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Roller

RD 11

REPAIR MANUAL

0162632en 002

0507 en

0 1 6 2 6 3 2 E N

Foreword

Operating / Parts InformationYou must be familiar with the operation of this machine before youattempt to troubleshoot or repair it. Basic operating and maintenanceprocedures are described in the Operator’s Manual supplied with themachine. Keep a copy of the Operator’s Manual with the machine at alltimes. Use the separate Parts Book supplied with the machine to orderreplacement parts. If you are missing either of the documents, pleasecontact Wacker Corporation to order a replacement.

Damage caused by misuse or neglect of the unit should be brought tothe attention of the operator to prevent similar occurrences fromhappening in the future.

This manual provides information and procedures to safely repair andmaintain the above Wacker model(s). For your own safety andprotection from injury, carefully read, understand, and observe allinstructions described in this manual. THE INFORMATIONCONTAINED IN THIS MANUAL IS BASED ON MACHINESMANUFACTURED UP TO THE TIME OF PUBLICATION. WACKERCORPORATION RESERVES THE RIGHT TO CHANGE ANYPORTION OF THIS INFORMATION WITHOUT NOTICE.

This manual covers machines with Item Number:0007693, 0007694, 0007695

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Foreword

CALIFORNIAProposition 65 Warning:

Engine exhaust, some of its constituents, and certain vehiclecomponents, contain or emit chemicals known to the State ofCalifornia to cause cancer and birth defects or other reproductiveharm.

Laws Pertaining to Spark ArrestersNotice: State Health Safety Codes and Public Resources Codesspecify that in certain locations spark arresters be used on internalcombustion engines that use hydrocarbon fuels. A spark arrester is adevice designed to prevent accidental discharge of sparks or flamesfrom the engine exhaust. Spark arresters are qualified and rated bythe United States Forest Service for this purpose.In order to comply with local laws regarding spark arresters, consultthe engine distributor or the local Health and Safety Administrator.

All rights, especially copying and distribution rights, are reserved.

Copyright 2007 by Wacker Corporation

No part of this publication may be reproduced in any form or by anymeans, electronic or mechanical, including photocopying, withoutexpress written permission from Wacker Corporation.

Any type of reproduction or distribution not authorized by WackerCorporation represents an infringement of valid copyrights, andviolators will be prosecuted. We expressly reserve the right to maketechnical modifications, even without due notice, which aim atimproving our machines or their safety standards.

WARNING

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RD 11 Repair Table of Contents
1. Safety Information 11
1.1 Operating Safety ................................................................................ 121.2 Operator Safety While Using Internal Combustion Engines ............... 131.3 Service Safety .................................................................................... 141.4 Label Locations .................................................................................. 151.5 Safety Labels ...................................................................................... 161.6 Operating Labels ................................................................................ 17

2. Technical Data 21

2.1 Engine ................................................................................................ 212.2 Roller .................................................................................................. 222.3 Lubrication .......................................................................................... 232.4 Dimensions ......................................................................................... 242.5 Sound and Vibration Measurements .................................................. 25

3. Operation 26

3.1 Information Regarding Operation ....................................................... 263.2 Operation and Service Locations ....................................................... 273.3 Starting (RD 11A / RD 11V) ............................................................... 293.4 Stopping/Parking (RD 11A / RD 11V) ................................................ 303.5 Direction and Speed (RD 11A / RD 11V) ........................................... 313.6 Braking Machine (RD 11A / RD 11V) ................................................. 323.7 Starting (RD 11AEC) .......................................................................... 333.8 Stopping/Parking (RD 11AEC) ........................................................... 343.9 Direction and Speed (RD 11AEC) ...................................................... 353.10 Braking Machine (RD 11AEC) ............................................................ 363.11 Vibration (RD 11A / RD 11V) .............................................................. 373.12 Vibration (RD 11AEC) ........................................................................ 383.13 Watering System ................................................................................ 383.14 Operator Presence System ................................................................ 39

4. Maintenance 41

4.1 Engine Maintenance ........................................................................... 414.2 Maintenance Schedule ....................................................................... 42

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Table of Contents RD 11 Repair
4.3 Lifting Machine ....................................................................................434.4 Transporting Machine ..........................................................................444.5 Towing (RD 11A / RD 11V) .................................................................454.6 Towing (RD 11AEC) ............................................................................464.7 Engine Oil Drain ..................................................................................474.8 Engine Oil ............................................................................................484.9 Oil Filter (Honda) .................................................................................494.10 Oil Filter (Vanguard) ............................................................................494.11 Air Cleaner (Honda) ............................................................................504.12 Air Cleaner (Vanguard) .......................................................................514.13 Hydraulic System Cleanliness .............................................................524.14 Hydraulic Oil Requirements .................................................................534.15 Hydraulic Oil Level ..............................................................................544.16 Suction Filter .......................................................................................544.17 Changing Hydraulic Oil & Filter ...........................................................554.18 Bleeding the Hydraulic System ...........................................................564.19 Spark Plug ...........................................................................................574.20 Carburetor (Vanguard) ........................................................................584.21 Grease Fittings ....................................................................................594.22 Fuel Filter ............................................................................................604.23 Scraper Bars .......................................................................................614.24 Parking Brake Adjustment (RD 11A/RD 11V) .....................................624.25 Throttle Solenoid Adjustment ..............................................................634.26 Storage ................................................................................................64
5. Engine Starting Troubleshooting 66

5.1 Starting System Component Locations ...............................................665.2 Troubleshooting Flowcharts ................................................................685.3 Engine Does Not Crank—Flowchart 1A ..............................................695.4 Checking Battery .................................................................................705.5 Checking 20A Fuses ...........................................................................725.6 Checking Keyswitch ............................................................................745.7 Checking Neutral Switch .....................................................................765.8 Checking Starter Relay .......................................................................785.9 Checking Power to Starter Solenoid (Honda engines only) ................805.10 Engine Cranks but Does Not Start—Flowchart 2A ..............................815.11 Checking Fuel System ........................................................................825.12 Checking Seat Switch .........................................................................835.13 Checking Anti-Afterfire Solenoid .........................................................84


6. Hydraulic System 87
6.1 Hydraulic System Precautions ........................................................... 876.2 Hydraulic System Service Basics ....................................................... 876.3 Hydraulic Schematic—RD 11A and RD 11V (parallel drive) .............. 886.4 Hydraulic Components—RD 11A and RD 11V (parallel drive) ........... 896.5 Hydraulic Diagram—RD 11A and RD 11V (parallel drive) ................. 906.6 Hydraulic Components—RD 11A and RD 11V (parallel drive) ........... 916.7 Hydraulic Piping—RD 11A, RD 11V (parallel drive) ........................... 926.8 Hydraulic Piping Components—RD 11A, RD 11V (parallel drive) ...... 936.9 Hydraulic Schematic—RD 11A, RD 11V (revisions 103–134) ........... 946.10 Hydraulic Components—RD 11A, RD 11V (revisions 103–134) ........ 956.11 Hydraulic Diagram—RD 11A, RD 11V (revisions 103–134) ............... 966.12 Hydraulic Components—RD 11A, RD 11V (revisions 103–134) ........ 976.13 Hydraulic Piping—RD 11A, RD 11V (revisions 103–134) .................. 986.14 Hydraulic Piping Components—RD 11A, RD 11V

(revisions 103–134) ............................................................................ 996.15 Hydraulic Schematic—RD 11A, RD 11V (revisions > 134) .............. 1006.16 Hydraulic Components—RD 11A, RD 11V (revisions > 134) ........... 1016.17 Hydraulic Diagram—RD 11A, RD 11V (revisions > 134) ................. 1026.18 Hydraulic Components—RD 11A, RD 11V (revisions >134) ............ 1036.19 Hydraulic Piping—RD 11A, RD 11V (revisions > 134) ..................... 1046.20 Hydraulic Piping Components—RD 11A, RD 11V (revisions > 134) 1056.21 Hydraulic Schematic—RD 11AEC ................................................... 1066.22 Hydraulic Components—RD 11AEC ................................................ 1076.23 Hydraulic Diagram—RD 11AEC ....................................................... 1086.24 Hydraulic Diagram Components—RD 11AEC ................................. 1096.25 Hydraulic Piping—RD 11AEC .......................................................... 1106.26 Hydraulic Piping Components—RD 11AEC ..................................... 1116.27 General Description .......................................................................... 1126.28 Drive Circuit—RD 11A and RD 11V ................................................. 1146.29 Drive Circuit—RD 11AEC ................................................................. 1166.30 Vibration and Steering—All Models .................................................. 1186.31 Hydraulic Manifold Blocks with Test Ports ....................................... 1206.32 Testing Hydraulic Pressure .............................................................. 1216.33 Checking Drive Circuit Pressures ..................................................... 1236.34 Checking Vibration Circuit Pressures ............................................... 1246.35 Checking Steering Circuit Pressures ................................................ 1246.36 Adjusting Relief Valves ..................................................................... 1256.37 Troubleshooting Flowcharts ............................................................. 1266.38 Drive System Troubleshooting—Flowchart 3A ................................. 1276.39 Checking Tow Valve (RD 11A and RD 11V only) ............................ 128


6.40 Checking Brake (RD 11AEC only) ....................................................1296.41 Checking Brake System Electrics .....................................................1306.42 Adjusting the Drive Control Cable .....................................................1316.43 Drive System Troubleshooting—Flowchart 3B ..................................1326.44 Checking Drive Motor for Binding ......................................................1336.45 Checking Drive Motors—Series Drive ...............................................1346.46 Checking Drive Motors—Parallel Drive .............................................1356.47 Vibration System Troubleshooting—Flowchart 4A ............................1366.48 Checking Exciter Electrical System ...................................................1386.49 Troubleshooting a System that Vibrates Poorly ................................1406.50 Checking Exciter and Exciter Motor ..................................................1416.51 Troubleshooting the Steering System ...............................................142
7. Electrical System 143

7.1 Checking Throttle Switch ...................................................................1437.2 Checking Throttle Solenoid ...............................................................1447.3 RD 11A Electrical Schematic (revisions 100–118) ............................1467.4 RD 11A Electrical Components (revisions 100–118) ........................1477.5 RD 11A Wiring Diagram (revisions 100–118) ...................................1487.6 RD 11A Electrical Components (revisions 100–118) ........................1497.7 RD 11A Electrical Schematic (revisions 119–123) ............................1507.8 RD 11A Electrical Components (revisions 119–123) ........................1517.9 RD 11A Wiring Diagram (revisions 119–123) ...................................1527.10 RD 11A Electrical Components (revisions 119–123) ........................1537.11 RD 11A Electrical Schematic (revisions 124–141) ............................1547.12 RD 11A Electrical Components (revisions 124–141) ........................1557.13 RD 11A Wiring Diagram (revisions 124–141) ...................................1567.14 RD 11A Electrical Components (revisions 124–141) ........................1577.15 RD 11A Electrical Schematic (revisions > 141) .................................1587.16 RD 11A Electrical Components (revisions > 141) .............................1597.17 RD 11A Wiring Diagram (revisions > 141) ........................................1607.18 RD 11A Electrical Components (revisions > 141) .............................1617.19 RD 11V Electrical Schematic (revisions 100–118) ............................1627.20 RD 11V Electrical Components (revisions 100–118) ........................1637.21 RD 11V Wiring Diagram (revisions 100–118) ...................................1647.22 RD 11V Electrical Components (revisions 100–118) ........................1657.23 RD 11V Electrical Schematic (revisions 119–138) ...........................1667.24 RD 11V Electrical Components (revisions 119–138) ........................1677.25 RD 11V Wiring Diagram (revisions 119–138) ..................................1687.26 RD 11V Electrical Components (revisions 119–138) ........................169


7.27 RD 11V Electrical Schematic (revisions 139–142) ........................... 1707.28 RD 11V Electrical Components (revisions 139–142) ....................... 1717.29 RD 11V Wiring Diagram (revisions 139–142) .................................. 1727.30 RD 11V Electrical Components (revisions 139–142) ....................... 1737.31 RD 11V Electrical Schematic (revisions > 142) ................................ 1747.32 RD 11V Electrical Components (revisions > 142) ............................ 1757.33 RD 11V Wiring Diagram (revisions > 142) ....................................... 1767.34 RD 11V Electrical Components (revisions > 142) ............................ 1777.35 RD 11AEC Electrical Schematic (revisions 100–111) ...................... 1787.36 RD 11AEC Electrical Components (revisions 100–111) ................. 1797.37 RD 11AEC Wiring Diagram (revisions 100–111) .............................. 1807.38 RD 11AEC Electrical Components (revisions 100–111) ................. 1817.39 RD 11AEC Electrical Schematic (revisions 112–125) ...................... 1827.40 RD 11AEC Electrical Components (revisions 112–125) .................. 1837.41 RD 11AEC Wiring Diagram (revisions 112–125) .............................. 1847.42 RD 11AEC Electrical Components (revisions 112–125) .................. 1857.43 RD 11AEC Electrical Schematic (revisions > 125) ........................... 1867.44 RD 11AEC Electrical Components (revisions > 125) ....................... 1877.45 RD 11AEC Wiring Diagram (revisions > 125) .................................. 1887.46 RD 11AEC Electrical Components (revisions > 125) ....................... 189
8. Disassembly and Assembly 191

8.1 Tools ................................................................................................. 1918.2 Ordering Parts .................................................................................. 1918.3 Reference Numbers ( ) ..................................................................... 1918.4 Weight Block .................................................................................... 1918.5 Threadlocking Compounds .............................................................. 1928.6 Front Drum Assembly Description .................................................... 1928.7 Replacing the Exciter Motor ............................................................. 1948.8 Removing the Front Drum ................................................................ 1968.9 Installing the Front Drum .................................................................. 1988.10 Replacing the Exciter and Exciter Bearings ..................................... 2008.11 Front Drive Motor (RD 11A and RD11V series drive) ....................... 2068.12 Front Drive Motor (RD 11A and RD 11V parallel drive) .................... 2088.13 Front Drive Motor RD 11AEC ........................................................... 2108.14 Rear Drum Assembly—Description .................................................. 2128.15 Replacing Brake and Brake Cable ................................................... 2148.16 Rear Drum (RD 11A and RD 11V revisions < 119) .......................... 2188.17 Replacing Rear Drive Motor (RD 11A and RD 11V

revisions < 104) ................................................................................ 220


8.18 Replacing Rear Drive Motor (RD 11A and RD 11V
revisions 104–118) ............................................................................2228.19 Removing the Rear Drum (RD 11A and RD 11V revisions > 118) ....2248.20 Installing the Rear Drum (RD 11A and RD 11V revisions > 118) ......2268.21 Removing Rear Drive Motor (RD 11A and RD 11V revisions > 118) 2288.22 Installing Rear Drive Motor (RD 11A and RD 11V revisions > 118) ..2308.23 Replacing Rear Drive Motor (RD 11AEC) .........................................2328.24 Replacing the Articulated Steering Joint ...........................................2348.25 Throttle/Choke Cables (revisions 100–118) ......................................2388.26 Choke Cable (revisions > 118) ..........................................................2408.27 Drive Control Cable (revisons 100–109) ...........................................2428.28 Drive Control Cable (revisons > 109) ................................................2448.29 Replacing the Water Tank .................................................................2488.30 Replacing Water Valves ....................................................................2508.31 Replacing the Fuel Tank ...................................................................2528.32 Replacing Steering Cylinder ..............................................................2568.33 Replacing the Drive Pump .................................................................2588.34 Replacing the Exciter Pump ..............................................................2608.35 Replacing the Engine ........................................................................262


RD 11 /... Safety Information
1. Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE andNOTE callouts which must be followed to reduce the possibility ofpersonal injury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potentialpersonal injury hazards. Obey all safety messages that follow thissymbol to avoid possible injury or death.

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

WARNING indicates a hazardous situation which, if not avoided, couldresult in death or serious injury.

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

NOTICE: Used without the safety alert symbol, NOTICE indicates ahazardous situation which, if not avoided, could result in propertydamage.

Note: Contains additional information important to a procedure.

DANGER

WARNING

CAUTION

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Safety Information RD 11 /...
1.1 Operating Safety
Familiarity and proper training are required for the safe operation of themachine. Machines operated improperly or by untrained personnelcan be dangerous. Read the operating instructions contained in boththis manual and the engine manual and familiarize yourself with thelocation and proper use of all controls. Inexperienced operators shouldreceive instruction from someone familiar with the machine beforebeing allowed to operate it.

1.1.1 ALWAYS disengage and stow the locking bar for the articulatedsteering joint before operating the machine. The machine cannot besteered when the locking bar is engaged.

1.1.2 ALWAYS check that all controls are functioning properly immediatelyafter start-up! DO NOT operate the machine unless all controls operatecorrectly.

1.1.3 ALWAYS remain aware of changing positions and the movement ofother equipment and personnel on the job site.

1.1.4 ALWAYS remain seated at all times while operating the machine.

1.1.5 ALWAYS remain aware of changing surface conditions and use extracare when operating over uneven ground, on hills, or over soft orcoarse material. The machine could shift or slide unexpectedly.

1.1.6 ALWAYS use caution when operating near the edges of pits, trenchesor platforms. Check to be sure that the ground surface is stable enoughto support the weight of the machine with the operator and that thereis no danger of the roller sliding, falling, or tipping.

1.1.7 ALWAYS wear protective clothing appropriate to the job site whenoperating equipment.

1.1.8 ALWAYS keep hands, feet, and loose clothing away from moving partsof the machine.

1.1.9 ALWAYS read, understand, and follow procedures in the Operator’sManual before attempting to operate the equipment.

1.1.10 ALWAYS store the equipment properly when it is not being used.Equipment should be stored in a clean, dry location out of the reach ofchildren.

1.1.11 ALWAYS operate the machine with all safety devices and guards inplace and in working order.

1.1.12 NEVER allow anyone to operate this equipment without propertraining. People operating this equipment must be familiar with therisks and hazards associated with it.

1.1.13 NEVER touch the engine or muffler while the engine is on orimmediately after it has been turned off. These areas get hot and maycause burns.

WARNING

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1.1.14 NEVER use accessories or attachments that are not recommended by
Wacker. Damage to equipment and injury to the user may result.

1.1.15 NEVER leave machine running unattended.

1.1.16 NEVER operate the machine with the fuel cap loose or missing.

1.2 Operator Safety While Using Internal Combustion Engines

Internal combustion engines present special hazards during operationand fueling. Read and follow the warning instructions in the engineowner’s manual and the safety guidelines below. Failure to follow thewarnings and safety guidelines could result in severe injury or death.

1.2.1 DO NOT smoke while operating the machine.

1.2.2 DO NOT smoke when refueling the engine.

1.2.3 DO NOT refuel a hot or running engine.

1.2.4 DO NOT refuel the engine near an open flame.

1.2.5 DO NOT spill fuel when refueling the engine.

1.2.6 DO NOT run the engine near open flames.

1.2.7 DO NOT run the machine indoors or in an enclosed area such as adeep trench unless adequate ventilation, through such items asexhaust fans or hoses, is provided. Exhaust gas from the enginecontains poisonous carbon monoxide gas; exposure to carbonmonoxide can cause loss of consciousness and may lead to death.

1.2.8 ALWAYS refill the fuel tank in a well-ventilated area.

1.2.9 ALWAYS replace the fuel tank cap after refueling.

1.2.10 ALWAYS keep the area around a hot exhaust pipe free of debris toreduce the chance of an accidental fire.

DANGER

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1.3 Service Safety
Poorly maintained machines can become a safety hazard! In order forthe machine to operate safely and properly over a long period of time,periodic maintenance and occasional repairs are necessary.

1.3.1 DO NOT attempt to clean or service the machine while it is running.Rotating parts can cause severe injury.

1.3.2 DO NOT crank a flooded engine with the spark plug removed ongasoline-powered engines. Fuel trapped in the cylinder will squirt outthe spark plug opening.

1.3.3 DO NOT test for spark on gasoline-powered engines if the engine isflooded or the smell of gasoline is present. A stray spark could ignitethe fumes.

1.3.4 DO NOT use gasoline or other types of fuels or flammable solvents toclean parts, especially in enclosed areas. Fumes from fuels andsolvents can become explosive.

1.3.5 DO NOT modify the machine without the express written approval ofthe manufacturer.

1.3.6 ALWAYS check all external fasteners at regular intervals.

1.3.7 ALWAYS keep the area around the muffler free of debris such asleaves, paper, cartons, etc. A hot muffler could ignite the debris andstart a fire.

1.3.8 ALWAYS replace worn or damaged components with spare partsdesigned and recommended by Wacker Corporation.

1.3.9 ALWAYS disconnect the spark plug on machines equipped withgasoline engines, before servicing, to avoid accidental start-up.

1.3.10 ALWAYS keep the machine clean and labels legible. Replace allmissing and hard-to-read labels. Labels provide important operatinginstructions and warn of dangers and hazards.

1.3.11 ALWAYS switch off the power supply at the battery disconnect beforeadjusting or maintaining the electrical equipment.

1.3.12 ALWAYS do Periodic Maintenance as recommended in the Operator’sManual.

WARNING

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1.4 Label Locations
Y

W

X

VU

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1.5 Safety Labels
Wacker machines use international pictorial labels where needed.These labels are described below:

Ref. Label Meaning

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

B DANGER! Before fueling, stop the engine. No sparks, flames, or burning objects near the machine. Use only fresh, clean fuel.

C WARNING! Hot surface!

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

E CAUTION!Read and understand the supplied Oper-ator’s Manuals before operating this machine. Failure to do so increases the risk of injury to yourself or others.

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

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1.6 Operating Labels

G WARNING! Always wear seat belt when operating roller.

H CAUTION! Lifting point.

I WARNING! Pinch point

Ref. Label Meaning

J Tie-down point.

K Hydraulic oil drain.

L Hydraulic oil reservoir fill tube.

M Hydraulic oil reservoir level

Ref. Label Meaning

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N Water level

O Gas level

P Torque battery hold-down nuts to 3.5 Nm (2.5 ft.lbs.) max.

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

R Water control valve.

S Guaranteed sound power level in dB(A).

Ref. Label Meaning

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

U Variable speed throttle

V Variable choke

W Variable direction control

X Vibration control

Y Key switch, engine start:OffOnStart

Ref. Label Meaning

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This machine may be covered by one or more patents.

Ref. Label Meaning

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RD 11 /... Technical Data
2. Technical Data
2.1 Engine

Item No. RD 11A0007693

RD 11AEC0007695

RD 11V0007694

Engine

Engine Type 4-stroke, 2 cylinder, air cooled

Engine Make Honda Honda Briggs & Stratton

Engine Model GX 610 QDF Vanguard 350447

Rated Power kW (Hp) 13.4 (18)

Displacement cm³ (in³) 614 (37.5) 570 (34.7)

Spark Plug (NGK) BPR6ES / (NGK) BPR6ESHigh Heat

Champion RC12YC

Electrode Gap mm (in) 0.71–0.79 (0.028–0.031) 0.76 (0.030)

Engine Speed—full load rpm 3200

1800Engine Speed—idle rpm

Valve Clearance (cold)intake:exhaust:

mm (in.) 0.10–0.16 (0.004–0.006)0.10–0.16 (0.004–0.006)

Battery V 12 VDC

Air Cleaner type Dual Element

Fuel type Regular Unleaded Gasoline

Fuel Tank Capacity l (gal.) 24 (6.3)

Fuel Consumption l (gal.)/hr. 4.6 (1.2)

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Technical Data RD 11 /...
2.2 Roller

RD 11AEC0007695

RD 11V0007694

Roller

Dry Weight 925 (2040) 1067 (2353) 925 (2040)

Curb Clearance: RightLeft

mm (in.) 470 (18.4)205 (8.1)

390 (15.4)210 (8.7)

470 (18.4)205 (8.1)

Water Tank Capacity l (gal.) 151 (40)

Outside Turning Radius m (ft.) 2.8 (9.2)

Forward / Reverse Speed

m (ft.) /min.

