Wacker Neuson RD 12A Repair Manual
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Wacker Neuson RD 12A Repair Manual

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Repair Manual

Roller
RD 12
EN
5000192242
02
0912
5
0
0
0
1
9
2
2
4
2

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Summary of Contents for Wacker Neuson RD 12A

  • Page 1: Repair Manual

    Repair Manual Roller RD 12 5000192242 0912...
  • Page 2 Copyright notice © Copyright 2012 by Wacker Neuson Production Americas LLC All rights, including copying and distribution rights, are reserved. This publication may be photocopied by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permission from Wacker Neuson Production Americas LLC.
  • Page 3 This manual provides information and procedures to safely repair and maintain the above Wacker Neuson model(s). For your own safety and protection from injury, carefully read, understand, and observe all instructions...
  • Page 4 No part of this publication may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission from Wacker Neuson Corporation. Any type of reproduction or distribution not authorized by Wacker Neuson Corporation represents an infringement of valid copyrights, and violators will be prosecuted.

  • Page 5: Table Of Contents

    Checking the Crank Relay ..............37 Checking the Neutral Switch .............. 38 Checking the Neutral Relay ..............39 Wacker Neuson Engine Starting System Checking the 20A Main Fuse ............. 41 Checking the Wiring to the Starter Solenoid & Anti-backfire Solenoid 42 Checking the Key Switch ..............
  • Page 6 Table of Contents RD 12/RD 12A Drive System Checking the Tow Valve ..............49 Adjusting the Drive Control Cable ............50 Checking the Drive System Operating Pressure .........51 Checking the Drive System Relief Pressure ........52 Checking Drive Motors for Binding ............53 Checking Oil Flow through the Drive Motors ........55 Vibration System and Steering Checking the Engine Speed and Vibration Speed ......57...
  • Page 7 Hydraulic Schematic Components ........... 121 10.3 Electrical Schematic Identification—RD 12A ........121 10.4 Electrical Schematic “A”—RD 12A ........... 122 10.5 Electrical Schematic “A” Components—RD 12A ......123 10.6 Electrical Schematic “B”—RD 12A ........... 124 10.7 Electrical Schematic “B” Components—RD 12A ......125 10.8 Electrical Schematic—RD 12 ............
  • Page 8 Table of Contents RD 12/RD 12A 11 Technical Data 11.1 Engine ....................128 11.2 Roller ....................129 11.3 Lubrication ..................129 11.4 Dimensions ..................130 11.5 Sound Measurements ...............131 11.6 Measurements of Operator Exposure to Vibration ......131 11.7 Hydraulic Pressures ................132 wc_br0170797en_002TOC.fm...

  • Page 9: Rd 12/Rd 12A

    RD 12/RD 12A Safety Information Safety Information This manual contains DANGER, WARNING, CAUTION, NOTICE and NOTE callouts which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

  • Page 10: Operating Safety

    These areas get hot and may cause burns. 1.1.5 Do not use accessories or attachments that are not recommended by Wacker Neuson. Damage to equipment and injury to the user may result. 1.1.6 NEVER leave the machine running unattended.
  • Page 11 RD 12/RD 12A Safety Information 1.1.12 ALWAYS remain aware of changing positions and the movement of other equipment and personnel on the job site. 1.1.13 ALWAYS remain seated and wear the seat belt at all times while operating the machine.

  • Page 12: Operator Safety While Using Internal Combustion Engines

    Safety Information RD 12/RD 12A Operator Safety while using Internal Combustion Engines Internal combustion engines present special hazards during operation and fueling. Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. Failure to follow the WARNING warnings and safety standards could result in severe injury or death.

  • Page 13: Service Safety

    RD 12/RD 12A Safety Information Service Safety A poorly maintained machine can become a safety hazard! In order for the machine to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. WARNING 1.3.1...
  • Page 14 A hot muffler could ignite the debris and start a fire. 1.3.15 Replace worn or damaged components with spare parts designed and recommended by Wacker Neuson Corporation. 1.3.16 Disconnect the spark plug on machines equipped with gasoline engines, before servicing, to avoid accidental start-up.

  • Page 15: Label Locations

    RD 12/RD 12A Safety Information Label Locations wc_si000302gb.fm...

  • Page 16: Safety And Operating Labels

    Safety Information RD 12/RD 12A Safety and Operating Labels Wacker Neuson machines use international pictorial labels where needed. These labels are described below: Ref. Label Meaning WARNING! Read and understand the supplied Operator’s Manual before operating the machine. Failure to do so increases the risk of injury to yourself or others.
  • Page 17 RD 12/RD 12A Safety Information Ref. Label Meaning WARNING! Hot surface! WARNING! Hot surface! Hydraulic oil reservoir fill tube. Torque nuts to 13.6-14.7 Nm (120-130 in.lbs.) maximum. CAUTION Lifting point. WARNING! To prevent hearing loss, wear hearing protection when operating this machine.
  • Page 18 Safety Information RD 12/RD 12A Ref. Label Meaning Choke: 0 = Open l = Closed Grease points: Inspect and lubricate every 100 hours of operation. WARNING! Avoid crushing area. Articulated steering joint locking location. Lock the articulated steering joint before servicing the machine.
  • Page 19 RD 12/RD 12A Safety Information Ref. Label Meaning A nameplate listing the model number, item number, revision number, and serial number is attached to each unit. Please record the information found on this plate so it will be available should the nameplate become lost or damaged.
  • Page 20 Safety Information RD 12/RD 12A Ref. Label Meaning This machine may be covered by one or more patents. wc_si000302gb.fm...
  • Page 21 RD 12/RD 12A Safety Information Notes wc_si000302gb.fm...

