Wacker Neuson DPU 4045H Repair Manual - PDF DOWNLOAD

DPU 4045H DPU 5045H

Repair Manual

Edition 04/08 Item number 0215959

1

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1 Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.1 Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.2 Service/maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5

Jigs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Covers and crank protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 V-belt/clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Apron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6 Upper mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 Guide handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8 Guide handle head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9 Base plate and exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10 Exciter shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11 Hydraulic line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 7.1 Covers and crank protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 7.2 V-belt/clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 7.3 Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 7.4 Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 7.5 Upper mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 7.6 Apron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 7.7 Guide handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 7.8 Guide handle head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 7.9 Base plate and exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 7.10 Exciter shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 7.11 Hydraulic line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

8

Hydraulic line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 8.1 Bleeding the hydraulic line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

1

13 13 19 25 31 35 39 43 47 53 57 69

9

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3 Hydraulic control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4 Exciter oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5 Exciter V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

11

Torque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

2

145 145 146 147 148 149

1 Foreword 1

Foreword This operator's manual contains information and procedures for the safe repair of the WACKER machine. In the interest of your own safety and to prevent accidents, you should carefully read through the safety information, familiarize yourself with it and observe it at all times.

The safety of the operator was one of the most important aspects taken into consideration when this machine was designed. However, an incorrect repair can pose a risk. Please repair your WACKER machine in accordance with the instructions in this manual.

All rights reserved, especially reproduction and distribution rights.

Copyright 2008 Wacker Construction Equipment AG

No part of this manual may be reproduced, processed, copied or distributed by any means without the expressed written permission of WACKER. Any type of reproduction, distribution or storage on data media of any type and form not authorized by WACKER represents an infringement of copyright and will be prosecuted.

We expressly reserve the right to make technical modifications – even without special notice – which aim at further improving our machines or their safety standards.

3

1 Foreword

4

2 Introduction 2

Introduction 2.1

Symbols used Warning symbols This manual contains safety regulations of the categories: DANGER, WARNING, CAUTION, NOTICE. They should be followed to prevent danger to life and limb or damage to equipment or improper service.

DANGER This warning notice indicates hazards that result in serious injury or even death. f

WARNING This warning notice indicates hazards that can result in serious injury or even death. f

CAUTION This warning notice indicates hazards that can result in minor injury. f

NOTICE This warning notice indicates hazards that can result in material damage. f

Instructions f

This symbol indicates there is something for you to do.

1.

This symbol indicates that you have to carry out something in a defined sequence.

5

Symbols used

2 Introduction 2.2

General notes Detail depth of the description These instructions only describe such work where an explanation is required.

How to change easy to replace spare parts, that e.g. are only attached by means of screws and can be easily changed by loosening the screwed connection, will not be described here.

Indication of location The designations front, rear, inside, outside, right or left always refer to the view direction from the working position of the operator.

Engine The machine is equipped with an EPA-certified engine. This manual does not contain any information on the maintenance of the engine. Engine maintenance details are contained in the separate manual provided by the manufacturer of the engine.

6

General notes

3 Safety information 3

Safety information 3.1

Principle Follow operator's manual This manual only contains maintenance instructions. Also observe the information contained in the operating instructions of the machine.

Qualification Only repair the machine if you are a qualified mechanical engineer or have a corresponding professional qualification.

Spare parts, accessories Only use spare parts and accessories from WACKER. Non-compliance will exempt the manufacturer from all liability.

Structural modifications Never attempt to modify the machine without the written permission of the manufacturer. Failure to do so will endanger your safety! In addition, this will void the warranty and the liability on behalf of the manufacturer.

Exclusion of liability WACKER will refuse to accept liability for injuries to persons or for damage to materials in the following cases:

Structural modifications.

Improper use.

Improper handling.

Use of spare parts and accessories not produced by WACKER. Repair by insufficiently qualified personnel.

Country-specific regulations Observe the country-specific regulations, standards and guidelines in reference to accident prevention and environmental safety, for example those pertaining to hazardous materials and wearing protective gear.

Complement the manual with additional instructions taking into account the operational, regulatory, national or generally applicable safety guidelines.

7

Principle

3 Safety information 3.2

Service/maintenance Service work/maintenance work Service and maintenance work must only be carried out to the extent described in this manual.

Turning off the engine Before commencing any work on the machine, switch off the engine.