0–126 (0–414)

Gradeability 27% (12°)

Vibration Frequency Hz (vpm) 65 (3900)

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2.3 Lubrication

RD 11AEC0007695

RD 11V0007694

Lubrication

Engine Lubrication typel (pt.)

SAE 10W30 Class SG, SF,or SE rated1.6 (3.5)

Hydraulic System typel (gal)

Premium grade, Anti-wear hydraulic fluid 10W3021.6 (5.7)

Exciter type Wheel Bearing Grease Filmite EMB

Rear Drum Drive Bearing

typeqty.

Shell Alvania RL2 Grease (1 grease fitting)2–3 shots with hand-held grease gun

Front Drum Drive Bearing

type Sealed Bearings—No lubrication required

Articulated Joint typeqty.

Shell Alvania RL2 Grease (1 grease fitting)2–3 shots with hand-held grease gun

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Technical Data RD 11 /...
2.4 Dimensions
wc_gr000213

1530 mm(60 in.)

560 mm(22 in.)

2210 mm(87 in.)

1127 mm(44 in.)

2100 mm(83 in.)

1025 mm(40 in.)

900 mm(35 in.)

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2.5 Sound and Vibration Measurements
The required sound specification, Paragraph 1.7.4.f of 89/392/EECMachinery Directive, is:The sound pressure level at operator’s location (LpA) = 89.1 dB(A).The guaranteed sound power level (LWA) = 109 dB(A).These noise values were obtained at the operator's location accordingto ISO 3744 for the sound power level (LWA) and ISO 6081 for thesound pressure level (LpA).The weighted effective acceleration value, determined according toISO 8662 Part 1, is approximately:Hands = 5.65 m/s2, Feet = 0.64 m/s2, Seat = 1.05 m/s2.The sound and vibration measurements were obtained with themachine operating on hard asphalt at maximum RPM and top speed.

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Operation RD 11 Repair
3. Operation
3.1 Information Regarding Operation

The information regarding the operation of the machine included in thismanual is condensed. Refer to the Operator’s Manual for completeoperating instructions. Always read, understand, and follow theprocedures in the Operator’s Manual when operating the machine.

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RD 11 Repair Operation
3.2 Operation and Service Locations
wc_gr000116

44 41 15 55 46

161028

56

177

451

25

32

6

19

31

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See Graphic: wc_gr000115 & wc_gr000116

Ref. Description Ref. Description1 Air cleaner 29 Water tank2 Articulated joint 30 Lockarm 3 Water level sight gauge 31 Drive manifold assembly

(valve block)4 Hand holds 32 Oil filter—engine5 Choke lever 33 Rear drum fill/drain plug6 Coupling—engine 34 Rear drum—static7 Dipstick 35 Scraper bar (4 places)8 Drain Plug—hydraulic tank 36 Sightglass—hydraulic tank9 Drive motor 37 Sprinkler tube (4)10 Drive pump 38 Steering wheel11 Engine hood 39 Steering cylinder12 Engine throttle control 40 Tiedown (2 places)13 Vibration control button 41 Battery disconnect (RD 11AEC)14 Exciter motor 42 Water system control—front drum15 Exciter/steering pump 43 Water system control—rear drum16 Filter—return line 44 Battery17 Filter—suction line 45 Hour meter/tachometer18 Forward / reverse control 46 Suction line19 Forward / reverse control cable 47 Grease fitting—exciter (2 places)20 Front Drum—vibratory 48 Fuel level sight gauge21 Fuel tank access door 49 Lifting eye (4 places)22 Fuel filter (under floor panel) 50 Step (2)23 Grease fitting—rear drum 51 ROPS24 Grease fittings—articulated joint

(4 places)52 Emergency stop pushbutton/

parking brake (RD 11AEC)25 Hydraulic tank fill port 53 Horn switch (RD 11AEC)26 Identification plate 54 Adjustable seat with seatbelt (RD

11AEC)27 Ignition switch 55 Brake release tow valve (RD

11AEC)28 Steering/exciter manifold 56 Horn (RD 11AEC)

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3.3 Starting (RD 11A / RD 11V)
See Graphic: wc_gr000123

3.3.1 If the engine is cold, place the choke lever in the closed position (b2).If the engine is warm, place the choke control in the open position (b1).

3.3.2 Set the forward/reverse control in the neutral position (e2).Note: The roller will not start unless the forward/reverse control is inneutral. On revisions 143 and above of RD 11V models, and revisions142 and above of RD 11A models, the roller will not start unless theforward/reverse control is in neutral and the operator is positioned inthe driver’s seat.

3.3.3 Check that the parking brake is set (d).3.3.4 Turn the ignition switch (f) to start the engine. If exciter indicator light

(g) is on, turn vibration off.

NOTICE: Do not crank the engine starter for more than 15 seconds atone time. Longer cranking cycles could lead to starter damage.

3.3.5 Gradually place the choke lever to the open position (b1) as the enginewarms up. Allow the engine to warm up for a few minutes beforeoperating the roller.

wc_gr000123

a2

a1

b2

b1

c

d

g

f

e3 e2 e1

wc_tx000531gb.fm 29

3.4 Stopping/Parking (RD 11A / RD 11V)

3.4.1 Turn vibration off.

3.4.2 Close both watering valves.

3.4.3 Return the engine throttle to idle (a1) by pressing the throttle switch,and allow the engine to cool down.

3.4.4 Stop the engine by turning the ignition switch to OFF.

3.4.5 Set the parking brake. To set the brake (d), pull the brake lever up untilthe brake pad engages the drum. To release, lower the lever. Alwaysset the parking brake before leaving the machine.

The parking brake is connected to the brake pads and can be adjustedby turning the knob (c) on the end of the handle. See Parking BrakeAdjustment.

Note: The parking brake engages the rear drum only.NOTICE: Avoid parking the roller on a hill or an incline. If the rollermust be parked on a hill, block the drums in addition to setting thebrake to prevent the roller from moving.

wc_tx000531gb.fm 30

3.5 Direction and Speed (RD 11A / RD 11V)

The forward/reverse lever controls both the direction and speed of theroller. Use the control lever, rather than the throttle, to control thespeed of the machine while compacting. Daily, before operating, check the machine for drift (movement with theforward/reverse control in the NEUTRAL position) and adjust asneeded. See section Adjusting the Drive Control Cable.Speed is controlled by the amount the lever is moved in the directionof travel—forward (e1) or reverse (e3).While operating the machine, run it at full throttle. To run the machineat full throttle, press and release the throttle switch (a2). This ensuresmaximum travel speeds and will produce the best compaction results.Operating the machine at slower engine speeds will reducecompaction, slow down machine functions, and damage hydrauliccomponents.NOTICE: Holding the throttle switch in for a period of time will trip thecircuit breaker.Note: On revisions 143 and above of RD 11V models, and revisions142 and above of RD 11A models, the engine will stop whenever theoperator rises from the driver’s seat. To restart the engine, return thecontrol lever to the NEUTRAL position, sit in the driver’s seat, turn thekey off then to start.

wc_gr000123

a2

a1

b2

b1

c

d

g

f

e3 e2 e1

wc_tx000531gb.fm 31

3.6 Braking Machine (RD 11A / RD 11V)

The machine will brake automatically when the control lever is returnedto neutral (e2). If the machine continues to drift, shift the control leverslightly in the opposite direction to stop movement and then return thelever to neutral. If it will not remain stationary in neutral, adjust asneeded. See Adjusting the Drive Control Cable.

Note: Do not stop the machine using the parking brake! The parkingbrake is not intended to be used to stop the machine.

wc_tx000531gb.fm 32

3.7 Starting (RD 11AEC)

3.7.1 If the engine is cold, place the choke lever in the closed position (b2).If the engine is warm, place the choke control in the open position (b1).

3.7.2 Set the forward/reverse control in the neutral position (c2).Note: The roller will not start unless the forward/reverse control is inneutral and the operator is positioned in the driver’s seat.

3.7.3 Push the emergency stop pushbutton (d) to make sure that the parkingbrake is set.

3.7.4 Turn the ignition switch (e) to start the engine.

NOTICE: Do not crank the engine starter for more than 15 seconds atone time. Longer cranking cycles could lead to starter damage.

3.7.5 Gradually place the choke lever to the open position (b1) as the enginewarms up. Allow the engine to warm up for a few minutes beforeoperating the roller.

3.7.6 Disengage the parking brake by turning the emergency stop button (d)until it pops out.

wc_gr000139

c3 c2 c1

d

e

b1

b2a2

a1

wc_tx000531gb.fm 33

3.8 Stopping/Parking (RD 11AEC)

3.8.1 Turn vibration off.

3.8.2 Close both watering valves.

3.8.3 Return engine throttle to idle (a1) by pressing the throttle switch andallow the engine to cool down.

3.8.4 Stop the engine by turning the ignition switch to the OFF position.

3.8.5 To engage the parking brake (d), push the emergency stop button.This switch engages a hydraulically-activated brake on the drivemotors. Always set the parking brake before leaving the machine.

NOTICE: Avoid parking the roller on a hill or incline. If the roller mustbe parked on a hill, block the drums in addition to setting the brake toprevent the roller from moving.

wc_tx000531gb.fm 34

3.9 Direction and Speed (RD 11AEC)

The forward/reverse lever controls both the direction and speed of theroller. Use the control lever, rather than the throttle, to control thespeed of the machine while compacting. Daily, before operating, check the machine for drift (movement with theforward/reverse control in the NEUTRAL position) and adjust asneeded. See Adjusting the Drive Control Cable.

Speed is controlled by the amount the lever is moved in the directionof travel—forward (c1) or reverse (c3).During operation, to run the machine at full throttle (a2), quickly pressand release the throttle switch. This ensures maximum travel speedsand will produce the best compaction results. Operating the machineat slower engine speeds will reduce compaction, slow down machinefunctions, and damage hydraulic components.NOTICE: Holding the throttle switch in for a period of time will trip thecircuit breaker.Note: This machine is fitted with an operator presence safety systemwhich prevents the machine from moving if an operator is not seatedin the driver’s seat.

Do not use the machine without the Roll Over Protection Structure(ROPS) in place. The ROPS is designed to protect the operator in arollover accident.

Always wear the seat belt provided when operating the roller.

WARNING

WARNING

wc_gr000139

c3 c2 c1

d

e

b1

b2a2

a1

wc_tx000531gb.fm 35

3.10 Braking Machine (RD 11AEC)

Automatic functionsThe machine will brake automatically when the control lever is returnedto neutral. If the machine continues to drift, shift the control leverslightly in the opposite direction to stop movement and then return thelever to neutral. If the machine will not remain stationary in neutral,adjust it. See section Adjusting the Drive Control Cable.The emergency stop/parking brakes will automatically apply when:

• The emergency stop button is pushed.

• The engine is off.

• A loss of hydraulic or electrical power occurs.

• The operator rises from the driver’s seat, activating the operator presence system.

Note: The operator presence system will only trip after a one-halfsecond delay.

Emergency stop pushbuttonWhen pushed, the emergency stop pushbutton not only stops all travel(either forward or reverse) and applies the brake, but also stops excitervibration. When the emergency stop pushbutton is reset, vibration will notresume until it is turned ON. See section Vibration. Before releasing the emergency stop pushbutton, place the forward/reverse control in neutral.

wc_tx000531gb.fm 36

3.11 Vibration (RD 11A / RD 11V)

Vibration is turned ON or OFF by a push button (a) located in theuppermost portion of the forward/reverse control. Push the button toturn vibration on; push it again to turn it off. Vibration can be turned onwhile operating in either forward or reverse and will remain on until it isswitched off.NOTICE: If the machine has been turned off with the vibration on, thevibration will come on as soon as the machine is restarted. Therefore,for easier starting and to keep the surface finish smooth, be ready toswitch vibration off should it come on while cranking the engine.Note: Vibration will remain on even when the forward/reverse controlis in neutral. When operating on asphalt, to keep the surface finishsmooth, turn vibration off before stopping the roller.

wc_tx000531gb.fm 37

3.12 Vibration (RD 11AEC)

Vibration is turned ON or OFF by a pushbutton (a) located in theuppermost portion of the forward/reverse control. Press thepushbutton to turn vibration on; press it again to turn it off. Vibrationcan be turned on while operating in either forward or reverse and willremain on until it is switched off.Note: Vibration will always be OFF when the engine is started.

Note: Vibration will remain on even when the forward/reverse controlis in neutral. When operating on asphalt, to keep the surface finishsmooth, turn vibration off before stopping the roller.

Note: Pressing the emergency stop pushbutton will also stop vibration.After the emergency stop pushbutton has been reset, presspushbutton (a) to restart vibration.

3.13 Watering System


The watering system is controlled by two valves, one for each drum.The valve handles (a) are located to the right of the operator. Rotatethe valve handles to control the amount of water being applied to thedrum.

wc_gr000118

a

wc_tx000531gb.fm 38

3.14 Operator Presence System

All revisions of RD AEC models, revisions 143 and above of RD 11Vmodels, and revisions 142 and above of RD 11A models are equippedwith an “operator presence system”. This system is part of the driver'sseat and senses the weight of an operator in the seat. If the operatoris not sitting in the driver's seat, the roller will NOT drive, and theexciter will NOT vibrate. If the operator leaves the driver's seat, theroller will stop moving and vibrating. When the operator sits downagain, the forward/reverse lever must be placed in the neutral positionbefore the roller can be driven or the vibration can be started.A one-half second delay keeps the system from tripping when the rollerpasses over a bump.On RD 11AEC models, the seat can be adjusted as follows:

• Knob (a) for adjusting the seat tension to the driver's weight.

• Lever (b) for adjusting the distance from the seat to the driving controls.

Note: Do not change position of the driver’s seat while the machine ismoving. The “OPERATOR PRESENCE” safety device will prevent allmachine movements if an operator is not seated.

Always wear the seat belt provided when operating the roller.

WARNING

wc_tx000531gb.fm 39


wc_tx000531gb.fm 40

RD 11 Repair Maintenance
4. Maintenance
4.1 Engine MaintenanceThe chart below lists basic engine maintenance. Refer to the enginemanufacturer’s Operation Manual for additional information on enginemaintenance.

* Service more frequently in dusty conditions.**These items should be serviced by an authorized Honda dealer, unless the owner has the proper

tools and is mechanically proficient. See Honda shop manual.

Honda Dailybefore

starting

Afterfirst

20 hrs.

Every50

hrs.

Every100 hrs.

Every300hrs.

Check fuel level.

Check engine oil level.

Inspect air filter. Replace as needed. *

Change engine oil and filter.

Clean air cleaner. *

Check and clean spark plug.

Clean sediment cup.

Check and adjust idle speed. **

Check and adjust valve clearances. **

Replace fuel filter. **

Vanguard Dailybefore

starting

Afterfirst

8 hrs.

Every50

hrs.

Every100 hrs.

Every300hrs.

Check fuel level.

Check engine oil level.

Change engine oil.

Change oil filter.

Clean air cleaner.

Check and clean spark plug.

Check and adjust valve clearances.

Replace fuel filter.

wc_tx000530gb.fm 41

Maintenance RD 11 Repair

4.2 Maintenance Schedule

Periodically:• Check operation of the parking brake, making sure it engages.

• Check for leaks around hydraulic hoses and connections.

• Clean engine exterior, cooling fins, and blower housing.

• Check electrical wiring and connections.

• Check operation of the neutral safety switch.

New machines:• Change the engine oil per engine schedule.

• Replace the hydraulic system return line filter after the first month or 100 hours of operation.

All machines:• Increase air cleaner/filter inspections and cleaning under dusty

conditions.

RD 11 /... Dailybefore

starting

Every100hrs.

Every600hrs.

Every1200hrs.

Check external hardware.

Check level of hydraulic fluid.

Grease articulated joint.

Grease rear drum drive bearing.

Grease exciter bearing.

Change hydraulic system return line filter.

Check and adjust scraper bars.

Clean battery terminals.

Change hydraulic oil.

wc_tx000530gb.fm 42

4.3 Lifting Machine

Lock the front and rear machine halves together using the lockarm (a)at the articulation joint. Place slings or chains through each lifting eye(b) on the machine (4 places). Use four slings or chains with aminimum length of 2 meters (6 feet) on each leg connected to a centrallifting device, OR two slings or chains with a minimum length of 4meters (12 feet), one connecting the front lifting eyes and oneconnecting the rear lifting eyes, then brought together over the cranehook. Ensure that all lifting devices have sufficient weight-bearingcapacity.

To avoid being pinched by the machine halves, set the lockarm beforelifting the machine for transport or repairs!

NOTICE: Never use anything but the lifting eyes provided to lift themachine, as severe damage to the machine can result.

WARNING

wc_gr000205

b

b

a

wc_tx000530gb.fm 43

4.4 Transporting Machine

When transporting the machine place blocks in front of and behindeach drum and use the front and rear tie-down lugs (a) provided tosecurely fasten the machine to the trailer (2 places). NOTICE: Never use anything but the tiedown lugs provided to tie downthe machine, as severe damage to the machine can result.

a

wc_gr000204

wc_tx000530gb.fm 44

4.5 Towing (RD 11A / RD 11V)

The drive circuit is equipped with a towing valve to allow oil to bypassthe drive motors and let the roller freewheel for towing.The towing valve should be used in emergency situations where themachine has become bogged down in loose or muddy soil, or cannotbe driven due to an engine or hydraulic system failure.To open the bypass, shut the engine off and loosen the jam nut (b) onefull turn counterclockwise. Then turn the valve (a) one full turncounterclockwise.When resuming machine operation, make sure the bypass is closedtightly. Turn the valve (b) clockwise until fully seated. Then secure thevalve with the jam nut (a). If the valve is not closed completely, thedrive system may not respond or may perform sluggishly.

With the tow valve open, the drive circuit has no braking action and themachine will roll freely. Close the valve immediately after a towingoperation is complete to prevent the machine from rollingunexpectedly.

NOTICE: Do not tow the roller long distances or at speeds greater than3–5 km/h (2–3 mph). Damage to the drive motors may occur.

WARNING

a

b

wc_gr000202

wc_tx000530gb.fm 45

4.6 Towing (RD 11AEC)

The drive circuit is equipped with a brake release system to manuallyrelease the brakes and allow the roller to freewheel for towing.The brake release system should be used in emergency situationswhere the machine has become bogged down in loose or muddy soil,or cannot be driven due to an engine or hydraulic system failure.To release the brakes:

• Shut off the engine.

• Push down on the brake override valve (a).• Stroke the brake release pump (b) just until firm resistance is felt.

Note: It will take approximately 25 strokes of the pump to release thebrakes.

When resuming machine operation, pull up on the brake override valve(a).NOTICE: Do not tow the roller long distances or at speeds greaterthan 3–5 km/h (2–3 mph). Damage to the drive motors may occur.Note: The brake release system will automatically reset when theengine is started.

With the brakes released, the drive circuit has no braking action andthe machine will roll freely. Pull up on the brake override valveimmediately after the towing operation is complete to prevent themachine from rolling unexpectedly.

WARNING

a

wc_gr000203

b

wc_tx000530gb.fm 46

4.7 Engine Oil Drain

The engine oil drain (a) has been routed to the outside of the front halfof the RD 11. This is to make draining easier and to help keep theengine compartment clean.

wc_gr000164

a

wc_tx000530gb.fm 47

4.8 Engine Oil
See Graphic: wc_gr000173 (RD 11A / RD 11AEC)See Graphic: wc_gr000172 (RD 11V)

Drain the oil while the engine is still warm. To drain the oil:

4.8.1 Remove the filler cap (a), drain screw, and washer. Drain the oil into asuitable container.

Note: In the interests of environmental protection, place a plastic sheetand a container under the machine to collect any liquid which drainsoff. Dispose of this liquid in accordance with environmental protectionlegislation.

4.8.2 Re-insert the drain screw and washer and tighten the screw securely.

4.8.3 Fill the engine with the recommended oil to the upper limit mark on thedipstick (b). See Technical Data for correct oil type and amount.

Burn hazard! Care must be taken when draining hot engine oil. Hot oilcan burn!

WARNING

wc_gr000172

FU

LLA

DD

a

b

a

b

wc_gr000173

wc_tx000530gb.fm 48

4.9 Oil Filter (Honda)

Replace the oil filter after every 200 hours of operation.To change the filter:

4.9.1 Drain the engine oil. See Engine Oil. Remove the used filter.

4.9.2 Before installing a new filter, lightly oil the filter gasket (a) with fresh,clean engine oil. Screw the filter on by hand until gasket makescontact; then tighten an additional 7/8 turn.

4.9.3 Fill the engine with the recommended oil. See Engine Oil.

4.9.4 Start and run the engine to check for leaks. Stop the engine. Recheckthe oil level and add oil if required. Refer to the engine owner’s manual.

4.10 Oil Filter (Vanguard)


Replace the oil filter after every 100 hours of operation.

4.10.1 Drain the engine oil and replace it with fresh oil before removing theused oil filter. See Technical Data for oil quantity and type.


4.10.2 Remove the used filter before installing a new filter, lightly oil the filtergasket with fresh, clean engine oil.

4.10.3 Screw the filter (a) on by hand until the gasket makes contact, thentighten an additional 1/2 to 3/4 turn.

4.10.4 Start and run the engine to check for leaks. Stop the engine. Recheckthe oil level and add oil if required. See Engine Lubrication.

wc_gr000165

a

wc_gr000174

a

wc_tx000530gb.fm 49

4.11 Air Cleaner (Honda)

The Honda engine is equipped with a dual-element air cleaner. Toservice:

4.11.1 Remove the wing bolt (a) and cover (b).4.11.2 Remove the 5 mm screws (e) from the cover and remove paper

element (d) from the cover.

4.11.3 To clean the paper element, tap it lightly on a flat surface. Replace thepaper element if it is damaged or heavily soiled. Reassemble the paperelement to the cover. Include the gaskets (c, f).

4.11.4 To clean the foam element (g), wash it in liquid detergent and water.Squeeze it dry in a clean cloth. Once dry, saturate the foam element inengine oil, then squeeze out the excess. Replace the foam element ifit is damaged or heavily soiled. Reinstall the foam element andreassemble the air cleaner.

