operating the roller.

2.5.7 2.5 .7

Before Before moving moving the machin machine, e, rele release ase the parking parking brake brake by loweri lowering ng the the brake lever.

2.5.8 2.5 .8

Quickl Quickly y press press and release release the upper upper half half of the thrott throttle le switch switch (54)  to (54) to bring the engine to high throttle. Prolonged exposure to high noise levels can damage your hearing. Wear appropriate hearing protection while operating the roller.

WARNING

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28

 

RD 12/RD 12A

Operation

F

55

N

R

10 15

54

42 44

wc_gr002951

wc_tx000865gb.fm

29

 

Operation 2.6

RD 12/RD 12A

Stopping/Parking See Graphic: wc_gr002953

2.6.1 2.6 .1

Stop Stop the the machin machine e on on a flat flat surf surface ace with with a suitab suitable le load load beari bearing ng capacity.

2.6.2 2.6 .2

Turn Turn the the vibrat vibration ion off by pressin pressing g the the vibrat vibration ion control control button button (10)  on n (10) o

2. 2.6. 6.3 3

the forward/reverse lever (15) (15).. Pr Press ess th the e wate waterr spray spray swit switch ch to to the the O OFF FF pos posit itio ion n (61) (61)..

2.6. 2. 6.4 4

Set Set th the e fo forw rwar ard/ d/re reve vers rse e con contr trol ol (15) to the NEUTRAL position.

2.6.5 2.6 .5

Return Return the engine engine throt throttl tle e to idl idle e by pressin pressing g the the lower lower half half of the throttle switch (54)  and allow the engine to cool down. (54) and

2.6.6

Set the par parking bra rak ke (42) (42).. To set the parking brake, pull the brake lever up until the brake pad engages the drum. To release the brake, lower the brake lever. Always set the parking par king brake before leaving the machine. Note: The parking brake engages the rear drum only .

2. 2.6. 6.7 7

St Stop op th the e eng engin ine e by by tur turnin ning g the the ig igni niti tion on swit switch ch (55)  to the OFF position. position. (55) to If the vehicle constitutes a hazard or obstacle to traffic when parked, it should be marked with signs, lights, and other warnings.

WARNING

If the machine must be parked on a sloping surface, chock the drums with wedges to prevent any vehicle movement.  

F 55

N

R

10 15

54

42 61

wc_gr002953

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30

 

RD 12/RD 12A 2.7 2.7

Operation

Auxi Auxili liar ary yB Bat atte tery ry Posi Positi tive ve Te Term rmin inal al This machine is equipped with an auxiliary battery positive terminal (45) located (45)  located on top of the hydraulic tank (RD 12) or above the battery disconnect stud (RD 16). CAUTION! Electric shock hazard. Never touch this terminal and a metal portion of the machine simultaneously. CAUTION

45

wc_gr004357

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31

 

Ho n d a En g i n e St ar t i n g Sy s t em 3

RD 12/RD 12A

Hon onda da Engin ngine e Sta tart rtin ing g Sys yste tem m

Prerequisites

Sequence

 



Before troubleshooting engine starting issues, check the battery and the cable connections to the battery. The battery must be fully charged (approximately 12V).

Complete the troubleshooting in the following sequence: 1. Chec Check k the the 20 20A A mai main n fuse fuse.. 2. Check the the wiring wiring to the starter starter solenoi solenoid d and to the anti-ba anti-backfir ckfire e solenoid. solenoid. 3. Chec Check k tthe he key key s swi witc tch. h. 4. Chec Check k the the cr cran ank k rela relay y. 5. Chec Check k the the ne neut utra rall swit switch ch.. 6. Chec Check k the the ne neut utra rall rela relay y.

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32

 

RD 12/RD 12A 3.1

Ho n d a En g i n e St ar t i n g Sy s t em

Che hec ck kii n ng g th he e 20A Mai n Fus use e

Prerequisites Background

 



Key switch in OFF position.

There are three 20A fuses protecting the circuits in the RD 12:  

Main electricals Voltage Volt age regulator circuit



Optional light circuit Procedure

Follow the procedure below to check the 20A main fuse. 1. Ope Open n the ho hood od and and locate locate the the fuse fuse carri carrier er (a).

2. Remove Remove the protective protective cover from the the fuse fuse carrier carrier.. 3. Che Check ck the the condi conditio tion n of the the 20A 20A main main fuse fuse (b) . Is the 20A fuse OK? Yes ____

No ____

 

Continue

Replace the 20A main fuse with one of same size and rating.

4. Re-install Re-install the the 20A main main fuse and the the protective protective cover cover to the the fuse carrier carrier.. The 20A main fuse has now been checked.

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33

 

Ho n d a En g i n e St ar t i n g Sy s t em 3.2

RD 12/RD 12A

Che hecking cking Wiring to th the e Sta tarte rterr S Sole olenoid noid & Anti Anti--ba backfi ckfire re Sole olenoid noid

Prerequisites Background

 



Fully-charged (approximately 12V) battery

Black wire #20 delivers 12VDC to the starter solenoid when the key is in the START ST ART position. If this wire is broken or disconnected, the engine will not crank. The black/yellow wire delivers 12VDC to the anti-backfire solenoid when the key is in the ON or START positions. If this wire is broken or disconnected, the engine will not start.

Procedure

Follow the procedure below to check the wiring to the starter solenoid and to the anti-backfire solenoid. 1. Open the the hood and locate locate the the starter/ starter/star starter ter solenoid solenoid (a).

a

b

wc_gr003920

2. Check the conditi condition/c on/connect onnection ion of black wire #20 (b)  to the starter solenoid. Is the wiring OK? Yes ____

No ____

 

Continue

Reconnect or repair black wire #20.

3. Check the the condition/c condition/connect onnection ion of the black/yel black/yellow low wire to the anti-ba anti-backfir ckfire e solenoid. Is the wiring OK? Yes ____ The wiring is OK.

No ____   Reconnect or repair black/yellow wire.

This procedure continues on the next page.

wc_tx000693gb.fm

34

 

RD 12/RD 12A

Ho n d a En g i n e St ar t i n g Sy s t em

Continued from the previous page. 4. If the engine engine still still won’t start start but but cranks, cranks, remove remove the anti-bac anti-backfire kfire solenoid solenoid (c)   and clean the valve portion of it with carburetor cleaner. Re-install it and try to start the engine.

The wiring to the starter solenoid and anti-backfire solenoid has now been checked.

wc_tx000693gb.fm

35

 

Ho n d a En g i n e St ar t i n g Sy s t em 3.3

RD 12/RD 12A

Ch ec k i n g tth h e K ey S Sw witch

Prerequisites

 

  

Multimeter  Fully-charged (approximately 12V) battery Functioning 20A main fuse

Background

The key switch is a three-position switch: ON, START, and OFF. When in the START position, the key switch directs battery voltage to the crank relay.

Procedure

Follow the procedure below to check the key switch. 1. Remove Remove the s screws crews that se secure cure tthe he plate plate (a) to the back of the control panel and remove the plate.

2. Using the multimeter, multimeter, check the voltage between the BAT BAT terminal (b)  of the key switch and ground. For easier measuring, remove the plug and measure voltage at the plug.

Is battery voltage (approximately 12V) measured? Yes ____

No ____

 

Cont ontinu inue

Check eck the the co cont ntin inui uity ty of re red dw wir ire e# #13 13 be betw twee een n tthe he ke key y sw switch itch and and 20A main fuse. Repair red wire #13 as needed.

3. Place the the key swi switch tch in the S ST TART posiposition. 4. Re-install Re-install the plug plug to the key key swit switch. ch.

5. Check the voltage voltage between between the the “S” terminal (c)  of the key switch and ground.

Is battery voltage (approximately 12V) measured? Yes ____

N o ____

The key switch is OK.

The key switch has failed; replace it.

6. Re-install Re-install th the e plate to tthe he back of the the control control console. console. The key switch has now been checked. wc_tx000693gb.fm

36

 

 

RD 12/RD 12A 3.4

Ho n d a En g i n e St ar t i n g Sy s t em

Ch e ec c k i ng ng tth h e Cr a an n k Rel ay

Prerequisites

 

   

Multimeter  Fully-charged (approximately 12V) battery Functioning 20A main fuse Functioning key switch

Background

The coil of the crank relay is energized when the key switch is in the START START position.

Procedure

Follow the procedure below to check the crank relay. 1. Ope Open n the ho hood od and and locate locate the the crank crank rela relay y (a) .

2. Check the the voltage voltage between between terminal terminal 30 (red (red wire #38) and and ground. ground. This test test may be done at the plug (b) with it disconnected from the crank relay. relay. Is battery voltage (approximately 12V) measured? Yes ____

No ____

 

Continue

Repair red wire #38.

3. With the key key switch in the START START positio position, n, check the the voltage voltage between terminal terminal 86 (black wire #04) and ground. This test may be done at the plug  (b)  with it disconnected from the crank relay. relay. Is battery voltage (approximately 12V) measured? Yes ____

No ____

 

Continue

Repair black wire #04.

4. With the key key switch in the START START positio position, n, check the the voltage voltage between terminal terminal 87 and ground (red wire #35). For this test, the plug (b) must be connected to the crank relay. Position Position the plug as shown to allow access to terminal 87. Is battery voltage (approximately 12V) measured? Yes ____

No ____

The crank relay is OK.

The crank relay has failed; replace it.

The crank relay has now been checked. wc_tx000693gb.fm

37

 

 

Ho n d a En g i n e St ar t i n g Sy s t em 3.5

RD 12/RD 12A

Che hec ck kii n ng g th he e Neut utra rall Sw iitt ch ch

Prerequisites

 

    

Multimeter  Fully-charged (approximately 12V) battery Functioning main fuse Functioning key switch Seat platform in raised position. See section Rear Frame Access.

Background

The neutral switch, when closed (control lever in NEUTRAL position), allows voltage to the neutral relay.

Procedure

Follow the procedure below to check the neutral switch. 1. Loca Locate te the the con conne nect ctor or (a) for the neutral switch and disconnect it.

2. Place the contro controll lever lever in the NEUTR NEUTRAL AL positi position. on. 3. With the key key switch switch in the START START positio position, n, check the the continuity continuity between between the pins of the connector (green and white wires). Is there continuity? Yes ____

N o ____

 

Continue

The neutral switch has failed; replace it.

4. Place the the control control lever in in the FORWA FORWARD RD or REVER REVERSE SE posi position. tion. 5. With the key key switch switch in the START START positio position, n, check the the continuity continuity between between the pins of the connector (green and white wires). Is there continuity? Yes ____

N o ____

The neutral switch has failed; replace it.

Continue

 

6. Repeat Repeat the test test with with the control control lever lever in the REVER REVERSE SE pos position ition.. Is there continuity? Yes ____

N o ____

The neutral switch has failed: replace it.

The neutral switch is OK.

7. Reco Reconn nnec ectt the the wiri wiring ng.. 8. Low Lower er and and secur secure e the seat seat pla platf tform orm.. The neutral switch has now been checked.

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38

 

 

RD 12/RD 12A 3.6

Ho n d a En g i n e St ar t i n g Sy s t em

Che hec ck kii n ng g the the Neut utra rall R Re el ay ay

Prerequisites

 

    

Multimeter  Fully-charged (approximately 12V) battery Functioning 20A main fuse Functioning crank relay Functioning neutral switch

Background

The neutral relay relays battery voltage to the starter solenoid.

Procedure

Follow the procedure below to check the neutral relay. relay. 1. Ope Open n the ho hood od and and locate locate the the neutr neutral al relay relay (a). a b

30

85

R 35 86

B 31

87

wc_gr003918

B 20

2. Place the key key switch switch in the the START START position. position. 3. Check the the voltage voltage between between terminal terminal 30 (red (red wire #35) and and ground. ground. This test test may be done at the plug (b)  with it disconnected from the neutral relay relay.. Is battery voltage (approximately 12V) measured? Yes ____

No ____

 

Continue

Repair red wire #35.

4. Check the the voltage voltage between between terminal terminal 86 (black (black wire wire #31) and ground. ground. This This test may be done at plug (b)  with it disconnected from the neutral relay. relay. Is battery voltage (approximately 12V) measured? Yes ____

No ____

 

Continue

Repair red wire #31.

5. Check the the voltage voltage between between terminal terminal 87 (black (black wire wire #20) and ground. ground. For For this test, plug (b) must be connected to the crank relay. Pos Position ition the plug as shown to allow access to terminal 87. Is battery voltage (approximately 12V) measured? Yes ____

No ____

The neutral relay is OK.

The neutral relay has failed; replace it.

The neutral relay has now been checked.

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Wacker Neuson Engine Starting System 4

RD 12/RD 12A

Wa Wack cker er Ne Neus uson on En Engi gine ne Star Starti ting ng Sy Syst stem em

Prerequisites

Sequence

 



Before troubleshooting engine starting issues, check the battery and the cable connections to the battery. The battery must be fully charged (approximately 12V).