  • Page 22: Operation

    Operation RD 12/RD 12A Operation Operation and Service Locations See Graphic: wc_gr002946 Ref. Description Ref. Description Air cleaner Operator’s platform Articulated joint Engine oil filter Hand holds Rear drum fill/drain plug Control panel Rear drum—static Dipstick Scraper bar (4 places) Drain hose—hydraulic tank...
  • Page 23 RD 12/RD 12A Operation 25 2 5 13 wc_gr002946 wc_tx000865gb.fm...

  • Page 24: Control Panel

    Operation RD 12/RD 12A Control Panel See Graphic: wc_gr004114 Ref. Description Ref. Description Hour meter Ignition switch Vibration ON indicator Low fuel indicator Lights switch - ON and OFF Water spray switch - ON and OFF (if equipped) Throttle switch - HIGH and LOW Water spray dial wc_tx000865gb.fm...
  • Page 25 RD 12/RD 12A Operation wc_gr004114 wc_tx000865gb.fm...

  • Page 26: Vibration

    Operation RD 12/RD 12A Vibration See Graphic: wc_gr002955 The vibration is turned ON or OFF by a push button (10) located on the forward/reverse control (15). Press the button to turn vibration ON; press it again to turn it OFF. The vibration ON indicator (50) will light when vibration is on.

  • Page 27: Water Spray System

    RD 12/RD 12A Operation Water Spray System See Graphic: wc_gr002946, wc_gr003638 Water from the tank is fed to the spray bars by an electric pump. The flow of the water is controlled by a switch and a rotary dial. Press the upper half of the water spray switch (61) to turn the water pump on.

  • Page 28: Starting

    Operation RD 12/RD 12A Starting See Graphic: wc_gr002951 Exhaust gases are toxic. Do not start the engine in an enclosed space. WARNING 2.5.1 Sit down in the operator’s seat and fasten the seat belt. 2.5.2 Set the forward/reverse control (15) in the neutral position.
  • Page 29 RD 12/RD 12A Operation wc_gr002951 wc_tx000865gb.fm...

  • Page 30: Stopping/Parking

    Operation RD 12/RD 12A Stopping/Parking See Graphic: wc_gr002953 2.6.1 Stop the machine on a flat surface with a suitable load bearing capacity. 2.6.2 Turn the vibration off by pressing the vibration control button (10) on the forward/reverse lever (15). 2.6.3 Press the water spray switch to the OFF position (61).

  • Page 31: Auxiliary Battery Positive Terminal

    RD 12/RD 12A Operation Auxiliary Battery Positive Terminal This machine is equipped with an auxiliary battery positive terminal (45) located on top of the hydraulic tank (RD 12) or above the battery disconnect stud (RD 16). CAUTION! Electric shock hazard. Never touch this terminal and a metal portion of the machine simultaneously.

  • Page 32: Honda Engine Starting System

    Honda Engine Starting System RD 12/RD 12A Honda Engine Starting System Prerequisites Before troubleshooting engine starting issues, check the battery and the cable connections to the battery. The battery must be fully charged (approximately 12V). Sequence Complete the troubleshooting in the following sequence: 1.

  • Page 33: Checking The 20A Main Fuse

    RD 12/RD 12A Honda Engine Starting System Checking the 20A Main Fuse Prerequisites Key switch in OFF position. Background There are three 20A fuses protecting the circuits in the RD 12: Main electricals Voltage regulator circuit Optional light circuit Procedure Follow the procedure below to check the 20A main fuse.

  • Page 34: Checking Wiring To The Starter Solenoid & Anti-Backfire Solenoid

    Honda Engine Starting System RD 12/RD 12A Checking Wiring to the Starter Solenoid & Anti-backfire Solenoid Prerequisites Fully-charged (approximately 12V) battery Background Black wire #20 delivers 12VDC to the starter solenoid when the key is in the START position. If this wire is broken or disconnected, the engine will not crank.
  • Page 35 RD 12/RD 12A Honda Engine Starting System Continued from the previous page. 4. If the engine still won’t start but cranks, remove the anti-backfire solenoid and clean the valve portion of it with carburetor cleaner. Re-install it and try to start the engine.

  • Page 36: Checking The Key Switch

    Honda Engine Starting System RD 12/RD 12A Checking the Key Switch Prerequisites Multimeter Fully-charged (approximately 12V) battery Functioning 20A main fuse Background The key switch is a three-position switch: ON, START, and OFF. When in the START posi- tion, the key switch directs battery voltage to the crank relay.

  • Page 37: Checking The Crank Relay

    RD 12/RD 12A Honda Engine Starting System Checking the Crank Relay Prerequisites Multimeter Fully-charged (approximately 12V) battery Functioning 20A main fuse Functioning key switch Background The coil of the crank relay is energized when the key switch is in the START posi- tion.