Note: Do not use petroleum solvents to clean the precleaner or thecartridge. Petroleum-type solvents will damage them. Do not usepressurized air to clean the cartridge. Pressurized air can also damagethe cartridge.

wc_gr000175

a

b

c

de

g

f

wc_tx000530gb.fm 50

4.12 Air Cleaner (Vanguard)

To service air cleaner:

4.12.1 Remove the cover (a), knob (b), and retaining plate (c).4.12.2 Remove the foam precleaner (e) from the filter cartridge (d).4.12.3 Wash the precleaner in liquid detergent and water. Squeeze it dry in a

clean cloth. Saturate the precleaner in engine oil; squeeze out excessoil. Replace the precleaner if it is damaged or heavily soiled.

4.12.4 To clean the cartridge, remove it and tap it lightly on a flat surface.Replace the cartridge if it is damaged or heavily soiled.

Note: Do not use petroleum solvents to clean the precleaner orcartridge. Petroleum-type solvents will damage them. Do not usepressurized air to clean the cartridge. Pressurized air can also damagethe cartridge.

wc_tx000530gb.fm 51

4.13 Hydraulic System Cleanliness
Keeping the hydraulic oil clean is a vital factor affecting the service lifeof hydraulic components. Oil in hydraulic systems is used not only totransfer power, but also to lubricate the hydraulic components used inthe system. Keeping the hydraulic system clean will help avoid costlydowntime and repairs.Major sources of hydraulic system contamination include:

• Particles of dirt introduced when the hydraulic system is opened for maintenance or repair

• Contaminants generated by the mechanical components of the system during operation

• Improper storage and handling of hydraulic oil

• Use of the wrong type of hydraulic oil

• Leakage in lines and fittings

To minimize hydraulic oil contamination:CLEAN hydraulic connections before opening the lines. When addingoil, clean the hydraulic tank filler cap and surrounding area beforeremoving it.AVOID opening the pumps, motors, or hose connections unlessabsolutely necessary.PLUG or cap all open hydraulic connections while servicing thesystem.CLEAN and cover the containers, funnels, and spouts used to storeand transfer the hydraulic oil.CHANGE the hydraulic filters and oils at the recommended serviceintervals.

wc_tx000530gb.fm 52

4.14 Hydraulic Oil Requirements
Wacker recommends the use of a good petroleum-based, anti-wearhydraulic oil in the hydraulic system of this equipment. Good anti-wearhydraulic oils contain special additives to reduce oxidation, preventfoaming, and provide for good water separation.When selecting hydraulic oil for your machine, be sure to specify anti-wear properties. Most hydraulic oil suppliers will provide assistance infinding the correct hydraulic oil for your machine.Avoid mixing different brands and grades of hydraulic oils.Most hydraulic oils are available in different viscosities.The SAE number for an oil is used strictly to identify viscosity—it doesnot indicate the type of oil (engine, hydraulic, gear, etc.).When selecting a hydraulic oil be sure it matches the specified SAEviscosity rating and is intended to be used as a hydraulic oil. SeeTechnical Data—Lubrication.

wc_tx000530gb.fm 53

4.15 Hydraulic Oil Level

A hydraulic oil level sightglass (a) is located near the bottom left sideof the machine below the engine compartment.Check that the hydraulic oil level is visible in the sightglass. If it is not,add oil through the filler port (b) inside the engine compartment. Useonly clean hydraulic oil. Thoroughly clean the top of the filler cap before removing it from thetank. Care should be taken to prevent smaller dirt particles fromentering the system.If hydraulic oil continually needs to be added, inspect the hoses andconnections for possible leaks.

4.16 Suction Filter


A hydraulic filter (c) is located in the hydraulic tank. This filter will notnormally require service and does not need to be replaced whenchanging the hydraulic oil.

wc_gr000198

a

db

c

e

wc_tx000530gb.fm 54

4.17 Changing Hydraulic Oil & Filter

All oils eventually shear or thin out with use, reducing their lubricatingability. In addition, heat, oxidation, and contamination may cause theformation of sludge, gum, or varnish in the system. For these reasons,it is important to change the hydraulic oil at specified intervals. SeeMaintenance Schedule.

4.17.1 Remove the filler cap (b) from the top of the hydraulic tank.

4.17.2 Remove the drain plug (d) and allow the hydraulic fluid to drain.


4.17.3 Unscrew the return line filter (e) and replace the filter cartridge.

4.17.4 Install the drain plug.

4.17.5 Fill the hydraulic tank through the filler port with clean hydraulic fluid.

4.17.6 Bleed the hydraulic system. See Bleeding the Hydraulic System.

wc_tx000530gb.fm 55

4.18 Bleeding the Hydraulic System

4.18.1 Fill the hydraulic system with clean hydraulic oil until it is visible in thesightglass. Do not re-use used hydraulic oil.

4.18.2 Disconnect the line (a) from the drive pump. Fill the pump case withhydraulic oil through the open connection. Reconnect the line.

4.18.3 Disconnect the spark plug wires to prevent the engine from startingand crank the engine 5–10 seconds. This will allow oil to fill inlet lines.

4.18.4 Reconnect the spark plug wires and place the forward/reverse controllever in NEUTRAL. Start the engine and run the machine at idle for 3–4 minutes.

4.18.5 With the engine still running at idle, move the control slowly back andforth from forward to reverse for a short time to bleed air trapped in thedrive circuit.

4.18.6 Increase the engine speed to full throttle and operate all controls tobleed the remaining air from the hydraulic lines.

4.18.7 Check the hydraulic oil level and add oil as required.

Note: If the drive pump chatters or operation is noisy, turn the machineoff and check for air leaks in the inlet line of the charge pump.

wc_gr000199

a

wc_tx000530gb.fm 56

4.19 Spark Plug

Clean or replace the spark plug as needed to ensure proper operation.Refer to the engine owner’s manual. The muffler becomes very hot during operation and remains hot for awhile after stopping the engine. Do not touch the muffler while it is hot.

Note: Refer to the Technical Data for the recommended spark plugtype and the electrode gap setting.

4.19.1 Remove the spark plug and inspect it.

4.19.2 Replace the spark plug if the insulator is cracked or chipped.

4.19.3 Clean the spark plug electrodes with a wire brush.

4.19.4 Set the electrode gap (a).4.19.5 Tighten the spark plug securely.

NOTICE: A loose spark plug can become very hot and may causeengine damage.

WARNING

wc_tx000530gb.fm 57

4.20 Carburetor (Vanguard)

Note: The air cleaner must be in place and the engine warm whenmaking adjustments to the carburetor. To adjust:

4.20.1 With the engine running, place the throttle in the SLOW position androtate the carburetor throttle lever against the idle speed screw (a) andhold it there.

4.20.2 Turn the idle speed screw to obtain 2000 rpm.

4.20.3 While still holding the throttle lever against the idle speed screw, turnthe idle mixture valve (b) midway between limits.

4.20.4 Readjust the idle speed to 1750 rpm and release the carburetor throttlelever. The engine should accelerate smoothly when throttle is opened.If it does not, readjust the idle mixture valve slightly counterclockwise.

a

wc_gr000177

wc_tx000530gb.fm 58

4.21 Grease Fittings

See Technical Data—Lubrication.

Articulated Joint:The articulated joint is equipped with grease fittings (a) for lubrication. To avoid being pinched by the machine halves, set the lockarm beforegreasing the articulating joint!

Rear Drum:The rear drum drive bearing is equipped with a grease fitting (b)located at the center of the drum behind the right rear drum support.Exciter:The exciter is grease lubricated. There are two grease fittings (c), oneon each side of the machine, located behind the front drum supports.

WARNING

wc_gr000178

a

a

b

c c

wc_tx000530gb.fm 59

4.22 Fuel Filter

4.22.1 Change the in-line fuel filter (a) once per year. Check the fuel lines andfittings daily for cracks or leaks. Replace as needed.

Gasoline is extremely flammable! Turn the engine off and allow theengine to cool before replacing the fuel filter.

Note: The fuel filter is located under the floor panel of the operatingplatform.

WARNING

wc_gr002984

a

wc_tx000530gb.fm 60

4.23 Scraper Bars

Scraper bars, located in front of and behind each drum, are used toprevent dirt and asphalt from sticking to and accumulating on the drumsurface. These bars must be adjusted periodically as they wear.To adjust the scraper bar (a), loosen the bolts (b) connecting thescraper bars to the shockmounts (c) on both sides of the drum. Usinga 9 mm (3/8") drive ratchet extension in the socket (d), rotate theassembly away from the drum until the bolts are observed to haverotated approximately 6 mm (1/4") in slots, then tighten the bolts.Check that the scraper bar has a slight deflection where it contacts thedrum, and readjust as necessary.Note: A large deflection of the scraper bar indicates excessive pre-loading of the rubber shockmounts, which will result in prematurescraper wear.

wc_gr000179

a

b

cd

wc_tx000530gb.fm 61

4.24 Parking Brake Adjustment (RD 11A/RD 11V)

The parking brake is located on the rear drive motor drum support andis used to prevent the roller from moving when the roller is turned off.Adjust the brake for proper holding force as follows:

4.24.1 Unscrew the brake lever knob (a) until the brake can be applied withmoderate force (approximately 30 lbs.).

4.24.2 Start the roller on level ground and try to travel forward and reversewith the brake applied. If the roller drives through the brake, stop themachine, tighten the lever knob one turn and repeat the process.

4.24.3 When the machine no longer moves with the brake applied, stop themachine, turn the knob one more turn and the brake is properly set.

wc_gr000201

a

wc_tx000530gb.fm 62

4.25 Throttle Solenoid Adjustment

4.25.1 With the engine still operating, set the throttle lever stop screw (c) onthe engine to 3200 rpm.

4.25.2 Shut down the engine and then the turn key to the first position. (Donot start the engine.) Activate the throttle solenoid. While holding thethrottle lever (b) on the engine to the fully engaged position (as set instep 2), pull the cable tight through the throttle nut/set screw (d) andsecure the cable. Disengage the solenoid.

4.25.3 Turn the throttle lever stop screw (c) counter-clockwise three turns.

4.25.4 Start the engine and engage the solenoid. Using the 5/16-inchmounting nuts on the threaded casing end, adjust the top speed to3200 rpm.

wc_tx000530gb.fm 63

4.26 Storage
If the unit is to be stored for more than 30 days:

• Drain the fuel tank and the water tank. Also drain the rear drum, if ballast was added.

• Open the water valves and drain the water from the sprinkling system.

• Change the engine oil.

• Remove the spark plugs and pour approximately 3 ml (1 ounce) of SAE 30W oil into each engine cylinder through the spark plug opening.

• Install the spark plugs. Leave the ignition wires disconnected to prevent the engine from starting. Crank the engine for one or two seconds to distribute oil inside engine cylinders. Connect the igni-tion wires.

• Clean the entire roller and engine compartment.

• Remove any dirt from the cooling fins on the engine cylinders and on the blower housing.

• Set the lockarm to secure the roller halves together.

• Remove the battery from the machine and charge it periodically.

• Cover the entire machine and place it in a dry, protected area.

wc_tx000530gb.fm 64

Notes:
wc_tx000530gb.fm 65

Engine Starting Troubleshooting RD 11 Repair
5. Engine Starting Troubleshooting
5.1 Starting System Component Locations

1, 18

9

2

wc_gr002975

616

4

5

17

8

12

3

10

11

13

14

7

15

wc_tx000529gb.fm 66

RD 11 Repair Engine Starting Troubleshooting


Ref. Description Ref. Description

1 20 Amp fuse 10 Magneto kill

2 Battery 11 Exciter solenoid

3 Key switch 12 Vibration switch

4 Starter relay 13 Forward/reverse control

5 Throttle solenoid 14 Neutral safety switch

6 Starter 15 Backup alarm (optional)

7 Regulator/rectifier 16 Throttle switch

8 Alternator 17 12VDC relay

9 Anti-backfire 18 20 Amp circuit breaker

wc_tx000529gb.fm 67

5.2 Troubleshooting Flowcharts
The troubleshooting flowcharts are designed to take you through theprocess of determining the source of a problem with engine starting ormachine operation. Many of the tests involve live voltages andtherefore should only be attempted by qualified personnel. Detailedprocedures for carrying out the tests are included in this manual. Allhighlighted text within the flowcharts have matching sections in thismanual.

wc_tx000529gb.fm 68

5.3 Engine Does Not Crank—Flowchart 1A
wc_gr002965

Replace the 20A fuse.

No

Yes

Is 20A fuseOK?

* Battery voltageapproximately 12VRecharge or replace

the battery.NoIs the battery

OK?

Yes

Engine does not Crank

Checking battery

Check condition of the battery.

Checking 20A Fuse

Check the 20A fuse.

Replace the key switch.

See engine manufacturer’s

repair manual.

Yes

No

Is the key switchOK?

Checking key switch

Check the key switch.

Replace the starter relay.

No

Yes

Is the starter relayfunctioning?

Checking starter relay

Check the function ofthe starter relay.

Replace the neutral switch.

No

Yes

Is the neutral switch

OK?

Checking neutral switch

Check the neutral switch.

Replace the starter relay.

NoYes Is there power (12V*) to the starter

solenoid?

Checking power to starter solenoid

Check power to the starter solenoid.

wc_tx000529gb.fm 69

5.4 Checking Battery
Explosion hazard. Batteries can emit explosive hydrogen gas. Keep allsparks and flames away from the battery. Do not short-circuit batteryposts. Do not touch the machine frame or the negative terminal of thebattery when working on the positive terminal.

Battery fluid is poisonous and corrosive. In the event of ingestion orcontact with skin or eyes seek medical attention immediately.

Dispose of dead batteries in accordance with local environmentalregulations.

To disconnect the battery:

5.4.1 Stop the machine and shut down the engine.

5.4.2 Place all electrical switches in the OFF position.

5.4.3 Disconnect the negative battery cable from the battery.

5.4.4 Disconnect the positive battery cable from the battery.

To connect the battery:

5.4.5 Connect the positive battery cable to the battery.

5.4.6 Connect the negative battery cable to the battery.

WARNING

WARNING

1 2 3 4

wc_gr002565

wc_tx000529gb.fm 70

Inspect the battery periodically. Keep battery terminals clean andconnections tight.When necessary, tighten the cables and grease the cable clamps withpetroleum jelly.Maintain the battery at full charge to improve cold weather starting. Dispose of dead batteries in accordance with local environmentalregulations.
NOTICE: Observe the following to prevent serious damage to themachine’s electrical system:

• Never disconnect the battery with the machine running.

• Never attempt to run the machine without a battery.

• Never attempt to jump-start a machine.

• If the machine has a dead battery, either replace the battery with a fully charged battery or charge the battery using an appropriate battery charger.

Test the battery’s voltage by measuring across its terminals with avoltmeter or multimeter. An adequately charged battery will measure11–13V.

wc_tx000529gb.fm 71

5.5 Checking 20A Fuses

There are two 20A fuses (a and b) in the electric circuits of the RD 11.One of the 20A fuses feeds power to the keyswitch. The other feedspower to the voltage regulator. Both fuses are located within theengine compartment and housed within a covered fuse holder (c). Onolder model machines the fuses (d and e) are built into the wiringharness and are found near the starter relay.To check the fuses:

5.5.1 Open the engine compartment.

5.5.2 If necessary, cut the wire tie securing the cover to the fuse holder andthen remove the cover.

5.5.3 Pull the fuses from the fuse holder.

5.5.4 Replace the fuse(s) if it is blown. Replace with a fuse of equal ratingonly.

5.5.5 Secure the fuse cover with a new wire tie.

wc_tx000529gb.fm 72


wc_gr002976

a

c

b

e

d

wc_tx000529gb.fm 73

5.6 Checking Keyswitch

It is unlikely that the keyswitch will fail; however, if you feel thekeyswitch is malfunctioning, carry out the following procedures.Note: These procedures assume that the 20A fuse (feeding power tothe key switch) and the battery are both OK: The keyswitch feeds power to two circuits depending on its position. Inthe START position, power is fed to the starter motor solenoid via theneutral safety switch and the starter relay. In the ON position, power isfed to the anti-afterfire solenoid, the throttle switch, the vibrationswitch, and the optional horn. When testing the key switch, both theSTART position and the ON position will need to be tested. When thekey switch is in the OFF position, the engine’s magneto is shorted toground and no spark across the spark plug will occur. If the magnetokill wire is unintentionally shorted to ground, the engine will not start.Therefore, the OFF position should also be checked.To check the ON position:

5.6.1 Place the key switch in the ON position. Measure the voltage betweenthe tan wire at the anti-afterfire solenoid and ground.

• If 12VDC (battery voltage approximately 12V) is measured, the ON position is functioning.

• If 12VDC is not measured, go to step 3.

To check the START position:

5.6.2 Place the control lever in the neutral position. Then, place the keyswitch in the START position. Measure the voltage between terminalCP of the starter relay and ground.

• If 12VDC (battery voltage approximately 12V) is measured, the START position is functioning. Problems with engine starting are most likely to be within the starter motor. See the engine manufacturer’s repair manual.

• If 12VDC is not measured, continue.

5.6.3 Remove the control console (2) from the machine. Then, remove thekey switch (1) from the control console and disconnect the connectorplug (3).

5.6.4 Check the continuity between key switch terminals B and L when thekey switch is in the ON position.

5.6.5 Check the continuity between key switch terminals B and S when thekey switch is in the START position.

5.6.6 If the key switch fails either of the above continuity tests, replace it.

To check the OFF position:

wc_tx000529gb.fm 74

5.6.7 Place the keyswitch in the OFF position and check the continuity
between terminals G and M. When checking the OFF position, alsocheck the connection and continuity of the magneto kill wire. Repair orreplace the wire as needed.

* The forward/reverse control must be in neutral


a Start d Battery 12VDC

b On e Ground

c Stop (magneto kill) - ---

Switch position Continuity across terminals Voltage 12VDC

OFF G - M B

ON B - L L

START B - S S*

G

SL

M

B

wc_gr002977

a b

cd

e

ab

c

d

RD 11 AEC RD 11V & RD 11A

50 15

7530

S LG

B M

1

2

3

wc_tx000529gb.fm 75

5.7 Checking Neutral Switch

The forward/reverse control is equipped with a neutral safety switch (a)to prevent the engine from being started unless the forward/reversecontrol lever (b) is positioned in neutral.This switch is connected to the starter relay. When the forward/reversecontrol is in neutral, the switch is closed, allowing the starter relay tobe energized and complete the circuit from the battery through the keyswitch to the starter motor. If the forward/reverse control lever is shiftedaway from neutral, the neutral switch is open and the starter relaycannot be energized.To check the neutral switch:

5.7.1 Remove the seat and seat plate to access the neutral switch.

5.7.2 Disconnect the wiring harness (c) from the wire connector.

5.7.3 Use an ohmmeter and check for continuity across the white and greenwires with the forward/reverse control lever in neutral.

• If no continuity exists, replace the switch.

• If continuity does exist, continue.

5.7.4 With the ohmmeter still connected to the white and green wires, movethe control lever from the neutral position. Doing so should open theconnection between the wires.

• If the connection opens (there ceases to be continuity), the neutral switch is functioning.

• If the connection remains closed (wires maintain continuity), the neutral switch is malfunctioning; replace it.

wc_tx000529gb.fm 76


wc_gr002982

F

E

B

C

D

A

F

E

B

C

D

A

a

b

c

c

wc_tx000529gb.fm 77

5.8 Checking Starter Relay

5.8.1 The starter relay receives power (battery voltage approximately12VDC) in two places: 1) to its coil (labeled “CP” on the schematic);and 2) to the to-be-switched terminal (labeled “SI” on the schematic).When the relay’s coil receives power it energizes, the relay’s contactsclose, and power is switched to terminal SO and to the starter motorsolenoid through the pink wire. To check the function of the starterrelay, carry out the following procedures.

Note: These procedures require that the neutral switch be functioningproperly and that the connection between the battery and terminal SIof the starter relay be secure.

Note: The starter relay coil on newer model machines is groundedthrough the mounting bracket when mounted to a common ground.Thus, there is no wire connected to terminal CG.

5.8.2 Place the control lever in the neutral position and place the start switchin the START position. NOTICE: When measuring voltages, do not energize the relay longerthan 15–20 seconds at a time or the coil may overheat.

5.8.3 Measure the voltage between terminal CP of the starter relay andground.

• If 12VDC is not measured, check the continuity of the wire between the neutral switch and terminal CP of the starter relay. Repair or replace the wire as needed.

• If 12VDC is measured, continue.

5.8.4 Measure the voltage between terminal SO of the starter relay andground.

• If 12VDC is not measured, the starter relay is malfunctioning. Replace the starter relay.

• If 12VDC is measured, the starter relay is functioning.

wc_tx000529gb.fm 78


wc_gr002978

New machinesNeuere MaschinenMáquinas recientesMachines récentes

Older machinesÄltere MaschinenMáquinas antiguasAnciennes machines

SO

SO

SISI

CP

CP

CG

CG

wc_tx000529gb.fm 79

5.9 Checking Power to Starter Solenoid (Honda engines only)

The starter solenoid mounted to the starter motor receives power fromthe starter relay via the red wire. To check the power to the startersolenoid, carry out the following procedure:

5.9.1 Place the key switch in the START position.

5.9.2 Measure the voltage between the starter solenoid at the red wire (a)and ground.

• If 12VDC (battery voltage approximately 12V) is not measured, check the continuity of the red wire. Repair or replace the red wire as needed.

• If 12VDC is measured, there is a problem with the starter solenoid or starter motor. See the engine manufacturer’s repair manual.

a

wc_gr002979

wc_tx000529gb.fm 80

5.10 Engine Cranks but Does Not Start—Flowchart 2A
wc_gr003585

Replace the air filter.

Replace thespark plug(s).

Yes

No

Is the air filterOK?

Replace fuel, fuel lines, and fuel filteras needed.

NoIs the fuel system

OK?

Yes

Checking fuel system

Check condition of:

• Fuel in tank• Fuel lines• Fuel filter

Checking anti-afterfiresolenoid

Check condition of the anti-backfire solenoid.

No Is the spark plug

OK?

Yes

Check condition of the spark plug(s).

Replace the anti-afterfire solenoid.

See the engine manufacturer’s service manual for ignitionsystem service.

NoIs the anti-afterfire solenoid

OK?

Yes

Checking seat switch

Check function of seat switch.

Replace the seat switch.

YesIs the

seat switch OK?

No

Check the condition of the air filter.

Engine Cranks but Does Not Start

wc_tx000529gb.fm 81

5.11 Checking Fuel System

Gasoline is extremely flammable! Turn the engine off and allow theengine to cool before replacing the fuel filter.

If a fuel system problem is suspected, check the following:

• The condition of the fuel in the tank. If the age of the fuel in the tank is unknown, drain the tank and fill the tank with fresh fuel.

• The condition of the fuel filter. To access the fuel filter (b), remove the screws which secure the floor panel (a) and remove the floor panel. Replace the fuel filter according to the periodic maintenance schedule.

• The condition of the fuel hoses. Remove any blockages and relieve any spots where the fuel hoses may be pinched. Repair or replace the fuel hoses as needed.

