Wacker Neuson DPU6555 Vibratory platte Repair Instructions Manual - PDF DOWNLOAD

Repair Instructions Vibratory platte

07.2015 de 510005945/02

Manufacturer Wacker Neuson Produktion GmbH & Co. KG Preussenstrasse 41 80809 Munich www.wackerneuson.com Tel.: +49-(0)89-354 02-0 Fax: +49-(0)89-354 02-390 Original Repair Instructions

Table of Contents

1 2

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Qualification of the operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Protection equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Operating safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Safety when operating vibratory plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety when operating combustion engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Safety when operating hydraulic work tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4 5 6

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Disassembly / assembly of protective frame, covers and battery . . . . . . . . . . . . . . . . . . . 19

3.1

6.1 6.2

7

Disassembly of the wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly of the operator's controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harness assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's controls assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 32 34 37

The wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Disassembly of the clutch and replacing the V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Assembly of the clutch und installation of the V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Disassembly of the Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Assembly of the Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Diesel engine disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Diesel engine assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Disassembly of the upper mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Assembly of the upper mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Disassembly of the entire center pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Assembly of the entire center pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Disassembly of the center pole head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Assembly of the center pole head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Disassembly of the base plate and exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Assembly of the base plate and exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Disassembly of the exciter shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Assembly of the exciter shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Assembly and disassembly of the Compatec components . . . . . . . . . . . . . . . . . . . . . . . 120 25.1 25.2 25.3

26 27

Disassembly of the protective frame, covers and battery. . . . . . . . . . . . . . . . . . . . . . . . . 19 Assembly of protective frame, covers and battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Disassembly / assembly of wiring harness and operator's controls . . . . . . . . . . . . . . . . . . 28 7.1 7.2 7.3 7.4

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Disassembly of Compatec components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Assembly of the Compatec components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Troubleshooting and rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Compatec electrical wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Electrical troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

1

Preface

1

Preface This service manual contains information and procedures for the safe operation and safe maintenance of your Wacker Neuson machine. For your own safety and to protect against injuries, you must thoroughly read the safety instructions, familiarize yourself with them and observe them at all times.

This repair manual is not a manual for extensive maintenance or repair work. Such work should be carried out by the Wacker Neuson service or by certified personnel.

When building this equipment, great value was placed on the safety of its operator.

However, improper operation or improper maintenance can pose hazards. Please operate and maintain your Wacker Neuson machine in accordance with the information in this repair manual. It will reward your attention by providing you with trouble-free operation and high availability.

Defective machine parts must be replaced immediately!

Please contact your Wacker Neuson contact partner for questions regarding operation or maintenance.

All rights are reserved, in particular the right of duplication and distribution.

Copyright 2013 Wacker Neuson Produktion GmbH & Co. KG This manual – even in part – may only be reproduced, used, copied or distributed with the expressed, prior written consent from Wacker Neuson.

Any type of reproduction, distribution or storage on data carriers in any form or type that is not approved by Wacker Neuson represents a violation of the valid copyright and will be prosecuted.

We reserve the express right to technical changes that are used to improve our machines or raise the safety standard, even without special notice.

2

Safety instructions

2

Safety instructions 2.1

Policy Prior art The equipment is built according to prior art and the recognized technical safety rules.

Nevertheless, improper use can result in hazards to life and limb of the user or third parties or in damage to the equipment and other material assets.

Proper use The equipment may only be used for the following purposes:   

Soil compaction.

Asphalt compaction.

Vibrating paving stones.

The equipment may not be used for the following purposes:    

Compaction of very cohesive soils.

Compaction of frozen soils.

Compaction of hard, non-compressible soils.

Compaction of non-load-bearing soils.

Use in accordance with the intended purpose also includes the observation of all information in this operator's manual as well as complying with the prescribed care and maintenance instructions.

Any use that goes beyond instructions is considered improper. The manufacturer's liability and warranty are canceled for any damage resulting from improper use. The risk lies entirely with the operator.

Structural changes Do not carry out any structural changes without written approval from the manufacturer. You will thereby be endangering your safety and the safety of others!

Additionally, the manufacturer's liability and warranty will be canceled.

In particular, the following cases are considered structural changes: 





Opening the device and permanent removal of components that originate from Wacker Neuson.

Installing new components that do not originate from Wacker Neuson or are not comparable in the design system and quality of the original parts.

Attaching accessories that do not originate from Wacker Neuson.

You can safely install spare parts that originate from Wacker Neuson.

You can safely attach accessories that are available for your equipment in the  Wacker Neuson product range. To do so, please refer to the attachment regulation in this operator's manual.

3

Safety instructions Prerequisite for operation The flawless and safe operation of the equipment requires the following:   

Proper transport, storage and assembly.

Careful operation.

Careful care and maintenance.

Operation Only operate the equipment in accordance with the intended purpose and in a technically flawless condition.

Only operate the equipment in a safety and hazard-conscious manner and with all protective devices. Do not change or bypass any protective devices.

Before beginning work, check the effectiveness of the operator's controls and protective devices.

Never operate the unit in explosive environments.

Supervision Never leave equipment running without supervision!

Maintenance Regular maintenance work is required for flawless and permanent functioning of the equipment. Neglected maintenance reduces the equipment's safety.  

The prescribed maintenance intervals must be strictly observed.

Do not use the equipment if maintenance or repairs are needed.

Faults In the event of malfunctions, you must immediately switch the equipment off and secure it.

Immediately rectify faults that can impair safety!

Have damaged or defective components replaced immediately!

You can find more information in the chapter Troubleshooting.

Spare parts, accessories Only use spare parts from Wacker Neuson or such spare parts that are comparable in the design system and quality of the original parts.

Only use accessories by Wacker Neuson.

Non-observance cancels out any liability.

4

Safety instructions Disclaimer For the following violations, Wacker Neuson disclaims any liability for personal injury or material damage:     



Structural change.

Improper use.

Non-observance of this operator's manual.

Improper handling.

Using spare parts that do not originate from Wacker Neuson or are not comparable in the design system and quality of the original parts.

Using accessories that do not originate from Wacker Neuson.

Operator’s manual Always keep the operator's manual readily available on the equipment or at the place of application of the equipment.

If you should lose the operator's manual or require another copy, please contact your Wacker Neuson contact partner or download the operator's manual from the Internet (www.wackerneuson.com).

Hand over this operator's manual to every other operator or subsequent owner of the equipment.

Country-specific regulations Also observe country-specific regulations, standards and guidelines for accident prevention and environmental protection, such as dealing with hazardous substances and wearing personal protection equipment.

Supplement the operator's manual with additional instructions on taking operational, regulatory, national or generally applicable safety guidelines into consideration.

Operating elements Always keep the equipment's operator's controls dry, clean and free from oil and grease.

Operator's controls, such as the ON/OFF switch, throttle control handles, etc. may not be locked, manipulated or changed without permission.

Cleaning Always keep the equipment clean and clean it after every use.

Do not use any fuels or solvents. Explosion hazard!

Do not use any high pressure washers. Ingressing water can damage the unit. With electrical equipment, there is a serious risk of injury from electric shock.

Check for damage Check the shutdown equipment at least once per shift for externally visible damage and defects.

Do not operate the equipment if damage or defects are discernible.

Have damage and defects rectified immediately.

5

Safety instructions

2.2

Qualification of the operating personnel Qualification of the operator Only technically trained personnel may start and operate the equipment. In addition, the following conditions apply:    

 



They must be at least 18 years old.

They are physically and mentally suitable.

They are trained in the independent operation of the equipment.

They are trained in how to use the equipment in accordance with the intended purpose.

They are familiar with the necessary safety devices.

They are authorized to operate equipment and systems independently according to the standards of safety engineering.

They are appointed by the contractor or operator to independently work with the equipment.

Faulty operation In the event of faulty operation, misuse or operation by untrained personnel, dangers threaten the health of the operator or third parties as well as the condition of the device or other material assets.

User responsibilities The user must make the operator's manual available to the operator and ensure that the operator has read and understood them.

Recommendations for work Please observe the following recommendations:     

 

2.3

Only work in a good physical condition.

Work attentively, especially at the end of working hours.

Do not work with the equipment when you are tired.

Perform all work calmly, cautiously and carefully.

Never work under the influence of alcohol, drugs or medication. Your vision, reactivity and judgment may be impaired.

Work so that no third parties are harmed.

Make sure that there are no people or animals in the danger area.

Protection equipment Working clothes The clothing should be appropriate, i.e. tight fitting, but not cumbersome.

Generally, do not have any long hanging hair, loose clothing or jewelry (including rings) on construction sites. There is a risk of injury, for example from being snagged or pulled in on to moving equipment parts.

Only wear flame-resistant working clothing.

6

Safety instructions Personal Protection Equipment Use personal protection equipment in order to avoid injuries and health hazards:     

Safety shoes.

Work gloves made from sturdy material.

Overalls made from sturdy material.

Protective helmet.

Ear protection.

Ear protection With this equipment, it is possible to exceed the permissible, country-specific noise limit (personal rating level). This is why you may have to wear ear protection under certain circumstances. You can find the exact value in the chapter Technical Data of the Operator's Manual.

Work particularly cautiously and pay attention when wearing ear protection, as your ability to hear noises, such as screams or signal tones, is restricted.

Wacker Neuson recommends always wearing ear protection.

2.4

Transport Switch off the unit Switch the equipment off prior to transport and allow the engine to cool off.

Center pole in the transport position Prior to transport, put the center pole into the transport position. In doing so, lock the center pole into the center pole stop-lock.

Observe hazardous materials provisions Observe the hazardous materials provisions for the means of transport and the national safety standards.

Raising Observe the following information for lifting the equipment:   

  



Appoint a qualified instructor for the lifting operation.

You must be able to see or hear the flagman.

Only use suitable and tested hoisting gear, fixing gear and lifting accessories with sufficient load bearing capacity.

Only use attachment points according to the operator's manual.

Reliably secure the equipment to the hoisting gear.

Make sure that there are no people in the immediate vicinity or below the equipment.

Do not climb on the equipment.

7

Safety instructions Loading Loading ramps must be load-bearing and stable.

Make sure that no people are endangered by the equipment tipping over, falling down or sliding, or from equipment parts rising up or down.

Put the operating elements and moving components in the transport position.

Secure the equipment against tipping over, falling down or sliding by using tie-down straps. Only use attachment points for this according to the operator's manual.

Transport vehicle Only use suitable transport vehicles with sufficient load bearing capacity and appropriate tie-down lugs.

Transporting the equipment Secure the equipment on the means of transport from tipping over, falling down or sliding.

Only use the tie-down lugs specified in the operator's manual.

Also observe the country-specific regulations, standards and directives.

Recommissioning Before recommissioning, attach and fasten equipment, equipment parts, accessories or tools that were dismantled for transport purposes.

Proceed only according to the operator's manual.

2.5

Operating safety Explosive area Never operate the unit in explosive environments.

Work environment Familiarize yourself with the work environment before beginning work. For example, this includes the following points:   

 

Obstacles in the work and traffic area.

Load-bearing capacity of the soil.

Necessary protection of the construction site, especially for the public transport area.

Necessary protection of walls and ceilings.

Options available in the event of accidents.

Safety in the working area If you work with the equipment, pay particular attention to the following points:  

Electrical utility lines or pipes in the working area.

Gas lines or water lines in the working area.

8

Safety instructions Commissioning the unit Observe the safety information and warnings on the unit as well as those in the operator's manual.

Never start equipment that needs maintenance or repairs.

Start the equipment in accordance with the operator's manual.

Stability Always make sure that the equipment is stable and cannot tip, roll, slide or fall during operation.

Operator's location in accordance with the intended purpose Do not leave the intended operator's location while you are operating the equipment.

The intended operator’s location is located behind the equipment's center pole.

Leaving the danger area Risk of injury from moving equipment or ejected materials.

Make sure that other people keep at least a minimum safety distance of 2 meters from the equipment.

Beware of moving parts Keep hands, feet and loose clothing away from moving or rotating equipment parts.

Serious risk of injury from being pulled in or crushed.

Switch off the unit Switch off the engine in the following situations:  

Before breaks.

When you are not using the equipment.

Position the equipment so that it cannot tip over, fall down or slide.

Storage location After operation, store the cooled equipment in a locked, clean, frost-protected and dry location that is inaccessible to children.