  • Page 38: Checking The Neutral Switch

    Honda Engine Starting System RD 12/RD 12A Checking the Neutral Switch Prerequisites Multimeter Fully-charged (approximately 12V) battery Functioning main fuse Functioning key switch Seat platform in raised position. See section Rear Frame Access. Background The neutral switch, when closed (control lever in NEUTRAL position), allows volt- age to the neutral relay.

  • Page 39: Checking The Neutral Relay

    RD 12/RD 12A Honda Engine Starting System Checking the Neutral Relay Prerequisites Multimeter Fully-charged (approximately 12V) battery Functioning 20A main fuse Functioning crank relay Functioning neutral switch Background The neutral relay relays battery voltage to the starter solenoid. Procedure Follow the procedure below to check the neutral relay.

  • Page 40: Wacker Neuson Engine Starting System

    Wacker Neuson Engine Starting System RD 12/RD 12A Wacker Neuson Engine Starting System Before troubleshooting engine starting issues, check the battery and the cable Prerequisites connections to the battery. The battery must be fully charged (approximately 12V). Complete the troubleshooting in the following sequence: Sequence 1.

  • Page 41: Checking The 20A Main Fuse

    RD 12/RD 12A Wacker Neuson Engine Starting System 4.1 Checking the 20A Main Fuse Key switch in OFF position. Prerequisites There are three 20A fuses protecting the circuits in the RD 12: Background Main electricals Voltage regulator circuit Optional light circuit Procedure Follow the procedure below to check the 20A main fuse.

  • Page 42: Checking The Wiring To The Starter Solenoid & Anti-Backfire Solenoid

    Wacker Neuson Engine Starting System RD 12/RD 12A 4.2 Checking the Wiring to the Starter Solenoid & Anti-backfire Solenoid Fully-charged (approximately 12V) battery Prerequisites Black wire #20 delivers 12VDC to the starter solenoid when the key is in the Background START position.

  • Page 43: Checking The Wiring To The Starter Solenoid & Anti-Backfire Solenoid 42 4.3 Checking The Key Switch

    RD 12/RD 12A Wacker Neuson Engine Starting System 4.3 Checking the Key Switch Prerequisites Multimeter Fully-charged (approximately 12V) battery Functioning 20A main fuse Background The key switch is a three-position switch: ON, START, and OFF. When in the START posi- tion, the key switch directs battery voltage to the crank relay.

  • Page 44: Checking The Crank Relay

    Wacker Neuson Engine Starting System RD 12/RD 12A 4.4 Checking the Crank Relay Multimeter Prerequisites Fully-charged (approximately 12V) battery Functioning 20A main fuse Functioning key switch The coil of the crank relay is energized when the key switch is in the START posi- Background tion.

  • Page 45: Checking The Neutral Switch

    RD 12/RD 12A Wacker Neuson Engine Starting System 4.5 Checking the Neutral Switch Multimeter Prerequisites Fully-charged (approximately 12V) battery Functioning main fuse Functioning key switch Seat platform in raised position. See section Rear Frame Access. The neutral switch, when closed (control lever in NEUTRAL position), allows volt- Background age to the neutral relay.

  • Page 46: Checking The Neutral Relay

    Wacker Neuson Engine Starting System RD 12/RD 12A 4.6 Checking the Neutral Relay Multimeter Prerequisites Fully-charged (approximately 12V) battery Functioning 20A main fuse Functioning crank relay Functioning neutral switch The neutral relay relays battery voltage to the starter solenoid. Background Follow the procedure below to check the neutral relay.
  • Page 47 RD 12/RD 12A Wacker Neuson Engine Starting System 5. Check the voltage between terminal 87 (black wire #20) and ground. For this test, the plug must be connected to the crank relay. Position the plug as shown to allow access to terminal 87.

  • Page 48: Drive System

    Drive System RD 12/RD 12A Drive System Background The hydraulic system is powered by two pumps (exciter and drive) mounted in tandem— connected along their shafts through a solid-mounted coupling—and driven directly by the engine crankshaft through a flex coupling.

  • Page 49: Checking The Tow Valve

    RD 12/RD 12A Drive System 5.1 Checking the Tow Valve Background In order for the machine to operate properly, the tow valve must be completely closed. Procedure Follow the procedure below to open and close the tow valve. WARNING! With the tow valve open, the drive circuit has no braking action and the machine will roll freely.

  • Page 50: Adjusting The Drive Control Cable

    Drive System RD 12/RD 12A 5.2 Adjusting the Drive Control Cable If the roller tends to drift in either direction when the forward/reverse control is in Background NEUTRAL, the drive control cable (a) must be adjusted. Machine on a hard, level surface...

  • Page 51: Checking The Drive System Operating Pressure

    RD 12/RD 12A Drive System 5.3 Checking the Drive System Operating Pressure Background Failure of the drive circuit to reach operating pressures is normally caused by a worn or damaged drive pump; however, the problem could also be the result of a badly worn motor.

  • Page 52: Checking The Drive System Relief Pressure

    Drive System RD 12/RD 12A 5.4 Checking the Drive System Relief Pressure Prerequisites Machine on a firm, level surface 5000-psi pressure gauge Procedure Follow the procedure below to check the relief presure. 1. Place blocks in front of and behind both drums to prevent the machine from moving, or dead head the machine against a solid concrete abutment.