WARNING

wc_gr002980

a

b

wc_tx000529gb.fm 82

5.12 Checking Seat Switch

The seat switch is a normally open switch. It is attached directly to theunderside of the seat. To check the seat switch, carry out the followingprocedure:

5.12.1 Remove the screws that secure the seat mounting plate to themachine and flip the seat and the seat mounting plate over to revealthe seat switch.

5.12.2 Mark, then disconnect the wiring (a) to the seat switch.

5.12.3 Remove the seat switch (b) from the seat.

5.12.4 Check continuity across the terminals of the seat switch. When theseat switch is depressed, there should be continuity. When the seatswitch is not depressed, there should be no continuity. If the seatswitch does not perform accordingly, replace it.

wc_gr003586

a

b

wc_tx000529gb.fm 83

5.13 Checking Anti-Afterfire Solenoid

The engine carburetor is equipped with an anti-afterfire system. Thesystem contains a solenoid valve (a) controlled by the ignition switch.When the ignition switch is in the OFF position, the solenoid valve isde-energized and stops the fuel flow through the fixed high-speed jet(b). When the switch is turned to the ON or START position, thesolenoid is energized, moving the plunger away from the fuel jet,allowing normal fuel flow.The solenoid is operating correctly if a “click” is heard when the ignitionswitch is turned on and off. If no click is heard, the solenoid is notoperating and the engine will not start.To test the solenoid of the anti-afterfire system, carry out the followingprocedure:

5.13.1 Disconnect the solenoid from the tan wire of the engine harness. Thewire (c) from the solenoid is red on Vanguard engines, black andyellow on Honda engines.

5.13.2 Connect the solenoid wire to the positive terminal of a 9V transistorbattery.

5.13.3 Connect the negative terminal of the battery to the body of the solenoidor to a common ground. Listen for a click from the solenoid just as thebattery is connected. If a click is heard, the solenoid is functioning. If aclick is not heard, replace the solenoid.

wc_tx000529gb.fm 84


wc_gr003007

a

c

c

9V

b

wc_tx000529gb.fm 85

Notes
wc_tx000529gb.fm 86

RD 11 Repair Hydraulic System
6. Hydraulic System
6.1 Hydraulic System Precautions

Escaping hydraulic oil under pressure, even a pinhole size leak, canpenetrate body tissue, causing serious injury, and possible death. If oilis injected into your skin, you must be treated immediately by a doctorfamiliar with this kind of injury.

• Always use a board or cardboard when checking for hydraulic oil leaks.

• Relieve the hydraulic pressure before working on the machine.

• Personal injury can result from contact with hot hydraulic oil.

• Use extreme care and wear appropriate clothing, such as gloves and safety glasses, when working with hot hydraulic oil.

6.2 Hydraulic System Service Basics

Many hydraulic system problems may be rectified by basic service andmaintenance tasks. Before attempting in-depth service procedures,carry out the basic hydraulic service procedures listed below.

• Top off the hydraulic oil supply with the correct type and grade of oil.

• Clean and tighten all the hydraulic fittings. Check the hoses for holes and/or leaks. Air within the hydraulic system can greatly affect machine performance.

• Check/change the hydraulic filter. Particles and debris in the filter are signs of failing component(s). Change the hydraulic oil and clean all components if there is debris found in the filter. Locate and replace the failing component(s) before operating the machine.

• Carry out hydraulic tests with the machine/hydraulic oil warm. Start and operate the machine at high idle for several minutes before conducting troubleshooting procedures. The hydraulic oil should be between 37.4–48.6°C (100–120°F).

WARNING

wc_tx000527gb.fm 87

Hydraulic System RD 11 Repair
6.3 Hydraulic Schematic—RD 11A and RD 11V (parallel drive)
wc_gr003014

10 MICRON

P

2

3

P

G2

G3

T

L

R

138 bar (2000 psi)

48 bar (700 psi)

1 2

43

6

5

8 7

G1

21

13

12

11

10

22

20

9

19

200 bar (2900 psi)

1812 bar (174 psi)

1.7 bar (25 psi)

T

17

16

15

14

1

231 bar (14.5 psi)

wc_tx000527gb.fm 88

6.4 Hydraulic Components—RD 11A and RD 11V (parallel drive)


1 Exciter relief valve 13 Tow valve

2 Exciter manifold 14 Charge pump

3 Exciter control valve (solenoid) 15 Drive pump

4 Exciter motor 16 Exciter pump

5 Steering cylinder 17 Charge-pressure relief valve

6 Steering valve 18 Drive pump, internal relief valves

7 Rear drive motor 19 Steering relief valve

8 Front drive motor 20 Return manifold

9 Filter bypass 21 Drive manifold

10 Return-line filter assembly 22 Tank

11 Suction filter 23 Backpressure valve

12 Pump assembly - ---

wc_tx000527gb.fm 89

6.5 Hydraulic Diagram—RD 11A and RD 11V (parallel drive)
Pressure / Druck / Presión / Pression

Return / Rückfluss / Retorno / Retourwc_gr003015

11

121

6

9 8

5

2

3

4

7

wc_tx000527gb.fm 90

6.6 Hydraulic Components—RD 11A and RD 11V (parallel drive)


1 Exciter manifoldIncluding:Exciter relief valveExciter solenoid valve

7 Rear drive motor

2 Return manifold 8 Drive control manifoldIncluding:Tow valve

3 Steering valveIncluding:Steering relief valve

9 Front drive motor

4 Steering cylinder - ---

5 Suction filter 11 Return line filter assemblyIncluding:10 Micron filterFilter bypassBackpressure valve

6 Pump assemblyIncluding:Drive pumpExciter pumpCharge pumpDrive pump relief valvesCharge pressure relief valve

12 Exciter motor

wc_tx000527gb.fm 91

6.7 Hydraulic Piping—RD 11A, RD 11V (parallel drive)
wc_gr0030169

7

8

1

2

3

4

5

6

11

12

wc_tx000527gb.fm 92

6.8 Hydraulic Piping Components—RD 11A, RD 11V (parallel drive)



7 Rear drive motor



9 Front drive motor




12 Exciter motor

wc_tx000527gb.fm 93

6.9 Hydraulic Schematic—RD 11A, RD 11V (revisions 103–134)
wc_gr003013

10 MICRON

P

2

3

P

G2

G3

T

L

R

138 bar (2000 psi)

48 bar (700 psi)

1 2

43

6

5

8 7

G1

21

13

12

11

10

22

20

9

19

200 bar (2900 psi)

1812 bar (174 psi)

1.7 bar (25 psi)

T

17

16

15

14

1

231 bar (14.5 psi)

wc_tx000527gb.fm 94

6.10 Hydraulic Components—RD 11A, RD 11V (revisions 103–134)


1 Exciter relief valve 13 Tow valve

2 Exciter manifold 14 Charge pump

3 Exciter control valve (solenoid) 15 Drive pump

4 Exciter motor 16 Exciter pump

5 Steering cylinder 17 Charge-pressure relief valve

6 Steering valve 18 Drive pump, internal relief valves

7 Rear drive motor 19 Steering relief valve

8 Front drive motor 20 Return manifold

9 Filter bypass 21 Drive manifold

10 Return-line filter assembly 22 Tank

11 Suction filter 23 Backpressure valve

12 Pump assembly - ---

wc_tx000527gb.fm 95

6.11 Hydraulic Diagram—RD 11A, RD 11V (revisions 103–134)
wc_gr003017Pressure / Druck / Presión / Pression

Return / Rückfluss / Retorno / Retour

11

121

6

9 8

5

2

3

4

7

wc_tx000527gb.fm 96

6.12 Hydraulic Components—RD 11A, RD 11V (revisions 103–134)



7 Rear drive motor



9 Front drive motor




12 Exciter motor

wc_tx000527gb.fm 97

6.13 Hydraulic Piping—RD 11A, RD 11V (revisions 103–134)
wc_gr003012

9

7

8

1

2

3

4

5

6

11

12

wc_tx000527gb.fm 98

6.14 Hydraulic Piping Components—RD 11A, RD 11V (revisions103–134)



7 Rear drive motor



9 Front drive motor




12 Exciter motor

wc_tx000527gb.fm 99

6.15 Hydraulic Schematic—RD 11A, RD 11V (revisions > 134)
wc_gr002985

10 MICRON

P

2

3

P

G2

G3

T

L

R

138 bar(2000 psi)

48 bar (700 psi)

1 2

4

3

6

5

8 7

G1

21

13

12

11

10

22 20 9

19

200 bar (2900 psi)

1812 bar (174 psi)

1,7 bar (25 psi)

T

17

16

15

14

1

wc_tx000527gb.fm 100

6.16 Hydraulic Components—RD 11A, RD 11V (revisions > 134)


1 Exciter relief valve 12 Pump assembly

2 Exciter manifold 13 Tow valve

3 Exciter control valve (solenoid) 14 Charge pump

4 Exciter motor 15 Drive pump

5 Steering cylinder 16 Exciter pump

6 Steering valve 17 Charge-pressure relief valve

7 Rear drive motor 18 Drive pump, internal relief valves

8 Front drive motor 19 Steering relief valve

9 Filter bypass 20 Return manifold

10 Return-line filter assembly 21 Drive manifold

11 Suction filter 22 Tank


6.17 Hydraulic Diagram—RD 11A, RD 11V (revisions > 134)


11

121

6

9 8

5

2

3

4

7


6.18 Hydraulic Components—RD 11A, RD 11V (revisions >134)



7 Rear drive motor



9 Front drive motor


5 Suction filter 11 Return line filter assemblyIncluding:10 Micron filter with bypass


12 Exciter motor


6.19 Hydraulic Piping—RD 11A, RD 11V (revisions > 134)
wc_gr003011

1

2

3

4

5

6

7

9

8

11

12


6.20 Hydraulic Piping Components—RD 11A, RD 11V (revisions >134)



7 Rear drive motor



9 Front drive motor


5 Suction filter 11 Return line filter assemblyIncluding:10 Micron filter with bypass


12 Exciter motor


6.21 Hydraulic Schematic—RD 11AEC
wc_gr002992

4

63

2

1

5

8 7

17 18

15

1614

13

24 25

21

22

27

19

23

20

10

12

138 bar(2000 psi)

200 bar(2900 psi) G2

G1

R2

R1

T10 Micron

1.7 bar(25 psi)

P

T R

L

9

11

P1

F2

F1

P2

26

T1

12 bar(174 psi) 48 bar

(700 psi)

281 bar (14.5 psi)


6.22 Hydraulic Components—RD 11AEC


1 Exciter relief valve 15 Drive pump

2 Exciter manifold 16 Exciter pump

3 Exciter control valve (solenoid) 17 Charge pressure relief valve

4 Exciter motor 18 Internal drive pump relief valves

5 Steering cylinder 19 Steering relief valve

6 Steering valve 20 Return manifold

7 Rear drive motor 21 Manual override valve

8 Front drive motor 22 Brake valve (solenoid)

9 Filter bypass 23 Hand pump

10 Return line filter assembly 24 Shuttle valve

11 Suction filter 25 Pressure reducing valve

12 Pump assembly 26 Drive control manifold

13 Pump shunt valve (solenoid) 27 Brake manifold

14 Charge pump 28 Backpressure valve


6.23 Hydraulic Diagram—RD 11AEC


11

12

1

6

9

10

8

5

2

3

4

7


6.24 Hydraulic Diagram Components—RD 11AEC


1 Exciter manifoldIncluding:Exciter relief valveExciter control valve (solenoid)

7 Rear drive motor

2 Return manifold 8 Drive control manifoldIncluding:Pump shunt valve (solenoid)Shuttle valvePressure reducing valve


9 Front drive motor

4 Steering cylinder 10 Brake manifoldIncluding:Manual override valveBrake valve (solenoid)Hand pump



12 Exciter motor


6.25 Hydraulic Piping—RD 11AEC
wc_gr002986

1

2

3

4

5

6

7

8

9

10

11

12


6.26 Hydraulic Piping Components—RD 11AEC


1 Exciter manifoldIncluding:Exciter relief valveExciter control valve (solenoid)

7 Rear drive motor

2 Return manifold 8 Drive control manifoldIncluding:Pump shunt valve (solenoid)Shuttle valvePressure reducing valve


9 Front drive motor

4 Steering cylinder 10 Brake manifoldIncluding:Manual override valveBrake valve (solenoid)Hand pump



12 Exciter motor


6.27 General Description

The hydraulic system is powered by two pumps (exciter (a) and drive(b)) mounted in tandem—connected along their shafts through a solid-mounted coupling (c)—and driven directly by the engine crankshaftthrough a flex coupling (d). The exciter pump is a fixed displacementgear-type pump and provides a constant flow of oil to operate both thevibration and steering circuits. The drive pump is a variabledisplacement, axial piston pump and includes an integral charge pump(e). Flow through the drive pump is controlled by varying itsdisplacement through the movement of the control lever (f) attached tothe pump’s control shaft. This allows a full range of operating speedsin both forward and reverse.

All valves and test ports of the system are located in manifold blocks.There are varying manifold blocks depending on the model. Early RD11A and RD 11V models (revisions 100–102) include four manifoldblocks: exciter, drive, return-line filter head, and return. Later RD 11Aand RD 11V models (revisions 103–134) include three manifoldblocks: exciter, drive, and return. Model RD 11AEC includes fivemanifold blocks: exciter, brake, return-line filter head, drive control,and return.

The exciter manifold controls flow to both the exciter motor and thesteering valve. The exciter manifold also includes a pressure test port.

The drive manifold (models RD 11A and RD 11V only) includespressure test ports for the drive system. It also includes the towingvalve which, when open, allows oil flow to bypass the drive motors.

The return-line filter head manifold contains the back pressure valvewhich maintains pressure of 1 bar (14.5 psi) to the inlet side of thecharge pump. This pressure ensures positive flow to the drive pump toprevent cavitation. Note: On RD 11A and RD 11V models, the backpressure valve was discontinued after revision 133.

The brake manifold (models RD 11AEC only) contains the brake valve,the manual override valve, and the hand pump. This manifold and itsvalve controls flow to the hydraulic bakes that are integral to the drivemotors on Model RD 11AEC.

The drive control manifold (model RD 11AEC only) contains the drive-pump shunt valve, shuttle valve, and pressure reducing valve.The hydraulic tank is equipped with a strainer at the fill port to trap largeobjects or particles which may accidentally fall into the tank whileadding hydraulic fluid. Additional system protection is provided by asuction filter mounted in-line with the exciter pump inlet.


The hydraulic system is protected by a return-line filter which removesdirt particles down to 10 microns and includes a flow bypass for coldweather start-up.
wc_gr003059

a

b

e

f

c

d


6.28 Drive Circuit—RD 11A and RD 11V
See Graphic: wc_gr002987 and wc_gr003020

The drive system is a closed-loop circuit, consisting of a drive pump(a), charge pump (b), tow valve (c), relief valves (d), and front (e) andrear (f) drive motors arranged in parallel or series.The drive pump is a variable displacement, piston-type pump with anintegral charge pump. Charge pressure is supplied by return flow fromthe exciter/steering circuit tapped at the return-line filter head manifold.On RD 11A and RD 11V revisions 134 and higher, charge pressure istapped just after the outlet of the filter head. The charge pressure ismaintained at 14.5 bar (210 psi) through an internal relief valve (g).Excess charge pump flow is returned to the tank through the returnmanifold.The drive pump is manually activated by the forward/reverse controllever. When the control lever is shifted forward, oil is directed from thehigh-pressure side of the pump to the drive manifold block, anddownstream to both the front and rear drive motors. Return flow fromthe motors is directed back through the drive manifold and returns tothe low-pressure side of the drive pump. When operating in reverse,the high- and low-pressure sides of the drive pump are reversed. System pressure is limited to 200 bar (2900 psi) by the two relief valvesin the drive pump. The drive system is equipped with a tow valve. When open, this valveallows oil to flow directly across the ports of the drive manifold thusbypassing the drive motors and allowing the roller to freewheel fortowing.



wc_gr002987

10 MICRON

G2

G3

T

a b

g

c

e fd

wc_gr003020

10 MICRON

G2

a

b

gd

c

G3

T

ef


6.29 Drive Circuit—RD 11AEC

The drive system is a closed-loop circuit, consisting of a drive pump(a), charge pump (b), internal relief valves (c), pump shunt valve (d),shuttle valve (e), pressure reducing valve (f), brake valve (g), handpump (h), manual override valve (n), and front (i) and rear (j) drivemotors arranged in parallel.The drive pump is a variable displacement, piston-type pump with anintegral charge pump. Charge pressure is supplied by return flow fromthe exciter/steering circuit tapped at the return-line filter head manifold.Charge pressure is maintained between 14.5 bar (210 psi) through aninternal relief valve (k). Excess charge pump flow is returned to thetank through the return manifold.The drive pump is manually activated by the forward/reverse controllever. When the control lever is shifted forward, oil is directed from thehigh-pressure side of the pump to the manifold block (port R1), throughthe shuttle valve and downstream to both the front and rear drivemotors. Return flow from the motors is directed back through themanifold (port R2) and returns to the low-pressure side of the drivepump. Each drive motor includes a case drain. When operating in reverse, the high- and low-pressure sides of thedrive pump are reversed, with port R2 being the high-pressure sideand port R1 the low-pressure side.System pressure is limited to 200 bar (2900 psi) by two relief valves (f)in the drive pump. The pump shunt valve acts as a tow valve and provides the ability totow the machine without having to fight the flow of oil through the drivepump system.The shuttle valve provides oil flow to the pressure reducing valvewhether traveling forward or reverse. The pressure reducing valveprovides reduced pressure to disengage the brake. The manualoverride valve provides a conduit for flow to the brake. If it becomesnecessary to disengage the brake with the engine shutdown, adequatehydraulic pressure to disengage the brake can be provided by thehand pump.



wc_gr002990

G2

G1

R2

R1

T10 Micron

P1

F2

F1

P2T1

a

b

c d n

gi j

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k


6.30 Vibration and Steering—All Models

The vibration and steering system is an open loop, series circuit, drivenby a fixed displacement, gear-type pump (a) (exciter pump). It includesseparate relief valves (b* and c) for vibration and steering, an excitercontrol valve (d*) (*integral to exciter manifold block (e)), exciter motor(f), steering valve (g), and steering cylinder (h).The exciter pump pulls oil from the tank (w) through the suction filter(i) and sends it to the exciter manifold block. The vibration circuit iscontrolled by the solenoid valve mounted on the exciter manifold block.This valve is electrically operated by an ON/OFF switch located on theend of the forward/reverse control lever. Supply oil from the exciterpump enters the exciter manifold block at port “P” where it is directedto the exciter control valve. When the ON/OFF switch is in the OFFposition, the exciter control valve is open, allowing oil to passdownstream to the steering valve without driving the exciter motor.When the ON/OFF switch is in the ON position, the exciter controlvalve closes and directs oil from the exciter pump, out port “1” of theexciter manifold block to the exciter motor which drives the eccentricweights in the front drum. Return oil from the motor flows back into theexciter manifold through port “2” and is directed downstream to thesteering valve. A relief valve (b) connected across the exciter controlvalve limits system pressure to 138 bar (2000 psi).Steering is controlled by a steering valve and cylinder. The steeringwheel is spline-mounted directly to the steering valve. The steeringvalve reacts to the motion of the steering wheel to direct fluid to andfrom the steering cylinder. Oil returning from the vibration circuit isdirected out port “3” of the exciter manifold block, to port “P” of thesteering valve. If steering is inactive, fluid passes through the steeringvalve out port “T”, and back to the return-line filter manifold. or the filterhead. When the steering wheel is turned, the steering valve closes anddirects oil to the appropriate steering line (ports L and R) to extend orretract the cylinder.A relief valve is connected across the steering valve (c) and is set at48 bar (700 psi).The oil returning from the vibration and steering functions is directedout port “T” of the steering manifold block to a return-line filter (x). Afilter bypass relief valve (y), set at 1.7 bar (25 psi), protects the systemby routing oil past the filter if the filter is clogged. Some models includea back-pressure valve (z) located after the filter. It is used to maintain1 bar (14.5 psi) to the inlet side of the charge pump. When pressure tothe inlet of the charge pump exceeds 1 bar (14.5 psi), the valve opensand returns the excess flow back to the tank.



wc_gr002989

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z

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3 P

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6.31 Hydraulic Manifold Blocks with Test Ports

a Drive manifold RD 11V & RD 11A(parallel drive)

3 Forward drive test port

b Drive manifold RD 11V & RD 11A(series drive)

4 Pump shuttle valve

c Drive control manifold RD 11AEC 5 Exciter solenoid (normally open)

d Exciter/steering manifold 6 Exciter relief valve (138 bar/2000 psi)

1 Tow valve 7 Exciter/Steering test port

2 Reverse drive test port - ---

wc_gr003021

a

b d

c

1

2

2

3

3

1

2

3

4

5

6

7


6.32 Testing Hydraulic Pressure

Before making pressure checks:

6.32.1 Inspect the machine for hydraulic leaks.

6.32.2 Check the level of hydraulic fluid in the tank.

6.32.3 Check the engine operating speed at full throttle.

6.32.4 Run the machine for 5–10 minutes before testing to allow time for thehydraulic system to warm up.

Note: Test ports are equipped with quick disconnects and aredesigned for use with Wacker hydraulic test equipment.

Before opening hydraulic connections, shut the engine off and makesure all controls are in neutral.

WARNING

wc_gr003001

1

2

23

3

a

b

4c

5

6




1 Vibration and steering test port 4 Exciter manifold

2 Reverse test port 5 Drive manifold (RD 11A & RD 11V)

3 Forward test port 6 Drive control manifold (RD 11AEC)

Ref. Description Part no. Part no.

a Pressure gauges 10 mPa (1000 psi) 0077999 30 mPa (5000 psi) 0078000

b Gauge adapter 0078005 -

c Hose 0078002 -

Normal operating pressure bar (psi)

Relief valve pressure bar (psi)

Forward 27–41 (400–600) 200 (2900)

Reverse 27–41 (400–600) 200 (2900)

Exciter 55–69 (800–1000) 138 (2000)

Steering 13–35 (200–500) 48 (700)

Charge Pump 10–12 (150–174) 12 (174)

wc_gr003001

1

2

23

3

a

b

4c

5

6


6.33 Checking Drive Circuit Pressures

Operating Pressure:Check operating pressures with the machine on a firm, level surface.

6.33.1 Install a 5000-psi gauge in the forward test port (3) on the drivemanifold block.

6.33.2 Start the engine and run the machine at full throttle.

6.33.3 Shift the control lever to forward and read the forward operatingpressure.

6.33.4 Stop the engine. Install a gauge in the reverse test port (2) and repeatthe procedure while operating in reverse.

Note: Operating pressures will increase significantly when running themachine uphill, off road, or against an object.

Relief Pressure:

6.33.5 Place blocks in front of and behind both drums to prevent the machinefrom moving, or dead head the machine against a solid concreteabutment. Set the parking brake.

To avoid injury, make sure no one is in front of or behind the machine.

6.33.6 Install a 5000-psi gauge in the forward test port (3) on the drivemanifold block.

6.33.7 Start the engine and run the machine at full throttle. Shift the forward/reverse control slowly into forward until pressure on the gauge topsout. This is the forward relief valve pressure.

Note: Make sure the drums do not spin.