Do not use any starting aid sprays.

There is a fire hazard from highly flammable starting aid sprays.

Do not use any starting aid sprays.

Starting aid sprays are highly flammable and can cause misfires as well as engine damage.

9

Safety instructions Vibration exposure Vibration-induced long-term damage cannot be ruled out during intensive use of handoperated equipment.

Observe the respective statutory provisions and guidelines in order to keep the vibrations to a minimum.

You can find information about the vibration load of the equipment in the chapter Technical Data of the Operator's Manual.

2.6

Safety when operating vibratory plates Danger of tipping or falling over Operate the equipment so that there is no danger of tipping or falling over, e.g. on curbs, edges and slopes.

Load-bearing capacity of the soil Bear in mind that the load-bearing capacity of the soil to be compacted or the subgrade can be greatly reduced by the effects of vibration, e.g. near slopes.

Protect against crushing Control the equipment so that you protect yourself from being crushed between the equipment and an obstacle. Always look in the travel direction!

Notes about compacting on a slope Observe the following points when compacting on sloped surfaces (slopes, embankments):  



Always stay above the equipment on a slope.

Only approach gradients from below (a gradient that can be easily driven up, can also be driven down without any risk).

Do not stand in the direction of descent of the equipment. There is a serious risk of injury due to equipment slipping or tipping over.

Do not exceed the maximum permissible slanting position 



Do not exceed the maximum permissible slanting position (see chapter Technical Data of the operator's manual).

Only operate the equipment for a short time in the maximum permissible slanting position.

If you exceed the maximum permissible slanting position, this results in a failure of the engine lubrication and therefore inevitably causes causes damage to important engine parts.

10

Safety instructions Check effects of vibration Compaction work near buildings can cause damage to buildings. This is why you must always check the possible effects of vibrations on the surrounding buildings before the work is carried out.

In particular, you must include the following points in the assessment of the vibration impact: 





Oscillating behavior, sensitivity and resonance frequency of the surrounding buildings.

Distance of the building to the location vibration (= location of application of the equipment).

Composition of the soil.

It may be necessary to carry out measurements to determine the vibration velocity.

Also observe the relevant rules and regulations, in particular DIN 4150-3.

In addition, the subgrade must have sufficient load-bearing capacity to absorb the compaction energy. In cases of doubt, consult an expert (with a focus in soil mechanics) in the assessment.

Wacker Neuson assumes no liability for any damage to buildings.

2.7

Safety when operating combustion engines Check for damage At least once per shift, check the switched off engine for leaks and cracks in the fuel line, tank and fuel cap.

Do not operate the equipment if damage or defects are discernible.

Have damage and defects rectified immediately.

Dangers during operation In particular, there are dangers when operating and refueling combustion engines.

Read and follow all safety instructions. Otherwise, personal injury or property damage may occur!

You may not start the engine near spilled fuel or if you smell fuel – risk of explosion!  

Remove the equipment from such areas.

Remove the spilled fuel immediately!

Do not change the speed You may not change the pre-set engine speed, as this can lead to engine damage.

Preventing fires The use of open flames and smoking are prohibited in the immediate vicinity of the equipment.

Make sure that no trash, such as paper, dry leaves or dry grass, accumulates around the exhaust muffler. The trash could ignite.

11

Safety instructions Safety precautions when refueling Observe the following safety-related information when refueling:     

       



Do not refuel near open flames.

Do not smoke.

Switch off the engine and allow to cool before refueling.

Refuel in a well-ventilated vicinity.

Wear fuel-resistant protective gloves and, if there is a risk of splashing, safety glasses and protective clothing.

Do not inhale fuel vapors.

Avoid fuel contact with skin or eyes.

Use clean filling aids for refueling, such as a funnel.

Do not spill fuel, especially not on hot parts.

Immediately remove any spilled fuel.

Use the correct fuel type.

Do not mix fuel with other liquids.

Only fill the tank to the maximum mark. If there is no maximum mark, do not fill the tank completely.

Securely close the fuel cap after refueling.

Operation in closed spaces In closed or partially closed spaces, such as tunnels, ducts or deep trenches, you must provide sufficient aeration and ventilation, e.g. through a strong exhaust fan.

Risk of poisoning! Do not inhale exhaust fumes, as they contain poisonous carbon monoxide that can lead to unconsciousness or death.

Beware of hot parts Do not touch any hot parts, such as the engine block or exhaust muffler, during operation or shortly thereafter. These parts become very hot and can cause burns.

Clean engine Clean the cooled engine of dirt accumulation.

Do not use any fuels or solvents to do this. Explosion hazard!

Information about the EPA engine Caution The equipment is outfitted with an EPA-certified engine.

Changing the speed impacts the EPA-certification and the emissions. Settings for this engine may only be changed by a professional.

For more information, contact the nearest engine or Wacker Neuson contact partner.

Health hazard from exhaust fumes Warning The exhaust fumes of this engine contain chemicals, which the state of California knows can cause cancer, birth defects or other reproductive damage.

12

Safety instructions

2.8

Safety when operating hydraulic work tools Hydraulic oil Hydraulic oil can cause damage to health.

Wear safety glasses and protective gloves when handling hydraulic oil.

Avoid direct skin contact with hydraulic oil. Remove hydraulic oil from your skin immediately with soap and water.

Make sure that no hydraulic oil gets into your eyes or body. Seek immediate medical attention if hydraulic oil gets into your eyes or body.

Do not eat and drink while handling hydraulic oil.

Ensure extreme cleanliness. Contaminants in the hydraulic oil from dirt or water can lead to premature wear or failure of the equipment Dispose of drained and spilled hydraulic oil according to the applicable provisions for pollution control.

2.9

Maintenance Maintenance work Care and maintenance work may only be carried out insofar as it is described in this operator's manual. All other work must be taken over by the Wacker Neuson contact partner.

You can find more information in the chapter Maintenance.

Switch off the engine You must switch off the engine and allow it to cool down prior to care and maintenance work.

You must remove the spark plug cap for gasoline engines.

Disconnect the battery For equipment with an electric starter, you must disconnect the battery before working on electrical components.

Only use Wacker Neuson batteries Only replace defective batteries with Wacker Neuson batteries. See chapter Technical Data.

Only the Wacker Neuson battery is vibration proof and is therefore suitable for the high vibration exposure.

13

Safety instructions Working on the battery When working on the battery, it is necessary to observe the following protective measures:  

   

Flames, sparks and smoking are prohibited when handling batteries.

Batteries contain corrosive acid. Wear acid-proof protective gloves and safety glasses when handling batteries.

Avoid short-circuit from incorrect connection or from bridging with tools.

When disconnecting the battery, the negative terminal is to be disconnected first.

When connecting the battery, the positive terminal is to be connected first.

Re-fasten the terminal covers after connecting the battery.

Installing the protective devices If a disassembly of the protective devices was required, then these must be re-installed and checked immediately after completing the maintenance work.

Always tighten loosened screwed connections and adhere to prescribed torque settings in the process.

Safe handling of fuel, lubricants and coolants When handling fuel, lubricants and coolants, such as fuels, oils, grease, coolants, etc., observe the following points:    





Always wear personal protection equipment.

Avoid skin or eye contact with fuel, lubricants and coolants.

Do not inhale or ingest fuel, lubricants and coolants.

Especially avoid contact with hot fuel, lubricants and coolants. There is a risk of burning and scalding.

Dispose of replaced or spilled fuel, lubricants and coolants according to the applicable provisions for pollution control.

If fuel, lubricants and coolants escape from the equipment, do not operate the equipment any longer and have it repaired immediately by the Wacker Neuson contact partner.

14

Introduction

3

Introduction 3.1

General Information Observe operator's manual This manual only contains information for repair. Also, observe the information in the operator's manual for the unit.

Knowledge of the safety regulations and safety symbols described in the operating instructions and the appropriate personal protective equipment is required. In addition, the unit identification, as well as the correct handling of the device must be derived from the operating instructions.

You will also find all of the technical data about your device in the operator's manual.

Qualification of the repair personnel Only trained personnel may repair the equipment. In addition, the following conditions apply:    



They are physically and mentally suitable.

They are trained in the repair of the equipment.

They are familiar with the necessary safety measures for safe repair.

They are authorized to repair equipment and systems independently according to the standards of safety engineering.

They are appointed by the contractor or operator for the independent repair of the equipment.

Application and description depth The complete disassembly and subsequent assembly of the unit is described in logical order in these instructions. At the beginning of each subsection, a complementary component list is usually arranged. The user can therefore enter into the repair process at any desired location.

Individual components such as the stator or motor rotor of the electric motor will not be disassembled. Wacker Neuson disclaims all liability to persons and property for any further work that is not described here.

Location The designations front, back, inside, outside, right or left always refer to the operator's line of view from the working position.

15

Introduction

16

Technical data

4

Technical data Designation

Unit

DPU 6555H

DPU 6555He

DPU 6555Heap

DPU 6555Hec

5000610355

5000610354

5000610356

5100004060

464

481

510

483

28/20

28/20

28/20

28/20

69

69

69

69

Fuchs Titan 10 W 40

Fuchs Titan 10 W 40

Fuchs Titan 10 W 40

Fuchs Titan 10 W 40

0.8

0.8

0.8

0.8

2800

2800

2800

2800

Fuchs Titan 10 W 40

Fuchs Titan 10 W 40

Fuchs Titan 10 W 40

Fuchs Titan 10 W 40

1.9

1.9

1.9

1.9

Type

1D81S

1D81S

1D81S

1D81S

Fuel

Diesel

Diesel

Diesel

Diesel

Fuchs Renolin MR 520

Fuchs Renolin MR 520

Fuchs Renolin MR 520

Fuchs Renolin MR 520

0.4

0.4

0.4

0.4

Item number Weight

kg

Advance travel /  reverse travel

m/min

Exciter: Vibrations

1/s

Oil Oil quantity

L

Engine: RPM / speed

1/s

Oil Oil quantity

L

Hydraulics: Oil

Oil quantity

L

17

Special tools

5

Special tools

5000058929

5000047380

5000048585

5000205327 5000095512

5000094654

5000206626 5000206600

5000206627

Eye bolt M16 Open end wrench SW27

Material no.

Designation

5000004738

Press-fit piece

5000206600

Stamp

500048585

Tube

5000206626

Press-fit pipe

500058929

Bolt

5000206627

Press-fit pipe

500094654

Strap wrench

Eye bolt M16 (trade product)

500095512

Tube

Open-end wrench SW27 machined

5000205327

Safety device

Material no.

18

Designation

Disassembly / assembly of protective frame, covers and battery

6

Disassembly / assembly of protective frame, covers and battery 6.1

Disassembly of the protective frame, covers and battery.

Pos

Designation

Pos

Designation

1

Protective frame

10

Battery protection supports

2

Vibratory plate

11

Protective hood

3

Fitting

12

Upper mass

4

Frame

13

Seal

5

Battery cover, coupled

14

Belt guard

6

Seal

15

Protective side plate

7

Battery guard

8

Operating elements

9

Battery

19

Disassembly / assembly of protective frame, covers and battery

1. Loosen the 3 hexagon socket head cap screws with an Allen wrench SW10 and disassemble the belt guard (14).

2. Loosen the 4 hexagon socket head cap screws with SW8 and disassemble the protective side plate (15).

3. Loosen the 3 hexagon socket head cap screws with SW10 and disassemble the side cap (11).

20

Disassembly / assembly of protective frame, covers and battery

CAUTION The three covers (11, 14, 15) can fall down and cause injuries.  After disassembly, place each cover on its side before you begin with the disassembly of the next cover.

4. Loosen the 4 hexagon socket head cap screws with SW5 and remove the battery cover (5).

21

Disassembly / assembly of protective frame, covers and battery 5. Disassemble the protective frame (1).  Loosen both of the hexagon socket head cap screws with SW10.



Then loosen both of the hexagon socket head cap screws in the front area. The protective frame (1) can now be removed.

22

Disassembly / assembly of protective frame, covers and battery

CAUTION The frame is bulky and heavy.  Lift the protective frame (1) from the vibratory plate with a crane.

6. Remove the battery (9):  Loosen the overflow hose for the acid, to the right on the battery (9).  Loosen both poles of the battery (9) with SW13, beginning with the negative pole on the right side of the battery. You must open the red cover cap for the positive pole cable.  Then you can lift the battery (9) out of the vibratory plate.