  • Page 53: Checking Drive Motors For Binding

    RD 12/RD 12A Drive System 5.5 Checking Drive Motors for Binding Background High operating pressures indicate binding in the drive system. Binding can occur in the drive motor or may be the result of a poor or failing drive bearing.
  • Page 54 Drive System RD 12/RD 12A Continued from the previous page. 5. Secure the drum support with an appropriate crane and sling (e). 6. Remove the screws that secure the drum support and remove the drum support. wc_gr004127 7. Rotate the drive plate (f) by hand and make sure the motor turns freely.

  • Page 55: Checking Oil Flow Through The Drive Motors

    RD 12/RD 12A Drive System 5.6 Checking Oil Flow through the Drive Motors Background The drive motors are plumbed in series. Oil flow through one motor is virtually identical to the flow through the other, unless a problem with one of the motors exists.

  • Page 56: Vibration System And Steering

    Vibration System and Steering RD 12 / RD 12A Vibration System and Steering Both the vibration and steering system share the same open loop, series circuit, driven by a fixed displacement, gear-type pump (exciter pump). The system includes separate relief valves for vibration and steering, an exciter control valve exciter motor, steering valve, and steering cylinder.

  • Page 57: Checking The Engine Speed And Vibration Speed

    RD 12 / RD 12A Vibration System and Steering Checking the Engine Speed and Vibration Speed Vibrotach Prerequisites Vibration must turn on Follow the procedure below to check the engine rpm and drum vpm. Procedure 1. Start the engine and place the throttle switch in the FAST position.

  • Page 58: Troubleshooting A System That Vibrates Poorly

    Vibration System and Steering RD 12 / RD 12A Troubleshooting a System that Vibrates Poorly 3000-psi pressure gauge Prerequisites Compactible surface such as a bed of gravel or old tires The exciter pump is designed to put out a constant flow of oil at a set engine speed.
  • Page 59 RD 12 / RD 12A Vibration System and Steering Continued from the previous page. 5. Turn on the vibration and measure the relief and operating pressures. The relief pressure is the pressure registered on the gauge as soon as the vibration is turned on.

  • Page 60: Checking The Vibration Solenoid Valve

    Vibration System and Steering RD 12 / RD 12A Checking the Vibration Solenoid Valve When the roller’s engine is running, the solenoid (a) of the vibration manifold (b) Background receives power through the white wire via the vibration switch. When energized, the vibration solenoid valve shifts causing oil flow to the exciter motor.

  • Page 61: Checking The Vibration Switch

    RD 12 / RD 12A Vibration System and Steering Checking the Vibration Switch When the roller’s engine is running, the solenoid of the vibration manifold receives Background power through the white wire via the vibration switch. To check the function of the vibration electrical system, both the vibration solenoid and the vibration switch should be tested.

  • Page 62: Steering System

    Steering System RD 12/RD 12A Steering System Checking the Steering System Hydraulic Pressure Prerequisites 200-bar (3000-psi) pressure gauge Procedure Follow the procedure below to check the steering system hydraulic pressure. 1. Open the engine compartment. 2. Locate the exciter solenoid valve (a).

  • Page 63: Troubleshooting The Steering System

    RD 12/RD 12A Steering System Troubleshooting the Steering System Background Low hydraulic pressure in the steering circuit can be the result of a defective or worn steering valve or poor seals in the steering cylinder. A badly worn exciter pump will affect both the steering and the vibration circuits because these circuits operate in series using the same supply.

  • Page 64: Spray System

    Spray System RD 12/RD 16 Spray System Troubleshooting the Spray System Prerequisites The machine must be able to start in order to troubleshoot the spray system. If the machine does not start, see engine starting troubleshooting. Components The electrical components of the spray system consist of: Pump Pump timer module Spray system switch...

  • Page 65: Checking Power To The Spray Bar Pump

    RD 12/RD 16 Spray System Checking Power to the Spray Bar Pump Prerequisites Seat platform in raised position. See section Rear Frame Access. Procedure Follow the procedure below to check power to the spray bar pump. 1. Disconnect the wiring from the water pump (a). 2.

  • Page 66: Checking The Pump Timer Module

    Spray System RD 12/RD 16 Checking the Pump Timer Module Background The pump timer module is fed power in two locations: Via key switch on pink wire #01 Via spray system switch on pink wire #18 Procedure Follow the procedure below to check power to the pump timer module. 1.

  • Page 67: Checking The Spray System Switch

    RD 12/RD 16 Spray System Checking the Spray System Switch Background The spray system switch is fed power via the key switch on pink wire #29. When in the ON position, the spray system switch allows power to the pump control timer via pink wire #18. Procedure Follow the procedure below to check the spray system switch.

  • Page 68: Disassembly & Assembly

    When ordering a replacement Parts Book, please list the model number, item number, revision level, and serial number of the machine. Parts Books are also available on the Wacker Neuson Corporation Web site. See www.wackerneuson.com. Enter the site as a visitor.