Complete the troubleshooting in the following sequence: 1. Check Check the the 20A main main fuse. fuse. 2. Check the wiring to the starter starter solenoid and to the anti-backfire solenoid. 3. Check Check the the key swit switch. ch. 4. Check Check the the crank crank relay. relay. 5. Check Check the the neutra neutrall s switc witch. h. 6. Check the neutra neutrall relay relay.

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40

 

RD 12/RD 12A 4. 4.1 1

Wacker Neuson Engine Starting System

Chec Checki king ng th the e2 20A 0A Main Main Fu Fuse se

Prerequisites Background

 



There are three 20A fuses protecting the circuits in the RD 12:   

Procedure

Key switch in OFF position.

Main electricals Voltage Volta ge regulator circuit Optional light circuit

Follow the procedure below to check the 20A main fuse.

1. Open the the hood and and locate locate the fuse fuse carrier carrier (a).

b

a

wc_gr004128

2. Remove Remove the protectctive protectctive cover cover from the fuse carrier carrier.. 3. Check Check the conditi condition on of the the 20A main main fuse fuse (b) . Is the 20A fuse OK? Yes ____

No ____

 

Continue

Replace the 20A main fuse with one of same size and rating.

4. Re-install the 20A main fuse fuse and the protective protective cover to the fuse carrier. carrier. The 20A main fuse has now been checked.

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Wacker Neuson Engine Starting System 4.2

RD 12/RD 12A

Chec Checking king the Wiri Wiring ng to to the the Start Starter er S Soleno olenoid id & AntiAnti-back backfire fire Solen Solenoid oid

Prerequisites

 



Fully-charged (approximately 12V) battery

Background

Black wire #20 delivers 12VDC to the starter solenoid when the key is in the START ST ART position. If this wire is broken or disconnected, the engine will not start.

Procedure

Follow the procedure below to check the wiring to the starter solenoid. 1. Open the hood and locate locate the starter/s starter/start tarter er solenoid solenoid (a).

a

b

wc_gr004129

2. Check Check the condition/c condition/connec onnection tion of black black wire #20 (b)  to the starter solenoid. Is the wiring OK? Yes ____

No ____

 

Continue

Reconnect or repair red wire.

3. Check the condition condition and connection of the black/yellow black/yellow wire to the anti-backfire solenoid. Is the wiring OK? Yes ____

No ____

 

The wiring is OK.

Reconnect or repair red wire.

4. If the engine still won’t start start but cranks, cranks, remove the anti-backfire solenoid (c)   and clean the valve portion of it with carburetor cleaner. Re-install it and try to start the engine.

The wiring to the starter solenoid and anti-backfire solenoid has now been checked. wc_tx000746gb.fm

42

 

RD 12/RD 12A 4. 4.3 3

Wacker Neuson Engine Starting System

Chec Checki king ng th the e Key Key Sw Swit itch ch

Prerequisites

 

  

Multimeter  Fully-charged (approximately 12V) battery Functioning 20A main fuse

Background

The key switch is a three-position switch: ON, START, and OFF. When in the START position, the key switch directs battery voltage to the crank relay.

Procedure

Follow the procedure below to check the key switch. 1. Remove Remove the screws screws that s secure ecure the pla plate te (a) to the back of the control panel and remove the plate.

2. Using the multimeter, multimeter, check the voltage between the BAT BAT terminal (b)  of the key switch and ground. For easier measuring, remove the plug and measure voltage at the plug.

Is battery voltage (approximately 12V) measured? Yes ____

No ____

 

Cont ontinu inue

Check heck the co cont ntin inui uitty o off red red wire ire # #13 13 be bettween ween th the ek key ey sw swit itc ch a and nd 20A main fuse. Repair red wire #13 as needed.

3. Place the the key sw switch itch in the the START START posiposition. 4. Re-install Re-install the plug plug to the key key swit switch. ch.

5. Check the the voltage voltage between between the “S” “S” terminal (c)  of the key switch and ground.

Is battery voltage (approximately 12V) measured? Yes ____

No ____

The key switch is OK.

The key switch has failed; replace it.

6. Re-install Re-install th the e plate tto o the back of the the control control console. console. The key switch has now been checked.

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Wacker Neuson Engine Starting System 4. 4.4 4

RD 12/RD 12A

Chec Checki king ng th the e Cran Crank k Rela Relay y

Prerequisites

 

   

Multimeter  Fully-charged (approximately 12V) battery Functioning 20A main fuse Functioning key switch

Background

The coil of the crank relay is energized when the key switch is in the START START position.

Procedure

Follow the procedure below to check the crank relay. relay. 1. Open the the hood and and locate locate the crank crank relay relay (a).

a

b

30

85

R 40 86

B 04

87

wc_gr004130

R 35

2. Check the voltage voltage between terminal terminal 30 (red wire #40) and ground. This This test may be done at the plug (b)  with it disconnected from the crank relay. relay.  Is battery voltage (approximately 12V) measured? Yes ____

N o ____

 

Continue

Repair red wire #40.

3. With the key switch switch in the START START position, check the voltage voltage between terminal 86 (black wire #04) and ground. gr ound. This test may be done at the plug (b)  with it disconnected from the crank relay. Is battery voltage (approximately 12V) measured? Yes ____

N o ____

 

Continue

Repair black wire #04.

4. With the key switch switch in the START START position, check the voltage voltage between terminal 87 and ground (red wire #35). For this test, the plug (b  (b)) must be connected to the crank relay. Position Position the plug as shown to allow access to terminal 87. Is battery voltage (approximately 12V) measured? Yes ____

N o ____

The crank relay is OK.

The crank relay has failed; replace it.

The crank relay has now been checked. wc_tx000746gb.fm

44

 

 

RD 12/RD 12A 4. 4.5 5

Wacker Neuson Engine Starting System

Ch Chec ecki king ng tthe he N Neu eutr tral al Swi Switc tch h

Prerequisites

 

    

Multimeter  Fully-charged (approximately 12V) battery Functioning main fuse Functioning key switch Seat platform in raised position. See section Rear Frame Access.

Background

The neutral switch, when closed (control lever in NEUTRAL position), allows voltage to the neutral relay.

Procedure

Follow the procedure below to check the neutral switch. 1. Locate Locate tthe he connec connector tor (a) for the neutral switch and disconnect it.

2. Place Place the control control lever in the NEUTRA NEUTRAL L position. position. 3. With the key switch switch in the START START position, check the continuity between between the pins of the connector (green and white wires). Is there continuity? Yes ____

No ____

 

Continue

The neutral switch has failed; replace it.

4. Place the control control lever in the FORWARD FORWARD or REVERSE REVERSE position. 5. With the key switch switch in the START START position, check the continuity between between the pins of the connector (green and white wires). Is there continuity? Yes ____

No ____

The neutral switch has failed; replace it.

Continue

 

6. Repeat the test test with the control lever in the REVERSE REVERSE position. Is there continuity? Yes ____

No ____

The neutral switch has failed: replace it.

The neutral switch is OK.

7. Reconn Reconnect ect the the wiring wiring.. 8. Lower and secure secure the seat seat platfor platform. m. The neutral switch has now been checked.

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Wacker Neuson Engine Starting System 4. 4.6 6

RD 12/RD 12A

Chec Checki king ng th the eN Neu eutr tral al Rela Relay y

Prerequisites

 

    

Multimeter  Fully-charged (approximately 12V) battery Functioning 20A main fuse Functioning crank relay Functioning neutral switch

Background

The neutral relay relays battery voltage to the starter solenoid.

Procedure

Follow the procedure below to check the neutral relay. relay. 1. Open the the hood and and locate locate the neutral neutral relay (a).

a

b

30

85

R 39 86

87

B 31

wc_gr004131

B 20

2. Place Place the key switch switch in the START START positio position. n. 3. Check the voltage voltage between terminal terminal 30 (red wire #39) and ground. This This test may be done at the plug (b)  with it disconnected from the neutral relay relay.. Is battery voltage (approximately 12V) measured? Yes ____

N o ____

 

Continue

Repair red wire #39.

4. Check the voltage voltage between terminal terminal 86 (black wire #31) and ground. This test may be done at the plug (b)  with it disconnected from the neutral relay relay.. Is battery voltage (approximately 12V) measured?

wc_tx000746gb.fm

Yes ____

N o ____

Continue

Repair red wire #31.

46

 

 

RD 12/RD 12A

Wacker Neuson Engine Starting System

5. Check the voltage between terminal 87 (black wire #20) and ground. For this test, the plug (b)  must be connected to the crank relay. relay. Position the plug as shown to allow access to terminal 87. Is battery voltage (approximately 12V) measured? Yes ____

No ____

The neutral relay is OK.

The neutral relay has failed; replace it.

The neutral relay has now been checked.

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47

 

 

Drive System 5

RD 12/RD 12A

Drive System The hydraulic system is powered by two pumps (exciter and drive) mounted in tandem—  connected along their shafts through a solid-mounted coupling—and driven directly by the engine crankshaft through a flex coupling.

Background

Drive Pump

 





 

Drive Motors

System filters and strainers

 

Flow through the drive pump is controlled by varying its i ts displacement through the movement of the control lever coupled to the pump’s control shaft. This allows a full range of operating speeds in both forward and reverse. The drive pump includes pressure test ports for the drive system. The drive pump also includes the towing valve which, when open, allows oil flow to bypass the drive motors.



There are two drive motors—one mounted to each drum.



The drive motors are plumbed in series.







Troubleshooting sequence

The drive pump is a variable displacement, axial piston pump and includes an integral charge pump.

The hydraulic tank is equipped with a strainer at the fill port to trap large objects or particles which may accidentally fall into the tank while adding hydraulic fluid.  Additional system protection is provided by a suction filter m mounted ounted in-line with the exciter pump inlet. The hydraulic system is protected by a return-line filter which removes dirt particles down to 10 microns and  and includes a flow bypass for cold weather start-up.

When troubleshooting drive system problems, do so in the following sequence: 1. Check the tow tow ((bypa bypass) ss) valve. valve. 2. Check the function function of the drive drive cont control rol cab cable. le. 3. Pressure Pressure tes testt the drive drive pump an and d relief valve. valve. 4. Check the drive drive mo motors tors for for bind binding. ing. 5. Check the oil flow flow through through the the drive motors. motors.

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RD 12/RD 12A 5.1

Drive System

Che hec cki king ng the Tow Tow Va Valve lve

Background

In order for the machine to operate properly, the tow valve must be completely closed.

Procedure

Follow the procedure below to open and close the tow valve. WARNING! With the tow valve open, the drive circuit has no braking action and the

machine will roll freely freely..  Close the tow valve immediately after a towing operation is complete to prevent the machine from rolling unexpectedly. unexpectedly.

1. Tu Turn rn the the shaft shaft of the va valve lve (a) counterclockwise 90° to open the tow valve.

a

wc_gr004120

2. Turn the the shaft of the tow valve fully clockwise to close the tow valve. The tow valve has now been checked.

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49

 

Drive System 5.2 5.2

RD 12/RD 12A

Adju Adjust stin ing g tthe he Driv Drive eC Con ontr trol ol Ca Cabl ble e If the roller tends to drift in either direction when the forward/reverse control is in NEUTRAL, the drive control cable (a) must be adjusted.

Background

Prerequisites

 

 

Machine on a hard, level surface Engine running



Forward/reverse control in the NEUTRAL position Procedure

Follow the procedure below to adjust the drive control cable. 1. Loosen Loosen the lock lock nut (b) .

a b d c wc_gr004121

2. Move Move the turnbu turnbuckl ckle e (c)  as needed until machine movement stops. If adjusting the turnbuckle does not achieve the desired results, a gross adjustment can be made at the nut (d) and then fine-tuned as described above. The drive control cable has now been adjusted.

50

wc_tx000667gb.fm

 

RD 12/RD 12A 5.3

Drive System

Che Checki cking ng tthe he Drive Drive Sys System tem Ope Operat rating ing Pressu Pressure re

Background

Prerequisites

Procedure

Failure of the drive circuit to reach operating pressures is normally caused by a worn or damaged drive pump; however, the problem could also be the result of a badly worn motor.

 



Machine on a firm, level surface



3000-psi pressure gauge



Hydraulic oil warm

Follow the procedure below to test the drive system operating pressure. 1. Install Install a 3000-psi 3000-psi gauge gauge in the forward forward test test port (a) on the drive pump.

2. Start Start the engine engine and run the machine machine at full throttl throttle. e. 3. Shift the the control lever lever to forward and rec record ord the pressure pressure on the gauge. 4. Stop the engine engine.. 5. Install Install the gauge gauge in tthe he reverse reverse test test port port (b)  and repeat the procedure while operating in reverse. Note:  Operating pressures will increase significantly when running the machine uphill, off road, or against an object.

The drive system operating pressure has now been checked.