Note:

You are also lifting out the protectors (10) with the battery (9)!

CAUTION When lifting out the battery (9) from the vibratory plate, battery acid can run out of the side overflow opening.  Always keep the battery (9) horizontal so that no acid runs out. Wear safety glasses, protective gloves and tight-fitting work clothes.

23

Disassembly / assembly of protective frame, covers and battery

6.2

Assembly of protective frame, covers and battery

1. Check and install battery protection supports (10)  Make sure that both of the battery protection supports (10) are completely fitted with rubber shockmounts.  The rubber shockmounts may not be damaged. They can be easily removed and replaced by hand.  The rubber shockmounts can be ordered as a spare part.

Note:

The service life of the battery (9) is greatly dependent on the condition of the battery protection supports (10), since they absorb a part of the vibrations!

2. Make sure that the acid overflow hose is properly attached.

3. Attach both battery protection supports (10) to the battery (9).

4. Make sure that both battery protection supports (10) are properly attached before you lift the battery (9) into the vibratory plate.

24

Disassembly / assembly of protective frame, covers and battery

CAUTION When installing the battery (9) in the vibratory plate, battery acid can run out of the side overflow opening.  Always keep the battery (9) horizontal so that no acid runs out. Wear safety glasses, protective gloves and tight-fitting work clothes.

5. The battery (9) can be attached, even if the battery box is not attached. It is important that both poles face the engine and the acid overflow hose is attached in its bore in the upper mass (12).

6. This image again shows the attached  battery (9). You see:

• The attached seal on the upper mass (12).

• In the front area of both battery protection supports (10).

• Right of the acid overflow hose in its bore in the upper mass (12).

• The attached positive pole cable.

7. Then connect both poles. Begin with the positive pole. Please tighten the nuts handtight with an open-end wrench SW13. Then attach the red protection cap over the positive pole.

8. The negative pole is then attached without a protection cap.

25

Disassembly / assembly of protective frame, covers and battery 9. Make sure that the seal (6) is properly and completely attached and seal the battery guard (7) with the cover (5). Attach the 4 hexagon socket head cap screws with the SW5 Allen wrench. The torque is 10 N·m.

10. Attach the protective frame:

• Lift the protective frame (1) onto the vibratory plate with a suitable hoist.

• Screw in the 4 hexagon socket head cap screws by hand with the conical spring washers for bolted connections. The curvature of the conical spring washers for bolted connections faces upwards.

• As shown in the image, then begin tightening the hexagon socket head cap screws from the front with SW10 and 120 N·m.

11. Then go to the back and tighten both hexagon socket head cap screws to 120 N·m as well.

26

Disassembly / assembly of protective frame, covers and battery

Note:

The position of the curvature of the conical spring washers for bolted connections is very important. If it is inverted, the torque is then lower than the required 120 N·m! Make sure that the curvature faces upwards and can be pushed downward when tightening.

12. Attach the protective hood (11) to the vibratory plate with the 3 retaining screws and Allen wrench SW10. The torque is 86 N·m.

13. The belt guard (14) is attached as shown above. The 3 retaining screws are also tightened to 86 N·m.

14. Attach the protective side plate (15) with  4 hexagon socket head cap screws and SW6.

The torque is 25 N·m.

27

Disassembly / assembly of wiring harness and operator's controls

7

Disassembly / assembly of wiring harness and operator's controls 7.1

Disassembly of the wiring harness

Pos

Designation

Pos

1

Battery guard

11

Wiring harness

2

Seal

12

Plus pole cable on the starter side

3

Plate

13

Washer

4

Retaining screw

14

Hexagon socket head cap screw

5

Push button

15

Plus pole cable on the battery side

6

Ignition starter switch

16

Earth cable

7

LED lamp

17

Hexagonal bolt

8

Acoustic signal

18

Seal

9

Cable binder

19

Key

Application

20

Edge protection

10

28

Designation

Disassembly / assembly of wiring harness and operator's controls

Note:

The following describes the disassembly of the wiring harness (11), the plus pole cable (15) and the battery guard (1). It is not always necessary to dismantle everything in order to find and eliminate errors.

1. To disassemble the wiring harness, we first recommend:

• disassembling the cover • disassembling the battery with its protection support. Both are described in the chapter Disassembly of Protective Frames and Covers.

2. The wiring harness (11) connects the operator's controls with the battery and engine. In order to dismantle this, you must cut the connections at various places.

3. Cut the 4 cable binders with a wire cutter.

4. Pull both cables on the acoustic signal (8) and then cut both of the cable bridges.

29

Disassembly / assembly of wiring harness and operator's controls 5. Open the retaining screws (4) with the SW10.

6. Then carefully lift up the cover (3). Then disconnect the master connector from the ignition starter switch (6), both cables on the push button (5) as well as both connecting plugs of the LED lamp (7). The white plug of the LED lamp (7) is permanently embedded.

Only the two black plugs are separated.

7. The wiring harness (11) is then free on this side and can be pulled out through the opening in the battery guard (1). If you want to reuse it, we recommend doing this carefully.

8. The wiring harness (11) is connected with the plus pole cable (15). Open the screw with SW10 and cut both utility lines. The wiring harness (11) is then still connected with the engine via a wide plug. The utility line goes through the battery guard (1) with the plus pole cable.

9. In order to further dismantle the plus pole cable (15) and the wiring harness (11), the battery guard (1) must be dismantled from the upper mass.

30

Disassembly / assembly of wiring harness and operator's controls 10. Loosen the 4 hexagon socket head cap screws (14) on the battery guard (1) with the SW6 and dismantle with the washers (13) from the upper mass.

11. Loosen both hexagonal bolts with the openend wrench SW8 and then pull the master connector apart. The wiring harness (11) is now completely dismantled and can be tested and/or replaced.

12. Loosen the locking nuts of the plus pole cable (15) with the SW13 and remove this from the starter.

31

Disassembly / assembly of wiring harness and operator's controls

7.2

Disassembly of the operator's controls

1. Loosen the 4 retaining screws (4) with the open-end wrench SW10 and remove them.

2. Then carefully lift up the plate (3). There is a seal (2) here that may stick to the plate (3).

3. All 3 operator's controls have a part above the plate (3) and a connector below it. All three operator's controls are dismantled in the following.

4. Pull the lower black cable part by hand from the ignition starter switch (6).

5. Both of the crimp connectors are removed from the push button (5) by hand in just the same way.

6. Cut both of the cables of the LED lamp (7) at the crimp connectors.

32

Disassembly / assembly of wiring harness and operator's controls 7. Loosen the locking nut of the LED lamp (7) with the SW17. You can now disassemble the LED lamp (7). It cannot be disassembled any further.

8. Loosen the locking nut of the push button (5) with the SW27. You can then disassemble the push button (5).

9. Loosen the locking nuts of the ignition starter switch (6) with water pump pliers. You can remove the ignition starter switch (6) downwards.

33

Disassembly / assembly of wiring harness and operator's controls

7.3

Wiring harness assembly Note:

The wiring harness (11) is a safety component. It may not be repaired or changed. If must be completely replaced if it is defective.

1. Observe the following if you have dismantled the battery guard (1). First adhere the seal to the upper mass as can be seen in the picture.

You can also then assemble the earth cable (16) to the left next to the battery.

2. The battery is on the image by chance. It can also be assembled later.

3. First attach both cables in the battery guard (1).

4. Enclose the plus pole cable (12) and the wiring harness (11) with the tube (10).

5. Then place all 3 parts together in the recess provided in the battery guard (1) for this purpose.

10

12

11

34

Disassembly / assembly of wiring harness and operator's controls 6. Then attach the acoustic signal (8) in the battery guard (1). Please tighten the nuts hand-tight with the SW38. It is synthetic material that can break easily. Both connectors must show in the battery guard (1).

They will be connected to the wiring harness (11) later.

7. Place the battery guard (1) on the vibratory plate and fasten this with the 4 hexagon socket head cap screws (SW6, 14) plus the washer (13). The torque is 25 N·m.

8. The wiring harness (11) is fastened to the battery guard (1) with the 4 cable binders (9).

The bores are present and therefore provide the position of the cable binders (9) and the wiring harness (11).

35

Disassembly / assembly of wiring harness and operator's controls 9. Attach the edge protection (20).

10. Attach the wiring harness in the opening of the battery guard (1).

11. Connect the acoustic signal (8). In the process, the pink cable of the wiring harness (11) must be connected to the positive and the red-yellow cable must be connected to the negative.

12. Install the remaining cables in the opening.

They are then individually mounted when assembling the operator's controls.

13. Connect the socket plug of the wiring harness (1) with its counterpart from the engine and screw both of them together to the engine.

Tighten both of the hexagonal bolts hand-tight with the SW8.

14. The plus pole cable (12) is connected with the starter. Tighten the locking nuts with the SW13. After assembly, attach the protection cap using the nuts.

36

Disassembly / assembly of wiring harness and operator's controls

7.4

Operator's controls assembly

1. Attach the synthetic material ring on the ignition starter switch (6). Both noses of the synthetic material ring are located on one side in the ignition starter switch and on the other side in the plate (3).

2. The plate (3) has a seal.

3. The dust guard cap and retaining ring are attached from the top. Then tighten the retaining ring hand-tight.

4. Attach the push button (5) from above and the locking nut from below.

37

Disassembly / assembly of wiring harness and operator's controls 5. Tighten the locking nuts hand-tight with the SW27.

6. Install the LED lamp (7) in the plate (1) from above.

7. Tighten the locking nuts hand-tight with the SW17.

8. Pull the cable out of the wiring harness (11) somewhat so as to be able to recognize the correct cable.

38

Disassembly / assembly of wiring harness and operator's controls 9. The LED lamp (7) has a red cable that is connected to the pink cables. The black cable is connected with the red-yellow cables.

10. The push button (5) is connected to the black cable via a crimp connector. A clear clicking sound should be heard. Secondly, the pink dual cable with the protective casing is connected to the push button (5).

11. The ignition starter switch (6) is inserted into the black master connector. Its shape makes it impossible to invert.

12. After you have installed all of the operator's controls, turn the ignition starter switch (6) around. The LED lamp (7) must light up and the acoustic signal (8) must sound. Briefly press on the push button (5). The engine should start up briefly.

13. Make sure that the seal (2) is present under the plate (3) and close the cable duct. Attach the 4 retaining screws (4) with the SW10. The torque is 10 N·m.

39

The wiring harness

8

The wiring harness

40

The wiring harness

A

K J

B RT/GE

1

C

50 30

SW

GE

L

GE

RT

RT

BL

30 RT

SW

WS

GE/WS

GE/WS

1

SW

15

E

GR

D

G G

H

F

Wiring diagram legend A B C D E F G H J K L

Acoustic signal LED lamp Push button Ignition starter switch Fuse Battery Coil assembly / generator Voltage regulator Diesel engine starter Connecting plug Positive pole cable

41

The wiring harness

The wiring harness is a safety component. It may not be repaired. If it is defective, it must be replaced entirely.

In the event of problems, you can check the passage of current with a multimeter and check the functions according to the wiring diagram. Before replacing the wiring harness, we recommend cleaning the connections and checking for the proper fit of the connections.

42

Disassembly of the clutch and replacing the V-belt

9

Disassembly of the clutch and replacing the V-belt 1

2 3 5

4

6

7 8 10 9 11

20

12 19

11

13

18 17

14

16

Pos.

15

Designation 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Hexagon socket head cap screw Mushroom washer Disc spring Seal V-belt pulley DU-bushing Pin Clamping sleeve Hexagon socket head cap screw Clutch drum Deep groove ball bearing Retaining ring Centrifugal clutch Flange

43

15 16 17 18 19 20

V-belt Hexagon socket head cap screw Retaining ring Washer Retaining ring Bushing

Disassembly of the clutch and replacing the V-belt

1. The belt guard must first be removed. See chapter "6.1 Disassembling the protective frame, covers and battery."

2. Turn the clutch by hand and find the position in which the V-belt is the least tensioned.

3. Open the hexagon socket head cap screw (pos. 1) with the Allen wrench SW 6. The clutch is held in place with a strap wrench (5000094654).

4. Completely unscrew the hexagon socket head cap screw (pos. 1). When unscrewing, the 2 disc springs (pos. 3) remove tension. The original screw is long enough so that the disc springs remove tension before the screw exits the thread.