Safety devices When you have finished working on the machine, correctly refit the machine with all safety devices that you initially removed for executing such work.

Tilt machine For all work the machine must be placed in a position which is as horizontal as possible. Do not lay the machine on its side.

8

Service/maintenance

4 Technical data 4

Technical data Unit Item no.

Operating weight Without support plates (440 mm) With support plates (600 mm) with support plates (750 mm)

kg: kg: kg:

Advance/reverse travel

m/min:

Area capacity

m2/h:

DPU 4045H

DPU 4045H

DPU 5045H

0610044

0610051

0610047

367

367 390

367 390 406

406

Powertrain

0 - 20

0 - 24

732

878

From the drive motor over the automatic centrifugal clutch and V-belt directly to the exciter

Exciter Vibrations

rpm (Hz):

Centrifugal force

kN:

Oil Oil quantity

4,140 (69)

4,150 (69)

40

50

Fuchs Titan Unic 10W40 MC (SAE 10W40) l

Drive motor

Air-cooled, single-cylinder, four-cycle diesel engine

Engine displacement

cm3:

413

Engine speed

rpm

2,800 (220)

Rated power (*)

kW (HP):

Fuel

5.5 (7.5) Diesel

Fuel consumption

l/h:

1.5

Tank capacity

l:

5.0

Oil

Fuchs Titan Unic 10W40 MC (SAE 10W40)

Hydraulic Hydraulic oil

Fuchs Renolin MR 520

9

4 Technical data

Unit Sound pressure level at operator's station The weighted effective acceleration value, determined according to EN ISO 5349

L

DPU 4045H

DPU 4045H

: PA

92 dB(A)

m/s2:

Amounts to approx. 6.7

DPU 5045H 94 dB(A)

Amounts to approx. 6.0

(*) Corresponds to the installed effective power in accordance with Directive 2000/14/EC

10

5 Jigs 5

Jigs

0058929

0047380

0048585

0205327 0095512

0094654

0206626 0206600

0206627

Eye bolt M16 27 mm open end wrench

Item no.

Item no.

Designation

Designation

0047380

Pressing tool

0206600

Die

0048585

Pipe

0206626

Press-fit pipe

0058929

Bolt

0206627

Press-fit pipe

0094654

Strap wrench

Eye bolt M16 (Merchandise)

0095512

Pipe

27 mm open end wrench - machined

0205327

Safety device

11

5 Jigs

12

6 Disassembly 6

Disassembly 6.1

Covers and crank protector 31

1

14

30

2 15

29

3

13

16 17

4

12

5 11 28 6 15

7

27 25

24

23

18

25 24

10

98

26 19

22 20

21

Item

Designation

Item

Designation

Item

Designation

1

Handle

6

Cushion

11

Strap hinge

2

Cover

7

Bottom plate

12

Cheese head screw

3

Bolt

8

Bracket

13

Cushion

4

Rubber profile

9

Disc

14

Belt guard

5

Crank protection

10

Cheese head screw

15

Cheese head screw

13

Covers and crank protector

6 Disassembly

31

1

14

30

2 15

29

3

13

16 17

4

12

5 11 28 6 15

7

27 25

24

23

18

25 24

98

10

26 19

22 20

21

Item

Designation

Item

Designation

Item

Designation

16

Disc

22

Protective hood

28

Protective frame

17

Bracket

23

Protective side plate

29

Belt guard

18

Disc

24

Disc

30

Cheese head screw

19

Cheese head screw

25

Cheese head screw

31

Disc

20

Cheese head screw

26

Oil drain compl.

21

Disc

27

Lock washer

14

Covers and crank protector

6 Disassembly

18,19

21,20

22

1. Remove both of the upper cheese head screws (19) with the discs (18) using a 10 mm Allen wrench.

2. Remove both of the lower cheese head screws (20) with the discs (21) using a 6 mm Allen wrench. Take off the protective hood (22).

26

25,24 23

NOTICE Motor oil can spill.

The environment can be contaminated. f Avoid spilling oil. f Remove any spilled oil immediately. f Do not disconnect the oil drain hose.

3. Remove both of the cheese head screws (25) with the discs (24) using a 6 mm Allen wrench. Remove the oil drain compl. (26) and set aside, but do not disconnect from the hose.

4. Remove both of the lower cheese head screws (25) with the discs (24) using a 6 mm Allen wrench. Remove the protective side plate (23).