51

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Drive System 5.4

RD 12/RD 12A

Che Check cking ing the Drive Drive Sys System tem Rel Relief ief Pressu Pressure re

Prerequisites

Procedure

 



Machine on a firm, level surface



5000-psi pressure gauge

Follow the procedure below to check the relief reli ef presure. 1. Place blocks in front front of and behind both drums to prevent the machine from moving, or dead head the machine against a solid concrete abutment. 2. Set the p park arking ing brak brake. e. CAUTION! Crushing hazard.  To reduce the risk of injury, make sure no one is in i n front of or behind the machine during this test.

3. Install Install a 5000-psi 5000-psi gauge gauge in the forward forward ttest est por portt (a) on the drive pump.

b

200 bar (2900 psi) psi)

a wc_gr004124

4. Start Start the engine engine and run the machine machine at full full throttl throttle. e. 5. Shift the forward/reverse control slowly into forward until pressure pressure on the gauge tops out. This is the forward relief valve pressure. Note:  Make sure the drums do not spin.  

6. Install Install the gauge gauge in the reverse reverse ttest est po port rt (b)  and repeat the procedure while operating in reverse.

The relief pressure has now been checked.

52

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RD 12/RD 12A 5.5 5.5

Drive System

Chec Checki king ng Dr Driv ive eM Mot otor ors s for for Bi Bind ndin ing g

Background

Prerequisites

High operating pressures indicate binding in the drive system. Binding can occur in the drive motor or may be the result of a poor or failing drive bearing.

 



Machine stopped



Parking brake ON

 

Procedure

Battery disconnected Jacks

To check for binding in the drive motor: 1. Remove Remove the the drive motor motor cover cover (a).

a b wc_gr004125

2. Remove Remove th the e dru drum m support support cover (b) . 3. Support the machine machine before separating separating the drive plate from the drum by placing b blocks locks or jacks (c)  under the front frame just behind the drum.

d

c wc_gr004126

4. Disconnect Disconnect the hydraulic hydraulic lines (d)  to the drive motor. This procedure continues on the next page.

53

wc_tx000667gb.fm

 

Drive System

RD 12/RD 12A

Continued from the previous page.

5. Secure Secure the drum support support with with an appropriate appropriate crane crane and sling (e). 6. Remove the screws screws that secure the drum support and remove the the drum support support..

e

f wc_gr004127

7. Rotate Rotate the the dr drive ive plate plate (f) by hand and make sure the motor turns freely.

The drive motor has now been checked for binding.

54

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RD 12/RD 12A 5.6 5.6

Drive System

Ch Chec ecki king ng O Oil il F Flo low w thro throug ugh h the the Dr Driv ive e Moto Motors rs

Background

The drive motors are plumbed in series. Oil flow through one motor is virtually identical to the flow through the other, unless a problem with one of the motors exists.

Procedure

Follow the procedure below to check oil flow through the motors.

WARNING! Crushing  Use extreme care hazard. when carrying out the following procedure.

1. St Start art the engine and allow the hydraulic oil to warm warm up. S Shut hut off the engine. 2. Using a crane crane or overhead lift with enough load-bearing capacity to support the machine, lift the machine off the ground so that the drums are 2–5 cm (1–2 inches) off the ground. 3. Place a piece of tape on or boldly mark mark each drum. This will aid in obs observing erving the rotation rotation of the drums. 4. St Start art the engine and slowly shift shift the forward/reverse forward/reverse control lever into the FORWARD FORWARD position. Observe the drum rotation for any sign of difference di fference in the rotation of the drums. If one drum is rotating slower than the other, the drum with the slower rotation may be failing. 5. With the engine engine running and the drums rotating, slowly apply the parking brake to the rear drum. Observe the speed of both drums as the brake is applied. Both drums should slow down at the same rate. Apply the brake until the rear drum stops rotating. Note:  If the brake cannot stop the rear drum from rotating, the brake requires repair or replacement. With the rear drum held from rotating by the brake, the front drum should not be rotating. If it is, the seals of the rear drive motor are failing. Rebuild or replace the rear drive motor. 6. Release Release the brake brake from from the rear rear drum. drum. 7. Conduct the same test on the front drum. Use a sturdy piece of wood, s such uch as a 2x4, as an external brake. WARNING! Crushing hazard.  Do not jam the piece of wood between the drum and the floor. The roller will move.

Wedge the sturdy piece of wood between the drum and the machine frame to stop the drum rotation. If the rear drum rotates when the front drum is held from rotating by the external brake, the seals of the front drive motor are failing. fai ling. Rebuild or replace the front drive motor.

The oil flow through the drive motors has now been checked.

55

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Vibration System and Steering 6

RD 12 / RD 12A

Vibration S Sy ystem a an nd St Steering Both the vibration and steering system share the same open loop, series circuit, driven by a fixed displacement, gear-type pump (exciter pump). The system includes separate relief valves for vibration and steering, an exciter control valve exciter motor, motor, steering valve, and steering cylinder.

Vibration

The exciter pump pulls oil from the tank through the suction filter and sends it to the exciter

circuit

manifold block. The vibration circuit is controlled by on thethe exciter sol enoid valve. This valve electrically operated by an ON/OFF switch located end solenoid of the forward/reverse con-is trol lever. Supply oil from the exciter pump is directed to the exciter control valve. When the ON/OFF switch is in the OFF position, the exciter control valve is open, allowing oil to pass downstream to the steering valve without driving the exciter motor motor.. When the ON/OFF switch is in the ON position, the exciter control valve closes and directs oil to the exciter motor which drives the eccentric weights in the front drum. Return oil from the exciter motor flows to the steering valve. A relief valve connected across the exciter control valve limits pressure to 200 bar (2900 psi).

Steering circuit

Steering is controlled by a steering valve and cylinder. The steering wheel is spli Steering splinenemounted directly to the steering valve. The steering valve reacts to the motion of the steering wheel to direct oil to and from the steering cylinder. Oil returning from the vibration circuit is directed to the steering valve. If steering is inactive, oil passes through the steering valve and back to the return-line filter manifold. When the steering wheel is turned, the steering valve closes and directs oil to the appropriate steering line to extend or retract the cylinder.  A relief valve is connected across the steering valve and is set at 45–51 bar (650–7 (650–725 25 psi). Relief valves are also connected to each end of the steering cylinder. Each of these relief valves is also set at 45–51 bar (650–725 psi). The oil returning from the vibration and steering functions is directed back to the tank through a return-line filter. A filter bypass relief valve, set at 1.7 bar (25 psi), protects the return-line filter by routing oil past the filter if the filter is clogged.

Troubleshooting sequence

When troubleshooting: 



For systems that vibrate poorly poorly,, see section Troubleshooting a System that Vibrates Poorly. For complete vibration system failure, see sections Checking the Vibration Solenoid Valve and Checking the Vibration Switch.

56

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RD 12 / RD 12A 6. 6.1 1

Vibration System and Steering

Ch Chec ecki king ng th the eE Eng ngin ine e Spe Speed ed and and V Vib ibra rati tion on Sp Spee eed d

Prerequisites

 

 

Procedure

Vibrotach Vibration must turn on

Follow the procedure below to check the engine rpm and drum vpm. 1. Start Start the engine and place the throttle switch in the FAST FAST position. 2. Measure Measure the engine engine rpm using using a vibrotac vibrotach. h.

3. Measure the vpm vpm (vibrations per minute) by placing the vibrotach on the rim of the drum while vibration is on. 4. If the vpm is not 4150–425 4150–4250, 0, adjust adjust the throttle throttle screw (a) until it is.

The procedure to check the engine rpm and drum vpm is now complete.

57

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Vibration System and Steering 6. 6.2 2

RD 12 / RD 12A

Tr Trou oubl bles esho hoot otin ing g a Sy Syst stem em th that at Vi Vibr brat ates es Po Poor orly ly

Prerequisites

 

 

3000-psi pressure gauge Compactible surface such as a bed of gravel or old tires

Background

The exciter pump is designed to put out a constant flow of oil at a set engine speed. This ensures that the vibration frequency remains steady. When troubleshooting the exciter circuit, the vibration speed, operating pressure, and relief pressures must be known to help determine the cause of any problems.

Procedure

To measure vibration speed: 1. Start Start the machine and run it for several minutes to bring the hydraulic fluid up to normal operating temperature. 2. Drive the machine machine onto a compactible compactible surface such as a bed of gravel or old tires. 3. Run the machine at full throttle. Check the engine engine RPM using a tachometer or vibrotach. The engine must be running at the correct RPM to accurately measure vibration. 4. Start Start vibration. Hold the v vibrotach ibrotach (P/N 5 53397) 3397) against the outer rim of the drum and measure the vibration speed. Engine RPM

Vibration Frequency VPM

3100

4200

5. Shut Shut dow down n the mach machine ine.. To check vibration system operating pressure: 1. Open the engine engine comp compartmen artment. t. 2. Locate Locate the excite exciterr solenoid solenoid valve valve (a).

3. Connect Connect a 3000-psi 3000-psi gauge gauge to the test test port (b) . 4. Start the the engine and run the machine machine at ful fulll throttle. throttle. This procedure continues on the next page.

58

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RD 12 / RD 12A

Vibration System and Steering

Continued from the previous page.

5. Turn on the vibration and measure the relief and operating pressures. The relief pressure is the pressure registered on the gauge as soon as the vibration is turned on. The system will then settle into operating pressure. Record these two pressures. 6. Shut Shut dow down n the mach machine ine.. Compare the results from operating pressure, pump relief pressure, and exciter speed with the chart below. Operating Pressure

Pump Relief  Pressure

Exciter Speed

Probable Cause

N

N

N

System OK

H

N

N or L

Exciter bearings or motor binding

N or L

N

L

Exciter motor worn

L

L

L

Exciter pump damaged or worn, relief valve defective, or needs adjusting

N = Normal, L = Low, H = High If the exciter is binding or causing high operating pressures, perform the following: 1. Disconnec Disconnectt and remove remove the exciter exciter motor motor (c)  from the housing. 2. Turn the motor shaft shaft and exciter shaft by hand and check that they both turn freely.

c wc_gr004143

3. If either component component does not turn freely, freely, it has failed; replace it. The vibration system has now been checked for poor vibration.

59

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Vibration System and Steering 6.3 6.3

RD 12 / RD 12A

Ch Che eckin cking g the the Vibr Vibra atio ion n Sol Sole enoid noid Va Valv lve e

Background

When the roller’s engine is running, the solenoid (a) of the vibration manifold (b)   receives power through the white wire via the vibration switch. When energized, the vibration solenoid valve shifts causing oil flow to the exciter motor. To To check the function of the vibration electrical system, both the vibration solenoid and the vibration switch should be tested.

Procedure

Follow the procedure below to check the vibration solenoid. 1. Place Place the key key switch switch in the the ON position. position. 2. With your your hand around the the body of the vibration vibration solenoid solenoid (a), turn the vibration switch ON and feel for movement of the plunger inside the vibration solenoid. Note: If the movement of the plunger is hard to detect, remove the solenoid from the vibration manifold to make it easier.

Is the vibration solenoid functioning? Yes ____

No ____

 Any problems with vibration are in the hydraulic circuit, not the electrical system.

Continue

 

3. Disconnect Disconnect the the vibration vibration solenoid solenoid from the harness harness.. 4. Place the vibration vibration switch in the ON position and measure the voltage across the connector (b) . Is 12VDC (battery voltage approximately 12V) measured? Yes ____

N o ____

The vibration solenoid is receiving power and should be functioning. If it is not, it has failed; replace it.

Continue troubleshooting by checking the vibration switch.

The vibration solenoid has now been checked.

 

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RD 12 / RD 12A 6.4

Vibration System and Steering

Checking tth he V Viibration S Sw witch

Background

When the roller’s engine is running, the solenoid of the vibration manifold receives power through the white wire via the vibration switch. To To check the function of the vibration electrical system, both the vibration solenoid and the vibration switch should be tested.

Procedure

Follow the procedure below to check the vibration switch. 1. Remove the four four screws that secure the seat platform. Then, raise the platform. platform.

2. Locate Locate tthe he connec connector tor (a) for the vibration switch and disconnect it. 3. Press the switch several times while checking for continuity continuity between the pins of the connector (two black wires). Does the switch open and close Yes ____

No ____

The v viibration sw switch iis s OK OK.

Th The ev viibration switc itch has failed; replace lace it. it.

4. Reconn Reconnect ect the the wiring wiring.. The vibraton switch has now been checked.

 

61

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Steering System 7 7. 7.1 1

RD 12/RD 12A

Steering System Ch Chec ecki king ng tthe he S Ste teer erin ing g Sy Syst stem em Hyd Hydra raul ulic ic Pr Pres essu sure re

Prerequisites

200-bar (3000-psi) pressure gauge

Procedure

Follow the procedure below to check the steering system hydraulic pressure. 1. Ope Open n tthe he engi engine ne compar compartme tment. nt. 2. Loc Locate ate the excite exciterr solen solenoid oid v valv alve e (a).