5. The hexagon socket head cap screw (pos. 1), mushroom washer (pos. 2), disc springs (pos. 3) and seal (pos. 4) can be removed.

6. If the V-belt pulley (pos. 5) and a pin (pos. 7) are not marked, mark them so that the clutch parts are re-installed in the same position.

Marking on the clutch and pin

44

Disassembly of the clutch and replacing the V-belt 7. Remove the V-belt pulley (pos. 5).

8. The V-belt (pos. 15) is still located in the V-belt pulley of the exciter in the base plate. Push the V-belt (pos. 15) downward, pull it towards you and lift it out.

9. All of the steps listed until now are required when replacing the V-belt. For the Vbelt installation, see chapter 7.4 "Assembly of the clutch and installation of the Vbelt," from point 15.

10. Remove the retaining ring (pos. 19) with the pliers.

45

Disassembly of the clutch and replacing the V-belt

Locking ring

Washer

11. The washer (pos. 18) can be easily removed with the hexagon socket head cap screw (pos. 1). It is now sitting loosely in the clutch.

12. Remove the retaining ring (pos. 17) with the pliers. Loosen the hexagon socket head cap screw (pos. 9) and unscrew.

Hexagon socket head cap screw

13. The clutch is removed from the engine shaft with a pull-off disc. To do this, you need a hexagon socket head cap screw M16 that is at least 90 mm long (5000011382 screw DIN 931 M16x 90). Screw this into the existing thread and loosen with the corresponding key. The clutch (pos. 10-13) is sitting on a cone and releases suddenly.

46

Disassembly of the clutch and replacing the V-belt

14. Loosen the 4 hexagon socket head cap screws (pos. 16) on the flywheel of the engine and remove the flange (pos. 14). Lock the flywheel with a screw or bolt.

15. A hand press can be used to separate the clutch drum (pos. 10) from the centrifugal clutch (pos. 13).

47

Disassembly of the clutch and replacing the V-belt

16. The deep groove ball bearing (pos. 11) in the clutch drum (pos. 10) is removed as follows. Remove both retaining rings (pos. 12) with the pliers. The deep groove ball bearing (pos. 11) is sitting loosely in the clutch drum (pos. 10). With older machines, this can be pressed out with a hand press and slight pressure.

17. Remove the second deep groove ball bearing (pos. 11) from the centrifugal clutch (pos. 13) with the two-arm extractor.

18. The pins (pos. 7) can be pressed out of the clutch drum (pos. 10) by using a drift pin and a hand press.

19. The DU bushings (pos. 6) are pressed out of the V-belt pulley (pos. 5) by using a jig (bolt 5000058929) and a hand press.

20. The bushing (pos. 20) is also pressed out of the V-belt pulley using the hand press with a jig (stamp 5000206600) and pad.

Jig Clutch

Bushing Pad

21. The drawing below shows the clutch as a whole.

48

Disassembly of the clutch and replacing the V-belt

49

Assembly of the clutch und installation of the V-belt

10 Assembly of the clutch und installation of the V-belt 1. After replacing the defective parts, the assembly takes place in the reverse chronological order.

2. The wear parts are to be replaced if wear tracks are visible, roundness is lost or material wear is evident. The automatic system of the centrifugal clutch only works if the wear parts still have sufficient material. Wear parts are the pos. 3, 6, 7, 15 and 20.

3. Re-tensioning the V-belt is not required due to the automatic system. Problems in the drive system of the exciter indicate worn parts. Also see the chapter "Maintenance" in the operator's manual.

Note:

Do not oil or grease any clutch parts! This leads to destruction of the graphite parts of the bushings.

4. Press the pin or pins (pos. 7) into the clutch drum (pos. 10) using a hand press.

Pins (pos. 7) are flush with the rear side.

Note:

Always only press in bearings on the outer ring! Use corresponding jig.

5. Press the bushing (pos. 20) into the V-belt pulley (pos. 5) with a hand press and jig (stamp 5000206600). Also press the DU-bushings (pos. 6) into the V-belt pulley (pos. 5) with a jig (bolt 5000058929).

50

Assembly of the clutch und installation of the V-belt

Jig DU-bushing V-belt pulley

6. Install the deep groove ball bearing (pos. 11) into the clutch drum (pos. 10) by hand.

For older parts, the bearing may need to be installed with light pressure.

7. Press the second deep groove ball bearing (pos. 11) onto the shaft of the centrifugal clutch using a hand press. Only apply pressure to the outer ring.

8. Install both retaining rings (pos. 12) with the pliers.

9. Install the centrifugal clutch (pos. 13) with a hand pres. It must be possible for the centrifugal clutch (pos. 13) to easily rotate in the clutch drum (pos. 10) after installation. The clutch carriers have an equal clearance to the clutch drum (pos.

10) all around.

10. Turn the clutch drum (pos. 10) and install the retaining ring (pos. 17) with pliers.

Press in the clamping sleeve (pos. 8). Always replace both, even if just one is worn or defective.

11. Attach the flange (pos. 14) to the flywheel of the engine with 4 hexagon socket head cap screws (pos. 16). Lock the flywheel with a screw or bolt when tightening the hexagon socket head cap screws (pos. 16). The torque is 25 N·m. Tighten the screws crosswise.

51

Assembly of the clutch und installation of the V-belt

12. Attach the clutch (pos. 10-13) to the flange (pos. 14). The clutch (pos. 10-13) is sitting on the cone of the flange (pos. 14) and is locked with a hexagon socket head cap screw (pos. 9). Clean both conical flanges of grease before the installation.

Clean conical surfaces of grease

52

Assembly of the clutch und installation of the V-belt

13. During installation, the flywheel of the engine must be locked. Lock the flywheel with a bolt or a screw. Screw in the hexagon socket head cap screw (pos. 9). The torque is 86 N·m’.

14. Insert the washer (pos. 18) into the clutch drum (pos. 10). Install the retaining ring (pos. 19) with the pliers.

15. Install the V-belt (pos. 15). First install the V-belt (pos. 15) into the V-belt pulley of the exciter in the base plate. Then apply the V-belt (pos. 15) to the clutch drum (pos. 10).

16. Push the V-belt pulley (pos. 5) onto the clutch drum (pos. 10). Keep the V-belt (pos.

15) under tension and make sure that it remains in the V-belt pulley of the exciter.

17. When removing the V-belt pulley (pos. 5), the position was marked on the clutch drum (pos. 10). Observe this marking and put both parts back together in the same position.

53

Assembly of the clutch und installation of the V-belt

Note:

The V-belt is a wear part, which must be examined regularly and replaced if necessary. If the V-belt side should fall below the dimension of 15.5 mm, the V-belt is to be replaced.

18. Insert the seal (pos. 4) and disc springs (pos. 3) in the V-belt pulley (pos. 5). It must be ensured that the parts are in the exact recess provided for that purpose.

Note:

The seal (pos. 4) as well as both disc springs  (pos. 3) are also wear parts. In order to ensure the flawless and automatic operation of the clutch, these parts must be examined regularly and replaced if necessary.

19. As you can see in the image above, the disc springs (pos.3 ) do not lie above one another, but rather "in a gap."

20. The parts are affixed with a mushroom washer (pos. 2) and hexagon socket head cap screw (pos. 1). Tighten the hexagon socket head cap screw to 49 N·m with a torque wrench. Lock the clutch with a strap wrench. Perform a functional check by hand.

21. Re-attach the belt guard. See chapter "6.2 Assembling the protective frame, covers and battery."

54

Disassembly of the Bowden cable

11 Disassembly of the Bowden cable 1 2 3 4 5

7

6

8

9 13 12

10

14 11 Pos.

Designation 1 2 3 4 5 6 7 8 9 10 11

Pipe clamp Washer Hexagon socket head cap screw Actuating device / control lever Ball-shaped button Hexagon socket head cap screw Control (Bowden cable) Angle joint Lever Angle joint Hexagonal nut

12 13 14

55

Hexagon socket head cap screw Hexagonal nut Pipe feedthrough

Disassembly of the Bowden cable

1. Loosen and remove the hexagon socket head cap screw (pos. 12) from the lower angle joint (pos. 10) with the Allen wrench SW5.

Loosen the screw

2. Separate upper angle joint (pos. 8) with an open-end wrench and ring wrench  SW8 and SW10. Remove the hexagonal nut (pos. 13). The hexagonal nut  (pos. 13) is a locking nut. Remove the lever (pos. 9).

3. Loosen the adjusting nut with the open-end wrench SW17 and remove the control

56

Disassembly of the Bowden cable (pos. 7, Bowden cable) from the angle plate.

4. Loosen and unscrew the adjusting nut on the angle joint (pos. 8) with the open-end wrench SW10 and pliers. Unscrew and remove the angle joint (pos. 8).

Adjusting nuts

Dust cap

5. Unscrew and remove the black dust cap by hand. Unscrew both adjusting nuts from the control (pos. 7, Bowden cable). The control (pos. 7, Bowden cable) is now free from all attachments.

6. Loosen 3 pipe clamps (pos.1) with an Allen wrench SW5 and remove from the center pole with the hexagon socket head cap screw (pos. 3) and washer (pos. 2).

Slightly bend the pipe clamps (pos.1 ) if necessary.

57

Disassembly of the Bowden cable

7. Loosen the 2 hexagon socket head cap screws (pos. 6) with the Allen wrench SW5 and loosen the actuating device (pos. 4) from the center pole.

Note:

Actuating device (pos. 4) may fall down!

8. Loosen the pipe feedthrough (pos. 14), 2x on the upper mass, with a screwdriver and remove from the control (pos. 7, Bowden cable).

9. Knot the tear-resistant cord (as an auxiliary assembly tool when installing a new Bowden cable) about 1 meter long on the control thread (pos. 7, Bowden cable), possibly secure with electric tape. Clean the control (pos. 7, Bowden cable).

58

Disassembly of the Bowden cable

10. Pull the control (pos. 7, Bowden cable) out of the upper mass. It must be possible to remove the cord from the openings on both sides of the upper mass.

59

Assembly of the Bowden cable

12 Assembly of the Bowden cable 1. After replacing the defective control (pos. 7, Bowden cable), the installation takes place in the reverse chronological order.

2. Pull the pipe feedthrough (pos. 14) on the center pole side to the control  (pos. 7, Bowden cable).

3. Attach the cord end on the center pole side to the thread of the control  (pos. 7, Bowden cable) in order to bring the control (pos. 7, Bowden cable) with it through the upper mass. Slightly oil the control (pos. 7, Bowden cable).

4. From the center pole side with the thread forward, carefully introduce the new control (pos. 7, Bowden cable) into the upper mass. The cord makes it easier  to thread into the upper mass.

5. Pull the control (pos. 7, Bowden cable) through the upper mass so far that the thread extends about 35 mm over the edge of the upper mass. Remove the cord.

Important: In order to be able to install and adjust the control (pos. 7, Bowden cable) properly in the following steps, the ball-shaped button (pos. 5, throttle lever) must be on stop on the center pole!

Clearance approx. 35 mm

6. Pull the pipe feedthrough (pos. 14) on the engine side. Slightly oiling the upper mass prior to installation facilitates the installation.

7. Screw on both adjusting nuts. Screw in the rear nut to  about 50 mm.

60

Assembly of the Bowden cable

8. Slide on the dust cap until the stop. Screw in the front jam nut with clearance onto the rear jam nut.

9. Screw on the angle joint (pos. 8) according to the image. It facilitates the installation.

10. Install the control (pos. 7, Bowden cable) into the elbow. The lower adjusting nut fits on the console. The upper adjusting nut is tightened.

Upper nut is tightened.

Lower nut fits on the console.

61

Assembly of the Bowden cable

Note:

The control (pos. 7, Bowden cable) should not rest on the upper mass and should not be adjacent to the oil drain plug of the engine. If it does, check the settings. Do not clamp the control cable  next to the control (pos. 7, Bowden cable)!

11. Put lever (pos. 9) in the angle joint (pos. 8) and screw on the new locking nut (pos.

13). Tighten with ring wrench and open-end wrench SW8 and SW10.

12. Tighten nut on angle joint with open-end wrench SW10.

13. Connect the lever (pos. 9) to the bottom angle joint (pos. 10) with the hexagon socket head cap screw and Allen screw (pos. 12) SW5. The torque is 10 N·m.

14. The clearance of the lever (pos. 9) to the diesel engine (adjusting screws) should be about 10 mm.

15. Hold the actuating device (pos. 4) to the center pole and screw on with 2 hexagon socket head cap screws (pos. 6) with the Allen wrench SW5. The torque is 10 N·m.