6.33.8 Install the gauge in the reverse test port (2) and repeat the procedurewhile operating in reverse.

WARNING


6.34 Checking Vibration Circuit Pressures

Test the vibration with the front drum on soil or gravel. If testing is doneindoors, position the drum on a rubber tire or heavy mat to absorb thevibration. NOTICE: Do not run the vibration on concrete.

6.34.1 Install a 5000-psi gauge in the vibration test port (1).6.34.2 Start the engine and run the machine at full throttle, with the forward/

reverse control in neutral.

6.34.3 Switch the vibration on. The gauge will read the relief pressuremomentarily as the exciter starts and then fall to the normal operatingpressure as the exciter reaches full speed.

If it is not possible to read the relief valve pressure accurately,disconnect the exciter motor inlet line on the manifold. Cap off and plugthe open line connections. Start the engine and run the test. If thepump is in good condition, the gauge will immediately come up to reliefvalve pressure and remain there.

6.35 Checking Steering Circuit Pressures


6.35.1 Install a 1000-psi gauge in test port (1).6.35.2 Start the engine and run the machine at full throttle.

6.35.3 Turn the steering wheel until it reaches the end of its stroke and hold itthere to read the steering circuit relief pressure.

If the relief pressure cannot be reached, the cylinder seals may be bad.To check them, disconnect and cap off the hose connections to thecylinder and repeat the pressure check.NOTICE: Do not turn the vibration on at any time while checking thesteering circuit! Doing so will increase the line pressure and coulddamage the gauge.

6.35.1


6.36 Adjusting Relief Valves

Relief valves are preset at the factory and normally do not requirefurther adjustment. However, if a relief valve was replaced ordisassembled for inspection, adjustment may become necessary.Adjust the relief valves slowly by turning the adjusting screws in smallincrements. NOTICE: Do not increase pressures above the machinespecifications! Higher pressures can damage the pumps and motors.

Drive Circuit Reliefs:Current machines have relief valves built into the drive pump (1).These reliefs are preset at 20 mPa (2900 psi) and do not require furtheradjustment unless operating at below the recommended setting.

Exciter Relief Pressures: DO NOT remove the plug or attempt to set the relief valve while theengine is running or the system is under pressure!

6.36.1 Turn the engine off.

6.36.2 Remove the plug (4) from the end of the valve (3) to expose theadjusting screw.

6.36.3 Use a 1/4-inch Allen wrench (2) and turn the adjusting screw in or outuntil the correct pressure is set.

Do not start the engine until the plug (1) is installed back in the valve.

WARNING

WARNING

2

3

4

1

wc_gr001548


6.37 Troubleshooting Flowcharts
The troubleshooting flowcharts are designed to take you through theprocess of determining the source of a problem with engine starting ormachine operation. Many of the tests involve live voltages andtherefore should only be attempted by qualified personnel. Detailedprocedures for carrying out the tests are included in this manual. Allhighlighted text within the flowcharts have matching sections in thismanual.


6.38 Drive System Troubleshooting—Flowchart 3A
wc_gr002967

Replace hydraulichoses as needed.

Correct the setting.

Repair or replacethe drive control

cable.

No

Yes

Are the hydraulichoses OK?

Replace the hydraulic oilwith fresh, clean oil of thecorrect specification.

NoIs hydraulic oil

OK?

Yes

Checking hydraulic oil

Check:• Amount of oil in tank• Type of oil in tank• Condition of oil in tank

Yes

Is the tow valve set

correctly?

No

No Is thedrive control cable

OK?

Yes Repair or replacethe drive control

manifold or motor.

No

Checking tow valve

Check setting of tow valve.

Adjusting the drive control cable

Check function of drive control cable.

Is thebrake functioning

properly?

Yes

Checking brake

Check function of brake.

Check the condition of the hydraulic hoses.

Roller does not Travel (propel)

See Flowchart 3B See Flowchart 3B


6.39 Checking Tow Valve (RD 11A and RD 11V only)

When checking the tow valve, check the position of the tow valvehandle. In order for the machine to operate properly, the tow valvemust be completely closed. First, back off the jam nut (a) one full turncounterclockwise. Then, turn the tow valve handle (b) clockwise untilit is fully seated. Finally, secure the valve in the closed position byturning the jam nut clockwise until it is tight.

With the tow valve open, the drive circuit has no braking action and themachine will roll freely. Close the tow valve immediately after a towingoperation is complete to prevent the machine from rollingunexpectedly.

WARNING

wc_gr002983

b

ab


6.40 Checking Brake (RD 11AEC only)

When the brakes are working properly, the hydraulic motors should notbe able to overpower the brakes in either direction (forward orreverse). To test if the brakes are functioning properly, carry out thefollowing procedures:

6.40.1 Disconnect the wiring (a) from the brake solenoid valve.

6.40.2 Start the roller and attempt to drive through the brakes. Do so in bothforward and reverse.

6.40.3 If you are able to drive through the brakes, replace the drive motors.

6.40.4 Reconnect the brake solenoid.

If the brakes are not releasing, then the brake pressure is too low. Oilpressure for the brake lines is tapped from the drive circuit. The drivecontrol manifold includes integral shuttle and pressure reducingvalves. Pressure to the brakes is reduced to between 12 and 30 bar. Ifthe pressure falls below 12 bar, the brakes will not disengage. To testthe pressure to the brakes carry out the following procedures:

6.40.5 Disconnect the hose (b) leading from the drive control manifold to thebrake manifold.

6.40.6 Connect a 1000-psi gauge to the hose.

6.40.7 Start the roller and check the pressure of the oil flowing to the brakemanifold.

6.40.8 If the pressure is less than 12 bar (174 psi), replace the drive controlmanifold.

wc_gr003006

b

a


6.41 Checking Brake System Electrics

When the roller’s engine is running, the solenoid (a) of the brakemanifold (b) receives power through the tan/black wire. Whenenergized, the brake solenoid valve shifts causing oil flow to the drivemotor brakes which releases the brakes. To check the function of thebrake’s electric system, carry out the following procedures:

6.41.1 Place the keyswitch in the ON position.

6.41.2 With your hand around the body of the brake solenoid (a), turn thevibration switch ON and feel for movement of the plunger inside thebrake solenoid.

• If movement of the plunger can be felt, the brake solenoid is working. Note: If the brake solenoid is functioning, any problems with the brakes are in the hydraulic circuit not the electrical sys-tem.

• If the brake solenoid is not functioning, continue.

6.41.3 Disconnect the harness (c) from the brake solenoid.

6.41.4 Place the vibration switch in the ON position and measure the voltagebetween the tan/black wire (d) and ground.

• If 12VDC (battery voltage approximately 12V) is measured, the brake solenoid is receiving power. Check the wire (e) running to the solenoid for continuity. If it has continuity, the solenoid should be functioning. If the brake solenoid is not functioning, replace it.


6.41.5 Remove the seat to gain access to the vibration switch wiring.

6.41.6 Check the continuity of the wiring between the seat switch delay/neutral start module and the brake solenoid.

• If any of the wiring lacks continuity, repair or replace it.

• If the wiring has continuity, check the wiring to the seat switch delay/neutral start mod-ule. Replace the wiring and/or the seat switch delay/neutral start mod-ule if necessary.

wc_gr003008

d

c

a

be


6.42 Adjusting the Drive Control Cable

If the roller tends to drift in either direction when the forward/reversecontrol is in neutral, the drive control cable must be adjusted.Check the adjustment with the machine on a hard level surface, theengine running, and the forward/reverse control in NEUTRAL. Thepump control lever (a) should be centered. If the machine does notremain stationary, loosen the jam nuts (b) and move the turnbuckle (c)as needed until movement stops.If adjusting the turnbuckle does not achieve the desired results, agross adjustment can be made at nut (d) and then fine-tuned asdescribed above.


6.43 Drive System Troubleshooting—Flowchart 3B
wc_gr002972

Replacedrive pump.

No

No

Replacedrive motor(s).

Replacedrive bearings.

Yes

Is relief pressureOK?

Yes

Yes

No

No

Checking drive circuit pressure

Check relief pressure.

Are drive motorsbinding?

Checking drive motor for binding

Check drive motors for binding.

Checking drive motors

Check drive motors.Are drive bearings

OK?

Yes

Check drive bearings.

Replacedrive motors.

CallWacker.

No

Are drive motorsOK?

Yes

Continued from Flowchart 3A

Is relief pressure

OK?

Adjusting Relief Valves

Adjust exciter relief valve pressure.


6.44 Checking Drive Motor for Binding

Stop the machine, apply the parking brake, switch off the engine, anddisconnect the battery.High operating pressures indicate binding in the drive system. Bindingcan occur in the drive motor or may be the result of a poor or failingdrive bearing on the right side of the drum. To check for binding in the drive motor:

6.44.1 Remove the drive motor cover (4), drum support cover (3), and thedrum support (2).

6.44.2 Support the machine before separating the drive plate from the drumby placing blocks or jacks under the front frame just behind the drum.

Only use blocks or jacks with a suitable load-bearing capacity. Do notuse improvised blocks or jacks.

6.44.3 Separate the drive plate (5) from the left side of the drum.

6.44.4 Disconnect the hydraulic lines (1) to the motor.

6.44.5 Rotate the drive plate by hand and make sure the motor is turningfreely.

Failure of the drive circuit to reach operating pressures is normallycaused by a worn or damaged drive pump; however, the problemcould also be the result of a badly worn motor. Questions regarding thetesting and troubleshooting of drive components should be referred toWacker Corporation.

WARNING

wc_gr001550

1

2 3

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6.45 Checking Drive Motors—Series Drive
With revision 103 and thereafter, the drive motors on the RD 11A andRD 11V models are plumbed in series. Oil flow through one motor isvirtually identical to the flow through the other, unless a problem withone of the motors exists. To test the drive motors, carry out thefollowing procedure:Crushing hazard. Use extreme care when carrying out the followingprocedure.

6.45.1 Start the engine and allow the hydraulic oil to warm up. Shut off theengine.

6.45.2 Using a crane or overhead lift with enough load-bearing capacity tosupport the machine, lift the machine off the ground so that the drumsare 2–5 cm (1–2 inches) off the ground.

6.45.3 Place a piece of tape or boldly mark each drum. This will aid inobserving the rotation of the drums.

6.45.4 Start the engine and slowly shift the forward/reverse control lever intothe forward position. Observe the drum rotation for any sign ofdifference in the rotation of the drums. If one drum is rotating slowerthan the other, the drum with the slower rotation is suspect.

6.45.5 With the engine running and the drums rotating, slowly apply theparking brake to the rear drum. Observe the speed of both drums asthe brake is applied. Both drums should slow down at the same rate.Apply the brake until the rear drum stops rotating. Note: If the brakecannot stop the rear drum from rotating, the brake requires repair orreplacement. With the rear drum held from rotating by the brake, thefront drum should not be rotating. If it is, the seals of the rear drivemotor are failing. Rebuild or replace the rear drive motor.

Release the brake from the rear drum.

6.45.6 Conduct the same test on the front drum. Use a sturdy piece of woodsuch as a 2x4 as an external brake. Wedge the piece of wood betweenthe drum and the machine frame to stop the drum rotation. Do not jam the piece of wood between the drum and the floor. Theroller may move.

If the rear drum rotates when the front drum is held from rotating by theexternal brake, the seals of the front drive motor are failing. Rebuild orreplace the front drive motor.

WARNING

WARNING


6.46 Checking Drive Motors—Parallel Drive
With the release of the machines, and up to and including revision 102,the drive motors on the RD 11A and RD 11V models were plumbed inparallel. The drive motors on all revisions of model RD 11AEC areplumbed in parallel. With parallel drive, each drive motor worksindependently of the other. To test the drive motors, carry out thefollowing procedure:

6.46.1 Start the engine and allow the hydraulic oil to warm up.

6.46.2 Position the machine on a smooth, horizontal surface.

6.46.3 Shut off the engine.

6.46.4 Block the drums with appropriate devices so that the machine cannotmove.

6.46.5 Disconnect the case drain line from one of the drive motors and placeit in a suitable container.

6.46.6 Start the machine. Slowly shift the forward-reverse lever into forward,then reverse. Observe the flow from the case drain line. A steadyseries of drops dripping from the line is tolerable. A steady flow of oilindicates the motor’s seals are going bad and the pump should berebuilt or replaced.

6.46.7 Reconnect the drain line and conduct the test with the other drivemotor.


6.47 Vibration System Troubleshooting—Flowchart 4A
wc_gr002968

Replace the hydraulic oilwith fresh, clean oil of thecorrect specification.

YesIs hydraulic oil

OK?

No

Checking hydraulic oil

Check:• Amount of oil in tank• Type of oil in tank• Condition of oil in tank

Replacethe vibration

switch.

Replacethe exciter solenoid.

YesIs the exciter solenoid

working?

No

YesIs the vibration switch

working?

No

Checking exciter electrical system

Check the function of the exciter solenoid.

Check the function of the vibration switch.

Replace hydraulichoses as needed.

No

Yes

Are the hydraulichoses OK?

Check the condition of the hydraulic hoses.

Roller does not Vibrate

See section Troubleshootinga System that Vibrates Poorly


Notes

6.48 Checking Exciter Electrical System

When the roller’s engine is running, the solenoid (a) of the excitermanifold (b) receives power through the white wire via the vibrationswitch. When energized, the exciter solenoid valve shifts causing oilflow to the exciter motor. To check the function of the exciter electricsystem, both the exciter solenoid and the exciter switch should betested.

To check the exciter solenoid:

6.48.1 Place the key switch in the ON position.

6.48.2 With your hand around the body of the exciter solenoid (a), turn thevibration switch ON and feel for movement of the plunger inside theexciter solenoid. Note: If the movement of the plunger is hard todetect, remove the solenoid from the exciter manifold to make it easier.

• If the exciter solenoid is functioning, any problems with vibration are in the hydraulic circuit not the electrical system.

• If the exciter solenoid is not functioning, continue.

6.48.3 Disconnect (c) the harness from the exciter solenoid.

6.48.4 Place the vibration switch in the ON position and measure the voltagebetween the white wire (d) and ground.

• If 12VDC (battery voltage approximately 12V) is measured, the exciter solenoid is receiving power. Check the brown wire (e) for continuity. If it has continuity, the solenoid should be functioning. If the exciter solenoid is not functioning, replace it.

• If 12VDC is not measured, go to step 5.

6.48.5 Remove the seat to gain access to the vibration switch wiring.

6.48.6 Disconnect the control lever electronics from the harness (f).6.48.7 To test the function of the exciter switch, press the exciter switch ON

and OFF while checking the continuity across the pink and white wires.

• If the vibration switch has no continuity, replace it.

• If the vibration switch has continuity, continue.

6.48.8 Check the continuity of the wiring between the key switch and thevibration switch and also between the vibration switch and the excitersolenoid.

• If any of the wiring lacks continuity, repair or replace it.



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6.49 Troubleshooting a System that Vibrates Poorly
The exciter pump is designed to put out a constant flow of oil at a setengine speed. This ensures that the vibration frequency remainssteady. When troubleshooting the exciter circuit, the vibration speedshould be measured along with the operating and relief pressures tohelp determine the cause of any problems.To measure vibration speed:

6.49.1 Start the machine and run it for several minutes to bring the hydraulicfluid up to normal operating temperatures.

6.49.2 Check the engine RPM using a tachometer. The engine must berunning at the correct RPM to accurately measure vibration.

6.49.3 Position the roller on a rubber mat and start vibration. Hold thevibrotach (P/N 53397) against the outer rim of the drum and measurethe vibration speed.

6.49.4 The vibration speed along with the operating and relief valve pressurescan be used to determine the condition of the exciter system as shownin the chart below.

If the exciter is binding, causing high operating pressures, it will benecessary to disconnect and remove the exciter motor from thehousing to determine if the binding is occurring in the exciter bearingsor the motor. Turn the motor shaft and exciter shaft by hand and checkthat they turn freely.

N = Normal, L = Low, H = High

Engine RPM Minimum Vibration Speed

3200–3300 3800

3500–3600 4200

OperatingPressure

Pump ReliefPressure

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


6.50 Checking Exciter and Exciter Motor

6.50.1 Remove the two screws (a) which secure the exciter motor (b) to thehousing.

6.50.2 Rotate the exciter (c) and the motor shaft by hand. Each should turnfreely. Replace the exciter or the exciter motor if either are binding.

wc_gr003004

b

c

a


6.51 Troubleshooting the Steering System
Low hydraulic pressure in the steering circuit can be the result of adefective or worn steering valve or poor seals in the steering cylinder.To isolate the problem, recheck the steering relief pressure with thecylinder removed from the circuit and the hydraulic connections to itcapped or plugged. If the hydraulic pressure remains low, the problemis in the steering valve. If the hydraulic pressure increases, theproblem is in the cylinder. DO NOT drive the machine with the steering cylinder disconnected orinoperative!

A badly worn exciter pump will affect both the steering and thevibration circuits, because these circuits operate in series using thesame supply. If pressure to both circuits falls below operatingpressures, replace the exciter pump.Note: In some cases the exciter pump may be good enough to operatethe steering circuit but not the vibration circuit. This is due to the muchlower pressure requirements of the steering circuit.

WARNING


RD 11 Repair Electrical System
7. Electrical System
7.1 Checking Throttle Switch


To check the function of the throttle switch:

7.1.1 Remove the throttle switch (a) from the machine.

7.1.2 Check the throttle switch for continuity between the upper two spades(b) and the lower two spades (c) when the switch is in the FASTposition.

• If there is continuity, the throttle switch is functioning.

• If there is no continuity, replace the throttle switch.

wc_gr003052

a

b

c


Electrical System RD 11 Repair
7.2 Checking Throttle Solenoid

To check the function of the throttle solenoid:

7.2.1 Place the key switch in the ON position. Do not start the engine.

7.2.2 Place the throttle switch in the FAST position. A noticeable click shouldbe heard as the relay sends power to the solenoid. You should alsosee the arm of the solenoid move.

• If the arm of the solenoid moved, the solenoid is functioning. If you are still having problems with the FAST position, check the throttle cable.

• If the arm of the solenoid did not move, continue.

7.2.3 Disconnect the throttle solenoid. With a multimeter, measure DCvoltage (battery voltage approximately 12) between the connector (a)where the pink-red wire is connected and ground; do so with the keyswitch in the ON position and the throttle switch in the FAST position.

• If 12VDC is measured, replace the throttle solenoid.


7.2.4 Disconnect the 12V relay (throttle solenoid relay) (b). With amultimeter, measure DC voltage (battery voltage approximately 12)between red-white wire and ground.

• If 12VDC is not measured, check the continuity of the red-white wire from the connector through the 20A circuit breaker and back to the starter on models with Honda engine or back to the starter relay on models with the Vanguard engine. Repair or replace the wire as needed.

• If 12VDC is measured, continue.

7.2.5 With the 12V relay still disconnected, measure DC voltage (batteryvoltage approximately 12) between the connector where the pink wireis connected and ground; do so with the key switch in the ON positionand the throttle switch in the FAST position.

• If 12VDC is measured, replace the 12V relay.


7.2.6 Check the continuity of the pink wire from the connector back to thethrottle switch.

• If the wire has no continuity, replace it.

• If the wire has continuity, check the function of the throttle switch.



wc_gr003053

a b


7.3 RD 11A Electrical Schematic (revisions 100–118)
15A

20

wc_gr003022

A

BA

S I

A

B

B

D

A

C

1

2

3

4

5

15

67

8

10

1112

16

1314

9

P

P

Br

B

P

T

W/B

T/RBrR

B

B

B

R

G

W

G

w

R

R

R

B

Br

B

Br W B

B

T

T

T/R


7.4 RD 11A Electrical Components (revisions 100–118)


1 Vibration switch 9 Battery

2 Forward/reverse switch 10 Starter

3 Neutral safety switch 11 Voltage regulator

4 Backup alarm (optional) 12 Anti-afterfire solenoid

5 Keyswitch 13 Alternator

6 15-Amp fuse 14 Magneto kill

7 20-Amp fuse 15 Exciter control solenoid

8 Starter relay 16 Engine

Wire Colors

B Black R Red Y Yellow Or Orange

G Green T Tan Br Brown Pr Purple

L Blue V Violet Cl Clear Sh Shield

P Pink W White Gr Gray LL Light blue


7.5 RD 11A Wiring Diagram (revisions 100–118)
12

13

15

16

14

106

8

9

5

1

2

3

4

7

11

15A

20A

G

BrR

WG

B PB

P

R

W/B63

wc_gr003054

WPB

B

W

Br

Br

B

T

B

B

R

R

T/R

T/R

Br












Wire Colors






wc_gr003025

12

13

P

W

P

B

T

W/BT/RBrR

Br

P/R

P

P/B

BA

85

R

Br

Br

P/RR/W

86 30

87

T

R

BR

S I

3 6

20A

20A

30A

2 5

W

P

14

3

16

19

4

218

6

98

7

10

17

5

1

11

20

15

Br





2 Battery 12 Vibration switch

3 Keyswitch 13 Forward/reverse switch

4 30-Amp fuse 14 Neutral safety switch

5 Throttle solenoid 15 Backup alarm (optional)

6 Starter 16 Throttle switch

7 Magneto kill 17 12VDC relay

8 Alternator 18 Starter relay

9 Anti-afterfire solenoid 19 Vibration system indicator light

10 Engine 20 Voltage regulator

Wire Colors






430A

9

8

11

10

7

61

18

2

319

12

13

14

15

1

20

20A

20A

G

BrR

WG

B PB

P

R

W/B63

wc_gr003055

WPB

B

W

W Br

B

Br

T

B R

Br

B

B

R

T/R

Br

T/R

T P/B

R

5

17

16

R

P

P/R

Br

R/W






3 Keyswitch 13 Forward/reverse switch

4 30-Amp fuse 14 Neutral safety switch



7 Magneto kill 17 12VDC relay

8 Alternator 18 Starter relay

9 Anti-afterfire solenoid 19 Vibration system indicator light

10 Engine 20 Voltage regulator

Wire Colors






16

4

52

63 P/B

P/B

B B

B/Y

T

T

T/R

P

P

P

wc_gr002981

P/R

P/R

R/L

P

W

P A

B

B

D

C

A

PGr

B

W/B

R/W

R/W

Br

P/R

Br

R/W

85

86 30

RR/Y

R

R/W

R/W

Br

P

R/Y

R/L

Br

Br

Br

SI

SO

CG

CP

B

87

3

12

13

14

17

5

T

W/B

T/RBrR/L

Br W

108

7

GrGrB/YW/LWB

GrGrwW/LWB

19

9

6

2011

18

1 1

2

Br






3 Keyswitch 13 Forward/reverse control

4 Vibration system indicator light 14 Neutral safety switch



7 Voltage regulator 17 12VDC relay

8 Alternator 18 20-Amp circuit breaker

9 Anti-afterfire solenoid 19 Magneto kill

10 Engine 20 Starter relay

Wire Colors






18

20A

9

8

11

10

19

61

20

2

34

12

13

14

15

1

7

20A

20A

Gr

BrR

WG

B PB

P

R/L

W/B63

wc_gr003056

WPB

B

W

W Br

BB

Br

T

R/L R

R

BrBr

R/L

T/R

T/R

TT

B/Y P/B

P/B

W

R/Y

P

B

R/W

5

17

16

R/W

P

P/R

Br

R/W

R/Y














Wire Colors






7.15 RD 11A Electrical Schematic (revisions > 141)
16

4

52

63 P/B

P/B

B B

B/Y

T

T

T

T/R

P

P

P

wc_gr003581

P/R

P/R

R/L

P

W

P A

B

B

D

C

A

PGr

B

W/B

R/W

R/W

Br

P/R

Br

R/W

85

86 30

RR/Y

R

R/W

R/W

Br

P

R/Y

R/L

Br

Br

Br

SI

SO

CG

CP

B

87

3

12

13

14

21

17

5

T/Y

W/B

T/RBrR/L

Br W

108

7

GrGrB/YW/LWB

GrGrwW/LWB

19

9

6

2011

18

1 1

2

Br


7.16 RD 11A Electrical Components (revisions > 141)


1 20-Amp fuse 12 Vibration switch

2 Battery 13 Forward/reverse control

3 Keyswitch 14 Neutral safety switch

4 Vibration system indicator light 15 Backup alarm (optional)

5 Throttle solenoid 16 Throttle switch

6 Starter 17 12VDC relay

7 Voltage regulator 18 20-Amp circuit breaker

8 Alternator 19 Magneto kill

9 Anti-afterfire solenoid 20 Starter relay

10 Engine 21 Seat switch

11 Exciter control solenoid - ---

Wire Colors






7.17 RD 11A Wiring Diagram (revisions > 141)
18

20A

9

8

11

10

19

61

20

2

34

12

13

14

15

1

7

20A

20A

Gr

BrR

WG

B PB

P

R/L

W/B63

wc_gr003582

WPB

B

W

W Br

BB

Br

T/Y

R/L R

R

BrBr

R/L

T/R

T/R

TT

B/Y P/B

P/B

W

R/Y

P

B

R/W

5

17

16

R/W

P

P/R

Br

R/W

R/Y

21


7.18 RD 11A Electrical Components (revisions > 141)













Wire Colors






7.19 RD 11V Electrical Schematic (revisions 100–118)
15A

20

wc_gr003022

A

BA

S I

A

B

B

D

A

C

1

2

3

4

5

15

67

8

10

1112

16

1314

9

P

P

Br

B

P

T

W/B

T/RBrR

B

B

B

R

G

W

G

w

R

R

R

B

Br

B

Br W B

B

T

T

T/R


7.20 RD 11V Electrical Components (revisions 100–118)










Wire Colors






7.21 RD 11V Wiring Diagram (revisions 100–118)
12

13

15

16

14

106

8

9

5

1

2

3

4

7

11

15A

20A

G

BrR

WG

B PB

P

R

W/B63

wc_gr003054

WPB

B

W

Br

Br

B

T

B

B

R

R

T/R

T/R

Br












Wire Colors






wc_gr003024

12

13

P

W

P

B

T

W/BT/RBrR

Br

P/R

P

P/B

Br

85

R

Br

Br

P/RR/W

86 30

87

T

R

B

S I

3 6

15A

20A

30A

2 5

W

P

14

3

16

21

19 4

218

6

98

7

10

17

5

1

11

20

15

Br





2 Battery 13 Forward/reverse switch


4 30-Amp fuse 15 Backup alarm (optional)