3. Connect Connect a 200-bar 200-bar (3000-psi) (3000-psi) gauge to the the test test port port (b) . 4. Start art the the engi engine ne.. 5. Check the pressure pressure while while operatin operating g the steering steering.. See sectio section n Technical Data for values. Do not turn on the vibration while conducting this test. The 3000-psi gauge will be damaged.

NOTICE:

6. Remo Remove ve the the g gau auge ge.. The steering system hydraulic pressure has now been checked.

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RD 12/RD 12A 7.2

Steering System

Trou Troubl bles esho hoot otin ing g the the Stee Steeri ring ng Sy Sys stem tem

Background

Low hydraulic pressure in the steering circuit can be the result of a defective or worn steering valve or poor seals in the steering cylinder.  A badly worn exciter exciter pump will affect both the steering and the vibration vibration circuits because these circuits operate in series using the same supply. supply. In some cases the exciter pump may function well enough to operate the steering

circuit but not the vibration circuit. This is due to the much lower pressure requirements of Note: the steering circuit.

Procedure

Follow the procedure below to check the steering system. 1. Remove Remove the steering steering valve valve from from the the machine. machine. See See section section Removing the Steering Valve. WARNING! There is no steering control with the steering valve removed.  DO NOT drive the machine with the steering cylinder disconnected or inoperative!

2. Cap the the hydrauli hydraulic c lin lines es that that feed feed the the steering steering valve. valve. 3. Start art the the engi engine ne.. 4. Check the steering steering circuit circuit rrelief elief pressure. pressure. If

Hydraulic pressure remains low Hydraulic pressure increases

Th en

Problem is in the steering valve Problem is in the steering cylinder  

The steering system has now been checked.

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Spray System 8 8.1

RD 12/RD 16

Sp r ay Sy s t em Tro roub ubll es es h hoo oott ing ing tthe he Spra pray Sy Sy s stt em em

Prerequisites

The machine must be able to start in order to troubleshoot the spray system. If the machine does not start, see engine starting troubleshooting.

Components

The electrical components of the spray system consist of:

Sequence



Pump



Pump timer module



Spray system switch

When troubleshooting the spray system, do so in the following sequence: 1. Check Check power power to to the pu pump. mp. 2. Check the pump pump timer timer module. module. 3. Check the spray spray syste system m switch. switch.

64

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RD 12/RD 16 8.2

Spray System

Che heck ckin ing g Pow Powe er tto o tthe he Spra pray Ba Bar Pum Pump p

Prerequisites

Seat platform in raised position. See section Rear Frame Access.

Procedure

Follow the procedure below to check power to the spray bar pump. 1. Disconnec Disconnectt the wiring wiring from the the water pump pump (a).

2. Place Place the key switch switch in the the ON position. position. 3. Place Place the spray system system switch switch in the ON position position.. 4. Measure Measure the volta voltage ge at the the connector connector (b) . Is more than 9.8V measured? Yes ____

No ____

 

The pump has failed; replace it.

See section Checking Power to Pump Timer Module.

The procedure for checking the power to the spray bar pump is now complete.

65

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Spray System 8.3

RD 12/RD 16

Che hec ck kii n ng g the the Pump ump T Tii m me er M Mod odul ule e

Background

Procedure

The pump timer module is fed power in two locations: 

Via key switch on pink wire #01



Via spray system switch on pink wire #18

Follow the procedure below to check power to the pump timer module. 1. Remove Remove the contro controll console console cover cover (a).  

2. Disconnect Disconnect the the pump timer timer module module connector connector (b) . 3. Measure Measure the voltage voltage between between pink wire #01 (connector (connector pin 1) and ground. Is more than 9.8V measured? Yes ____

N o ____

 

Continue

Repair or replace pink wire #1.

4. Place Place the key key switch switch in the the ON position. position. 5. Place Place the spray system system switch switch in the ON positio position. n. 6. Measure the voltage voltage between pink wire #18 (connector pin 11) 11) and ground. Is more than 9.8V measured? Yes ____

N o ____

 

The pump timer module is receiving power

Repair or replace pink wire #18.

and should be working; continue.

7. Reconnect Reconnect the the pump timer module module conn connector ector.. 8. Measure Measure the voltage voltage between between pink wire #18 (backprobe (backprobe connector connector pin 6) and ground. Note: The voltage will be intermittent depending on the setting of the pump timer dial. Is more than 9.8V measured? Yes ____

N o ____

Th The e pum pump p ttim imer er modul odule e iis s fun funct ctio ioni ning ng..

Th The e pum pump p tim timer er modul odule eh ha as ffai aile led; d; replace it.

9. Re-instal Re-installl the control control console console cover. cover. The pump timer module has now been checked.

 

66

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RD 12/RD 16 8.4

Spray System

Che heck ckin ing g the the Spra pray Sys yste tem m Swi witc tch h

Background

The spray system switch is fed power via the key switch on pink wire #29. When in the ON position, the spray system switch allows power to the pump control timer via pink wire #18.

Procedure

Follow the procedure below to check the spray system switch. 1. Remove Remove th the e con control trol consol console e cove coverr (a).

2. Place Place the key switch switch in the the ON position. position. 3. Measure the voltage voltage between the incoming side of the spray sys system tem switch (b)   (pink wire #29) and ground. Is more than 9.8V measured? Yes ____

No ____

 

Continue

Check the continuity of pink wire #29. Repair or replace pink wire #29.

4. Place Place the spray system system switch switch in the ON position position.. 5. Measure the voltage voltage between the outgoing side of the spray system switch switch (pink wire #18) and ground. Is more than 9.8V measured? Yes ____

No ____

The spray system switch is

The spray system switch has failed;

functioning.

replace it.

The spray system switch has now been checked.

 

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Disassembly & Assembly 9 9.1 9.1

Disassembly & Assembly Too Tools ls Re Requ quir ired ed for for Di Disa sass ssem embl bly/ y/As Asse semb mbly ly Pr Proc oced edur ures es 





9. 9.2 2

It is up to the mechanic to use common sense and good judgment in tool selection to reduce the risk of injury while repairing the machine. In cases where a special tool is required, the special tool is listed in the prerequisite section of the procedure. Before substituting another tool or procedure from those recommended in this manual, the mechanic must be satisfied that neither personal injury nor damage to the machine will result due to the substitution.

Info Inform rmat atio ion n Rega Regard rdin ing g Repl Replac acem emen entt Pa Part rts s  







9. 9.3 3

RD 12/RD 12A

The repair procedures contained in this manual do not include part numbers. For replacement parts information, refer to the Parts Book originally supplied with the machine. If the original Parts Book has been lost, a replacement may be ordered from Wacker Neuson 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 Neuson Corporation Web site. See www.wackerneuson.com. www.wackerneuson.com. Enter the site as a visitor. visitor.

Info Inform rmat atio ion n Reg Regar ardi ding ng Re Refe fere renc nce eN Num umbe bers rs ( ) Repair procedures contain contain reference numbers enclosed in parentheses 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.

9. 9.4 4

Info Inform rmat atio ion n Rega Regard rdin ing g Thre Thread adlo lock ckin ing g Co Comp mpou ound nds s

Background

Due to the heavy vibration inherent in this type of equipment, the repair and service procedures described in this manual specify the use of threadlocking compounds. These compounds should be used where indicated to prevent the fasteners from becoming loose.

Recommended threadlockers

 Although Loctite® is referred referred to throughout this manual, any equivalent type of sealant such as Hernon®, Prolock, or Omnifit may be used. For a complete list of recommended sealing and locking compounds, refer to the Use of Threadlockers and Sealants chart at the end of this manual.

Applying threadlockers

Clean the screw threads and wipe off any oil or grease before applying a threadlocking compound.

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RD 12/RD 12A 9.5

Disassembly & Assembly

Removing tthe he Articulating Jo Joint

Prerequisites Procedure

 



Crane and jacks

Follow the procedure below to remove the articulating joint. joi nt. 1. Support the rear rear half of the machine with jacks and the front front half with an appropriate crane so that the machine will not fall in on itself when the articulating joint is removed. 2. Disconnect Disconnect the steering steering cylinde cylinderr (a) from the pivot plate (b) .

a

c b wc_gr004136

3. Remove Remove the screws screws that se secure cure each of the the pillow blocks blocks (c)  to the frame. 4. Rotate/spread the machine halves as needed to better access to the articulating joint. 5. Remove Remove the scr screws ews that secure secure tthe he pivot p plate late (b)  and remove the pivot plate.

c

b wc_gr004137

6. Remove Remove tthe he pillow pillow b bloc locks ks (c) . 7. Remove Remove the do dowel wel pin and the castle n nut ut (d) .

f

d e wc_gr004138

8. Pull Pull th the e housi housing ng (e) from the shaft (f) . 9. Remove Remove the sc screws rews that that secure secure the the shaf shaftt (f)  to the front frame and remove the shaft. The procedure to remove the articulating joint is i s now complete.

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Disassembly & Assembly 9.6 9.6

RD 12/RD 12A

Ins In sta tall llin ing g the Art Articul icula ati ting ng Joi oint nt

Prerequisites Procedure

 



Crane and jacks

Follow the procedure below to install the articulating joint. 1. Support the rear half of the machine with jacks and the front front half with an appropriate crane so that the machine will not fall in on itself when the articulating joint is removed. 2. Alig Align n th the e shaf shaftt (a) so that the dowel hole (b)  is parallel to the ground. Apply Loctite 243 to the screws (c)  and secure the shaft to the frame.

c a  

e

d

b wc_gr004139

3. Slide Slide tthe he housing housing (d)  onto the shaft. Secure the housing with the castle nut (e) and the dowel pin. 4. Apply Loctite Loctite 243 to the the screws screws (g)  and secure the pivot plate (f) to the housing.

h g

f wc_gr004140

5. Add the pill pillow ow block blocks s (h)  to the housing. 6. Apply Loctite Loctite 243 to the the screws screws (i)  and secure the pillow blocks to the frame.

j i

f wc_gr004141

7. Connect Connect the the s steerin teering g cylinder cylinder (j (j)) to the pivot plate (f) . The procedure to install the articulating joint is now complete.

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RD 12/RD 12A 9.7

Disassembly & Assembly

Removing the Rear Drum

Prerequisites

Procedure

 



Jacks



Crane and appropriate sling

Follow the procedure below to remove the rear drum. 1. Chock Chock tthe he fron frontt drum. drum. 2. Support Support the machine machine with with jjacks acks (a).

a

b

wc_gr004194

3. Remove Remove th the e dru drum m support support covers covers (b) . 4. Remove Remove th the e bear bearing ing co cover ver (c)  from the non-drive-motor side of the drum.

d c

wc_gr004195

5. Disconnect Disconnect and remove remove the br brake ake ca cable ble (d)  from the drum. 6. Remove Remove the the metal metal hydra hydraulic ulic lines lines (e) from the hydraulic hoses. Cap and store the hydraulic hoses in the machine frame.

e

wc_gr004196

This procedure continues on the next page.

71

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Disassembly & Assembly

RD 12/RD 12A

Continued from the previous page. 7. Support Support the drum suppor supportt with an appro appropriat priate e sling and crane crane..

f

g wc_gr004197

8. Remove Remove tthe he four four screw screws s (f)  that secure the drum support to the machine and slide the drum (g)  from underneath the machine.

The procedure to remove the front drum is now complete.

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RD 12/RD 12A 9.8

Disassembly & Assembly

Installing the Rear Drum

Prerequisites

Procedure

 



Crane and appropriate sling



Non-drive-motor side drum support installed

Follow the procedure below to install the rear drum. 1. Chock Chock tthe he fron frontt drum. drum. 2. Insta Installll the the beari bearing ng (h)  onto the shaft of the drum.

h

c

wc_gr004198

3. Position Position the d drum rum underne underneath ath th the e machine. machine. 4. Insta Installll the beari bearing ng cov cover er (c)  to the non-drive-motor side of the drum. 5. Apply Apply Loc Loctite tite 243 to to screws screws (f) and secure the drum support to the machine. Torque the screws to 79 Nm (58 ft.lbs.).

e f

wc_gr004199

6. Install Install the the met metal al hydraulic hydraulic lines (e).

This procedure continues on the next page.

73

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Disassembly & Assembly

RD 12/RD 12A

Continued from the previous page. 7. Insta Installll the the brake brake cable cable (d)  to the drum.

d

b

wc_gr004200

8. Install Install the the dru drum m support support cover covers s (b) .

The procedure to install the rear drum is now complete.