16. Screw on the 3 pipe clamps (pos. 1) with the hexagon socket head cap screw (pos.

3) and washer (pos. 2). The torque is 10 N·m.

62

Assembly of the Bowden cable 17. Tighten the middle adjusting nut in the actuating device (pos. 4) with a ring wrench SW10 so that the position of the ball-shaped button (pos. 5) does not change when adjusting the throttle.

63

Diesel engine disassembly

13 Diesel engine disassembly 1

2

3

15

14

2 4

13 12

11

5 6 10 9

7 8

Pos.

Designation 1 2 3 4 5 6 7

Angle Washer Hexagonal bolt Hexagon socket head cap screw Hexagon socket head cap screw Lock washer Button head screw

8

Lever

9 10 11 12 13 14 15

64

Washer Hexagonal nut Hexagon socket head cap screw Washer Console Seal Diesel engine

Diesel engine disassembly

1. First remove the side covers and electrical switches. See chapter "6.1 Disassembling the protective frame, cover and battery." Carry out all steps.

2. Completely remove the clutch. See Chapter "9. Disassembly of the clutch and replacing the V-belt." Carry out all steps.

3. Remove the Bowden cable. See Chapter "11. Disassembly of the Bowden cable."

With an intact control (Bowden cable), only remove the control from the engine.  A replacement is not necessary 4. Lift the battery from the battery box. Note the ventilation hose.

5. Loosen and remove 2 hexagon socket head cap screws (pos. 11) with washer (pos.

12). Remove the console (pos. 13).

Loosen both screws.

6. Loosen the hexagonal nut (pos. 10) with washer (pos. 9) with the open-end wrench SW10 and remove with button head screw (pos. 7). Remove lever (pos. 8) from the shaft.

65

Diesel engine disassembly

Loosen the screw Remove lever

7. Loosen and remove the 2 hexagon socket head cap screws (pos. 3) and washer (pos.

2) with the open-end wrench SW8. Loosen the hexagon socket head cap screw (pos.

4) with washer (pos. 2) with the Allen wrench SW5 and remove the console (pos. 1).

8. Loosen the 3 hexagon socket head cap screws (pos. 5) with the SW10 and unscrew to 75%. Keep the cable to the side.

9. Due to the shaft, the hexagon socket head cap screw (pos. 5) under the throttle control is not directly accessible. 

66

Diesel engine disassembly

10. This hexagon socket head cap screw (pos. 5) can either be opened with a ball joint socket screw key or a truncated Allen wrench SW10.

11. In order to remove the hexagon socket head cap screw from the thread, the engine must be tilted to the side (which is why the 3 other hexagon socket head cap screws are to be left some turns in the thread).

Tilt the engine forward.

Note:

There is a danger of being crushed between the shaft of the throttle control and the hexagon socket head cap screw (pos. 5).

12. Remove the hexagon socket head cap screw (pos. 11) and washer (pos. 12). Lift the engine from the upper mass.

13. In the disassembled state, the seal (pos. 14) can be removed from the engine.

Simply tear the defective seal from the diesel engine (pos. 15). Remove the seal residue.

14. The further disassembly of the diesel engine is to be carried out according to the engine manufacturer's manual.

67

Diesel engine assembly

14 Diesel engine assembly 1. After replacing the defective parts on the diesel engine (pos. 15), affix the new seal (pos. 14) if necessary. The surface must be free of residue and grease. Pull off the foil on the back of the seal (pos. 14) and adhere it to the diesel engine (pos. 15)

.

2. If a new diesel engine is to be attached (pos. 15), the positions 7-10 (lever with button head screw) must be removed. Otherwise the diesel engine (pos. 15) cannot be attached to the upper mass. Loosen the hexagonal nut (pos. 10) with washer (pos. 9) with the open-end wrench SW10 and remove with button head screw (pos.

7). Remove lever (pos. 8) from the shaft.

3. Lift the engine onto the upper mass with the lifting bar.  Screw in 3 hexagon socket head cap screws (pos. 5) with new lock washers  (pos. 6) a few turns.

Note:

The 3 hexagon socket head cap screws (pos. 5) must be screwed into the thread against the pressure of the rubber seal (pos. 14).

4. In order to be able to screw in the 4 hexagon socket head cap screws (pos. 5) with a new lock washer (pos. 6), the diesel engine (pos. 15) must be slightly tilted to the side.

Note:

There is a danger of being crushed between the shaft of the throttle control and the hexagon socket head cap screw (pos. 5)

68

Diesel engine assembly

.

5. Tighten the hexagon socket head cap screws (pos. 5) with an Allen wrench SW10.

The torque is 86 N·m.

6. The 4th hexagon socket head cap screw (pos. 5) can either be tightened with a ball joint socket screw key or a truncated Allen wrench SW10. The torque is 86 N·m.

7. Attach the console (pos. 1) with 2 hexagonal bolts (pos. 3) and a washer (pos. 2).

Tighten with an open-end wrench SW8. The torque is 49 N·m.  Screw in the hexagon socket head cap screw (pos. 4) with washer (pos. 2) and tighten with an Allen wrench SW5. The torque is 10 N·m.

8. Insert the battery and introduce the ventilation hose in the opening.

9. Screw in the console (pos. 13) with 2 hexagon socket head cap screws (pos. 11), washer (pos. 12) and an Allen wrench SW5. The torque is 10 N·m.

69

Diesel engine assembly

Tip:

When tightening the console (pos. 13), press to the right and utilize the play in the bores. The clearance of the console (pos. 13) - diesel engine (pos. 15) should be about 10 mm.

Push the console to tthe right and tighten the screw Clearance approx. 10mm 10. Push the gas disc on the diesel engine to the right until the stop (see next image).

11. Place the lever (pos. 8) on the shaft.

12. Loosely screw in the button head screw (pos. 7) with washer (pos. 9) with hexagonal nut (pos. 10).

Push the gas disc to the right

13. Install the Bowden cable, see chapter 7.6.

Note:

The gas regulation lever on the center pole must be in the stop position.

14. Connect lever (pos. 8) with the bottom angle joint. Tighten the jam nut with the open-end wrench SW11 and SW13. The throttle setting automatically results from the correct version and can be axially moved on the shaft.

15. Tighten the button head screw (pos. 7) with washer (pos. 9) and hexagonal nut (pos. 10) with an open-end wrench SW10.

70

Diesel engine assembly

16. Completely attach the clutch. See Chapter "10. Assembly of the clutch und installation of the V-belt." Carry out the required steps.

17. Attach the side covers and electrical switches. See chapter "6.1 Assembling the protective frame, covers and battery." Connect the battery and check the voltage.

71

Disassembly of the upper mass

15 Disassembly of the upper mass

8

7

1

3

6 4

2

Pos.

Designation 1 2 3 4 5 6 7 8

Hexagon socket head cap screw Lock washer Hollow screw Seal Hose pipe Hexagon socket head cap screw Pipe clamp Upper mass

72

5

Disassembly of the upper mass

1. First remove the side covers. See chapter "6.1 Disassembling the protective frame, covers and battery." The protective frame and battery box can remain on the machine.

2. Remove the clutch. See chapter "9 Disassembly of the clutch and replacing the Vbelt." Dismantle the clutch until the V-belt can be removed.

3. Loosen the hexagon socket head cap screws (pos. 1) with an Allen wrench SW10 and remove with lock washer (pos. 2). 8 hexagon socket head cap screws (pos. 1) are to be removed, 4 pieces each in the front and back.

4. Lift up the upper mass (pos. 8) about 100 mm with a crane and suitable hoisting gear.

Note:

The upper mass and base plate are still connected via the hydraulic hose!

5. The working area is to be secured when detaching the hydraulic hose, for example with wood between the upper mass and base plate (assembly safety).

6. Loosen the hollow screw (pos. 3) with a ring wrench SW19 and remove with hose pipe (pos. 5). The hose pipe (pos. 5) has 2 seals (pos. 4). Loosen the hexagon socket head cap screw (pos. 6) with the Allen wrench SW5 and remove with pipe clamp (pos. 7).

73

Disassembly of the upper mass

Note:

Oil will escape when detaching the hose pipe (pos. 5).  The oil may not make its way into the subgrade. The hose pipe (pos. 5) can be sealed with the hexagon socket head cap screw (pos. 6), a matching nut and the two seals (pos. 4).

7. The upper mass (pos. 8) can be lifted.

74

Assembly of the upper mass

16 Assembly of the upper mass 1. Lift the upper mass (pos. 8) onto the base plate with the crane and suitable hoisting gear. Secure the upper mass (pos. 8) from falling down (assembly safety).

2. Screw in the hose pipe (pos. 5) with 2 new seals (pos. 4) and a hollow screw (pos.

3) and tighten with SW19.

Seals

3. When tightening, rotate the hose pipe (pos. 5) about 10° so that the pipe clamp (pos. 7) does not kink the hose pipe (pos. 5).

4. Fasten the pipe clamp (pos. 7) with the hexagon socket head cap screw (pos. 6) and Allen wrench SW5. The hexagon socket head cap screw (pos. 6) is glued in place.

Note:

The hexagon socket head cap screw (pos. 6) is screwed on synthetic material. Do not over-tighten.

5. Remove the assembly safeguard and place the upper mass (pos. 8) on the base plate. The bores in the upper mass (pos. 8) do not automatically fit on the threaded bores in the base plate. Gently slide the upper mass (pos. 8) onto the shockmount support.

6. Screw in the 8 hexagon socket head cap screws (pos. 1) with a new lock washer (pos. 2) and tighten. The torque is 86 N·m.

Add oil!

7. The hydraulic line aeration is described in chapter 20 "Assembly of the center pole head."

75

Disassembly of the entire center pole

17 Disassembly of the entire center pole 32

6 7

31 30

8

29

9

26 11 12

28 4 2 27

3

13 14 15

5

1

16 17 20 19 21 22

23 24

25

76

18

10

Disassembly of the entire center pole

Pos. Designation 1

Hexagonal bolt

12

2 3 4 5

Fixing device coupling Hexagonal bolt Worm drive hose clip Bellows

13 14 15 16

6 7 8 9

Shim Rubber element Frame Mushroom washer

17 18 19 20

10 Hexagon socket head cap screw 11 Threaded spindle coupling

21

Hexagon socket head cap screw Console Washer Rubber shockmount Hexagon socket head cap screw Washer Holder Plate Hexagon socket head cap screw Fitting

22

Cover

23

Hexagon socket  head cap screw Fitting Apron Center pole Hose pipe 

24 25 26 27  28 29 30 31

Locking pin Compression spring Threaded pin Washer 

32

Flat knob 

1. Remove the covers on the switch side. See chapter "6.1 Disassembling the protective frame, covers and battery."

2. Remove the 3 pipe clamps control (Bowden cable) as well as the actuating device.

See chapter "11 Disassembly of the Bowden cable."

3. Use a SW10 to loosen the 4 hexagon socket head cap screws, 2 each in front and back, of the connection between the upper mass and base plate. See chapter "15 Disassembly of the upper mass."

4. Loosen the 2 hexagon socket head cap screws (pos. 1) with a ring wrench SW24 and remove with plate (pos. 19).

5. Loosen the 2 hexagon socket head cap screws (pos. 20) with the Allen wrench SW5 and remove with the fitting (pos. 21) and cover (pos. 22)

77

Disassembly of the entire center pole

.

6. Loosen the 3 hexagon socket head cap screws (pos. 23) with the Allen wrench SW5. Do not unscrew completely. Leave the fitting (pos. 24) on the machine. Open and pull out the apron (pos. 25). Only partially pull out the apron.

7. Laterally lift out and secure the upper mass with a crane and suitable hoisting gear.

8. Loosen the hollow screw with a ring wrench SW19 and remove with hose pipe (pos.

27). The hose pipe (pos. 27) has 2 seals. Loosen the hexagon socket head cap screw with the Allen wrench SW5 and remove with pipe clamp.  Also see "15 Disassembly of the upper mass."

78

Disassembly of the entire center pole

Note:

Oil will escape when detaching the hose pipe (pos. 27).  Oil may not make its way into the subgrade. The hose pipe (pos. 27) can be sealed with the hexagon socket head cap screw, a matching nut and the two seals.