  • Page 69: Removing The Articulating Joint

    RD 12/RD 12A Disassembly & Assembly Removing the Articulating Joint Prerequisites Crane and jacks Procedure Follow the procedure below to remove the articulating joint. 1. Support the rear half of the machine with jacks and the front half with an appropriate crane so that the machine will not fall in on itself when the articulating joint is removed.

  • Page 70: Installing The Articulating Joint

    Disassembly & Assembly RD 12/RD 12A Installing the Articulating Joint Prerequisites Crane and jacks Procedure Follow the procedure below to install the articulating joint. 1. Support the rear half of the machine with jacks and the front half with an appropriate crane so that the machine will not fall in on itself when the articulating joint is removed.

  • Page 71: Removing The Rear Drum

    RD 12/RD 12A Disassembly & Assembly Removing the Rear Drum Prerequisites Jacks Crane and appropriate sling Procedure Follow the procedure below to remove the rear drum. 1. Chock the front drum. 2. Support the machine with jacks (a). wc_gr004194 3. Remove the drum support covers (b).
  • Page 72 Disassembly & Assembly RD 12/RD 12A Continued from the previous page. 7. Support the drum support with an appropriate sling and crane. wc_gr004197 8. Remove the four screws (f) that secure the drum support to the machine and slide the drum (g) from underneath the machine.

  • Page 73: Installing The Rear Drum

    RD 12/RD 12A Disassembly & Assembly Installing the Rear Drum Prerequisites Crane and appropriate sling Non-drive-motor side drum support installed Procedure Follow the procedure below to install the rear drum. 1. Chock the front drum. 2. Install the bearing (h) onto the shaft of the drum.
  • Page 74 Disassembly & Assembly RD 12/RD 12A Continued from the previous page. 7. Install the brake cable (d) to the drum. wc_gr004200 8. Install the drum support covers (b). The procedure to install the rear drum is now complete. wc_tx000671gb.fm...

  • Page 75: Removing The Brake And Brake Cable

    RD 12/RD 12A Disassembly & Assembly Removing the Brake and Brake Cable Prerequisites Engine off Procedure Follow the procedure below to remove the brake. 1. Chock the drums. 2. Remove the drum support cover (a). wc_gr004209 3. Remove the screws (b) that secure the brake lever assembly to the machine.
  • Page 76 Disassembly & Assembly RD 12/RD 12A Continued from the previous page. 8. Support the rear of the machine with an appropriate crane. wc_gr004224 9. Remove the screws (i) that secure the drive plate to the shock mounts. 10.Remove the screws (h) that secure the brake caliper to the drive plate.

  • Page 77: Installing The Brake And Brake Cable

    RD 12/RD 12A Disassembly & Assembly 9.10 Installing the Brake and Brake Cable Prerequisites Appropriate crane and sling Procedure Follow the procedure below to install the brake. 1. Raise the rear half of the machine approximately 10 cm (4 in.) off the rear drum.
  • Page 78 Disassembly & Assembly RD 12/RD 12A Continued from the previous page. 7. Install the two screws (g), nuts, and bracket which secure the cable (h) to the machine. wc_gr004215 8. Install the hitch pin (e) and the clevis pin (f).

  • Page 79: Removing Rear Drive Motor

    RD 12/RD 12A Disassembly & Assembly 9.11 Removing Rear Drive Motor Prerequisites Rear drum removed Procedure Follow the procedure below to remove the rear drive motor. 1. Rotate the drive motor assembly as needed to reach the three screws (a) which mount the drive plate to the drum.
  • Page 80 Disassembly & Assembly RD 12/RD 12A Continued from the previous page. 6. Remove the motor guard (g). wc_gr004219 7. Remove the brake bracket (h). 8. Remove the drive motor (i) from the drum support. wc_gr004220 9. Remove the hydraulic lines (j) and fittings from the drive motor if not already removed.

  • Page 81: Installing The Rear Drive Motor

    RD 12/RD 12A Disassembly & Assembly 9.12 Installing the Rear Drive Motor Prerequisites Rear drum removed Procedure Follow the procedure below to install the rear drive motor. 1. Connect the hydraulic lines (j) and fittings to the drive motor. wc_gr004221 2.
  • Page 82 Disassembly & Assembly RD 12/RD 12A Continued from the previous page. 7. Install the brake assembly (c). See section Installing the Brake. wc_gr004223 8. Using an appropriate crane, position the drum support/drive motor assembly (b) on the drum. Using Loctite 243 on the three screws (a), secure the drive motor assembly to the drum.

  • Page 83: Removing The Front Drum

    RD 12/RD 12A Disassembly & Assembly 9.13 Removing the Front Drum Prerequisites Crane and appropriate sling Jacks Procedure Follow the procedure below to remove the front drum. 1. Support the front half of machine with jacks (a). wc_gr004145 2. Remove the drum support covers (b) from each side of the machine.
  • Page 84 Disassembly & Assembly RD 12/RD 12A Continued from the previous page. 7. Remove the screws (g) that secure the drum support to the machine. wc_gr004148 8. Lift the drum support (h) and drive motor from the machine. 9. Disconnect and plug the hydraulic lines (i) from the exciter motor. Then, remove the exciter motor.