74

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RD 12/RD 12A 9.9

Disassembly & Assembly

Remo Remov vin ing g the the Bra rak ke and Brak rake Cab able le

Prerequisites Procedure

 



Engine off 

Follow the procedure below to remove the brake. 1. Choc Chock k the the dr drum ums. s. 2. Remove Remove th the e dru drum m support support cover (a).

a b

wc_gr004209

3. Remove Remove the screws screws (b)  that secure the brake lever assembly to the machine. 4. Discon Disconnec nectt the brake brake cable cable (c) from the brake and the drum.

c

wc_gr004210

5. Remove Remove the brake lev lever er and brake brake cable from the the machine. machine. 6. Remove Remove tthe he cotte cotterr pin (d)  and the castle nut (e).

g e

f

d

wc_gr004211

7. Remo Remove ve th the e arm arm (f)  and the spring (g) .

This procedure continues on the next page.

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Disassembly & Assembly

RD 12/RD 12A

Continued from the previous page. 8. Support Support the rear of of the machin machine e with an appropriat appropriate e crane.

i

wc_gr004224

9. Remove Remove the screws screws (i)  that secure the drive plate to the shock mounts. 10.Remove the screws (h)  that secure the brake caliper to the drive plate.

h

j

wc_gr004212

11. 1.Raise Raise the machine (rear drum should remain on the ground) enough to remove the brake caliper (j) .

The procedure to remove the brake and brake cable is now complete.

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RD 12/RD 12A 9.10 9.10

Disassembly & Assembly

Inst Instal alli ling ng th the eB Bra rake ke an and dB Bra rake ke Ca Cabl ble e

Prerequisites Procedure

 



 Appropriate crane and sling

Follow the procedure below to install the brake. 1. Raise the rear half of the machine approximately 10 cm (4 in.) off the rrear ear drum. 2. Away Away from the ma machine, chine, loosely loosely install install the four screws screws (i)  and nuts that hold the brake caliper (j)  together; do not tighten the nuts. Slide the brake caliper around the drive plate; then tighten the four screws (i)  and nuts.

i

h

j

wc_gr004213

3. Place the brake caliper into position so so that when installed the two screws (h)  will hold the brake caliper. Then, using Loctite 243 or an equivalent on the two screws, secure the two screws to the brake bracket. 4. Lower the rear half of the machine and reconnect the drive plate to the shock mounts. Torque the screws to 76 Nm (56 ft.lbs.). 5. Insta Installll tthe he spri spring ng (l)  and the arm (k) .

l k

j i

wc_gr004214

6. Insta Installll the the castle castle n nut ut (j)  and the cotter pin (i) .

This procedure continues on the next page.

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Disassembly & Assembly

RD 12/RD 12A

Continued from the previous page. 7. Instal Installl the tw two o scr screws ews (g) , nuts, and bracket which secure the cable (h)  to the machine.

g h e

f wc_gr004215

8. Insta Installll the the hitch hitch pin (e) and the clevis pin (f) . 9. Run the cable cable through through the drum support support and connect connect it to the brake brake handle handle (b) .

b

wc_gr004216

10.Secure the brake handle (b)  to the machine. 11. 1.Install Install the drum support cover c over..

The procedure to install the brake and brake cable is now complete.

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RD 12/RD 12A 9. 9.11 11

Disassembly & Assembly

Re Remo movi ving ng Re Rear ar Dr Driv ive e Moto Motorr

Prerequisites Procedure

 



Rear drum removed

Follow the procedure below to remove the rear drive motor. 1. Rotate the drive motor assembly assembly as needed to to reach the three screws ((a) a) which mount the drive plate to the drum. Remove the three screws. Note:  If the motor assembly is difficult to turn, loosen the caps on the hydraulic lines leading to the to motor to allow the release of any hydraulic pressure. These are the caps connected the lines while removing the drum.

b c a wc_gr004217

2. Using an appropri appropriate ate cran crane, e, lift the dr drum um support support (b) , with the drive motor still attached, up and off of the drum. 3. Remove Remove th the e brak brake e assembl assembly y (c) . See section Removing the Brake and Brake Cable. 4. Remo Remove ve the the n nut ut (d) .

f e g d wc_gr004218

5. Remove Remove the screws screws (e) that secure the drive plate (f)  to the hub (g) .

This procedure continues on the next page.

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Disassembly & Assembly

RD 12/RD 12A

Continued from the previous page. 6. Remove Remove tthe he motor motor guar guard d (g) .

h

g wc_gr004219

7. Remove Remove tthe he brake brake bra bracke ckett (h) . 8. Remove Remove tthe he drive drive m moto otorr (i (i)) from the drum support.

j

i wc_gr004220

9. Remove Remove the the hydraulic hydraulic lines (j)  and fittings from the drive motor if not already removed.

The procedure to remove the rear drive motor is now complete.

80

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RD 12/RD 12A 9. 9.12 12

Disassembly & Assembly

Inst Instal alli ling ng tthe he R Rea earr Dr Driv ive e Mo Moto torr

Prerequisites Procedure

 



Rear drum removed

Follow the procedure below to install the rear drive motor. motor. 1. Connect Connect the hydraulic hydraulic lines (j)  and fittings to the drive motor.

j

i wc_gr004221

2. Apply Loctite Loctite 243 to th the e screws and and secure the dr drive ive moto motorr (i)  to the drum support. Torque the screws to 76 Nm (56 ft.lbs.). 3. Insta Installll the brake brake brack bracket et (h) .

h

g wc_gr004219

4. Insta Installll the moto motorr guard guard (g) . 5. Insta Installll the the drive drive plat plate e (f)  to the hub (g)  with the screws (e). Torque the screws to 44 Nm (32 ft.lbs.).

f e g d wc_gr004222

6. motor Install. the keyLoctite on the243 drive motor . Place the hub/drive plate assembly onto the drive motor. Using onmotor. the nut (d) , secure the hub/drive plate assembly to the drive motor. Torque the nut to 410 Nm (300 ft.lbs.). This procedure continues on the next page.

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Disassembly & Assembly

RD 12/RD 12A

Continued from the previous page.

7. Install Install the brake assembly assembly (c) . See section Installing the Brake.

b c a wc_gr004223

8. Using an appropriate appropriate crane, position the drum drum support/drive motor assembly (b)  on the drum. Using Loctite 243 on the three screws (a), secure the drive motor assembly to the drum. Torque the screws to 76 Nm (56 ft.lbs.).

The procedure to install the rear drive motor is now complete.

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RD 12/RD 12A 9.1 .13 3

Disassembly & Assembly

Re Remo mov vin ing g tthe he Fron Frontt Dru Drum m

Prerequisites

Procedure

 



Crane and appropriate sling



Jacks

Follow the procedure below to remove the front drum. 1. Support Support the front front half of of machine machine with jacks jacks (a).

b

a wc_gr004145

2. Remove Remove th the e dru drum m support support covers covers (b)  from each side of the machine. 3. Remove Remove the the d drive rive motor guard (c) .

d

c wc_gr004146

4. Remove Remove the screws screws (d)  that secure the drive plate to the drum. 5. Disconnect Disconnect and plug plug the hydraulic hydraulic lines lines (e) from the drive motor.

e f d

wc_gr004147

6. Secure Secure the drum drum support support with an appropr appropriate iate sling sling (f)  and crane.

This procedure continues on the next page.

83

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Disassembly & Assembly

RD 12/RD 12A

Continued from the previous page. 7. Remove Remove the screws screws (g)  that secure the drum support to the machine.

g

h

wc_gr004148

8. Lift Lift the the drum drum suppor supportt (h) and drive motor from the machine. 9. Disconnect Disconnect and plug plug the hydraulic hydraulic lines lines (i)  from the exciter motor motor.. Then, remove the exciter motor motor..

j

i

wc_gr004149

10.Secure the drum support with an appropriate sling and crane. 11. 1.Remove Remove the screws (j)   that secure the drum support to the machine and pull the drum from underneath the machine.

wc_gr004150

The procedure to remove the front drum is now complete.

84

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RD 12/RD 12A 9. 9.14 14

Disassembly & Assembly

Inst Instal alli ling ng th the e Fron Frontt Drum Drum

Prerequisites

Procedure

 



Crane and appropriate sling



Jacks

Follow the procedure below to install the front drum. 1. Slide the the drum int into o position position under underneath neath the the machine. machine.

a

wc_gr004151

2. Apply Loctite Loctite 243 to the the screws screws (a) and secure the exciter-motor-side drum support to the frame. Torque Torque the screws to 79 Nm (58 ft.lbs.). 3. Reconnect Reconnect the hydraulic hydraulic lines (b)  to the exciter motor. Apply Lotite 243 to the screws and secure the exciter motor (c)  to the drum support.

b

c

wc_gr004152

4. Apply Loctite Loctite 243 to th the e screws and and secure the ex exciter citer mo motor tor (c)  to the drum support. Torque the screws to 44 Nm (32 ft.lbs.).

This procedure continues on the next page.

85

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Disassembly & Assembly

RD 12/RD 12A

Continued from the previous page. 5. Position the drum drum so that the drive plate can be installed to the three shock mounts (d) . Install the drive plate to the drum. Torque Torque the nuts (e) to 76 Nm (56 ft.lbs.).

d

f e

wc_gr004153

6. Reconnect Reconnect the hydrau hydraulic lic lines lines (f)  to the drive motor. 7. Apply Loctite Loctite 24 243 3 to screw screws s (g)  and secure the drive-motor-side drum support to the frame. Torque Torque the screws to 79 Nm (58 ft.lbs.).

g

h wc_gr004154

8. Install Install the the drive drive motor motor guard guard (h) . 9. Install Install the the dru drum m support support cover covers s (i)  to each side of the machine.

i

wc_gr004155

The procedure to install the front drum is now complete.

86

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RD 12/RD 12A 9. 9.15 15

Disassembly & Assembly

Re Remo movi ving ng the the Fron Frontt Dri Drive ve Mo Moto torr

Prerequisites

Procedure

 



Front drum removed



Puller 

Follow the procedure below to remove the front drive motor. 1. Remove Remove the front drum. drum. See section section Removing the Front Drum. 2. Remo Remove ve th the e nut nut (a) that secures the hub  (b)  to the drive motor.

c  

b

d

a wc_gr004157

3. Remove Remove the screws screws (c)  that secure the drive plate (d  (d)) to the hub. 4. Slide Slide the the driv drive e pl plate ate (d) off the hub.

d

 

e

wc_gr004156

5. Pull the hub fro from m the drive drive motor motor using using a pulle puller  r  (e)  (e). 6. Remove Remove the scr screws ews that that secur secure e the driv drive e motor (f)  to the drum support (g)  and remove the drive motor.

g

f wc_gr004158

The procedure to remove the front drive motor is now complete.

87

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Disassembly & Assembly 9. 9.16 16

RD 12/RD 12A

Inst Instal alli ling ng tthe he F Fro ront nt Dri Drive ve M Mot otor or

Prerequisites Procedure

 



Front drum removed

Follow the procedure below to install the front drive motor. 1. Apply Loctite Loctite 243 to the sc screws rews and install install the the drive mot motor or (a) to the drum support  (b) . Torque the the screws to 76 Nm (56 ft.lbs.).

b

d

c

a

wc_gr004159

2. Positio Position n the driv drive e pla plate te (c)  and the hub (d)  onto the shaft of the drive motor. motor. 3. screws Apply Loctite Loctit 24 243 3(32 to screw screws s (e) and secure the drive plate (c)  to the hub. Torque the to 44e Nm ft.lbs.).

e c f wc_gr004160

4. Apply Loctite Loctite 24 243 3 to the nut (f (f)) and secure the hub to the drive motor. Torque the nut to 407 Nm (300 ft.lbs.).

The procedure to install the front drive motor is now complete.

88

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RD 12/RD 12A 9.1 .17 7

Disassembly & Assembly

Re Remo mov vin ing g the the Excit xciter er

Prerequisites Procedure

 



Front drum removed

Follow the procedure below to remove the exciter. 1. Remove Remove the screws screws (a) that secure the drum support (b)  to the shock mounts and remove the drum support.

 

b

d

a

c

wc_gr004161

2. Mark (c)  the position of the motor mount (d) . 3. Remove Remove tthe he motor motor moun mountt (d) .

e d

wc_gr004162

4. Remove Remove th the e sh shock ock mount mount plate (e). 5. Mark Mark tthe he positio position n (f)  of the bearing housing.

g f

wc_gr004163

6. Remove Remove th the e bear bearing ing hou housin sing g (g) .

This procedure continues on the next page.

89

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Disassembly & Assembly

RD 12/RD 12A

Continued from the previous page. 7. Pull Pull the the excit exciter er (h)  up and out of the drum.

h

wc_gr004164

The procedure to remove the exciter is now complete.