9. Loosen the 2 screws (pos. 16) with the Allen wrench SW10 and remove with the washers (pos. 17) and holder (pos. 18)

10. Open the worm drive hose clip (pos. 4) with a screwdriver and allow to hang loose.

11. Remove the bellows (pos. 5). If it is difficult, help it along on the edges with a blunt object. Do not destroy the bellows (pos. 5).

12. Loosen 2 hexagonal bolts (pos. 3) with an open-end wrench SW13 on each side.

79

Disassembly of the entire center pole

Note:

The center pole (pos. 26) is fastened to the machine with  these 4 screws (pos. 3). The center pole (pos. 26) is heavy. Hang on the crane and secure before disassembly.

13. Remove the fixing device (pos. 2) with the center pole (pos. 26) from the machine.

The hose pipe (pos. 27) is still hanging in the machine. Use caution during disassembly to ensure that this is not kinked.

14. Disassemble the handle grip: Loosen the hexagon socket head cap screws (pos.

10) with an Allen wrench SW12 and remove the entire handle grip (pos. 6-9) from the center pole head. The process applies to both sides.

Note:

The entire handle grip can fall out with its parts!

15. Disassemble the rubber shockmount: Loosen the 4 hexagon socket head cap screws (pos. 12) with the Allen wrench SW8 and remove with the console (pos. 13) and rubber shockmount (pos.11 -15)

16. The threaded spindle (pos. 11) is screwed into the rubber shockmount (pos. 15) with the washer (pos. 14), glued and tightened, which means it is difficult to loosen.

17. Screw on the flat knob (pos. 32). Since the knob (pos. 32) is glued, the parts can be heated with an industrial blow dryer. Remove the flat knob (pos. 32) with washer (pos. 31). The locking pin (pos. 28) can be pulled out downward. The compression spring (pos. 29) can be removed.

80

Assembly of the entire center pole

18 Assembly of the entire center pole 1. Screw the center pole (pos. 26) with the two fixing devices (pos. 2) and the associated hexagonal bolts (pos. 3) onto the upper mass. The torque is 25 N·m.

2. Pull the bellows (pos. 5) up to the frame. Attach the worm drive hose clip (pos. 4) over the bellows (pos. 5) and tighten hand-tight with a screwdriver.

3. Screw on the holder (pos. 18) with the hexagon socket head cap screw (pos. 16) and washer (pos. 17) above the center pole with the Allen wrench SW10. Make certain here that the recess faces the center pole. The torque is 86 N·m.

4. Place the center pole (pos. 26) upright and snap the stop-lock into place. Screw on the control (throttle lever). See chapter 12.

5. Apply the shim (pos. 6) to the center pole head. Connect the rubber element (pos.

7), frame (pos. 8) and mushroom washer (pos. 9) with the hexagon socket head cap screw (pos. 10). Screw in and tighten the hexagon socket head cap screw with the Allen wrench SW10. The torque is 86 N·m.

6. Screw the hose pipe (pos. 27) onto the exciter. See chapter "7.10. Assembly of the upper mass."

81

Assembly of the entire center pole 7. Install the apron (pos. 25). It is recommended to begin on the left side (hose connection on the exciter). Thread the apron (pos. 25) from below into the provided groove.

8. The fittings (pos. 24) are screwed in loosely. The apron (pos. 25) is easy to slide in. Go around the machine once with the apron (pos. 25). At the end, the ends must match the bores provided.

9. If this is not the case, pull the apron (pos. 25) over all of the corners in the desired direction, always beginning from the left.

10. Tighten the hexagon socket head cap screws (pos. 23) of both fittings (pos. 24) with the Allen wrench SW6. The torque is 25 N·m. Screw on both hexagon socket head cap screws (pos. 20) with the fitting (pos. 21) and the cover (pos. 22) and tighten with the Allen wrench SW5. The torque is 10 N·m.

11. Screw on the plate (pos. 19) with the hexagonal bolt (pos. 1). Tighten the hexagonal bolts with the key SW24. The torque is 210 N·m.

12. Screw the 4 hexagon socket head cap screws (pos. 12) with console (pos. 13) onto the center pole with the Allen wrench SW8. The torque is 49 N·m. Daub the threaded spindle (pos. 11) with Omnifit 100M bonding compound in the bottom part and screw with the washer (pos. 14) into the rubber shockmount (pos. 15) and tighten. The center pole position can be set here more or less with a screwed-in threaded spindle (pos. 11).

13. Screw the threaded pin (pos. 30) with the Omnifit 100M bonding compound into the locking pin (pos. 28) and tighten. Install both into the fixing device of the center pole (pos. 26) from below together with the compression spring (pos. 29). Screw the flat knob (pos. 32) with the washer (pos. 31) onto the threaded pin (pos. 30) and tighten. Beforehand, drip-impregnate the threaded pin (pos. 30) with Omnifit 100M bonding compound.

82

Disassembly of the center pole head

19 Disassembly of the center pole head 8 7 3

1

2

6

4

9 10 11

5

12

Pos.

Designation 1

Hexagon socket head cap screw

2

O-ring

3

Control piston coupling

4

Piston sealing ring

5

Control piston

6

Compression spring

7

Guide

8

Center pole head

9

Gear shaft

10

O-ring

11

Spacer

12

O-ring

83

Disassembly of the center pole head

1. First disassemble the left handle grip: Loosen the hexagon socket head cap screw with an Allen wrench SW12 and remove the entire handle grip from the center pole head. The process applies to both sides. See chapter "17 Disassembly of the entire center pole."

Note: The entire handle grip can fall out with its parts!

Important: During disassembly, the gear shaft (pos. 9) is in the position shown on the image. It may only be re-installed in this position. The parallel piece looks like the milled surface!

Note:

Danger to life!  The control piston (pos. 3) built into the center pole head (pos. 8) is under spring pressure! Never have control pistons face your body! The center pole head is filled with oil. Have an oil  collecting tray ready.

2. The center pole head (pos. 8) may only be removed with the safety device (5000205327). Properly fit the jig and tighten the screw.

5000205327

3. Loosen the 4 hexagon socket head cap screws (pos. 1) with the Allen wrench SW6 and remove. Remove the O-ring (pos. 2) between the center pole head (pos. 8) and center pole.

84

Disassembly of the center pole head

4. Decompress the spring (pos. 6) using a hand press and remove with the control piston (pos. 3). The safety device (5000205327) is to be removed before decompressing and with an applied press (see image).

5. If the seal (pos. 4) is defective, this can be removed with a screwdriver. New seals are composed of 2 parts. Older seals are composed of one part. Remove all parts.

6. Press out the gear shaft (pos. 9) with a drift pin.

85

Disassembly of the center pole head

Note:

The gear shaft (pos. 9) and spacer (pos. 11) fall out.

7. In order to press out the spacer (pos. 11), insert the gear shaft (pos. 9) again and press out with a drift pin.

8. The spacer (pos. 11) has an O-ring inside (pos. 12) and an O-ring outside (pos. 10).

9. If defective, both O-rings can be removed with a screwdriver.

10. The guide (pos. 7) can be pressed out through the oil filling opening with a drift pin using a hand press.

86

Assembly of the center pole head

20 Assembly of the center pole head 1. After replacing the defective parts, the assembly takes place in the reverse chronological order.

2. Press guide (pos. 7) into the center pole head with a drift pin and hand press until the stop.

3. Attach the new two-piece seal (pos. 4) to control piston (pos. 5). First install the black lower part into the groove. Then install the blue upper part with the double lip.

Lower part

Upper part

4. Both spacers (pos. 11) each have 2 seals. Carefully slide the O-ring (pos. 10) into the groove on the outside. There are 2 grooves inside. In the installed state, both O-rings (pos. 10 and 12) are near the groove on one side. The open groove is filled with grease.

O-ring

Grease 5. Carry out the pre-assembly of the center pole head by using a hand press.

6. Press the spacer (pos. 11) into the center pole head (pos. 8) until the center pole head machining surface and the crank spacer (pos. 11) conform. Insert the gear shaft (pos. 9) and second spacer (pos. 11).

7. Both special tools (5000206626, 5000206627) avoid the first spacer (pos. 11) being pressed out again if the second spacer is pressed in.

87

Assembly of the center pole head

8. Place the compression spring (pos. 6) on the control piston (pos. 3) and lower into the center pole head (pos. 8). The control piston (pos. 3) gearing engages in the gearing of the gear shaft (pos. 9). It may be necessary to turn both parts with light pressure with the hand press.

Note:

Danger to life!  The control piston (pos. 3) build into the center pole head (pos. 8) is under spring pressure! Never have control pistons face your body!

Important: If the control piston and center pole head must be nearly flush, then the gear shaft must have the position as shown in the image.

9. If the position shown is not reached in the retracted state, the setting must be corrected.

10. Extend the hand press until the spring (pos. 6) is decompressed. Rotate the gear shaft (pos. 9) by hand accordingly. Retract the hand press with the control piston (pos. 3) and compression spring (pos. 6) again. The process is to be repeated until the position shown is reached. The entire process for adjusting the gear shaft (pos.

9) to the correct position must take place smoothly and effortlessly and without force. Gearing may not be damaged.

11. Slightly move the gear shaft (pos. 9) when immersing the guide pin (pos. 5) so that the gearing can engage.

12. Screw on the safety device and leave until attachment on the center pole. Attach the handle grip to the center pole head:

88

Assembly of the center pole head

13. Insert the O-ring (pos. 2) into the groove.

14. Place the entire center pole head onto the center pole and screw in and tighten with 4 hexagon socket head cap screws (pos. 1). The torque is 25 N·m.

Note:

Do not crush and destroy the O-ring!

15. Unscrew the safety device and attach the 2nd handle grip.

Fill with about 0.4 liters of oil in the center pole head. To do this, place the center pole vertically and fill oil (Fuchs Renolit MR 520) through the opening in the center pole head until the marking. Then close the bore again.

Venting the hydraulic line is simple. The center pole is still vertical. Start the engine and allow it to idle. The opening in the center pole head remains open. Monitor the oil level and add oil if necessary. Allow the engine to run for about 10 minutes. The vibrations will provide the aeration.

Note: Before attaching the center pole head, check the oil level  in the center pole (hose). If necessary, fill to the top. This facilitates aeration later.

89

Disassembly of the base plate and exciter

21 Disassembly of the base plate and exciter 1 2

9

8

10 7 11

3

7

4 6 5 Pos.

Designation 1

Hexagon socket head cap screw

7

2

Exciter coupling

8

Hexagonal bolt

3

Shock bushing

9

Rubber shockmount

4

Hexagonal bolt

10

Shockmount support

5

Lock washer

11

Hexagon socket head cap screw

6

Mounting plate

90

Conical spring washer

Disassembly of the base plate and exciter

1. First carry out the steps from chapter 15 "Disassembly of the upper mass."

2. Lift the upper mass with a crane or fork lift. Observe permissible weights of the hoisting gear.

3. If the rubber shockmount is defective, loosen and remove the hexagon socket head cap screw (pos. 11) with the Allen wrench SW10. Secure the rubber shockmount (pos. 9) with a strap wrench (5000094654). Remove the hexagon socket head cap screw (pos. 11), conical spring washer (pos. 7) and shockmount support (pos. 10).

4. Loosen the hexagonal bolt (pos. 8) with the ring wrench SW24. Secure the rubber shockmount (pos. 9) with the strap wrench. Unscrew the hexagonal bolt (pos. 8) out of the rubber shockmount (pos. 9) with the conical spring washer and remove the rubber shockmount (pos. 9).

91

Disassembly of the base plate and exciter

5. The corresponding mounting plate (pos. 6) must be removed for the disassembly of one or more rubber shockmounts (pos. 9).

6. Loosen the 4 hexagonal bolts (pos. 4) from a mount plate (pos. 6) with the ring wrench SW24 (possibly with extension if difficult to access) and unscrew with the lock washer (pos. 5).

Note:

Mounting plate (pos. 6) can fall down. Risk of injury!

7. If the shock bushing (pos. 3) is defective, this can be removed by hand.

92

Disassembly of the base plate and exciter

Note:

Mark the position of the exciter (pos. 2) on the base plate.

8. Loosen the connecting screws of the base plate to the exciter (pos. 2). There are 12 hexagon socket head cap screws (pos. 1) to remove. Remove all screws.

9. Screw the eye bolts (M 16) into 2 opposite bores in the exciter (pos. 2) for transport.

Connect both eye bolts with an appropriate transport rope. Transport the exciter (pos. 2) to a workbench with suitable means of transport.