7 Magneto kill 18 Starter relay

8 Alternator 19 15-Amp fuse

9 Anti-afterfire solenoid 20 Voltage regulator

10 Engine 21 Vibration system indicator light


Wire Colors






430A

9

8

11

10

7

619

18

2

321

12

13

14

15

1

20

15A

20A

G

BrR

WG

B PB

P

R

W/B63

wc_gr003055

WPB

B

W

W Br

B

Br

T

R

Br

R

T/R

Br

T/R

T P/B

R

5

17

16

R

P

P/R

Br

R/W





2 Battery 13 Forward/reverse switch


4 30-Amp fuse 15 Backup alarm (optional)



7 Magneto kill 18 Starter relay

8 Alternator 19 15-Amp fuse

9 Anti-afterfire solenoid 20 Voltage regulator

10 Engine 21 Vibration system indicator light


Wire Colors






16

4

52

63 P/B

P/B

B B

R

T

T

T

Y

Y

R

RR/Y

T/R

P

P

P

wc_gr002997

P/R

P/R

R/L

R/L

P

W

P A

B

B

D

C

A

PGr

B

W/B

R/W

R/W

Br

P/R

Br

R/W

85

86 30

R

R/WBr

B

R/Y

R/YBr

Br

Br

SI

SO

CG

CPB

87

3

12

13

14

17

5

T

W/B

T/RBrR/L

Br W

1087

19

6

2011

18

1 12R/W

Br














Wire Colors






18

20A

61

2

1

20A

20A

R

R

R

9

8

11

10

19

61

20

2

34

12

13

14

15

1

7

20A

20A

Gr

BrR

WG

B PB

P

R/L

W/B63

wc_gr003058

WPB

B

W

W Br

BB

Br

T

R/Y

R/L

B

Br

R/L

T/R

T/R

TT

TR P/B

P/BR/Y

5

17

16

R/W

P

P/R

Br

R/W

R/W

Br

YY














Wire Colors






7.31 RD 11V Electrical Schematic (revisions > 142)
16

4

52

63 P/B

P/B

B B

R

T

T

T

Y

Y

R

RR/Y

T/R

P

P

P

wc_gr003583

P/R

P/R

R/L

R/L

P

W

P A

B

B

D

C

A

PGr

B

W/B

R/W

R/W

Br

P/R

Br

R/W

85

86 30

R

R/WBr

B

R/Y

R/YBr

Br

Br

SI

SO

CG

CPB

87

3

12

13

14

17

5

T/Y

W/B

T/RBrR/L

Br W

1087

19

21

6

2011

18

1 12R/W

Br


7.32 RD 11V Electrical Components (revisions > 142)













Wire Colors






7.33 RD 11V Wiring Diagram (revisions > 142)
18

20A

61

2

1

20A

20A

R

R

R

9

8

11

10

19

61

20

2

34

12

13

14

15

1

7

20A

20A

Gr

BrR

WG

B PB

P

R/L

W/B63

wc_gr003584

WPB

B

W

W Br

BB

Br

T

R/Y

R/L

B

Br

R/L

T/R

T/R

TT

TR P/B

P/BR/Y

5

17

16

R/W

P

P/R

Br

R/W

R/W

Br

YY

21


7.34 RD 11V Electrical Components (revisions > 142)













Wire Colors






7.35 RD 11AEC Electrical Schematic (revisions 100–111)
A

B

CD

E

F14

15

16

18

1720

19

3

21

22 11

12 13 2

1

10

6

5

44

8

9

7

P

W

P

G

B

W/B

T

T/B

W/BBr

P

Y

Y

B

B

B

RG

W

P

T

W/BR

P P T/B R Br W B T T

G/W

R T

B

R

Br

T/B

Br

T/BB

wc_gr002027


7.36 RD 11AEC Electrical Components (revisions 100–111)


1 Battery disconnect 12 Brake solenoid

2 Battery 13 Pump shunt solenoid

3 Keyswitch 14 Vibration switch

4 20-Amp fuse 15 Forward/reverse control

5 Starter relay 16 Neutral safety switch

6 Starter 17 Seat switch

7 Regulator/Rectifier 18 Seat switch delay and neutral start module

8 Alternator 19 Backup alarm (optional)

9 Anti-afterfire solenoid 20 Emergency stop pushbutton

10 Engine 21 Horn switch

11 Exciter control solenoid 22 Horn

Wire Colors






7.37 RD 11AEC Wiring Diagram (revisions 100–111)
E

F

B

C

D

A

F

E

B

C

D

A

E

F

B

C

D

A

F

E

B

C

D

A

wc_gr002029

R R

TP

W/B

R

T

WBr

T/BBr

T/B

Br

W/BT/B

WB

T

PP

P

P

P

G/W

W/B

Br

G

117

8

13

9

22

21

20

19

18

1716

15

1413

12

11

1

2

3

4 4

5

6

7 8

9

10















Wire Colors






7.39 RD 11AEC Electrical Schematic (revisions 112–125)
A

B

CD

E

F14

15

16

18

17

19

7

20

3

21

22 11

212 13

1

10

6

5

44

8

9

P

Y

P

G

B

W/B

W

T/B

W/BBr

P

R

Br

B

B

B

RG

W

P

T

W/BR

P P T/B R Br W B T T

G/W

R T

B

R

Br

T/B

Br

T/BB

wc_gr002028

Y















Wire Colors






7.41 RD 11AEC Wiring Diagram (revisions 112–125)
E

F

B

C

D

A

F

E

B

C

D

A

E

F

B

C

D

A

F

E

B

C

D

A

wc_gr002030

R R

TP

W/B

R

T

WBr

T/BBr

T/B

Br

W/BT/B

WB

PP

P

P

P

G/W

W/B

Br

G

117

8

13

9

22

21

20

19

18

1716

15

1413

12

11

1

2

3

4 4

5

6

7 8

9

10

Y















Wire Colors






7.43 RD 11AEC Electrical Schematic (revisions > 125)
21

3

7

5

6

22

26

25

27

24

23

1718

16

20

1915

14

8

9

10

12

P

P P

wc_gr002991

W/B

Y

WT/B

W/BBr

PP

Y

WT/B

Br

R

Br

Gr

B/Y

B

W/L

Gr

WW/L

B

T/R

T

T

P/B

BB

P

Br

Br

Br

Br

Br

R

R B

P P

P/B

Br

P

B

R/W

R/W

2 5

AC

D

B

FEP

Y

P

G

B

CPR/W

B/P

B/Y

P/R

Br

G/W


7.44 RD 11AEC Electrical Components (revisions > 125)


1 Battery disconnect 15 Forward/reverse control

2 Battery 16 Neutral safety switch

3 Keyswitch 17 Seat switch

4 20-Amp fuse 18 Seat switch delay and neutral start module

5 Starter relay 19 Backup alarm (optional)

6 Starter 20 Emergency stop pushbutton

7 Voltage regulator 21 Horn switch

8 Alternator 22 Horn

9 Anti-afterfire solenoid 23 Throttle solenoid

10 Engine 24 12VDC relay

11 Exciter control solenoid 25 Throttle switch

12 Brake solenoid 26 20-Amp circuit breaker

13 Pump shunt solenoid 27 Magneto kill

14 Vibration switch - ---

Wire Colors






7.45 RD 11AEC Wiring Diagram (revisions > 125)
S LG

B M

E

F

B

C

D

A

F

E

B

C

D

A

E

F

B

C

D

A

F

E

B

C

D

A

wc_gr003026

R/LR/Y

B/P

R

T/R

P

P

R

W/B

W

T

WBr

T/BBr

T/B

Br

W/BT/B

WB

PP

P

P

P

G/W

W/B

Br

G

117

8

13

9

22

21

20

19

18

1716

15

1413

12

11

1

2

3

26

44

5

6

727

8

9 10

Y

Br

24

23

BrB

R/W

R/W

R/W

P/R

Br

25

P

P/B

63

2 5

TT


7.46 RD 11AEC Electrical Components (revisions > 125)


1 Battery disconnect 15 Forward/reverse control

2 Battery 16 Neutral safety switch

3 Keyswitch 17 Seat switch

4 20-Amp fuse 18 Seat switch delay and neutral start module

5 Starter relay 19 Backup alarm (optional)

6 Starter 20 Emergency stop pushbutton

7 Voltage regulator 21 Horn switch

8 Alternator 22 Horn

9 Anti-afterfire solenoid 23 Throttle solenoid

10 Engine 24 12VDC relay

11 Exciter control solenoid 25 Throttle switch

12 Brake solenoid 26 20-Amp circuit breaker

13 Pump shunt solenoid 27 Magneto kill

14 Vibration switch - ---

Wire Colors






Notes

RD 11 Repair Disassembly and Assembly
8. Disassembly and Assembly
8.1 Tools

Because all possible problems encountered while repairing themachine cannot be anticipated, it is up to the mechanic to use commonsense and good judgement in tool selection. The use of any special tools is recommended only for those operationswhere the use of conventional tools proves inadequate.Before substituting another tool or procedure, you should be satisfiedthat neither personal injury nor damage to the component will result.

8.2 Ordering Parts

The repair procedures contained in this manual do not include partnumbers. For parts replacement information, refer to the Parts Bookoriginally supplied with the machine. If the original Parts Book has been lost, a replacement may be orderedfrom Wacker Corporation. When ordering a replacement Parts Book,please list the model number, item number, revision level, and serialnumber of the machine. Parts Books are also available on the WackerCorporation Web site. See www.wackergroup.com. Enter the site as avisitor.

8.3 Reference Numbers ( )

Repair procedures contain reference numbers enclosed inparentheses ( ). These numbers refer to the item numbers shown onthe assembly drawings and other detailed drawings. They are includedto aid the mechanic in identifying parts and assembling components.

8.4 Weight Block


The weight block symbol gives an approximate weight measurementto aid the mechanic when lifting/hoisting larger components.

250 kg(550 lbs.)

wc_gr000843


Disassembly and Assembly RD 11 Repair
8.5 Threadlocking Compounds
Due to the heavy vibration inherent in this type of equipment, the repairand service procedures described in this manual specify the use ofthreadlocking compounds. These compounds should be used whereindicated to prevent the fasteners from becoming loose.Although Loctite® is referred to throughout this manual, any equivalenttype of sealant such as Hernon, Prolock, or Omnifit may be used.Clean the screw threads and wipe off any oil or grease before applyinga threadlocking compound.For a complete list of recommended sealing and locking compounds,refer to the Use of Threadlockers and Sealants chart at the end of thisRepair Manual.

8.6 Front Drum Assembly Description


The front drum is designed to apply high frequency vibrations to theground to aid in compaction. Vibrations are produced by an eccentricweight which rotates at a high speed inside the drum assembly. Thecentrifugal force created by the revolving weight helps compress theasphalt. This method of compaction produces results equal to or betterthan those produced by larger and heavier static type rollers.The front drum is driven by a single hydraulic motor (1) mounted to adrive plate (2), which is shockmounted directly to the left side of thedrum. The drive motor is designed to provide low speeds and hightorques without the need for any type of speed reduction gears, beltsor pulleys.The exciter assembly is driven by a gear-type hydraulic motor (3)coupled directly to the exciter shaft. The exciter shaft turns inside thedrum and is supported on each end by heavy duty roller bearings (4).The exciter is grease lubricated. There are two grease fittings, one oneach side of the machine, located behind the front drum supports.A sealed drive bearing (5), along with three large shockmounts (6),support the right side of the drum.Weight plate (7) is used on early machines only (prior to REV. #103).Note: Wacker Corporation does not recommend the disassembly orattempted repair of hydraulic components (pumps, motors, or steeringcylinder) by anyone other than a trained hydraulic repair technician.The repair and rebuilding of hydraulic components may be availablefrom component manufacturers. Hydraulic component parts are notavailable from Wacker Corporation.




a. RD 11AEC b. RD 11A Parallel Drive

c. RD 11A/V Series Drive

a

b

c

2

1

2

1

2

1

7

5

3

6

4

wc_gr001555

250 kg(550 lbs.)

wc_gr000843


8.7 Replacing the Exciter Motor

Removal:

8.7.1 Disconnect the hydraulic fittings (a) running to the exciter motor (b).Cap all the fittings to reduce the risk of contaminating the hydraulicsystem.Note: If you need only to access the exciter, the hydraulic fittings canremain connected to the exciter motor.

8.7.2 Remove the two screws (c) which secure the exciter motor to the drumhub (d) and remove the exciter motor.

Installation:

8.7.3 Place the key and the gear (e) of the coupling on the shaft of the excitermotor (b). There is a set screw on the gear; do not tighten the set screwat this time.

8.7.4 To obtain the correct placement of the gear on the shaft of the excitermotor, insert the exciter motor into the drum so that the gear on themotor shaft contacts the gear (f) on the exciter (g). Allow the gear onthe exciter to push the gear on the shaft. Be sure to position the excitermotor so that its mounting flange meets the mating mounting surface(h) of the drum hub.

8.7.5 Pull the exciter motor back out of the drum hub. Mark the position ofthe gear on the motor’s shaft, then slide the gear 3 mm (1/8 in.) closerto the exciter motor and tighten the set screw. NOTICE: Do not slide the gear so far that it contacts the housing of theexciter motor; damage to the exciter motor and the gear will result.Also, there may be insufficient contact within the coupling.

8.7.6 Install the flexible portion (i) of the coupling onto the exciter.

8.7.7 Position the exciter motor back into the drum hub so that the gear onthe exciter motor’s shaft slides into the flexible portion of the coupling.Using Loctite 243 or an equivalent on two screws (c), secure theexciter motor to the drum hub. Torque the screws to 85 Nm (65 ft.lbs.).



3 mm(1/8 in.)

wc_gr003028

ab

i

f b

d

e

i

gh

dc


8.8 Removing the Front Drum

NOTICE: Before removing the drum, clean and wash the completedrum assembly to remove as much dirt as possible. Be especiallythorough when cleaning the area around the tube and hoseconnections on the motors. This will minimize the chance ofcontamination when opening the hydraulic lines.

8.8.1 Block the back drum.

8.8.2 Open the tow valve.

8.8.3 Disconnect the battery.

8.8.4 Support the front end of the machine with an appropriate crane, jackstands (a), or screw jacks. Only use cranes, stands, or jacks with a suitable load-bearing capacity.

8.8.5 On the right side of the machine (exciter motor side), remove the fourscrews (b) which secure the drum support cover (c) to the drumsupport and remove the drum support cover.

8.8.6 Remove the two screws (d) which secure the exciter motor (e) to thedrum support and place the exciter motor to the side.

8.8.7 On the right side of the machine remove the three nuts (f) which securethe drum support (g) to the shock mount plate (h).

8.8.8 On the right side of the machine remove the four screws which securethe drum support to the machine. Slide the drum support away fromthe machine.

8.8.9 On the left side (drive motor side), remove the four screws (i) whichsecure the drum support cover (j) to the drum support and remove thedrum support cover.

8.8.10 Remove the screw and clamp (k) which secures the hydraulic tube tothe manifold block.

8.8.11 Disconnect the hydraulic tubes (l and m) to the front drive motor. Plugthe fittings to reduce the risk of contamination to the hydraulic system.

8.8.12 Remove the four screws (p) which secure the left-side drum support(q) to the machine.

8.8.13 Pull the drum (r) out from underneath the front frame.

WARNING



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8.9 Installing the Front Drum

8.9.1 On the right side of the machine use Loctite 243 or an equivalent onfour screws and secure the right-side drum support to the machine.Torque the screws to 118 Nm (87 ft.lbs.).

8.9.2 Position the drum underneath the machine. On the right side of themachine install the three nuts (f) which secure the drum support (g) tothe shock mount plate (h).

8.9.3 Using Loctite 243 or an equivalent on two screws (d) secure the excitermotor (e) to the drum support.

8.9.4 Using Loctite 243 or an equivalent on four screws (p) secure the left-side drum support (q) to the machine. Torque the screws to 118 Nm(87 ft.lbs.).

8.9.5 Reconnect the hydraulic tubes (l and m). Install the screw and clamp(k) which secures the hydraulic tube to the manifold block.

8.9.6 Using four screws for each, secure the drum support covers (c and j)to the drum supports.

8.9.7 Close the tow valve.

8.9.8 Reconnect the battery



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8.10 Replacing the Exciter and Exciter Bearings

Exciter Removal:

8.10.1 Disconnect the exciter motor (a) from the drum hub.

8.10.2 Remove the four screws which secure the right-side drum support (b)and position the drum support to the side.

8.10.3 To aid in installation, label or mark the position (c) of the shoulder onthe bearing flange.

8.10.4 Remove the six screws (d) which secure the bearing flange (e) and theshockmount plate (f) to the drum hub and remove the bearing flangeand the shockmount plate.

8.10.5 Mark on the drum the position (g) of the drum hub (i). 8.10.6 Remove the six screws (h) securing the drum hub (i) to the drum and

carefully remove the drum hub from the drum. The exciter will drop outof the drum hub when the drum hub is removed.

Note: The photos show the drum in an upright position; however, it isnot necessary to stand the drum on end to remove the drum hub.

8.10.7 Remove the exciter (j) from the drum.

Note: The photos show the drum in an upright position; however, it isnot necessary to stand the drum on end to remove the exciter.



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Bearing removal:

8.10.1 On the exciter side of the drum, two bearings and their flanges makeup the drum hub (d). To disassemble the drum hub, carry out thefollowing procedures:

• Remove the retaining ring (e).• Use a puller to pull the smaller bearing flange (f) and bearing (h)

from the shaft of the larger bearing flange (g). Then, use a press to press out the bearing (h) from the smaller bearing flange.

• On the larger bearing flange, remove the outer seal (i) and use the two set screws (j) to push the outer bearing race (k1) from the larger bearing flange.

• Remove the inner seal (l) if necessary.

8.10.2 In order to remove the drive-motor-side exciter bearing, first removethe drive motor and the left-side drum support from the machine. Seesection Front Drive Motor.

8.10.3 Remove the six screws (a) which secure the drive-motor-side bearingflange (b) and remove the bearing flange. Note: The drive-motor-sidebearing flange is removed from inside the drum.

8.10.4 Remove the two screws (m) from the drive-motor-side bearing flange(b). In their place, insert two M8 pusher screws. Use the screws topush the outer bearing race (c1) from the drive-motor-side bearingflange (b).

8.10.5 Use a puller to remove the inner bearing races (c2 and k2) from theexciter.



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Bearing installation:

8.10.1 Press new inner bearing races (c2 and k2) onto the exciter.

8.10.2 Install the outer bearing race into the drive-motor-side bearing flange(b).

8.10.3 Using Loctite 234 or an equivalent on six screws (a) secure the drive-motor-side bearing flange to the drum. Torque the screws to 49 Nm (36ft.lbs.).

8.10.4 Be sure set screws (j) are recessed on the larger bearing flange (g).Install a new inner seal (l). Lightly grease the outer bearing race andpress it into the larger bearing flange.

8.10.5 Install a new outer seal (i) on the shaft of the larger bearing flange.

8.10.6 Press the bearing (h) into the smaller bearing flange (f).8.10.7 Press the two bearing flanges together to create the drum hub.

8.10.8 Install the retaining ring (e).8.10.9 Lubricate the exciter bearings with wheel bearing grease Filmite EMB

or equivalent.

8.10.10 See Exciter Installation for procedures regarding installing the drumhub.


Exciter Installation:

8.10.1 Install the key and the gear (h) of the exciter motor coupling onto theexciter. Secure the gear to the exciter with the set screw.

8.10.2 Slide the exciter (a) through the drum and into the drive-motor-sidebearing race. Note: The photo shows the drum in an upright position;however, it is not necessary to stand the drum on end to install theexciter.