90

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RD 12/RD 12A 9.1 .18 8

Disassembly & Assembly

Ins In stal alli ling ng th the eE Ex xcit iter er

Prerequisites

Procedure

 



Front drum removed



Drive-motor-side exciter bearing installed

Follow the procedure below to install the exciter. 1. Insta Installll the key key and tthe he gear gear (a) of the exciter motor coupling coupli ng onto the exciter. Secure the gear to the exciter exci ter with the set screw. screw.

a b

wc_gr004165

2. Slide Slide the excite exciterr (b)  through the drum and into the drive-motor-side bearing race. 3. Temporarily emporarily inst install all the exciter exciter-side -side drum hub hub (c) onto the drum using three screws.

d c c d 5 mm (3/16 in.)

b

wc_gr004166

4. Check the exciter for end-play. end-play. To To do so, gr grab ab the exciter (b)  with a needle-nosed pliers and pull and push it back and forth inside the drum. There needs to be 5±1 mm (3/16±1/16 in.) of end-play for correct performance. If the correct amount of end-play is not found, remove the drum hub and install shims (d)  as needed to obtain the correct amount of end-play. Then, using Loctite 243 on the six screws, secure the drum hub to the drum. Torque the screws to 49 Nm (36 ft.lbs.). This procedure continues on the next page.

This procedure continues on the next page.

91

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Disassembly & Assembly

RD 12/RD 12A

Continued from the previous page.

5. Using Loctit Loctite e 243 on the six screws screws (e), secure the bearing cover (f)  and the shock mount plate (g)  to the drum support. Torque Torque the screws to 50 Nm (36 ft.lbs.).

e

g f

wc_gr004167

.

The procedure to install the exciter is now complete.

92

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RD 12/RD 12A 9.19 9.19

Disassembly & Assembly

Di Disa sass ssem embl blin ing g tthe he Exci Excite terr B Bea eari ring ngs s

Prerequisites

Procedure

 



Front drum removed



Puller 

On the exciter side of the drum, two bearings and their flanges make up the drum hub (d) . Follow the procedure below to disassemble the exciter bearings.

1. Remove Remove th the e ret retain aining ing ri ring ng (e).

h e

f

g

wc_gr004169

2. Use a puller puller to pull pull the smaller smaller bearin bearing g flange flange (f)  and bearing (h) from the shaft of the larger bearing flange (g) . Then, use a press to press out the bearing (h)  from the smaller bearing flange.

This procedure continues on the next page.

93

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Disassembly & Assembly

RD 12/RD 12A

Continued from the previous page. 3. On the larger larger bearing bearing flang flange, e, remo remove ve the outer outer seal (i)  and use the two set screws (j)  to push the outer bearing race (k1) from the larger bearing flange.

i i

l

j

k1 j

wc_gr004170

wc_gr004244

4. Remove Remove the inner inner s seal eal (l)  if necessary. In order to remove the drive-motor-side exciter bearing, the drive motor and the left-side drum support must be removed. See section Removing Front Drive Motor. 5. Remove Remove tthe he six six scr screws ews (a) which secure the drive-motor-side bearing flange (b)  and remove the bearing flange. Note:  The drive-motor-side bearing flange is removed from inside the drum.

c1 a b b

m

wc_gr004171

6. Remove Remove tthe he two two scr screws ews (m)  from the drive-motor-side bearing flange (b) . In their place, insertthe twodrive-motor-side M8 pusher screws. Use the pusher from bearing flange (b) . screws to push the outer bearing race (c1)  7. Use a puller puller to remove remove the inner inner bear bearing ing rac races es (c2  and k2)  from the exciter.

k2

c2

wc_gr004172

The procedure to disassemble the exciter bearings is now complete.

94

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RD 12/RD 12A 9.20 9.20

Disassembly & Assembly

As Asse semb mbli ling ng th the e Exci Excite terr Be Bear arin ings gs

Prerequisites Procedure

 



Front drum removed

Follow the procedure below to assemble the exciter bearings. 1. Press new inner bearing bearing races races (c2  and k2)  onto the exciter.

i l

k2

k1 c2

wc_gr004172

j

wc_gr004244

2. Install Install the outer bearing bearing race into the drive-mot drive-motor-si or-side de bearing fla flange nge (b) .

3. Using Loctit Loctite e 234 on the six screws screws (a), secure the drive-motor-side bearing flange to the drum. Torque the screws to 49 Nm (36 ft.lbs.).

This procedure continues on the next page.

95

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Disassembly & Assembly

RD 12/RD 12A

Continued from the previous page. 4. Be sure sure s set et th the e scr screws ews (j)  are recessed on the larger bearing flange (g) . Install a new inner seal (l) . Lightly grease the outer bearing race and press it into the larger bearing flange.

e i

h

f i

j

g l

g

j

k1

d wc_gr004181

5. Insta Installll a new new outer outer se seal al (i)  on the shaft of the larger bearing flange. 6. Press Press the bearing bearing (h)  into the smaller bearing flange (f) .

h e f g

wc_gr004182

7. Press the the two beari bearing ng flanges flanges together together to create create the drum hub. hub. 8. Install Install the retaining retaining ring (e). 9. Lubricate the exciter bearings with wheel bearing grease Mobil XHP222 or equivalent.

The procedure to assemble the exciter bearings is now complete.

96

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RD 12/RD 12A 9.21 9.21

Disassembly & Assembly

Re Remo movi ving ng the the C Con ontr trol ol C Cab able le a and nd Cont Contro roll Leve Leverr

Prerequisites

Procedure

 



Machine OFF and engine cool



Seat platform in raised position

Follow the procedure below to remove the control cable and the control lever.

CAUTION!  Burn hazard. The engine exhaust pipes are extremely hot while the engine is running and for a period of time after the engine has shut down. 

 Allow the exhaust pipes to cool cool before performing this pro procedure. cedure.

1. Disconnect Disconnect the control control cable (a) from the drive pump.

a

 

b

wc_gr004189

2. Cut the wir wire e ties ties (b)  that secure the hoses, wires, and cables. Maneuver the cable around the engine so that it i t is free up to the control lever. 3. Disconnect Disconnect tthe he wiring wiring at th the e connector connector (c) .

d c

wc_gr004190

4. Remove Remove tthe he cable cable clam clamp p (d) .

This procedure continues on the next page.

97

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Disassembly & Assembly

RD 12/RD 12A

Continued from the previous page. 5. Remove Remove the screws screws (e) that secure the control lever assembly (f)  and remove the control lever assembly from the machine.

f a e

wc_gr004191

6. Disconnect Disconnect the control control cable cable (a) from the control lever assembly.

The procedure to remove the control cable and the control lever is now complete.

98

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RD 12/RD 12A 9.22 9.2 2

Disassembly & Assembly

Ins Instal tallin ling g tthe he Contro Controll Cabl Cable e and and Con Contro troll Leve Leverr

Prerequisites Procedure

 



Seat platform in raised position

Follow the procedure below to install the control cable and the control lever. 1. Check that the the clamp bracket is positioned correctly. correctly. It should be positioned with the screws (g)  in the first and third holes of the control lever assembly (f) .  

g

2. Connec Connectt the co contr ntrol ol cable cable (a) to the control lever assembly (f) . 3. Install Install contro controll lever lever a assem ssembly bly (f) with the screws (e)

d c

wc_gr004190

4. Insta Installll the cabl cable e clam clamp p (d) . 5. Connect Connect th the e wiring wiring at the the connecto connectorr (c) . 6. Secure Secure the hoses hoses,, wires, wires, and cables wi with th new wire ties ties (b) .

b

a

wc_gr004193

7. Maneuv Maneuver er the contr control ol cable cable (a) around the engine and connect it to the drive pump. The procedure to install the control cable and the control lever is now complete.

99

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Disassembly & Assembly 9. 9.23 23

RD 12/RD 12A

Re Remo movi ving ng th the e Exci Excite terr Pu Pump mp

Prerequisites

Procedure

 



Machine OFF and engine cool



Hose plug

Follow the procedure below to remove the exciter pump. CAUTION! Burn hazard. The engine exhaust pipes are extremely hot while the engine is running and for a period of time after the engine has shut down.   Allow the exhaust pipes to cool before performing this pr procedure. ocedure.

1. Place a plastic sheet sheet and a container container under the machine machine to collect any liquid which which drains off. Dispose of this liquid in accordance with environmental protection legislation. 2. Disconnect Disconnect an and d cap the outgoing outgoing hydraul hydraulic ic line (a).

a b

c wc_gr004183

3. Remove Remove tthe he two two scr screw ews s (b)  that secure the exciter pump to the drive pump. 4. Loosen Loosen the hose hose cla clamp mp (c)  and pull the exciter motor from the machine. Immediately plug (d)  the hose.

c

d wc_gr004184

The procedure to remove the exciter pump is now complete.

100

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RD 12/RD 12A 9. 9.24 24

Disassembly & Assembly

Inst Instal alli ling ng th the eE Exc xcit iter er Pump Pump

Prerequisites Procedure

 



Machine OFF and engine cool.

Follow the procedure below to install the exciter pump. 1. Place a plastic sheet and a container container under the machine to collect any any liquid which drains off. Dispose of this liquid in accordance with environmental protection legislation. 2. Connect Connect the hydraulic hydraulic hose to the the exciter pump pump with the ho hose se clamp (c) .

a b

c wc_gr004183

3. Secure Secure the excit exciter er pump to the dri drive ve pump with with two screw screws s (b)  . 4. Connect Connect the the outgoing outgoing hydra hydraulic ulic line line (a). 5. Check the the level of the hydr hydraulic aulic oil; ad add d hydrau hydraulic lic oil as necessary necessary..

The procedure to install the exciter pump is now complete.

101

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Disassembly & Assembly 9.25 9.25

RD 12/RD 12A

Re Remo mov vin ing g tthe he Dri Drive Pu Pum mp

Prerequisites

Procedure

 



Machine OFF and engine cool



Exciter pump removed

Follow the procedure below to remove the drive pump.

Burn hazard. The engine exhaust pipes are extremely hot while the engine is running and for a period of time after the engine has shut down. 

 Allow the exhaust pipes to cool before performing this pr procedure. ocedure.

1. Place a plastic sheet sheet and a container container under the machine machine to collect any liquid which which drains off. Dispose of this liquid in accordance with environmental protection legislation. 2. Disconnect Disconnect the control control cable cable (a). 3. Disconnect Disconnect and the the plug hydra hydraulic ulic lines lines (b  and c) .

c d e

b

a wc_gr004186

4. Loosen the hose hose clamp from tthe he hydr hydraulic aulic hos hose e (d) . 5. Remove Remove the screws screws (e) that secure the hydraulic pump to the adapter. 6. Remove Remove th the e hydr hydraul aulic ic pum pump p (f)  from the adapter and immediately plug the hydraulic hose (d) .

The procedure to remove the drive pump is now complete.

102

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RD 12/RD 12A 9. 9.26 26

Disassembly & Assembly

Inst Instal alli ling ng th the e Driv Drive e Pump Pump

Prerequisites Procedure

 



Engine and adapter installed

Follow the procedure below to install the drive pump. 1. Place a plastic sheet and a container container under the machine to collect any any liquid which drains off. Dispose of this liquid in accordance with environmental protection legislation. 2. Remove Remove the plug plug from from the hydraul hydraulic ic hose (d)  and connect the hydraulic hose to the drive pump.

d f

wc_gr004187

3. Apply Loctite Loctite 243 to the sc screws rews and secure secure the dr drive ive pump (f)  to the adapter. Torque the screws to 44 Nm (32 ft.lbs.). 4. Connect Connect the hydraulic hydraulic lines (b  & c)  to the drive pump.

c d e

b

a wc_gr004186

5. Reconn Reconnect ect the the control control cable cable (a).

The procedure install the drive pump is now complete.

103

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Disassembly & Assembly 9.27

RD 12/RD 12A

Removing th the E En ngine

Prerequisites

Procedure

 



Crane and appropriate sling



Exciter pump and drive pump removed

Follow the procedure below to remove the engine.

Burnand hazard. engine exhaust pipes are extremely while the engine is running for aThe period of time after the engine has shut hot down. 

 Allow the exhaust pipes to cool before performing this pr procedure. ocedure.

1. Discon Disconnec nectt the harne harness ss (a) and the wiring (b) .

c

d b

a

wc_gr004173

2. Discon Disconnec nectt the ex exhau haust st (c)  and the choke cable (d) . 3. Cut the wire wire ties tthat hat secu secure re the oil dr drain ain hose (e).

e f

c

wc_gr004174

4. Discon Disconnec nectt the fuel fuel line line (f) .

This procedure continues on the next page.

104

wc_tx000671gb.fm

 

RD 12/RD 12A

Disassembly & Assembly

Continued from the previous page. 5. Discon Disconnec nectt the lanya lanyard rd (g)  from the hydraulic tank.

g h

wc_gr004177

6. Discon Disconnec nectt the air cylind cylinder er (h)  from the hydraulic tank. Support the hood in the open position. 7. Disconnect Disconnect an and d plug the exciter exciter motor motor hy hydraul draulic ic line (i)  from the hydraulic tank.

i

j wc_gr004175

8. Remove the screws that secure secure the hydraulic tank to the machine. Position the tank (j)   so that you can access the screws that secure the engine to the frame. 9. Remove Remove the screw screws s that secure secure the engine to the fr frame. ame.

wc_gr004176

10.Using an appropriate crane, lift the engine from the machine.