93

Assembly of the base plate and exciter

22 Assembly of the base plate and exciter 1. After replacing the defective parts, the assembly takes place in the reverse chronological order.

2. Screw the eye bolts (M 16) into 2 opposite bores in the exciter (pos. 2) for transport.

Connect both eye bolts with an appropriate transport rope. Transport the exciter to the base plate with suitable means of transport. Observe the marking you applied for the exciter position.

3. The flat-faced surface of the base plate must be cleaned prior to assembling the exciter (pos. 2). 0.8 liters of oil, 10W40, are put into the tray. Put sealant Omnivisc 1002 onto the flat-faced surface according to the image.

94

Assembly of the base plate and exciter

0.8 liters of oil 10W40

Omnivisc Sealant

4. Screw in the connecting screws of the base plate to the exciter (pos. 2). Tighten the 12 hexagon socket head cap screws (pos. 1) with a torque of 120 N·m.

5. Screw the rubber shockmount (pos. 9) with conical spring washer (pos. 7) and hexagonal bolt (pos. 8) onto the base plate. Use a new conical spring washer  (pos. 7). The torque is 86 N·m. Hold with a strap wrench (5000094654).

95

Assembly of the base plate and exciter

6. Screw the shockmount support (pos. 10) with conical spring washer (pos. 7) and hexagon socket head cap screw (pos. 11) onto the rubber shockmount. Use a new conical spring washer (pos. 7). The torque is 86 N·m. Observe the horizontal position of the bearing surface of the shockmount support (pos. 10). Hold with a strap wrench (5000094654).

7. Screw on the mounting plate (pos. 6) with hexagonal bolt (pos. 4) and lock washer (pos. 5). Use a new lock washer (pos. 5). Clean surfaces between the base plate and mounting plate (pos. 6). The torque is 210 N·m.

96

Assembly of the base plate and exciter

8. Install the shock bushing (pos. 3) by hand.

9. Attach the upper mass. See chapter "16 Assembly of the upper mass."

97

Disassembly of the exciter shafts

23 Disassembly of the exciter shafts 5

3

6

1 2 4

7

8

9

29 11

28

6

27

10

22 26

25

19 24

17 23

12 21

20 18 16 15 14 13 11

98

Disassembly of the exciter shafts

Pos.

Designation 1

Hexagonal bolt

2

Body shim

3

Plate

4

V-belt pulley

5

Hexagonal bolt

6

Spring washer

7

Protection housing

8

Rotary shaft seal

9

Cylinder cover

10

Hexagon socket head cap screw

11

Cylindrical roller bearing

12

Bolt coupling

13

Lip seal ring

14

O-ring

15

Bolt

16

Retaining ring

17

Deep groove ball bearing

18

Spring washer

19

Hexagonal bolt

20

Adjusting pin

21

Retaining ring

22

Retaining ring

23

Deep groove ball bearing

24

Adjusting sleeve

25

Shaft

26

Tripping pin

27

Eccentric weight

28

Lock washer

29

Hexagon socket head cap screw

99

Disassembly of the exciter shafts

31 10 6

32 30

6 10 40 28 33

39

28 34 11

37 35

35 11

38

36 Pos.

Designation

06

Spring washer

10

Hexagon socket head cap screw

11

Cylindrical roller bearing

36

Feather key

28

Lock washer

37

Gear wheel

30

Breather cover

38

Shaft

31

Exciter housing

39

Eccentric weight

32

Cover

40

Hexagon socket head cap screw

33

Hexagon socket head cap screw

34 35

100

Eccentric weight Retaining ring

Disassembly of the exciter shafts

Caution:

The shafts are not secured and turn freely.  The eccentric weights (pos. 39, 34, 27) mounted on them can cause serious injuries to your fingers!

1. First carry out the steps from chapter 21 "Disassembly of the base plate and exciter."

2. Loosen the 6 hexagonal bolts (pos. 1) with the key SW10 and remove with body shims (pos. 2). The screws are glued and may be difficult to remove.

3. The plate (pos. 3) is glued to the protection housing (pos. 7)  with a sealant. Remove the plate (pos. 3) with a soft hammer and light impacts.

4. Remove the V-belt pulley (pos. 4) with a taper punch and breaker. The V-belt pulley (pos. 4) has a left hand thread. Maintain the correct direction of rotation to the right, i.e. clockwise, when removing!

5. Loosen the 9 screws (pos. 5) with an Allen wrench SW5 and unscrew with the screw (pos. 6). The screws are glued and may be difficult to remove.

101

Disassembly of the exciter shafts

Caution: The protection housing may fall down.

6. Remove the protection housing (pos. 7). If difficulties are encountered, loosen the protection housing (pos. 7) from the exciter housing (pos. 31) with a soft hammer and light impacts.

7. Remove the rotary shaft seal (pos. 8) from the bore with a screwdriver. Remove if defective. A rotary shaft seal (pos. 8) can only be used once.

8. Prior to disassembly, mark all 4 openings in the exciter housing (pos. 31) with the corresponding covers so as to avoid confusion during assembly.

9. Loosen and remove the 5 screws (pos. 10) with spring washers (pos. 6) on the cylinder cover (pos. 9) with the Allen wrench SW5. The screws are glued and may be difficult to remove.

10. Axially pull off the cylinder cover (pos. 9) by hand. The cylinder cover (pos. 9) must be pulled against the seal of the control piston. Do not use a synthetic material hammer or similar aid!

11. Loosen the 4 screws (pos. 10) on the cover (pos. 32) with an Allen wrench SW5 and remove with the spring washer (pos. 6). The screws are glued and may be difficult to remove.

12. Remove the cover (pos. 32). One bore is free. A hose clamp shall be attached here during assembly. The cover (pos. 32) is sealed. If difficulties are encountered, carefully use a screwdriver.

102

Disassembly of the exciter shafts

13. Loosen the 5 screws (pos. 10) on the breather cover (pos. 30) with an Allen wrench SW5 and remove with the spring washer (pos. 6). The screws are glued and may be difficult to remove.

14. Remove the breather cover (pos. 30). The cover (pos. 30) is sealed. If difficulties are encountered, carefully use a screwdriver.

15. Place the exciter upright and secure with a c-clamp on the right side.

The eccentric weight cannot be directly disassembled.

16. Loosen 5 hexagon socket head cap screws (pos. 29, 33, 40) with the Allen wrench SW14 and remove with the lock washer (pos. 28. At the time, remove the corresponding eccentric weights (pos. 27, 34, 39).

103

Disassembly of the exciter shafts

Caution:

Eccentric weights (pos. 27, 34, 39) are not secured and fall down.

17. An eccentric weight (pos. 27) in this state cannot be disassembled. Place the exciter on a workbench, lightly drive in the shaft (pos. 25) a few millimeters with a synthetic material hammer and remove the eccentric weight (pos. 27).

18. Both of the shafts can be pressed out with the bearings. If the bearings are to be re-installed, these are to be installed in the same position in the exciter housing, so they are therefore to be marked. Assemble the exciter using a hand press. The bearing to be pressed out with the shaft must be free here. This means that the exciter must be assembled on a jig, which makes it possible for both parts to be pressed out.

19. Press out the bearings with a jig (press-fit piece 5000047380).

Press-in jig

Note:

Mark the bearing outer and inner ring. They must not be confused if re-used.

20. To be able to remove the shafts (pos. 25, 38) from the exciter housing (pos. 31), the outer rings of the bearings (pos. 11) must be removed. Then remove the shafts (pos. 25, 38) from the exciter housing (pos. 31).

21. Disassemble the shaft (pos. 38). Pull off the inner rings of the bearing (pos. 11) with the two-arm extractor.

104

Disassembly of the exciter shafts

22. Remove the retaining rings (pos. 35) with pliers.

23. Press out the gear wheel (pos. 37) with a hand press. The shaft (pos. 38) is disassembled up to the feather key (pos. 36).

24. Disassemble the shaft (pos. 25). Pull off the inner rings of the bearing (pos. 11) with the two-arm extractor and jig (support 5000047383).

105

Disassembly of the exciter shafts

5000047383

25. Remove the two retaining rings (pos. 21, 22) with pliers. The adjusting sleeve (pos.

24) will then fall down. Remove the shaft (pos. 25) from the adjusting sleeve (pos.

24).

26. Remove the bearing (pos. 23) from the adjusting sleeve (pos. 24).

27. Drive out the tripping pin (pos. 26).

Caution:

The tripping pin (pos. 26) can fall down!

28. Remove the retaining ring (pos. 16) with pliers. Remove the adjusting  pin (pos. 20).

106

Disassembly of the exciter shafts

29. Loosen the 10 hexagonal bolts (pos. 5) with an Allen wrench SW10 and remove with the spring washer (pos. 18). The screw is glued and may be difficult to loosen.

30. Pull both deep groove ball bearings (pos. 17) from the bolt (pos. 15) with the twoarm extractor.

31. If necessary, remove the lip seal ring (pos. 13) and O-ring (pos. 14).

107

Assembly of the exciter shafts

24 Assembly of the exciter shafts 1. Push the retaining ring (pos. 16) onto the bolt (pos. 15). Then press both deep groove ball bearings (pos. 17) onto the bolt with a hand press. Daub the hexagonal bolt (pos. 19) with a spring washer (18) with the bonding compound Omnivisc 100M, screw into the bolt (pos. 15) and tighten to 10 N·m. Use "soft" aluminum jaws in the vise.

2. Insert the bolt (pos. 15) into the adjusting pin (pos. 20). Install the retaining ring (pos. 16) with pliers.

3. Oil the O-ring (pos. 14) and put it on the bolt (pos. 15) by hand. Also oil the lip seal ring (pos. 13) and put it on the bolt (pos. 15) by hand.

4. Attach the shaft (pos. 25) with the adjusting sleeve (pos. 24).

5. Insert the assembled bolts (pos. 12, 20) into the shaft (pos. 25). Drive the tripping pin (pos. 26) through the shaft (pos. 25) into the bolt (pos. 20). This can be done with a hand press or with a synthetic material hammer.

108

Assembly of the exciter shafts

6. After the installation, the tripping pin (pos. 26) must protrude evenly on both sides of the shaft (pos. 25) about 4.2 mm. If necessary, balance it out by re-pressing.

7. Install the retaining ring (pos. 22) with the pliers. This deals with the bottom retaining ring (pos. 22), because the deep groove ball bearing (pos. 23) is then pressed in afterwards. Press the deep groove ball bearing (pos. 23) with jig (pipe 5000095512) onto the shaft (pos. 25) using a hand press.

8. Install the retaining ring (pos. 22) above the deep groove ball bearing (pos. 23) with pliers.

109

Assembly of the exciter shafts

9. Put the adjusting sleeve (pos. 24) together with the shaft (pos. 25). It absolutely must be ensured here that the marking with the center punch on the gear wheel and the bore in the shaft are opposite each other, as shown in the image.

Marking on the gear wheel, with center punch Bore

10. If the shaft (pos. 25) and the adjusting sleeve (pos. 24) are pushed together for the aforementioned point, the adjusting pin (pos. 12) is completely retracted and the marking and bore are on one side.

Bore M16 and gear wheel marking in one plane

110

Tripping pin above

Assembly of the exciter shafts

Note:

If the machine only drives backwards after the repair, this point has been done incorrectly.

11. Install the retaining ring (pos. 21) with the pliers.

12. Now the shaft (pos. 25) is assembled. The function can be checked. The adjusting pin (pos. 12) will come out by rotating the shaft (pos. 25) in the adjusting sleeve (pos. 24) upward. If you release the shaft (pos. 25) in the adjusting sleeve (pos. 24), the shaft (pos. 25) must rotate down by itself and the adjusting pin (pos. 12) must immerse again. The smoothness and effortlessness of this function makes the machine's change of direction possible.

111

Assembly of the exciter shafts 13. Attach the shaft (pos. 38) with the gear wheel (pos. 37): 14. First install the retaining ring (pos. 35) on the shaft (pos. 38) with pliers. Install the feather key (pos. 36) in the shaft (pos. 38).

15. Press the gear wheel (pos. 37) on the shaft (pos. 38) with a hand press. The crank on the gear wheel (pos. 37) must face both bores for the eccentric weights (pos.

34, 39) here.