  • Page 85: Installing The Front Drum

    RD 12/RD 12A Disassembly & Assembly 9.14 Installing the Front Drum Prerequisites Crane and appropriate sling Jacks Procedure Follow the procedure below to install the front drum. 1. Slide the drum into position underneath the machine. wc_gr004151 2. Apply Loctite 243 to the screws (a) and secure the exciter-motor-side drum support to the frame.
  • Page 86 Disassembly & Assembly RD 12/RD 12A Continued from the previous page. 5. Position the drum so that the drive plate can be installed to the three shock mounts (d). Install the drive plate to the drum. Torque the nuts (e) to 76 Nm (56 ft.lbs.).

  • Page 87: Removing The Front Drive Motor

    RD 12/RD 12A Disassembly & Assembly 9.15 Removing the Front Drive Motor Prerequisites Front drum removed Puller Procedure Follow the procedure below to remove the front drive motor. 1. Remove the front drum. See section Removing the Front Drum. 2. Remove the nut (a) that secures the hub (b) to the drive motor.

  • Page 88: Installing The Front Drive Motor

    Disassembly & Assembly RD 12/RD 12A 9.16 Installing the Front Drive Motor Prerequisites Front drum removed Procedure Follow the procedure below to install the front drive motor. 1. Apply Loctite 243 to the screws and install the drive motor (a) to the drum support (b).

  • Page 89: Removing The Exciter

    RD 12/RD 12A Disassembly & Assembly 9.17 Removing the Exciter Prerequisites Front drum removed Procedure Follow the procedure below to remove the exciter. 1. Remove the screws (a) that secure the drum support (b) to the shock mounts and remove the drum support.
  • Page 90 Disassembly & Assembly RD 12/RD 12A Continued from the previous page. 7. Pull the exciter (h) up and out of the drum. wc_gr004164 The procedure to remove the exciter is now complete. wc_tx000671gb.fm...

  • Page 91: Installing The Exciter

    RD 12/RD 12A Disassembly & Assembly 9.18 Installing the Exciter Prerequisites Front drum removed Drive-motor-side exciter bearing installed Procedure Follow the procedure below to install the exciter. 1. Install the key and the gear (a) of the exciter motor coupling onto the exciter. Secure the gear to the exciter with the set screw.
  • Page 92 Disassembly & Assembly RD 12/RD 12A Continued from the previous page. 5. Using Loctite 243 on the six screws (e), secure the bearing cover (f) and the shock mount plate (g) to the drum support. Torque the screws to 50 Nm (36 ft.lbs.).

  • Page 93: Disassembling The Exciter Bearings

    RD 12/RD 12A Disassembly & Assembly 9.19 Disassembling the Exciter Bearings Prerequisites Front drum removed Puller Procedure On the exciter side of the drum, two bearings and their flanges make up the drum hub (d). Follow the procedure below to disassemble the exciter bearings.
  • Page 94 Disassembly & Assembly RD 12/RD 12A Continued from the previous page. 3. 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.

  • Page 95: Assembling The Exciter Bearings

    RD 12/RD 12A Disassembly & Assembly 9.20 Assembling the Exciter Bearings Prerequisites Front drum removed Procedure Follow the procedure below to assemble the exciter bearings. 1. Press new inner bearing races (c2 and k2) onto the exciter. wc_gr004244 wc_gr004172 2. Install the outer bearing race into the drive-motor-side bearing flange (b).
  • Page 96 Disassembly & Assembly RD 12/RD 12A Continued from the previous page. 4. Be sure set the screws (j) are recessed on the larger bearing flange (g). Install a new inner seal (l). Lightly grease the outer bearing race and press it into the larger bearing flange.

  • Page 97: Removing The Control Cable And Control Lever

    RD 12/RD 12A Disassembly & Assembly 9.21 Removing the Control Cable and Control Lever Prerequisites Machine OFF and engine cool Seat platform in raised position Procedure Follow the procedure below to remove the control cable and the control lever. CAUTION! Burn hazard. The engine exhaust pipes are extremely hot while the engine is running and for a period of time after the engine has shut down.
  • Page 98 Disassembly & Assembly RD 12/RD 12A Continued from the previous page. 5. Remove the screws (e) that secure the control lever assembly (f) and remove the con- trol lever assembly from the machine. wc_gr004191 6. Disconnect the control cable (a) from the control lever assembly.

  • Page 99: Installing The Control Cable And Control Lever

    RD 12/RD 12A Disassembly & Assembly 9.22 Installing the Control Cable and Control Lever Prerequisites Seat platform in raised position Procedure Follow the procedure below to install the control cable and the control lever. 1. Check that the clamp bracket is positioned correctly. It should be positioned with the screws (g) in the first and third holes of the control lever assembly (f).

  • Page 100: Removing The Exciter Pump

    Disassembly & Assembly RD 12/RD 12A 9.23 Removing the Exciter Pump Prerequisites Machine OFF and engine cool Hose plug Procedure Follow the procedure below to remove the exciter pump. CAUTION! Burn hazard. The engine exhaust pipes are extremely hot while the engine is running and for a period of time after the engine has shut down.

  • Page 101: Installing The Exciter Pump

    RD 12/RD 12A Disassembly & Assembly 9.24 Installing the Exciter Pump Prerequisites Machine OFF and engine cool. Procedure Follow the procedure below to install the exciter pump. 1. Place a plastic sheet and a container under the machine to collect any liquid which drains off.