The procedure to remove the engine is now n ow complete.

105

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Disassembly & Assembly 9.28 9.28

RD 12/RD 12A

Inst In sta all llin ing g the the Engi Engine ne

Prerequisites Procedure

 



Machine OFF and engine cool.

Follow the procedure below to install the engine. en gine. 1. Position Position the engine into the the frame. frame.

a

wc_gr004178

2. Reconn Reconnect ect the the exhau exhaust st (a). 3. Apply Loctite 243 to the screws screws and secure the engine to the frame. Torque Torque the screws to 44 Nm (32 ft.lbs.). 4. Discon Disconnec nectt the harne harness ss (b)  and the wiring (c) .

d c b

wc_gr004179

5. Reconn Reconnect ect the the choke choke cab cable le (d) . 6. Secure Secure the the oil drai drain n hos hose e (e) with new wire ties.

e f

c

wc_gr004174

7. Reconn Reconnect ect the the fuel fuel lin line e (f) .

This procedure continues on the next page.

106

wc_tx000671gb.fm

 

RD 12/RD 12A

Disassembly & Assembly

Continued from the previous page. 8. Reconn Reconnect ect the the lanya lanyard rd (g)  to the hydraulic tank.

g h

wc_gr004177

9. Reconn Reconnect ect the the air cylinde cylinderr (h)  to the hydraulic tank. 10.Reconnect the exciter motor hydraulic line (i)  from the hydraulic tank.

i

wc_gr004180

11. 1.Secure Secure the hydraulic tank to the machine. Torque the nuts to 25 Nm (18 ft.lbs.).

The procedure to install the engine is now complete.

107

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Disassembly & Assembly 9. 9.29 29

RD 12/RD 12A

Re Remo movi ving ng th the eS Ste teer erin ing gV Val alve ve

Prerequisites Procedure

 



Machine OFF and engine cool.

Follow the procedure below to remove the steering valve. 1. Remove Remove the front console console panel panel (a).

2. Remove Remove tthe he cable cable clam clamp p (b) . 3. Remove Remove tthe he small small cove coverr (c)  on the steering wheel.

c d

wc_gr004202

4. Remo Remove ve the the n nut ut (d)  that secures the steering wheel and remove the steering wheel. 5. Remove Remove the scr screws ews that that secur secure e the cho choke ke control control (e). Allow the choke control to to hang out of the way.

e

 

f

wc_gr004203

6. Label, disconn disconnect, ect, an and d plug the hy hydrauli draulic c lines (f) .

This procedure continues on the next page.

This procedure continues on the next page.

108

wc_tx000671gb.fm

 

RD 12/RD 12A

Disassembly & Assembly

Continued from the previous page. 7. Remove Remove the screws screws (g)  that secure the bracket (h)  to the console.

j i h g g

h

wc_gr004203

8. Remove Remove the screws screws (i)  that secure the steering servo. Maneuver the steering valve (j) out of the control console.

The procedure to remove the steering valve is now complete.

109

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Disassembly & Assembly 9. 9.30 30

RD 12/RD 12A

Inst Instal alli ling ng tthe he S Ste teer erin ing g Va Valv lve e

Prerequisites Procedure

 



Machine OFF and engine cool

Follow the procedure below to install the steering valve. 1. Positio Position n the steer steering ing valve valve (j) and bracket (h) into the control console. Secure the steering valve to the bracket with screws (i)  .

i h g g j

h wc_gr004240

2. Secure Secure the bracke brackett (h)  to the console with the screws (g) . 3. Connec Connectt the hyd hydrau raulic lic lines lines (f).

f

e

wc_gr004241

4. Insta Installll the choke choke co contr ntrol ol (e).

This procedure continues on the next page.

110

wc_tx000671gb.fm

 

RD 12/RD 12A

Disassembly & Assembly

Continued from the previous page. 5. Install Install the steering steering wheel wheel and se secure cure it w with ith the nut nut (d) .

c d

wc_gr004202

6. Insta Installll the the small small cover cover (c)  on the steering wheel. 7. Insta Installll the cabl cable e clam clamp p (b) .

a b

wc_gr004242

8. Install Install the the fr front ont console console panel (a)

The procedure to install the steering valve is i s now complete.

111

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Disassembly & Assembly 9. 9.31 31

RD 12/RD 12A

Re Remo movi ving ng th the eH Hyd ydra raul ulic ic Tank  Tank 

Prerequisites Procedure

 



Engine cool

Follow the procedure below to remove the hydraulic tank. 1. Place a plastic sheet sheet and a container container under the machine machine to collect any liquid which which drains off. Dispose of this liquid in accordance with environmental protection legislation. 2. Drain the the hydraulic hydraulic ttank. ank. See See sec section tion Changing Hydraulic Oil and Filter . 3. Discon Disconnec nectt the lanya lanyard rd (g)  and the air cylinder (h)  from the hydraulic tank. Support the hood in the open position.

g

a

h

wc_gr004205

4. Remove Remove and ca cap p the three three hydrauli hydraulic c lines (a). 5. Remove Remove tthe he mounting mounting bracket bracket (b) .

b

c wc_gr004207

c

6. Remove Remove the screws screws (c)  that secure the hydraulic tank to the frame.

This procedure continues on the next page.

112

wc_tx000671gb.fm

 

RD 12/RD 12A

Disassembly & Assembly

Continued from the previous page. 7. Loosen the the hose clamps clamps that secure secure the hydr hydraulic aulic hoses hoses (d  and e) to the drive and exciter pumps.

e

d wc_gr004206

8. Pull the hydraulic tank from the hydraulic hoses (loosen the fitt fittings ings if necessary) and out of the frame.

The procedure to remove the hydraulic tank is now complete.

113

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Disassembly & Assembly 9. 9.32 32

RD 12/RD 12A

Inst Instal alli ling ng tthe he H Hyd ydra raul ulic ic T Tan ank  k 

Prerequisites Procedure

 



Engine cool

Follow the procedure below to install the hydraulic tank. 1. Place a plastic sheet sheet and a container container under the machine machine to collect any liquid which which drains off. Dispose of this liquid in accordance with environmental protection legislation. 2. Connect the hydraulic hydraulic hoses to the the hydraulic tank and position the hydraulic tank into the frame. Tighten the fittings if loosened during the removal procedure.

e

d wc_gr004206

3. Install Install the the mountin mounting g br bracket acket (b) .

b

c wc_gr004207

c

4. Instal Installl th the e sc screw rews s (c)  that secure the hydraulic tank to the frame.

This procedure continues on the next page.

114

wc_tx000671gb.fm

 

RD 12/RD 12A

Disassembly & Assembly

Continued from the previous page. 5. Connec Connectt th the e lanya lanyard rd (g)  and the air cylinder (h)  to the hydraulic tank.

a g h

wc_gr004205

6. Connect Connect the the three three h hydrau ydraulic lic lines lines (a). 7. Fill the the hydr hydraulic aulic ttank. ank. See section section Changing Hydraulic Oil and Filter .

The procedure to install the hydraulic tank is now complete.

115

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Disassembly & Assembly 9.33 9.33

RD 12/RD 12A

Re Remo mov vin ing g tthe he Fue Fuel Ta Tank 

Prerequisites

Procedure

 



Machine shut down



Platform in upright position. See section Rear Frame Access.

Follow the procedure below to remove the fuel tank. 1. Drain the the fuel from th the e fuel tank by disconne disconnecting cting the fu fuel el hose (a) at the engine.

2. Remove Remove the screws screws (b)  that secure the fuel spill guard, also remove the fuel cap (c) . 3. Discon Disconnec nectt the gas strut struts s (d) .

4. Support Support the platform platform in the open position—ap position—approxim proximately ately 70°.

This procedure continues on the next page.

116

wc_tx000671gb.fm

 

RD 12/RD 12A

Disassembly & Assembly

Continued from the previous page. 5. Disconnect Disconnect the fuel sensor sensor (e) from the wiring harness.

6. Remove Remove th the e gas strut brack brackets ets (f)  from the water tank and the fuel tank. Remove the cable clip (g) . 7. Remove Remove th the e moun mountin ting g plate plate (h)  from the water tank and the fuel tank, and pull the fuel tank from the platform.

The procedure to remove the fuel tank is now complete.

117

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Disassembly & Assembly 9.34 9.34

RD 12/RD 12A

Ins In sta tall lliing th the eF Fue uell T Ta ank 

Prerequisites Procedure

 



Platform in upright position. See section Rear Frame Access.

Follow the procedure below to install the fuel tank. 1. Route the fuel fuel le level vel sensor sensor wiring wiring (i)  around the control lever side of the fuel tank. Then, position the fuel tank into the water tank and secure it with the mounting plate (h) . Connect the fuel level sensor to the harness.

2. Install Install the the gas strut brack brackets ets (f)  to the water tank and the fuel tank. 3. Insta Installll the the cable cable clip clip (g) . 4. Connec Connectt th the e fuel fuel line line (i)  to the fuel tank.

5. Connec Connectt the g gas as strut struts s (d) . 6. Instal Installl th the e sc screw rews s (b)  that secure the fuel spill guard. Then, re-install the fuel cap (c) .

The procedure to install the fuel tank is i s now complete. wc_tx000671gb.fm

118

 

RD 12/RD 12A

Disassembly & Assembly

wc_tx000671gb.fm

119

 

Schematics 10 Sc h em at i c s 10.1 Hydr ydra aulic ulic Sc Sche hema matic tic

RD 12/RD 12A

120

wc_tx001073gb.fm

 

RD 12/RD 12A

Schematics

10.2 Hydra ydraulic ulic S Sche chema matic tic Compon Compone ents

Ref.

Description

Ref.

Description

1

Steering cylinder

8

Return filter

2

Steering unit

9

Tank

3

Drive motor

10

Suction strainer

4

Bypass lever

11

Vibration solenoid valve

5

Charge pump

12

Exciter motor

6

Main pump

13

Pressure relief valve

7

Exciter pump

-

---

10..3 Ele 10 Electrical ctrical Sche Schematic matic Ide Identification—R ntification—RD D 12A 12A Use the chart below to determine which electrical schematic applies to your machine.

 

Electrical Schematic

Roller

Item No.

Revisions

RD 12A

0620058

111 & higher

B

110 & lower

A

109 & higher

B

108 & lower

A

111 & higher

B

110 & lower

A

0620320

0620369

wc_tx001073gb.fm

121

 

Schematics 10.4 Ele lectri ctrica call Sche Schema matic tic “ A” —RD 1 12 2A

RD 12/RD 12A

122

wc_tx001073gb.fm

 

RD 12/RD 12A

Schematics

10. 0.5 5 Ele lectrica ctricall S Sche chema matic tic “ A” Compone omponents— nts—R RD 12A 12A

Ref.

Description

Ref.

Description

1

Work light switch

16

Rear light (optional)

2

Throttle switch

17

Left head light (optional)

3

Pump switch

18

Right head light (optional)

4

Key switch

19

To magneto kill

5

Vibration indicator light (green)

20

Crank relay

6

Low fuel indicator light (amber)

21

Neutral relay

7

Alternator (30A)

22

Spray bar pump

8

Starter solenoid

23

Fuel cutoff solenoid

9

Starter motor

24

Reverse switch

10

Battery

25

Vibration switch

11

Fuel level sensor

26

Neutral switch

12

Vibration solenoid (front)

27

Seat switch

13

Throttle solenoid

28

Strobe light (optional)

14

Pump timer module

29

Backup alarm (optional)

15

Hourmeter

-

---

Wire Colors B

Black

R

Red

Y

Yellow

Or

Orange

G

Green

T

Tan

Br

Brown

Pr

Purple

L

Blue

V

Violet

Cl

Clear

Sh

Shield

P

Pink

W

White

Gr

Gray

LL

Light blue

wc_tx001073gb.fm

123

 

Schematics 10.6 Ele lectri ctrica call Sche Schema matic tic “ B” —RD 1 12 2A

RD 12/RD 12A

124

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RD 12/RD 12A

Schematics

10. 0.7 7 Ele lectrica ctricall S Sche chema matic tic “ B” Compone omponents— nts—R RD 12A 12A

Ref.

Description

Ref.