Crank

Bores 16. Install the second retaining ring (pos. 35) with the pliers. Press on both inner rings of the cylindrical roller bearing (pos. 11) with a hand press. In the process, the type face on the bearing shell must face inward.

Type face on the bearing

Note:

The outer shells of the bearings must be assigned to the correct inner ring.

17. After assembling the shafts (pos. 38, 25), the installation in the exciter housing (pos. 31) takes place.

18. Press two bearing outer shells (pos. 11) with a jig (press-fit piece 0047380) into the exciter housing (pos. 31) with a hand press. Ensure a level pad. Allow the bearing outer ring (pos. 11) to be flush with the exciter housing (pos. 31). The exact fitting position will be set later.

112

Assembly of the exciter shafts

Note:

The type face on the bearing must face in the exciter housing!  If the bearings have been marked, the exact installation position in the exciter housing must be observed.

19. Fit both shafts (pos. 38, 25) into the bearings (pos. 11). Both gear wheels have markings with a center punch. These must both face each other.

Marking 20. Press in the two other bearing outer rings (pos. 11) flush with the exciter housing (pos. 31) with a hand press and jig (press-fit piece 5000047380). Ensure a level pad. Markings must face each other.

113

Assembly of the exciter shafts

21. Install the cover (pos. 32). Hold the cover (pos. 32) to the exciter housing (pos. 31), daub the screws (pos. 10) with the Omnifit 100M bonding compound and screw in with the spring washers (pos. 6). The torque is 10 N·m. The bearing (pos. 11) is pushed into its final position. Daub the flat-faced surface with the sealant Omnivisc 1002. The chronological order in which the 3 covers (pos. 9, 30, 32) are installed does not matter.

22. When installing the cylinder cover (pos. 9), the bore must be daubed with oil, as the cylinder cover (pos. 9) must be axially pushed over the lip seal ring (pos. 13). Also daub the flat-faced surface on the cylinder cover (pos. 9) with the sealant Omnivisc 1002. Screw in the hexagon socket head cap screws (pos. 10) with spring washer (pos. 6). The torque is 10 N·m. Spread the bonding compound Omnifit 100m on the thread.

114

Assembly of the exciter shafts

Note: Check the shaft for free movement!

23. Install the eccentric weights (pos. 27). Attach the eccentric weights (pos. 27) with a hexagon socket head cap screw (pos. 29) and lock washer (pos. 28) to the shaft (pos. 25) with an Allen wrench SW14. The torque is 295 N·m.

24. In order to avoid injuries, it is recommended placing the exciter housing (pos. 31) upright on the workbench.

25. Attach the eccentric weights of the shaft (pos. 38) in the same way. The large eccentric weight (pos. 34) is installed in the middle of the shaft (pos. 38). The two small eccentric weights (pos. 39), one above and one below the screwed in cranks, prevent confusion. After installation, the eccentric weights must be next to each other, as shown in the representation. Screw in and tighten the hexagon socket head cap screws (pos. 33 and 34) with the lock washer (pos. 28).

26. The torque is 295 N·m. The exciter housing can be secured to the workbench with a c-clamp.

27. The function of the exciter can be checked after the installation. To this end, the exciter must be placed on the workbench.

115

Assembly of the exciter shafts

Caution:

Pay attention to the eccentric weights. There is a risk of injury. Both shafts with the eccentric weights must be freely  and easily rotatable. If the shaft (pos. 25) sticks, check the adjusting pin (pos. 12) in the cylinder cover (pos. 9).

28. Press the rotary shaft seal (pos. 8) into the protection housing (pos. 7) with a jig and hand press. Daub the rotary shaft seal (pos. 8) on the outside with oil. It facilitates the installation.

Note:

The rotary shaft seal (pos. 8) is a sensitive spare part. Pressure may only be applied to the horizontal ring surface!

29. Fill the play between the dust and sealing lip with Shell Gadus S3 grease.

30. Attach the protection housing (pos. 7) with hexagonal bolt (pos. 5) and washer (pos. 6) to the exciter. Ensure the correct fitting position. Daub the hexagonal bolts (pos. 5) with the Omnifit 100M bonding compound. Seal the flat-faced surface with Omnivisc 1002. The torque is 10 N·m.

116

Assembly of the exciter shafts

31. Install the V-belt pulley (pos. 4). The V-belt pulley (pos. 4) has a left hand thread.

Maintain the correct direction of rotation to the right, i.e. counter-clockwise, when installing! Hand-tight tightening is sufficient.

32. Daub the outside of the plate (pos. 3) with Omnivisc 1002 sealant and screw on.

Daub the hexagonal bolts (pos. 1) with Omnifit 100M bonding compound and attach to protection housing (pos. 7) with the washer (pos. 2). Tighten the screws with the key SW10. The torque is 10 N·m.

117

Assembly of the exciter shafts

33. Attach the entire exciter to the base plate. See chapter "22 Assembly of the base plate and exciter."

118

Assembly of the exciter shafts

119

Assembly and disassembly of the Compatec components

25 Assembly and disassembly of the Compatec components

Pos

Designation

Pos

Designation

1

Cable binder

8

Cable holder

2

Sensor coupling

9

Display unit

3

Hexagon socket head cap screws

10

Bushing

4

Battery cover

11

Hexagonal nut

5

Retaining screw

12

Hexagonal nut

6

Retaining screw

13

Cable grommet

7

Battery shockmount

14

Socket head cap screw

120

Assembly and disassembly of the Compatec components

Note:

25.1

You can retroactively attach the Compatec compaction control to  a DPU 6555. The retrofit kit 5100003855 is available for this purpose.

Disassembly of Compatec components

1. First, you must loosen and remove the 4 retaining screws (5, 6) with SW10. Then you can lift the battery cover (4) with the display unit (9) from the vibratory plate, even if the protective frame is still attached. However, if the cable is still attached, it is designed to be long enough to be able to place the battery cover (4) next to the machine.

2. The display unit (9) points to the vibratory plate and the battery cover (4) is next to the vibratory plate. The cable is designed for this disassembly.

3. You will find this situation. The wiring harness for the data 4. of the Compatec compaction control is located next to the wiring harness of the vibratory plate. It can be separated in the middle. Both of the wiring harness parts are each potted with the sensor (2) and the display unit (9) and can only be disassembled and replaced as a whole unit.

5. Remove the battery so that you can work more easily.

121

Assembly and disassembly of the Compatec components 6. You will see the plug in the wiring harness that connects the Compatec sensor (2) and display unit (9) components with each other.

7. Use the Allen wrench SW5 to loosen both hexagon socket head cap screws (14) of the cable holder (8) in order to remove the wiring harness. You can lift the display unit (9) with the battery cover (4).

8. Next to this is still the wiring harness of the voltage supply. One cable goes to the ground contact and another to the acoustic signal.

You must also cut both of these. Cut the cable binders with a wire cutter.

9. Loosen both hexagon socket head cap screws (3) from the sensor (2) with an Allen wrench SW6 and remove. The cable binders here are also to be cut.

122

Assembly and disassembly of the Compatec components

25.2

Assembly of the Compatec components

1. When assembling a display unit (9) on a battery cover (4), first check the battery shockmount (7) for completeness and good condition. In addition, the cable grommet (13) and the edge protection must be attached.

Then run the data cable through the cable grommet and attach the display unit (9).

2. Attach the display unit (9) in the position shown on the battery cover (4). It is fastened to the battery cover (4) with the 4 hexagonal nuts (11) SW10. The torque is 10 N·m.

3.

4. Open the nuts of the plug and attach the cable to the cable holder (8). Then tighten the nuts hand-tight.

123

Assembly and disassembly of the Compatec components 5. For fastening, you need the hexagon socket head cap screw (14), the bushing (10),  a washer and the hexagonal nut (12).

6. Attach the hexagon socket head cap screws (14) and the bushings (10) on one side of the battery box and the washer with nut (12) on the other side. The torque is 10 N·m.

7. The voltage supply for the Compatec takes place via the acoustic signal. The red-yellow cable is connected to the negative. It is the right connection on the image. The pink cable is connected to the red cable of the Compatec via a bridge and is connected to the positive, to the left on the image.

8. Connect the black Compatec earth cable  to the earth cable of the battery.

124

Assembly and disassembly of the Compatec components 9. Attach the sensor (2) on the upper mass. The closed side of the sensor (2) faces the battery.

Attach both hexagon socket head crap screws (3) with washers with SW6. The torque is 10 N·m.

10. Connect the two cables together and fasten these to the battery housing with the cable binders.

11. Attach the battery cover (4) with the display unit (9) on the vibratory plate. The assembly is also possible with an attached protective frame. Attach the 4 retaining screws with the SW10. The torque is 10 N·m.

125

Assembly and disassembly of the Compatec components

25.3

Troubleshooting and rectification

Note:

The display unit (9) and the sensor (2) cannot be opened and repaired!

If defective, please replace the respective component as a whole unit.

Before doing so, please proceed through the following points for troubleshooting.

Type of fault

Tests to be carried out

Possible causes

The diodes of the display unit do not light up.

Check the battery voltage

Battery voltage too low

Check all cables and plug Cabling defect connections Ensure the correct connection of the Lack of voltage supply to red and pink colored cable to the the system acoustic signal + pole Display unit may be defective Cabling defect

Simultaneous flashing of all diodes does not take place

Check all cables and plug connections

No, wrong or only partial compaction display

Check all cables and plug connections

(The basis for the correct compaction display is use in accordance with the intended purpose pursuant to the operator's manual)

Check the sensor's fastening

The sensor is loose

Check the engine speed

Engine speed is incorrectly set

Check the fitting position of the sensor

The sensor is installed rotated by 180°

The display flickers under constant light conditions

Check all cables and plug connections

126

The sensor is defective Cabling defect

The sensor is defective Cabling defect

26 Compatec electrical wiring diagram

26 Compatec electrical wiring diagram

Elektroschaltplan_HEC.fm

127

Electrical troubleshooting

27 Electrical troubleshooting The vibratory plates with electric starter are equipped with an LED charge control lamp. If this goes out or is not illuminated, there may be several errors. It may be possible that the engine will not start.

Options are worked out in the following.

You can also start the Hatz diesel engine with a crank.

You will find the manual for this in the operator's manual.

1. The engine starts and the machine runs normally, but the LED lamp is always off.

The LED lamp is likely defective and must be replaced.

Please follow the steps from the chapter "Disassembly and assembly of the operator's controls" and replace the LED lamp.

2. The engine will not start and the LED lamp  is not on.

Check the battery.

To do this, open the 6 cover of the battery and check the fluid.

If the liquid is clear, then it is OK. If it is turbid, then particles have dissolved and the battery is defective and must be replaced.

If the fill height is sloping to one side, then the battery  is being supplied too much voltage by the voltage regulator and is outgassing. Check the voltage regulator. Look toward the end of this chapter.

If liquid is missing, fill it up with distilled water.

Check the acidity. It must at least be 1.28 g/dm³.

If the liquid is OK, the battery voltage must be  12.5 volts.

128

Electrical troubleshooting Charge the battery with the charger supplied by Wacker Neuson. It will indicate to you the actual state of the battery.

Material number: 5000974236.

With a low-grade measuring instrument, you can measure 12.5 volts, but the engine is not turning. The battery is then either not properly charged or is still defective.

3. The battery is charged, the engine starts with a new battery and the LED lamp is off.

Check the coil assembly. The coil assembly is the "alternator" in the engine. It supplies the battery with voltage via the voltage regulator.

You will find an access in the front area of the engine.

Prepare a multimeter with test prods and select the AC voltage range.

129

Electrical troubleshooting Open the switch and measure the AC voltage. You must measure the following values: Normal value: approximately 32 volts AC +/- 5 volts Minimum value: approximately 22 volts AC +/- 5 volts.

If the minimum value is is not reached, the distance of 0.7 mm is exceeded in the coil assembly or the coil assembly is defective and must be replaced.

4. The battery will not charge or is overcharged and the LED lamp is off.

First check the battery, then the coil assembly. If the values are OK, then the voltage regulator must be checked.

Start the engine, possibly with a crank.

Hold one test prod to the starter and the other test prod to the earth.

You must take the lower of the two connection screws.

The positive pole cable will be clamped at the top.

The voltage must increase to 14.5 +/- 0.2 volts. The voltage regulator is defective if the value is smaller or greater. Replace the voltage regulator. It is not possible to repair the voltage regulator.

130

Electrical troubleshooting

131