8.10.3 Temporarily install the exciter-side drum hub onto the drum using threescrews (b). Check the exciter for end-play. To do so, grab the exciter(a) with a needle-nosed pliers and pull and push it back and forth insidethe drum. There needs to be 5±1 mm (3/16±1/16 in.) of end-play forcorrect performance. If the correct amount of end-play is not found,remove the drum hub and install shims (d) as needed to obtain thecorrect amount of end-play. Then, using Loctite 243 or an equivalenton six screws, secure the drum hub to the drum. Torque the screws to49 Nm (36 ft.lbs.).

8.10.4 Using Loctite 243 or equivalent on six screws (e), secure the bearingcover (f) and the shockmount plate (g) to the drum support. Torque thescrews to 50 Nm (36 ft.lbs.).



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8.11 Front Drive Motor (RD 11A and RD11V series drive)

Removal:

8.11.1 Remove the front drum. See section Removing the Front Drum.

8.11.2 With the drum standing on end, remove the three nuts (a) which securethe drive motor assembly (b) to the drum.

8.11.3 Using an appropriate crane, lift the drive motor assembly out of thedrum and secure it in a vise as shown.

8.11.4 Back off the large nut (c) on the end of the drive motor until it is flushwith the end of the shaft of the drive motor.

8.11.5 Using a dead-blow hammer, strike the nut/shaft until the tapered motorshaft is free from the drive hub assembly (d). Remove the nutcompletely and slide the drive motor assembly from the hub assembly.Note: If this method does not work, remove the six screws securing thedrive plate to the drum hub. Then, use a puller to pull the drum hubfrom the drive motor.

8.11.6 Remove the four screws (e) which secure the motor guard (f) andremove the motor guard.

8.11.7 Remove the four screws (g) which secure the drive motor (h) to thedrum support (i) and remove the drive motor.

8.11.8 Remove the hydraulic lines (j) and fittings from the drive motor.

Installation:

8.11.9 Install the hydraulic fittings to the drive motor (h).8.11.10 Using Loctite 243 or an equivalent on four screws (g), secure the drive

motor (h) to the drum support (i). Torque the screws to 49 Nm (36ft.lbs.)

8.11.11 Using Loctite 243 or an equivalent on six screws, secure the hub (d) tothe drive plate (l). Torque the screws to 49 Nm (36 ft.lbs.)

8.11.12 Install the key (k).8.11.13 Place the hub/drive plate assembly onto the drive motor. Using Loctite

243 or an equivalent on nut (c) secure the hub/drive plate assembly tothe drive motor. Torque the nut to 410–540 Nm (300–400 ft.lbs.).

8.11.14 Attach the hydraulic lines (j) to the drive motor.

8.11.15 Using four screws (e), secure the motor guard (f) to the drum support.



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8.12 Front Drive Motor (RD 11A and RD 11V parallel drive)

Removal:

8.12.1 Remove the drive motor assembly from the drum. See Front Drum.Place the drive motor assembly on a clean work bench.

8.12.2 Disconnect the hydraulic fitting (1) from the drive motor (2).8.12.3 Remove the four screws (3) that mount the motor guard (4) to the drum

support (5).8.12.4 Loosen the nut (6) on the end of the drive motor shaft. Rap on the end

of the shaft to break the shaft free of the taper in the drum hub (7). Ifthe shaft does not break free, employ a puller.

8.12.5 Remove the four screws (8) that mount the drive motor to the drumsupport.

8.12.6 Remove the six screws (9) and the washers (10) that secure the drumhub to the drive plate (11).

Installation:

8.12.7 Attach the drive motor (2) to the drum support (5). Secure the screws(8) using Loctite 271 or an equivalent high-strength threadlocker andtorque the screws to 86 Nm (63 ft.lbs.).

8.12.8 Install the Woodruff key (12) in the motor shaft.

8.12.9 Attach the motor guard (4).8.12.10 Install the drum hub (7) to the drive plate (11). Secure the screws (9)

using Loctite 271 or an equivalent and torque the screws to 49 Nm (36ft.lbs.).

8.12.11 Place the drive plate and the hub on the motor shaft. Install the nut (6)and torque it to 410–540 Nm (300–400 ft.lbs.).

8.12.12 Inspect the fitting and the piping O-rings for cracks and deterioration;replace if necessary.

8.12.13 Fasten the hydraulic fitting (1) to the drive motor (2).8.12.14 Connect the tube assemblies (13) to the drive motor.

Note: See sealant and torque reference charts in the back of thismanual for appropriate threadlocking adhesives and torque values.

Before you start the machine, ensure that all tools have been removedfrom the machine and that replacement parts and adjusters are firmlytightened.WARNING



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8.13 Front Drive Motor RD 11AEC

Removal:

8.13.1 Remove the drive motor assembly from the drum. See Front Drum.Place the drive motor assembly on a clean work bench.

8.13.2 Disconnect the hydraulic fitting (1) from the drive motor (2).8.13.3 Remove the four screws (3) that secure the motor guard (4) to the

drum support (5).8.13.4 Remove the four screws (6) and washers (7) that secure the drum

support to the drive motor.

8.13.5 Remove the five screws (8) and washers (9) that secure the drivemotor to the drive plate (10).

Installation:

8.13.6 Secure the drive motor (2) to the drive plate (10). Secure screws (8)and washers (9) using Loctite 271 or an equivalent high strengththreadlocker and torque them to 86 Nm (63 ft.lbs.).

8.13.7 Secure the drum support (5) to the drive motor. Secure the screws (6)using Loctite 271 or an equivalent and torque them to 86 Nm (63ft.lbs.).

8.13.8 Attach the motor guard (4).8.13.9 Inspect the fitting and piping O-rings for cracks and deterioration;

replace if neccessary.

8.13.10 Fasten the hydraulic fitting (1) to the drive motor (2).8.13.11 Install the completed drive assembly to the drum. Attach the drive plate

to the shockmounts (11) using locknuts (12).8.13.12 Secure the bolts (13) holding the drum support to the frame using

Loctite 271 or an equivalent high strength threadlocker. Torque thebolts to 118 Nm (88 ft.lbs.).

8.13.13 Connect the tube assemblies (14) to the drive motor.





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8.14 Rear Drum Assembly—Description

The rear drum operates as a static roller to aid in smoothing andfinishing. A plug (1) is provided on the right side, allowing the inside ofthe drum to be filled with ballast. If water is used in areas wheretemperatures are below freezing, add antifreeze or drain drum afteruse.Note: Drum capacity: 114 liters (30.2 gal.) Added weight (water ballast): 113 kg (250 lbs.).

The rear drum is driven by a single hydraulic motor (2) mounted to adrive plate (3), which is mounted directly to the left side of the drum.The drive motor is designed to provide low speeds and high torqueswithout the need for any type of speed reduction gears, belts, orpulleys. On RD 11V & RD 11A machines (shown), a mechanical parking brake(4) is attached to the drive plate on the left side and is engaged by theoperator.On RD11 AEC machines, the parking brake is incorporated into thedrive motor and is automatically engaged.The right side of the drum axle (5) is supported by a bearing block (6)mounted directly to the drum support (7).Note: Wacker Corporation does not recommend the disassembly orattempted repair of hydraulic components (pumps, motors, steeringcylinder) by anyone other than a trained hydraulic repair technician.The repair and rebuilding of hydraulic components may be availablefrom component manufacturers. Hydraulic component parts are notavailable from Wacker Corporation.



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8.15 Replacing Brake and Brake Cable

Removal:

8.15.1 Remove the screws which secure the seat plate and remove the seat/seat plate assembly.


8.15.3 Remove the two screws (a) which secure the hand brake (b) andremove the brake from the upper frame.

8.15.4 Remove the four screws (c) which secure the drum support plate (d)and remove the drum support plate.

8.15.5 Remove the hitch pin (e) and the clevis pin (f) from the end of thecable.

8.15.6 Remove the two screws (g), nuts, and bracket which secure the cableto the machine.

8.15.7 Pull the cable (h) through the drum support and out from the machine.

8.15.8 Remove the cotter pin (i) from the castle nut (j) and remove the castlenut.

8.15.9 Remove the arm (k) and the spring (l).8.15.10 Remove the two screws (m) which secure the brake assembly to the

drive plate.

8.15.11 Remove the four screws (n) and nuts which secure the brake caliper(o) together and remove the brake caliper from the machine.

Alternative method forremoving brake caliper:

8.15.1 Support the rear of themachine with an appropriatecrane or hoist.

8.15.2 Disconnect the brake cablefrom (z) the brake caliper (y).

8.15.3 Remove the two screws (x)which hold the brake caliper.

8.15.4 Remove the three screws(w) which secure the driveplate to the shock mountplate.

8.15.5 Raise the machine (the drum should remain on the ground) enough toremove the brake caliper.

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Installation:

8.15.1 Away from the machine, loosely install the four screws (n) and nuts (p)which hold the brake caliper (o) together; do not tighten nuts.

8.15.2 Slide the brake caliper (o) around the drive plate; then tighten the fourscrews (n) and nuts (p).

8.15.3 Place the brake caliper into position so that when installed the twoscrews (m) will hold the brake caliper. Then, using Loctite 243 or anequivalent on the two screws (m), secure the two screws to the brakebracket.

8.15.4 Install the spring (l) and the arm (k).8.15.5 Install the castle nut (j) and the cotter pin (i).8.15.6 Install the two screws (g), nuts, and bracket which secure the cable (h)

to the machine.

8.15.7 Install the hitch pin (e) and the clevis pin (f).8.15.8 Run the cable (h) through the drum support and connect it to the brake

handle.

8.15.9 Using two screws (a), secure the brake handle (b) to the upper frame.

8.15.10 Using four screws (c), secure the drum support plate (d) to the drumsupport.

8.15.11 Reconnect the battery.

8.15.12 Using four screws, secure the seat/seat plate assembly to the machineframe.



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8.16 Rear Drum (RD 11A and RD 11V revisions < 119)

Removal:Stop the machine, apply the parking brake, switch off the machine, setthe locking arm and disconnect the battery.NOTICE: Before removing the drum, clean and wash the completedrum assembly to remove as much dirt as possible. Be especiallythorough when cleaning the area around tube and hose connectionson the motors. This will minimize the chance of contamination whenopening the hydraulic lines.

8.16.1 Block the front drum.

8.16.2 Support the rear machine frame by placing blocks or screw jacks (20)under the frame in front of both sides of the drum.

Only use blocks or jacks with a suitable load-bearing capacity. Do notuse improvised blocks or jacks.

8.16.3 Open the tow valve. See Towing Valve.

8.16.4 Tag and disconnect the hoses to the tube assemblies (2). Cap or plugall open connections to prevent spillage.

Before dismantling the hydraulic connectors or hoses, ensure that allpressure has been bled from the circuit. See Bleeding the HydraulicSystem.

Note: In the interests of environmental protection, place a plastic sheetand a container under the machine to collect the liquid which drains offand dispose of them properly.

8.16.5 Remove the three screws (18) holding the brake bracket (19) to thedrum. Rotate the drum to gain access to all screws.

8.16.6 Remove the pin (14) that mounts the brake cable (15) to the brakelever (16). Remove the nuts (17) from the cable clamp.

8.16.7 Remove the four screws (3) that mount the drum support cover (4) tothe drum support (5) on the right side.

8.16.8 Remove the four screws (6) that mount the drum support to the rearframe.

8.16.9 Loosen the two set screws (7) which secure the bushing in the bearinghousing (8) to the drum axle (9).

8.16.10 Attach ropes or chains to the lifting eye of the drum support andremove it from the drum.

Only use steel ropes or chains for hoisting. Ropes or chains must havethe suitable specified lifting capacity. Do not use improvised ropes orchains.

WARNING

WARNING

WARNING


8.16.11 Remove the four screws (10) that mount the drum support cover (11)
to the drum support (12) on the left side.

8.16.12 Remove the four screws (13) that mount the drum support to theframe.

8.16.13 Pull the drum assembly out from the right side of the machine.

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8.17 Replacing Rear Drive Motor (RD 11A and RD 11V revisions <104)

Removal:

8.17.1 Remove the drive motor assembly from the drum. See section RearDrum. Place it on a clean work bench.

8.17.2 Remove the four screws (1) that mount the motor guard (2) to the drumsupport (3).

8.17.3 Loosen the nut (4) on the end of the shaft on the drive motor (5). Rapon the end of the shaft to break the shaft free of the taper in the drumhub (6). If the shaft does not break free, use a puller.

Note: Remove the six screws (10) and back disc away from the hub(6). The puller can be used against the hub.

8.17.4 Remove the four screws (7) and nuts (8) that secure the drive motorand brake bracket (9) to the drum support.

8.17.5 Remove the six screws (10) and washers (11) that mount the drum hubto the drive plate (12).

8.17.6 Disconnect the hydraulic fitting (13) from the drive motor.

Installation:

8.17.7 Fasten the hydraulic fitting (13) to the drive motor.

8.17.8 Mount the drive motor (5) to the drum support (3). Secure the screws(7) using Loctite 271 or an equivalent high-strength threadlocker andtorque to 86 Nm (63 ft.lbs.).

8.17.9 Secure the brake bracket (9) over the screw studs (7) and fasten withlocknuts (8).

8.17.10 Attach the motor guard (2) with screws (1).8.17.11 Install the drum hub (6) to the drive plate (12). Secure the screws (10)

using Loctite 271 or an equivalent and torque screws to 49 Nm (36ft.lbs.).

8.17.12 Place the drive plate and the hub on the motor shaft. Install the nut (4)and torque to 410–540 Nm (300–400 ft.lbs.).






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8.18 Replacing Rear Drive Motor (RD 11A and RD 11V revisions104–118)

Removal:

8.18.1 Remove the drive motor assembly from the drum. See section RearDrum. Place it on a clean work bench.

8.18.2 Remove the four screws (1) that mount the motor guard (2) to the drumsupport (3).

8.18.3 Loosen the nut (4) on end of the shaft on the drive motor (5). Rap onend of the shaft to break it free of the taper in the drum hub (6). If theshaft does not break free, use a puller.

Note: Remove the six screws (10) and back disc away from the hub(6). The puller can be used against the hub.

8.18.4 Remove the four screws (7) and nuts (8) that mount the drive motorand the brake bracket (9) to the drum support.

8.18.5 Remove the six screws (10) and washers (11) that mount the drum hubto the drive plate (12).


Installation:


8.18.8 Mount the drive motor (5) to the drum support (3). Secure the screws(7) using Loctite 271 or an equivalent high-strength threadlocker andtorque to 86 Nm (63 ft.lbs.).

8.18.9 Mount the brake bracket (9) over screw studs (7) and fasten withlocknuts (8).

8.18.10 Install the Woodruff key (14) in the motor shaft.

8.18.11 Attach the motor guard (2) with screws (1).8.18.12 Install the drum hub (6) to the drive plate (12). Secure screws (10)

using Loctite 271 or an equivalent and torque screws to 49 Nm (36ft.lbs.).

8.18.13 Place the drive plate and hub on the motor shaft. Install the nut (4) andtorque to 410–540 Nm (300–400 ft.lbs.).






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8.19 Removing the Rear Drum (RD 11A and RD 11V revisions > 118)

NOTICE: Before removing the drum, clean and wash the completedrum assembly to remove as much dirt as possible. Be especiallythorough when cleaning the area around the tube and hoseconnections on the motors. This will minimize the chance ofcontamination when opening the hydraulic lines.

8.19.1 Block the front drum.

8.19.2 Open the tow valve.

8.19.3 Support the rear of the machine with an appropriate crane, jack stands,or screw jacks.

Only use cranes, stands, or jacks with a suitable load-bearing capacity.


8.19.5 Disconnect and remove the battery.

8.19.6 Remove the screws (a) which secure the battery bracket (b) to theupper frame and remove the battery bracket.

8.19.7 Remove the screw (c) which secures the bracket (d) and remove thebracket.

8.19.8 Label, then disconnect the hydraulic hoses (e).8.19.9 Remove the four screws (f) which secure the drum support plate (g) to

the drum support and remove the drum support plate.

8.19.10 Remove the hitch pin (h) and the clevis pin (i) from the brakeassembly. Also remove the two screws (j) which secure the cableretaining bracket. Route the brake cable (o) away from the rear drum.

8.19.11 On the right side of the drum (side opposite that with the drive motor),remove the four screws (k) which secure the bearing cover (l) to thedrum support.

8.19.12 On the left side of the drum (side with the drive motor) remove the fourscrews (m) which secure the drum support (n) to the machine.

8.19.13 With the aid of an assistant or an appropriate crane, pull the rear drumfrom the machine.

WARNING



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8.20 Installing the Rear Drum (RD 11A and RD 11V revisions > 118)

8.20.1 On the right side of the drum (side opposite that with the drive motor),use four screws (k) to secure the bearing cover (l) to the drum support.

8.20.2 Position the rear drum underneath the machine and into the bearing ofthe right-side drum support.

8.20.3 On the left side of the drum (drum with the drive motor) use Loctite 243or an equivalent on four screws (m) and secure the drum support (n)to the machine. Torque the screws to 118 Nm (87 ft.lbs.).

8.20.4 Route the brake cable (o) through the drum support and to the brake.Connect the cable to the brake with the clevis pin (i) and the hitch pin(h).

8.20.5 Secure the cable bracket around the brake cable with screws (j). 8.20.6 Use four screws (f) to secure the drum support plate (g) to the drum

support.

8.20.7 Reconnect the hydraulic hoses (e).8.20.8 Secure the hydraulic lines with the bracket (d) using screw (c). 8.20.9 Use four screws (a) to secure the battery bracket (b) to the upper

frame.

8.20.10 Reconnect the battery.

8.20.11 Use four screws to secure the seat/seat plate assembly to the frame.

8.20.12 Remove the jacks, jack stands, and blocks.



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8.21 Removing Rear Drive Motor (RD 11A and RD 11V revisions >118)

8.21.1 Remove the rear drum from the machine. See section Removing theRear Drum.

8.21.2 Rotate the drive motor assembly as needed to reach the three screws(a) which mount the drive plate to the drum. Remove the three screws.Note: If the motor assembly is difficult to turn, you may need to loosenthe caps on the hydraulic lines leading to the motor to allow the releaseof any hydraulic pressure. These are the caps connected to the lineswhile removing the drum. Using an appropriate crane, lift the drum support (b), with the drivemotor still attached, up and off of the drum.

8.21.3 Remove the brake assembly (c). See section Replacing the Brake.

8.21.4 Mount the assembly in a vise as shown.

8.21.5 Back off the large nut (d) until it reaches the end of the shaft.

8.21.6 Using a dead-blow hammer, strike the nut/shaft until the tapered motorshaft is free from the drive hub assembly. Remove the nut completelyand slide the drive motor assembly from the hub assembly.Note: If this method does not work, remove the six screws securing thedrive plate to the drum hub. Then, use a puller to pull the drum hubfrom the drive motor.

8.21.7 Remove the four screws (e) which secure the motor protector plate (f)and remove the motor protector plate.

8.21.8 Remove the nuts (g) which secure the brake bracket (h) and removethe brake bracket.

8.21.9 Remove the screws (i) which secure the drive motor to the drumsupport and remove the drive motor from the drum support.

8.21.10 Remove the hydraulic lines (j) and fittings from the drive motor.



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8.22 Installing Rear Drive Motor (RD 11A and RD 11V revisions >118)

8.22.1 Install the fittings and hydraulic lines (j) to the drive motor.

8.22.2 Using Loctite 243 or an equivalent on four screws (i), secure the drivemotor to the drum support. Torque the screws to 85 Nm (62 ft.lbs.).

8.22.3 Secure the brake bracket (h) with nuts (g). 8.22.4 Use four screws (e) to secure the motor protector plate (f) to the drum

support.

8.22.5 Install the key on the drive motor. Place the hub/drive plate assemblyonto the drive motor. Using Loctite 243 on nut (d), secure the hub/driveplate assembly to the drive motor. Torque the nut to 410–540 Nm(300–400 ft.lbs.).

8.22.6 Reinstall the brake (c).8.22.7 Using an appropriate crane, position the drum support/drive motor

assembly (b) on the drum. Using Loctite 243 or an equivalent on threescrews (a), secure the drive motor assembly to the drum. Torque thescrews to 85 Nm (62 ft.lbs.).

8.22.8 Reinstall the rear drum. See section Removing the Rear Drum.



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8.23 Replacing Rear Drive Motor (RD 11AEC)

Removal:

8.23.1 Remove the drive motor assembly from the drum. See Rear Drum.Place the drive motor assembly on a clean work bench.

8.23.2 Remove the four screws (1) and washers that secure the motor guard(2) to the drum support (3).

8.23.3 Remove the four screws (4) and washers (5) that secure the drumsupport to the drive motor (6).

8.23.4 Remove the five screws (7) and washers (8) that secure the backingplate (9) and drive plate (10) to the drive motor.


Installation:


8.23.7 Secure the drum support (3) to the drive motor (6). Secure the screws(4) using Loctite 271 or an equivalent high-strength threadlocker andtorque to 85 Nm (63 ft.lbs.).

8.23.8 Attach the motor guard (2) with screws (1).8.23.9 Secure the drive plate (10) and backing plate (9) to the drive motor.

Secure the screws (7) using Loctite 271 or an equivalent and torquescrews to 85 Nm (63 ft.lbs.).





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8.24 Replacing the Articulated Steering Joint

Removal:

8.24.1 Stop the machine, apply the parking brake, switch off the machine, anddisconnect the battery.

8.24.2 Remove the front panel (a) and the floor (b).8.24.3 Support the rear machine frame by placing blocks or screw jacks under

the frame both in front of and behind the drum.

8.24.4 Support the front half of the machine with an appropriate crane.

8.24.5 Remove the two screws (c) that mount each pillow block (d) to theframe.

8.24.6 Disconnect the steering cylinder (f) from the pivot plate (h) byremoving the screws (e) and nuts. Place the steering cylinder in theframe.

8.24.7 Remove the four screws (g) that mount the pivot plate (h) to thearticulated steering joint housing (l).

8.24.8 Remove the pin (i) and locknut (j) from the end of the articulatedsteering joint shaft (k).

8.24.9 Remove the housing (l) from the shaft (k).8.24.10 Inspect the bearings (n), (o), and (p) and replace them if necessary.

Use pullers to remove the bearings.

8.24.11 Remove the eight screws (m) that mount the articulated steering jointshaft to the front frame.



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Installation:This procedure requires Loctite 603 or an equivalent retainingcompound.

8.24.12 Press the bearings (n and p) into the articulated joint housing (l).8.24.13 Using Loctite 243 or an equivalent on eight screws (m), secure the

articulated steering joint shaft (k) to the front frame. Torque the screwsto 118 Nm (87 ft.lbs.).

8.24.14 Place the seals (q) into the pillow blocks (d) and press the bearings (o)into the pillow blocks. Lubricate the bearings with Shell Alvania No. 2grease or equivalent.

8.24.15 Slide the housing (l) over the shaft (k) and secure it with a locknut (j).Torque the locknut to 271 Nm (199 ft.lbs); then, insert the pin (i).

8.24.16 Using Loctite 243 or an equivalent on four screws, secure the pivotplate (h) to the housing (l).

8.24.17 Secure the steering cylinder (f) to the pivot plate (h) with two screws(e) and nuts. Torque the screws to 86 Nm (63 ft.lbs.).