  • Page 102: Removing The Drive Pump

    Disassembly & Assembly RD 12/RD 12A 9.25 Removing the Drive Pump Prerequisites Machine OFF and engine cool Exciter pump removed Procedure Follow the procedure below to remove the drive pump. Burn hazard. The engine exhaust pipes are extremely hot while the engine is run- ning and for a period of time after the engine has shut down.

  • Page 103: Installing The Drive Pump

    RD 12/RD 12A Disassembly & Assembly 9.26 Installing the Drive Pump Prerequisites Engine and adapter installed Procedure Follow the procedure below to install the drive pump. 1. Place a plastic sheet and a container under the machine to collect any liquid which drains off.

  • Page 104: Removing The Engine

    Disassembly & Assembly RD 12/RD 12A 9.27 Removing the Engine Prerequisites Crane and appropriate sling Exciter pump and drive pump removed Procedure Follow the procedure below to remove the engine. Burn hazard. The engine exhaust pipes are extremely hot while the engine is run- ning and for a period of time after the engine has shut down.
  • Page 105 RD 12/RD 12A Disassembly & Assembly Continued from the previous page. 5. Disconnect the lanyard (g) from the hydraulic tank. wc_gr004177 6. Disconnect the air cylinder (h) from the hydraulic tank. Support the hood in the open position. 7. Disconnect and plug the exciter motor hydraulic line (i) from the hydraulic tank.

  • Page 106: Installing The Engine

    Disassembly & Assembly RD 12/RD 12A 9.28 Installing the Engine Prerequisites Machine OFF and engine cool. Procedure Follow the procedure below to install the engine. 1. Position the engine into the frame. wc_gr004178 2. Reconnect the exhaust (a). 3. Apply Loctite 243 to the screws and secure the engine to the frame. Torque the screws to 44 Nm (32 ft.lbs.).
  • Page 107 RD 12/RD 12A Disassembly & Assembly Continued from the previous page. 8. Reconnect the lanyard (g) to the hydraulic tank. wc_gr004177 9. Reconnect the air cylinder (h) to the hydraulic tank. 10.Reconnect the exciter motor hydraulic line (i) from the hydraulic tank.

  • Page 108: Removing The Steering Valve

    Disassembly & Assembly RD 12/RD 12A 9.29 Removing the Steering Valve Prerequisites Machine OFF and engine cool. Procedure Follow the procedure below to remove the steering valve. 1. Remove the front console panel (a). 2. Remove the cable clamp (b).
  • Page 109 RD 12/RD 12A Disassembly & Assembly Continued from the previous page. 7. Remove the screws (g) that secure the bracket (h) to the console. wc_gr004203 8. Remove the screws (i) that secure the steering servo. Maneuver the steering valve (j) out of the control console.

  • Page 110: Installing The Steering Valve

    Disassembly & Assembly RD 12/RD 12A 9.30 Installing the Steering Valve Prerequisites Machine OFF and engine cool Procedure Follow the procedure below to install the steering valve. 1. Position the steering valve (j) and bracket (h) into the control console. Secure the steer- ing valve to the bracket with screws (i) .
  • Page 111 RD 12/RD 12A Disassembly & Assembly Continued from the previous page. 5. Install the steering wheel and secure it with the nut (d). wc_gr004202 6. Install the small cover (c) on the steering wheel. 7. Install the cable clamp (b).

  • Page 112: Removing The Hydraulic Tank

    Disassembly & Assembly RD 12/RD 12A 9.31 Removing the Hydraulic Tank Prerequisites Engine cool Procedure Follow the procedure below to remove the hydraulic tank. 1. Place a plastic sheet and a container under the machine to collect any liquid which drains off.
  • Page 113 RD 12/RD 12A Disassembly & Assembly Continued from the previous page. 7. Loosen the hose clamps that secure the hydraulic hoses (d and e) to the drive and exciter pumps. wc_gr004206 8. Pull the hydraulic tank from the hydraulic hoses (loosen the fittings if necessary) and out of the frame.

  • Page 114: Installing The Hydraulic Tank

    Disassembly & Assembly RD 12/RD 12A 9.32 Installing the Hydraulic Tank Prerequisites Engine cool Procedure Follow the procedure below to install the hydraulic tank. 1. Place a plastic sheet and a container under the machine to collect any liquid which drains off.
  • Page 115 RD 12/RD 12A Disassembly & Assembly Continued from the previous page. 5. Connect the lanyard (g) and the air cylinder (h) to the hydraulic tank. wc_gr004205 6. Connect the three hydraulic lines (a). 7. Fill the hydraulic tank. See section Changing Hydraulic Oil and Filter.

  • Page 116: Removing The Fuel Tank

    Disassembly & Assembly RD 12/RD 12A 9.33 Removing the Fuel Tank Prerequisites Machine shut down Platform in upright position. See section Rear Frame Access. Procedure Follow the procedure below to remove the fuel tank. 1. Drain the fuel from the fuel tank by disconnecting the fuel hose (a) at the engine.
  • Page 117 RD 12/RD 12A Disassembly & Assembly Continued from the previous page. 5. Disconnect the fuel sensor (e) from the wiring harness. 6. Remove the gas strut brackets (f) from the water tank and the fuel tank. Remove the cable clip (g).