Description

1

Work light switch

16

Rear light (optional)

2

Throttle switch

17

Left head light (optional)

3

Pump switch

18

Right head light (optional)

4

Key switch

19

To magneto kill

5

Vibration indicator light (green)

20

Crank relay

6

Low fuel indicator light (amber)

21

Neutral relay

7

Alternator (30A)

22

Spray bar pump

8

Starter solenoid

23

Fuel cutoff solenoid

9

Starter motor

24

Reverse switch

10

Battery

25

Vibration switch

11

Fuel level sensor

26

Neutral switch

12

Vibration solenoid (front)

27

Seat switch

13

Throttle solenoid

28

Strobe light (optional)

14

Pump timer module

29

Backup alarm (optional)

15

Hourmeter

30

Voltage regulator relay

Wire Colors B

Black

R

Red

Y

Yellow

Or

Orange

G

Green

T

Tan

Br

Brown

Pr

Purple

L

Blue

V

Violet

Cl

Clear

Sh

Shield

P

Pink

W

White

Gr

Gray

LL

Light blue

wc_tx001073gb.fm

125

 

Schematics 10..8 Ele 10 lectrica ctricall S Sche chema matic— tic—R RD 12

RD 12/RD 12A

126

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RD 12/RD 12A

Schematics

10. 0.9 9 Ele lectrica ctricall Sche Schema matic tic Components— Components—R RD 1 12 2

Ref.

Description

Ref.

Description

1

Work light switch

17

Left head light (optional)

2

Throttle switch

18

Right head light (optional)

3

Pump switch

19

To magneto kill

4

Key switch

20

Crank relay

5

Vibration indicator light (green)

21

Neutral relay

6

Low fuel indicator light (amber)

22

Spray bar pump

7

Alternator (30A)

23

Fuel cutoff solenoid

8

Starter solenoid

24

Reverse switch

9 10

Starter motor Battery

25 26

Vibration switch Neutral switch

11

Fuel level sensor

27

Seat switch

12

Vibration solenoid (front)

28

Strobe light (optional)

13

Throttle solenoid

29

Backup alarm (optional)

14

Pump timer module

30

Throttle relay

15

Hourmeter

31

Quick shut-off relay

16

Rear light (optional)

—

—

Wire Colors B

Black

R

Red

Y

Yellow

Or

Orange

G

Green

T

Tan

Br

Brown

Pr

Purple

L

Blue

V

Violet

Cl

Clear

Sh

Shield

P

Pink

W

White

Gr

Gray

LL

Light blue

127

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Technical Data

RD 12/RD 12A

11 Tec h hni nic ca all Da Dat a 11.1 En g i n e Engine Power Rating RD 12A: Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. RD 12: Gross power rating per SAE J1995. Actual power output may vary due to conditions of specific use. Item no.

RD 12A

RD 12

Engine Engine type

4-stroke, 2 cylinder, air cooled

Engine make

Honda

Wacker Neuson

Engine model

GX 610

WM 650

kW (hp)

13.4 13.4 ((18 18.0 .0)) @ 360 3600 0 rpm rpm

15.3 15.3 (20 (20.5 .5)) @ 360 3600 0 rpm rpm

cm³ (in³)

614 (37.5)

653 (39.9)

(NGK) BPR6ES / (NGK) BPR6ES high heat

NGK-BP6ES

0.71-0.79  (0.028-0.031)

0.6-0.7  (0.024-0.027)

Max. rated power @ rated speed

Displacement Spark plug

Electrode gap

mm  (in.)

Engine speed - operating

rpm

3100

Engine speed - idle

rpm

2000

Valve clearance (cold) intake: exhaust:

mm  (in.)

Battery

0.10-0.16 (0.004-0.006) 0.10-0.16 (0.004-0.006)

0.08-0.115 (0.0031-0.0045) 0.08-0.115 (0.0031-0.0045) 12VDC

V

Air cleaner

type

Dual element

Fuel

type

Regular unleaded gasoline

Fuel tank capacity

L (gal)

Fuel consumption

L (gal)/hr

Engine oil

23 (6.1) 4.9 (1.3)

6.0 (1.35)

10W30 SG, SF/CC, CD

type L (qt)

1.2 (1.3) Coolant capacity

L (gal)

--

--

Roller 

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RD 12/RD 12A

Technical Data

11.2 Ro l l er   Item No.

RD 12A

RD 12

Roller Dry Weight Curb Clearance: Right Left

kg (lb.)

1002 (2171)

mm (in.)

400 (15.7) 208 (8.2)

Water Tank Capacity

l (gal.)

100 (26.4)

Outside Turning Radius

m (ft.)

2.44 (8.0)

Forward / Reverse Speed

km/hr. (mph)

0-8.7 (0-5.4)

Gradeability Vibration Frequency

30% 4200

vpm

11.3 Lu Lubr brii ca cat ion ion

Item No.

RD 12A

RD 12

Lubrication Engine Lubrication Hydraulic System

type l (pt.)

SAE 10W30 Class SG, SF,or SE rated 1.6 (3.5)

type l (gal.)

Premium grade, anti-wear hydraulic fluid 10W30

Exciter

type

21.6 (5.7) Mobil XHP222

Rear Drum Drive Bearing

type qty.

Mobil XHP222 2-3 shots with hand-held grease gun

Articulated Joint

type qty.

Mobil XHP222 2-3 shots with hand-held grease gun

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Technical Data

RD 12/RD 12A

11.4 Di m me ens nsii ons ons mm (in.)

2300 (90.6)

560 (22) 1265 (49.8) 1824 (71.8)

900 (35.4) 1035 (40.8)

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RD 12/RD 12A

Technical Data

11.5 Soun ound d Measur sure ements ments The operating sound level, measured per the requirements of Appendix 1, Paragraph 1.7.4.f of the EC-Machine Regulations, is: •

the guar guaran antteed eed sou sound nd powe powerr lev level el (LWA):

•

RD 12 = 102 dB(A) th the e sou sound nd pr pres essur sure e llev evel el at ope opera rato tor’ r’s s loca locati tion on (LpA): RD 12 = 85.6 dB(A)

This sound value was determined according to ISO 3744 for the sound power level (LWA).

11. 1.6 6 Measure sureme ments nts of Ope Operat rator or Exposure to Vibration Vibration The operator of this machine should expect to be exposed to vibration levels listed below when using the machine in performance of its normally intended function: •

Maxi Maximu mum m hand hand/a /arm rm vibr vibrat atio ion n leve levels ls are: are: RD 12 = 1.4 m/s2  (4.6 ft/s2) These are the representative values of the weighted root mean square (rms) (rms) acceleration  acceleration to which the hands and arms are subjected. These weighted rm s  values are measured according to ISO 5349-1.

•

Whol Whole e bod body y vib vibra rati tion on leve levels ls do not not exc excee eed: d: RD 12 = 0.22 m/s2  (0.7 ft/s2) These are the representative values of the weighted root mean square (rms) (rms) acceleration  acceleration to which the whole body is subjected. These weighted rm s  values are measured according to ISO 2631-1.

The results are compliant to the limit limi t and action vibration values (hand/ arm and whole body) as specified in European directive 2002/44/EC.

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Technical Data

RD 12/RD 12A

11.7 Hydr ydra aulic ulic Pr Pre essure ssures s

S y s t em

Op er at i n g Pr es s u r e

Rel i ef Pr es s u r e

bar

psi

bar

psi

55–69

800–1000

200

2900

Steering*  —while turning

0–41

0–725

45–51

650–725

Vibration  —single drum

55–76

800–1100 800–1100

200

2900

Drive**

* Values for hard-packed surface shown. Values may differ depending on surface. ** Charge pressure: 11.4 – 12.8 bar (165 –185 psi).

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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 Neuson equipment. TYPE ( ) = Europe

COLOR USAGE

PART NO. – SIZE

Loctite 222 Hernon 420 Omnifit 1150 (50M)

Purpl Pu rple e

Low Low stren strengt gth, h, for for loc locki king ng thre thread ads s smal smalle lerr 73287 - 10 ml than 6 mm (1/4”). Hand tool removable. Temp. range: -54 to 149°C (-65 to 300°F)

Loctite 243 Hernon 423 Omnifit 1350 (100M)

Bl Blue ue

Medi edium st stre reng ngth th,, for lo lock ckiing thr hrea eads ds 29311 - .5 ml larger than 6 mm (1/4”). 17380 - 50 ml Hand tool removable. Temp. range: -54 to 149°C (-65 to 300°F)

Loctite 271/277 Hernon 427 Omnifit 1550 (220M)

Red

High st streng ength, ffo or al all th thre rea ads up up to to 2 25 5 mm mm 29312 - .5 ml (1”). 26685 - 10 ml Heat parts before disassembly. 73285 - 50 ml Temp. range: -54 to 149°C (-65 to 300°F)

Loctite 290 Gree Gr een n Hernon 431 Omnifit 1710 (230LL)

Medi Medium um to hi high gh stren strengt gth, h, for for lo locki cking ng 28824 - .5 ml preassembled threads and for sealing 25316 - 10 ml weld porosity (wicking). Gaps up to 0.13 mm (0.005”) Temp. range: -54 to 149°C (-65 to 300°F)

Loctite 609 Hernon 822 Omnifit 1730 (230L)

Gree Gr een n

Medi Medium um st stren rengt gth h ret retai aini ning ng compou compound nd for for 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 300°F)

Loctite 545 Hernon 947 Omnifit 1150 (50M)

Brown

Hydra rau ulic se sealant 79356 - 50 ml Temp. range: -54 to 149°C (-65 to 300°F)

Loctite 592 Hernon 920 Omnifit 790

Whit Wh ite e

Pi Pipe pe seal sealan antt wit with h Tef Teflo lon n for for mode modera rate te 26695 - 6 ml pressures. 73289 - 50 ml Temp. range: -54 to 149°C (-65 to 300°F)

Loctite 515 Hernon 910 Omnifit 10

Purpl Pu rple e

Form Form-i -inn-pl plac ace e gaske gaskett for for fl flexi exibl ble e joint joints. s. 70735 - 50 ml Fills gaps up to 1.3 mm (0.05”) Temp. range: -54 to 149°C (-65 to 300°F)

 

Threadlockers and Sealants Threadlockers and Sealants (continued) Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container. The sealants listed are recommended for use on Wacker Neuson equipment. TYPE ( ) = Europe

COLOR USAGE

Loctite 496 Cl Clea earr Hernon 110 Omnifit Sicomet 7000

Loctite Primer T Hernon Primer 10 Omnifit VC Activator

In Inst stan antt adhe adhesi sive ve fo forr bond bondin ing g ru rubb bber er,, metal and plastics; general purpose. For gaps up to 0.15 mm (0.006”) Read caution instructions before using. Temp. range: -54 to 82°C (-65 to 180°F)

Aerosol Fast curing primer for threadlocking, Spray retaining and sealing compounds. Must be used with stainless steel hardware. Recommended for use with gasket sealants.

PART NO. – SIZE

52676 - 1oz.

2006124-6 oz.

 

Torque Values Torque Values Metric Fasteners (DIN)

TORQUE VALUES (Based VALUES (Based on Bolt Size and Hardness)

8.8 Size

10.9

 

WRENCH SIZE

12.9

Nm

ft.lb.

Nm

ft.lb.

Nm

ft.lb.

Metric

Inch

Metric

Inch

M3

 

1 .2 1.

*11

1.6

*14

2.1

*19

5.5

7/32

2.5

–

M4

 

2.9 2.

*26

4.1

*36

4.9

*43

7

9/32

3

–

M5

 

6.0

*53

8.5

6

10

7

8

5/16

4

–

M6 M8

   

10 25

7 18

14 35

10 26

17 41

13 30

10 13

– 1/2

5 6

– –

M10

 

49

36

69

51

83

61

17

11/16

8

–

M12

 

86

63

120

88

145

107

19

3/4

10

–

M14

 

135

99

190

140

230

169

22

7/8

12

–

M16

 

210

155

295

217

355

262

24

15/16

14

–

M18

 

290

214

405

298

485

357

27

1-1/16

14

–

M20

 

410

302

580

427

690

508

30

1-1/4

17

–

1 ft.lb. = 1.357 Nm

* = in.lb.

1 inch = 25.4 mm

 

Torque Values Torque Values (continued) Inch Fasteners (SAE)

Size

Nm

ft.lb.

Nm

ft.lb.

Nm

ft.lb.

Metric

Inch

Metric

Inch

No.4

 

0.7

*6

1.0

*14

1.4

*12

5.5

1/4

–

3/32

No.6

 

1.4

*12

1.9

*17

2.4

*21

8

5/16

–

7/64

No.8

 

2.5

*22

3.5

*31

4.7

*42

9

11/32

–

9/64

No.10

 

3.6

*32

5.1

*45

6.8

*60

–

3/8

–

5/32

1/4

 

8.1

6

12

9

16

12

–

7/16

–

3/32

5/16

 

18

13

26

19

33

24

13

1/2

–

1/4

3/8

 

31 31

23

45

33

58

43

–

9/16

–

5/16

7/16

 

50

37

71

52

94

69

16

5/8

–

3/8

1/2

 

77 77

57

109

80

142

105

19

3/4

–

3/8

9/16

 

111

82

156

115

214

158

–

13/16

–

–

5/8

 

152 15

112

216

159

265

195

24

15/16

–

1/2

3/4

 

271 27

200

383

282

479

353

–

1-1/8

–

5/8

1 ft.lb. = 1.357 Nm

* = in.lb.

1 inch = 25.4 mm