8.24.18 Apply Loctite 603 or an equivalent retaining compound to the shafts ofthe housing and install the bearing sleeves (q).

8.24.19 Using Loctite 243 or an equivalent on four screws, secure each pillowblock (d) to the frame. Torque the screws to 210 Nm (154 ft.lbs.).

8.24.20 Install the front panel (a) and the floor (b).



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8.25 Throttle/Choke Cables (revisions 100–118)

Removal:To replace either the throttle or choke cable:

8.25.1 Remove all the screws (1) holding the cover (2) to the steering columnand the frame.

Note: If the clip nuts (3) should loosen and fall out, save them forinstallation of the cover.

8.25.2 Remove the cap (4) and nut (5) that secure the steering wheel (17) andremove the steering wheel.

8.25.3 Remove all the screws (6) holding the control housing (7) to thecolumn bracket (8).

8.25.4 Remove the two screws (9) and nuts mounting the throttle/chokebracket (11) to the column bracket.

8.25.5 Disconnect either throttle or choke cable from the engine.

8.25.6 Pull the cable (12) through the casing (13) and the lever (14).

To remove the casing:Remove the screws (15) holding the clamp (16) to the throttle/chokebracket.Note: The throttle clamp, casing, and the cable are shown.

Installation:

8.25.7 Feed the cable (12) through the lever (14) and the casing (13).8.25.8 Reconnect on the engine.

8.25.9 Assemble the throttle/choke bracket (11) to the column bracket (8) andsecure with screws (9).

8.25.10 Assemble the control housing (7) to the column bracket (8) and securewith screws (6).

8.25.11 Assemble the steering wheel (17) onto the column and secure with nut(5). Place the cap (4) over the nut.

8.25.12 With all the clip nuts (3) in place assemble the cover (2) to the steeringcolumn and the frame.

Before you start the machine, ensure that all tools have been removedfrom the machine and that replacement parts and adjusters are firmlytightenedWARNING



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8.26 Choke Cable (revisions > 118)

Removal:

8.26.1 Loosen the two screws (a) which retain the cable to the engine.

8.26.2 Remove the front console plate (b).8.26.3 Remove the shoulder bolt (c).8.26.4 Remove the two screws and nuts which secure the cable clamp (d)

and remove the cable clamp.

8.26.5 Feed the choke cable (e) through the engine compartment, through thecontrol console, and up and out of the machine.

Installation:

8.26.6 Feed the choke cable (e) through the control console, through themachine, and into the engine compartment.

8.26.7 Using Loctite 243 or an equivalent on the shoulder bolt (c), secure thechoke lever to the bracket.

8.26.8 Using two screws and nuts, secure the cable with the cable clamp (d).8.26.9 Connect the cable to the engine with screws (a).8.26.10 Reinstall the front console plate (b).



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8.27 Drive Control Cable (revisons 100–109)

Removal:Stop the machine, apply the parking brake, switch off the machine, anddisconnect the battery.

8.27.1 Remove the two front screws (1) holding the drive control (2) to theframe. Loosen the two rear screws (3) only half way and remove thecomplete drive control assembly from the rear frame.

Removing the drive control cable:

8.27.2 Disconnect the cable (4) from the hydraulic pump (8) in the frontsection.

8.27.3 Remove the pin (5) from the cable swivel connector (6).8.27.4 Loosen the clamp (7) holding the cable to the lower bracket and

remove the cable.

Removing the neutral safety switch:

8.27.5 Disconnect the wiring (9) from the main harness.

8.27.6 Remove the two black wires (10) from the connector (positions E andF).

8.27.7 Remove the screw (11) which secures the switch (12) to the lowerbracket.

8.27.8 Remove the pin (13) holding the switch to the lever arm.

Removing the hand grip housing:

8.27.9 Remove the screws (14) holding the grip housing (15) and switch cap(16) to gain access to the switch.

Installation:Installing the neutral safety switch:

8.27.10 Place the end of the mounting switch (12) into the hole of the lever armbracket, and assemble the washer (17) and insert pin (13).

8.27.11 Secure the other end of the switch to the lower bracket. Secure theswitch with screw (11) and nut (21). Note: Make sure the spacer (18), washer (19), and star washer (20)are assembled as shown.

8.27.12 Reconnect the two black wires (10) to the connector (E & F).

8.27.13 Reconnect the wiring (9) to the main harness.

Installing the drive control cable:


8.27.14 Route the cable through the clamp (7) and place the end of the cable
(4) with the cable swivel connector (6) into the hole of the lever armbracket and insert the pin (5) into the swivel connector.

8.27.15 Secure the cable to the lower bracket by tightening the clamp.

8.27.16 Route the cable through the rear frame and across the articulated joint.Secure the cable to the hydraulic pump (8).Note: For adjusting the cable, see Adjusting the Drive Control Cable.

8.27.17 When mounting the drive control (2), the frame is to be in between theupper black plate (22) and the lower bracket (23). Secure it with screws(1) and (3). Before you start the machine, ensure that all tools have been removedfrom the machine and that replacement parts and adjusters are firmlytightened.WARNING

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8.28 Drive Control Cable (revisons > 109)

Removal:



8.28.3 Disconnect the wiring harness from the forward/reverse control at theconnector (a).

8.28.4 Remove the screws (b) which secure the forward/reverse control to theupper frame and remove the forward/reverse control from the upperframe.

8.28.5 Remove the nut (c) which secures the cable to the control arm (d) ofthe drive pump.

8.28.6 Remove the turnbuckle (e) from the cable as shown.

8.28.7 Remove the nut (f) which secures the cable to the machine frame.Slide the nut and the lockwasher off the end of the cable.

8.28.8 Cut the two wire (g) ties at the articulating steering joint.

8.28.9 Pull the cable through the machine frame and out of the machine.

8.28.10 Remove pin (h) from the cable swivel connector (i).8.28.11 Loosen the clamp (j) holding the cable to the lower bracket and remove

the cable.

8.28.12 To remove the neutral safety switch (k), remove the screw (l) and hitchpin.



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Installation:

8.28.1 Install the neutral safety (k) switch with the screw (l), washer and hitchpin (m). Be sure the star washer (x), washer (y), and spacer (z) arepositioned as shown.

8.28.2 Connect the cable with pin (h) and swivel connector (i).8.28.3 Secure the cable to the lower bracket with clamp (j).8.28.4 Feed the cable through the rear frame, across the articulated steering

joint, and into the front frame. Arrange the cables as shown and securethe cables with two new wire ties (g1 and g2).

8.28.5 Secure the cable to the front frame with nut (f).8.28.6 Install the turnbuckle (e) to the end of the cable.

8.28.7 Secure the cable to the control arm (d) with nut (c).8.28.8 Secure the forward/reverse control to the upper frame with four screws

(b) and plate (n).8.28.9 Connect the wiring harness (a).8.28.10 Reconnect the battery.

8.28.11 Reinstall the seat/seat plate.

8.28.12 Adjust the drive control cable. See section Adjusting the Drive ControlCable.

1 Choke cable 6 Water hose

2 Brake cable 7 Drive control cable

3 Electrical 8 Reverse hydraulic hose

4 Forward hydraulic hose 9 Pressure hose

5 Tank hydraulic hose - ---

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8.29 Replacing the Water Tank

Removal:

8.29.1 Using an appropriate crane, support the ROPS (a).8.29.2 Remove the screws (b) which secure the ROPS and remove the

ROPS.

8.29.3 Remove the seven screws (c) which secure the back panel (d) andremove the back panel.

8.29.4 Remove the four screws (e) from underneath the frame and pull thewater tank (f) slightly out of the machine. Then, remove the two hoses(g) connected to the water tank.

8.29.5 Remove the water tank fully from the machine.

Installation:

8.29.6 Position the water tank (f) within the frame.

8.29.7 Connect the two hoses (g) to the water tank.

8.29.8 Secure the water tank to the frame with four screws (e). 8.29.9 Secure the back panel (d) with seven screws (c).8.29.10 Using Loctite 243 or an equivalent on screws (b), secure the ROPS (a)

to the frame. Torque the screws to 120 Nm (88 ft.lbs.).



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8.30 Replacing Water Valves

Removal:

8.30.1 Remove water tank. See section Replacing Water Tank.

8.30.2 Remove the two screws and nuts from each water-valve control rod(a). Unscrew each rod from each valve.Note: The handles (b) on each rod are pressed on. If you havedifficulty keeping the handles on the rods, use a high-strengthadhesive to bond the handles to the rods.

8.30.3 Make note of the positions of the valve-turning brackets (c); thenremove them.

8.30.4 Remove the hoses (d) from the valves.

8.30.5 Remove the two screws (e) which secure each valve (f) to the valvemounting brackets; remove the valves from the machine.

Installation:

8.30.6 Secure each valve (f) to the valve mounting bracket with two screws(e).

8.30.7 Connect the hoses (d) to each valve.

8.30.8 Install the valve-turning brackets (c).8.30.9 Thread the water-valve control rod (a) onto the valve and secure it with

two screws and nuts.

8.30.10 Install the water tank. See section Replacing Water Tank.



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8.31 Replacing the Fuel Tank

Removal:


8.31.2 Disconnect and remove the battery.

8.31.3 Support the ROPS with an appropriate overhead crane.

8.31.4 Remove the screws which secure the ROPS and remove the ROPS.

8.31.5 Remove the seven screws securing the back panel and remove theback panel (a).

8.31.6 Remove the four screws underneath the frame which secure the watertank. Disconnect the water hoses (b) from the water tank (c) andremove the water tank. See section Replacing Water Tank.

8.31.7 Disconnect the wiring harness (d) from the forward/reverse control atthe connector. Remove the screws which secure the forward/reversecontrol to the upper frame and remove the forward/reverse control (e)from the upper frame.

8.31.8 Remove the two screws and nuts from the water-valve control rods (f).Unscrew each rod from each valve.

8.31.9 Remove the screws which secure the brake handle and remove thebrake handle from the upper frame.

8.31.10 Remove the four nuts which secure the fuel tank nozzle (g) to theupper frame.

8.31.11 Remove the screws which secure the front plate (h) and remove thefront plate.

8.31.12 Remove the screws which secure the floor plate (i) and remove thefloor plate.

8.31.13 Remove the eight screws which secure the upper frame (j). Then, withthe aid of an assistant, pull the upper frame up and off the machine.

8.31.14 Remove the four screws which secure the fuel gauge (k) to the lowerframe.

8.31.15 Disconnect and plug the fuel hose at the fuel filter.

8.31.16 Remove the two screws which secure the fuel tank (l) to the lowerframe, and the two screws which secure the fuel tank to the lowerframe from underneath the frame. With the aid of an assistant, pull thefuel tank up and out of the lower frame.



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Installation:

8.31.1 Position the fuel tank (l) within the frame. Secure it to the frame withfour screws.

8.31.2 Connect the fuel hose at the fuel filter.

8.31.3 Secure the fuel gauge (k) with four screws.

8.31.4 With the aid of an assistant, position the upper frame (j) on the lowerframe and secure it with eight screws.

8.31.5 Secure the floor plate (i) to the lower frame.

8.31.6 Secure the front plate (h) to the lower frame and control tower.

8.31.7 Secure the fuel tank nozzle (g) to the upper frame.

8.31.8 Secure the brake handle to the upper frame with two screws.

8.31.9 Screw the water-valve control rods (f) onto the valves and secure themwith screws and nuts.

8.31.10 Secure the forward/reverse control (e) to the upper frame andreconnect the wiring harness (d).

8.31.11 Position the water tank into the frame. Reconnect the water hoses (b)to the water tank (c).

8.31.12 Install the back panel (a).8.31.13 Reinstall the ROPS.

8.31.14 Reinstall and reconnect the battery.

8.31.15 Reinstall the seat/seat plate assembly.



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8.32 Replacing Steering Cylinder

Removal:


8.32.2 Remove the front console plate (a).8.32.3 Disconnect the wiring harness (b) from the key switch (c), throttle

switch (d), and vibration indicator light (e).8.32.4 Remove the plastic cap (f) from the center of the steering wheel.

8.32.5 Remove the nut (g) which secures the steering wheel and remove thesteering wheel.

8.32.6 Remove the three screws (h) which secure the control console cover.

8.32.7 Remove the two screws (i) which secure the choke cable bracket (j).Allow the bracket with the choke lever attached to dangle freely.

8.32.8 Remove the control console cover (k) from the machine.

8.32.9 Label the four hydraulic hoses (l) leading into the steering valve. Then,disconnect the hydraulic hoses and cap them as soon as they aredisconnected to reduce the risk of contaminating the hydraulic system.

8.32.10 Remove the four screws (m) securing the steering valve (n) to themachine and remove the steering valve.

Installation:

8.32.11 Using four screws (m), secure the steering valve (n) to the machine.Torque the screws to 25 Nm (18 ft.lbs.)

8.32.12 Connect the four hydraulic hoses (l) to the steering valve.

8.32.13 Position the control console cover (k) on the machine but do notsecure it to the machine.

8.32.14 Using two screws (i), secure the choke cable bracket (j) to themachine.

8.32.15 Using the three screws (h), secure the control console cover.

8.32.16 Position the steering wheel and secure it to the machine with nut (g).Install plastic cap (f).

8.32.17 Connect the wiring harness (b) to the throttle switch (c), key switch (d),and vibration indicator light (e).

8.32.18 Install the front console plate (a).8.32.19 Connect the battery.



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8.33 Replacing the Drive Pump

NOTICE: The failure of a drive pump or motor caused by factors otherthan normal wear can contaminate the drive circuit with metal particles. Removal:

8.33.1 Thoroughly clean the pump and hose connections.

Burn hazard! The pump may be hot; use care when working withhydraulic components and oil. Hot oil can burn!

8.33.2 Tag and disconnect the hose lines (6) from the pump. Cap or plug allopen connections to reduce the risk of contaminating the hydraulicsystem.


8.33.3 Disconnect the cable (7) from the control lever (5).8.33.4 Remove the support bracket (8) from the exciter pump (9). Save the

locknuts (10) and washers (11) for installation.

8.33.5 Remove the two locknuts (12) holding the exciter pump to the drivepump (13).

8.33.6 Remove the two screws (14) holding the drive pump to the engine/pump adapter.

8.33.7 Remove the control lever (5), hydraulic fittings (4), O-ring (3), coupling(2), and key (1), and transfer them to the new pump.

Installation:

8.33.8 Install the new pump and fasten it to the engine/pump adapter. Securethe mounting screws (14) using Loctite 271 or an equivalent high-strength threadlocker.

8.33.9 Install the exciter pump (9) to the new drive pump using locknuts (12).8.33.10 Install the support bracket (8) to the exciter pump using locknuts (10)

and washers (11).8.33.11 Reconnect the hose lines (6) to the fittings.

8.33.12 Bleed the drive circuit.

NOTICE: It is recommended that the drive circuit be flushed after apump failure to remove any contaminants which may be trapped in thelines.

WARNING

WARNING


Before you start the machine, ensure that all tools have been removedfrom the machine and that replacement parts and adjusters are firmlytightened.
WARNING

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8.34 Replacing the Exciter Pump

Removal:

8.34.1 Thoroughly clean the pump and hose connections.

Burn hazard! The pump may be hot; use care when working withhydraulic components and oil. Hot oil can burn!

8.34.2 Tag and disconnect the hose lines (1) from the exciter pump (3). Capor plug all open connections to reduce the risk of contaminating thehydraulic system.


8.34.3 Remove the support bracket (2) from the exciter pump (3). Savelocknuts (4) and washers (5) for installation.

8.34.4 Remove the two locknuts (6) holding the exciter pump to the drivepump (7).

8.34.5 Remove the O-ring (8), coupling (9) and fittings (10) and transfer themto the new pump.

Installation:

8.34.6 Install the new exciter pump (3) to the drive pump (7) using locknuts(6).

8.34.7 Install the support bracket (2) to the exciter pump using locknuts (4)and washers (5).

8.34.8 Reconnect the hose lines (1) to the fittings (10).8.34.9 Bleed the hydraulic system before starting the engine.



WARNING

WARNING

WARNING



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8.35 Replacing the Engine

Removal:Stop the machine, apply the parking brake, switch off the machine anddisconnect the battery.

8.35.1 Tag and disconnect all the electrical connections, hoses and thethrottle cable that are attached to the engine.

8.35.2 Tag and disconnect all the hose lines from the exciter and the drivepumps. Disconnect the control lever cable mounted to the drive pump(1). Cap all open connections.


8.35.3 Remove the pump support bracket at the front of the exciter pump (2).8.35.4 Remove the muffler (3). Save all hardware (4) and gaskets (5) for

remounting to the new engine.

8.35.5 Attach lifting ropes or chains to the engine’s lifting device.

Only use steel ropes or chains for hoisting. Ropes or chains must havethe suitable lifting capacity. Do not use improvised ropes or chains.

8.35.6 Remove the screws (6) and nuts (7) that secure the engine to theframe.

8.35.7 Leaving the pump mounted to the engine, lift the engine slightly tocheck that it is correctly balanced.

8.35.8 Lift and remove the engine from the machine.

Do not stand under, or get near the engine, while it is being hoisted ormoved.

8.35.9 Remove the engine/pump adapter (8), shaft coupling (9), shaft spacer(10), and key (11).

WARNING

WARNING

WARNING



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Installation:

8.35.10 Slide the shaft spacer (10) on to the engine crankshaft.

8.35.11 Place the key (11) in the groove of the shaft and tap the shaft coupling(9) over it against the end of the spacer.

8.35.12 Apply a medium-strength threadlocker to the set screw (12) andtighten it down to secure the coupling in place.

8.35.13 Mount the adapter (8) and the muffler bracket (13) to the engine.Torque the screws (14) to 31 Nm (23 ft. lbs.).

8.35.14 Attach the pump assembly (15) to the engine.

8.35.15 Attach the lifting ropes or chains to the engine’s lifting device.

Only use steel ropes or chains for hoisting. Ropes or chains must havethe suitable lifting capacity. Do not use improvised ropes or chains.

8.35.16 Lift the engine and place it into the machine.

8.35.17 Install the pump support bracket onto the exciter pump.

8.35.18 Secure the engine to the frame reusing the screws (6) and nuts (7).8.35.19 Attach the pump support bracket to the frame.

8.35.20 Attach the muffler (3) to the engine reusing the gaskets (5) and nuts(4).

8.35.21 Attach all the hose lines to the pumps.

8.35.22 Attach all electrical wiring and the throttle cable to the engine.

8.35.23 Attach the control cable to the drive pump (1). The drive control cablemay need to be adjusted. See Adjusting the Drive Control Cable.

8.35.24 The engine speed (RPM) may need to be adjusted. See Engine SpeedAdjustment.



WARNING

WARNING


Threadlockers and Sealants


Threadlocking adhesives and sealants are specified throughout thismanual by a notation of “S” plus a number (S#) and should be usedwhere indicated. Threadlocking compounds normally break down attemperatures above 175°C (350°F). If a screw or bolt is hard toremove, heat it using a small propane torch to break down the sealant.When applying sealants, follow instructions on container. The sealantslisted are recommended for use on Wacker equipment.

TYPE( ) = Europe COLOR USAGE

PART NO. –SIZE

Loctite 222Hernon 420Omnifit 1150 (50M)

Purple Low strength, for locking threads smaller than 6 mm (1/4”).Hand tool removable.Temp. range: -54 to 149°C (-65 to 300°F)

73287 - 10 ml


Blue Medium strength, for locking threads larger than 6 mm (1/4”).Hand tool removable.Temp. range: -54 to 149°C (-65 to 300°F)

29311 - .5 ml17380 - 50 ml

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

Red High strength, for all threads up to 25 mm (1”).Heat parts before disassembly.Temp. range: -54 to 149°C (-65 to 300°F)

29312 - .5 ml26685 - 10 ml73285 - 50 ml

Loctite 290Hernon 431Omnifit 1710 (230LL)

Green Medium to high strength, for locking preassembled threads and for sealing weld porosity (wicking).Gaps up to 0.13 mm (0.005”)Temp. range: -54 to 149°C (-65 to 300°F)

28824 - .5 ml25316 - 10 ml

Loctite 609Hernon 822Omnifit 1730 (230L)

Green Medium strength retaining compound for 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)

29314 - .5 ml


Brown Hydraulic sealantTemp. range: -54 to 149°C (-65 to 300°F)

79356 - 50 ml

Loctite 592Hernon 920Omnifit 790

White Pipe sealant with Teflon for moderate pressures.Temp. range: -54 to 149°C (-65 to 300°F)

26695 - 6 ml73289 - 50 ml

Loctite 515Hernon 910Omnifit 10

Purple Form-in-place gasket for flexible joints.Fills gaps up to 1.3 mm (0.05”)Temp. range: -54 to 149°C (-65 to 300°F)

70735 - 50 ml


Threadlockers and Sealants (continued)

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

TYPE( ) = Europe COLOR USAGE

PART NO. –SIZE

Loctite 496Hernon 110Omnifit Sicomet 7000

Clear Instant adhesive for bonding rubber, 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)

52676 - 1oz.

Loctite Primer THernon Primer 10Omnifit VC Activator

AerosolSpray

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

2006124-6 oz.

Torque Values

Torque Values

Metric Fasteners (DIN)

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

Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch

M3 1.2 *11 1.6 *14 2.1 *19 5.5 7/32 2.5 –

M4 2.9 *26 4.1 *36 4.9 *43 7 9/32 3 –

M5 6.0 *53 8.5 6 10 7 8 5/16 4 –

M6 10 7 14 10 17 13 10 – 5 –

M8 25 18 35 26 41 30 13 1/2 6 –

M10 49 36 69 51 83 61 17 11/16 8 –

M12 86 63 120 88 145 107 19 3/4 10 –

M14 135 99 190 140 230 169 22 7/8 12 –

M16 210 155 295 217 355 262 24 15/16 14 –

M18 290 214 405 298 485 357 27 1-1/16 14 –

M20 410 302 580 427 690 508 30 1-1/4 17 –

1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm

8.8 10.9 12.9

Torque Values

Torque Values (continued)

Inch Fasteners (SAE)

Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch

No.4 0.7 *6 1.0 *14 1.4 *12 5.5 1/4 – 3/32

No.6 1.4 *12 1.9 *17 2.4 *21 8 5/16 – 7/64

No.8 2.5 *22 3.5 *31 4.7 *42 9 11/32 – 9/64

No.10 3.6 *32 5.1 *45 6.8 *60 – 3/8 – 5/32

1/4 8.1 6 12 9 16 12 – 7/16 – 3/32

5/16 18 13 26 19 33 24 13 1/2 – 1/4

3/8 31 23 45 33 58 43 – 9/16 – 5/16

7/16 50 37 71 52 94 69 16 5/8 – 3/8

1/2 77 57 109 80 142 105 19 3/4 – 3/8

9/16 111 82 156 115 214 158 – 13/16 – –

5/8 152 112 216 159 265 195 24 15/16 – 1/2

3/4 271 200 383 282 479 353 – 1-1/8 – 5/8

1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm

Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. +852 2406 60 32 · Fax: +852 2406 60 21

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