  • Page 118: Installing The Fuel Tank

    Disassembly & Assembly RD 12/RD 12A 9.34 Installing the Fuel Tank Prerequisites Platform in upright position. See section Rear Frame Access. Procedure Follow the procedure below to install the fuel tank. 1. Route the fuel level sensor wiring (i) around the control lever side of the fuel tank. Then, position the fuel tank into the water tank and secure it with the mounting plate (h).
  • Page 119 RD 12/RD 12A Disassembly & Assembly wc_tx000671gb.fm...

  • Page 120: Schematics

    Schematics RD 12/RD 12A 10 Schematics 10.1 Hydraulic Schematic wc_tx001073gb.fm...

  • Page 121: Hydraulic Schematic Components

    Bypass lever Vibration solenoid valve Charge pump Exciter motor Main pump Pressure relief valve Exciter pump 10.3 Electrical Schematic Identification—RD 12A Use the chart below to determine which electrical schematic applies to your machine. Roller Item No. Revisions Electrical Schematic...

  • Page 122: Electrical Schematic "A"-Rd 12A

    Schematics RD 12/RD 12A 10.4 Electrical Schematic “A”—RD 12A wc_tx001073gb.fm...

  • Page 123: Electrical Schematic "A" Components-Rd 12A

    RD 12/RD 12A Schematics 10.5 Electrical Schematic “A” Components—RD 12A Ref. Description Ref. Description Work light switch Rear light (optional) Throttle switch Left head light (optional) Pump switch Right head light (optional) Key switch To magneto kill Vibration indicator light (green)

  • Page 124: Electrical Schematic "B"-Rd 12A

    Schematics RD 12/RD 12A 10.6 Electrical Schematic “B”—RD 12A wc_tx001073gb.fm...

  • Page 125: Electrical Schematic "B" Components-Rd 12A

    RD 12/RD 12A Schematics 10.7 Electrical Schematic “B” Components—RD 12A Ref. Description Ref. Description Work light switch Rear light (optional) Throttle switch Left head light (optional) Pump switch Right head light (optional) Key switch To magneto kill Vibration indicator light (green)

  • Page 126: Electrical Schematic-Rd 12

    Schematics RD 12/RD 12A 10.8 Electrical Schematic—RD 12 wc_tx001073gb.fm...

  • Page 127: Electrical Schematic Components-Rd 12

    RD 12/RD 12A Schematics 10.9 Electrical Schematic Components—RD 12 Ref. Description Ref. Description Work light switch Left head light (optional) Throttle switch Right head light (optional) Pump switch To magneto kill Key switch Crank relay Vibration indicator light (green) Neutral relay...

  • Page 128: Technical Data

    Technical Data RD 12/RD 12A 11 Technical Data 11.1 Engine Engine Power Rating RD 12A: Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. RD 12: Gross power rating per SAE J1995. Actual power output may vary due to conditions of specific use.

  • Page 129: Roller

    RD 12/RD 12A Technical Data 11.2 Roller Item No. RD 12A RD 12 Roller Dry Weight 1002 (2171) kg (lb.) Curb Clearance: mm (in.) Right 400 (15.7) Left 208 (8.2) Water Tank Capacity 100 (26.4) l (gal.) Outside Turning Radius 2.44 (8.0)

  • Page 130: Dimensions

    Technical Data RD 12/RD 12A 11.4 Dimensions mm (in.) 2300 (90.6) (22) 1265 (49.8) (35.4) 1035 1824 (71.8) (40.8) wc_td000311gb.fm...

  • Page 131: Sound Measurements

    RD 12/RD 12A Technical Data 11.5 Sound Measurements The operating sound level, measured per the requirements of Appendix 1, Paragraph 1.7.4.f of the EC-Machine Regulations, is: • the guaranteed sound power level (L RD 12 = 102 dB(A) • the sound pressure level at operator’s location (L RD 12 = 85.6 dB(A)

  • Page 132: Hydraulic Pressures

    Technical Data RD 12/RD 12A 11.7 Hydraulic Pressures System Operating Pressure Relief Pressure Drive** 55–69 800–1000 2900 Steering* 45–51 650–725 —while turning 0–41 0–725 Vibration 2900 —single drum 55–76 800–1100 * Values for hard-packed surface shown. Values may differ depending on surface.
  • Page 133 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container. The sealants listed are recommended for use on Wacker Neuson equipment. TYPE PART NO. –...
  • Page 134 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container. The sealants listed are recommended for use on Wacker Neuson equipment. TYPE PART NO. –...
  • Page 135 Torque Values Torque Values Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE 10.9 12.9 Size ft.lb. ft.lb. ft.lb. Metric Inch Metric Inch 7/32 – 9/32 – 5/16 – – – – 11/16 – – – 15/16 –...
  • Page 136 Torque Values Torque Values (continued) Inch Fasteners (SAE) Size ft.lb. ft.lb. ft.lb. Metric Inch Metric Inch No.4 – 3/32 No.6 5/16 – 7/64 No.8 11/32 – 9/64 No.10 – – 5/32 – 7/16 – 3/32 5/16 – – 9/16 – 5/16 7/16 –...
  • Page 138 Fax: +49 - (0)89-3 54 02-390 Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.

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