15

Covers and crank protector

6 Disassembly

14

31,30

5. Remove both of the cheese head screws (30) with the discs (31) using an 8 mm Allen wrench. Remove the belt guard (14) in an upward direction.

28

27,15

27,15 15,27

6. Remove the cheese head screws (15) with lock washers (27) with an 10 mm Allen wrench. Detach the protective frame (28).

16

Covers and crank protector

6 Disassembly

17 15

16

7. Unscrew the cheese head screw (15) with the disc (16) using a 10 mm Allen wrench and remove it together with the bracket (17). Applies to both brackets (17).

1

c b

a 8. Replace handle (1) if necessary. To do this, unscrew the screw (a) and remove the lock (b).

9. Unscrew the hexagonal nut (c) and remove the handle (1).

Note:

The screw (a) and the hexagonal nut (c) are glued on and therefore difficult to remove.

17

Covers and crank protector

6 Disassembly

2

3 12 11

10. Unscrew the cheese head screws (12) with a 6 mm Allen wrench and remove the cover (2) with strap hinge (11).

11. Remove the bolt (3) with taper punch from the strap hinge (11).

12. If necessary, detach the cushion (13, 6) and remove residue.

8 10,9

13. Unscrew the cheese head screws (10) with a 5 mm Allen wrench. Remove discs (9) and bracket (8).

18

Covers and crank protector

6 Disassembly 6.2

V-belt/clutch

1

2 3

5

4

6

7 8

10 9 11

20

19 18

12

11

13

17

14

16

Item

Designation

Item

Designation

Item

15

Designation

1

Cheese head screw

8

Clamping sleeve

15

V-belt

2

Mushroom washer

9

Cheese head screw

16

Cheese head screw

3

Disc spring

10

Clutch drum

17

Retaining clip

4

Seal

11

Deep groove ball bearing

18

Disc

5

V-belt pulley

12

Retaining clip

19

Retaining clip

6

DU-bushing

13

Centrifugal clutch

20

Bushing

7

Pin

14

Flange

19

V-belt/clutch

6 Disassembly

First, the belt guard must be removed on the right side. See chapter 6.1 "Disassembling covers and the crank protector."

0094654

1

1. Turn the clutch by hand and find the location where the V-belt is under the smallest amount of tension.

2. Open the cheese head screw (1) with a 6 mm Allen wrench. The clutch is held in place with strap wrench 0094654 (see chapter 5 "Jigs").

3. Completely unscrew the cheese head screw (1). The 2 disc springs (3) are released during unscrewing. The original screw is long enough that the disc springs release before the screw leaves the thread.

4. The cheese head screw (1), mushroom washer (2), disc springs (3) and seal (4) can be removed.

a

5. If the mark (a) on the V-belt pulley (5) and pin (7) is missing, mark these locations so that the clutch members can be fitted in the same position again.

20

V-belt/clutch

6 Disassembly

6. Remove the V-belt pulley (5).

b

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

19

8. All steps completed to this point are necessary for the changeover of the V-belt.

V-belt installation see 7.2 "Assembling the V-belt/clutch, item 15".

9. Remove retaining clip (19) with pliers.

21

V-belt/clutch

6 Disassembly

9

10. The disc (18) can be easily removed with the cheese head screw (1) because it now sits loose in the clutch.

11. Remove snap ring (17) with pliers. Loosen and unscrew the cheese head screw (9).

12. The centrifugal clutch (13) is detached from the engine shaft with a pulling screw.

To do so, one needs a cheese head screw M16 with a minimum length of 90 mm (0011382 screw DIN 931 M16x90). Screw this cheese head screw into the existing thread and release the centrifugal clutch (13) with the appropriate wrench.

Note:

The clutch drum (10 - 13) sits on a cone flange (14) and suddenly releases.

22

V-belt/clutch

6 Disassembly

16

14

c

13. Loosen the 4 cheese head screws (16) on the disc flywheel of the motor and remove the flange (14). Lock the disc flywheel with a screw (c) or bolt.

14. Under a hand press, the clutch drum (10) can be separated from the centrifugal clutch (13).

15. The deep groove ball bearing (11) in the clutch drum (10) is dismantled as follows: Remove both of the retaining clips (12) with pliers. The deep groove ball bearing (11) sits loosely in the clutch drum (10), on older machines, press out with a hand press and light pressure.

16. Remove the second deep groove ball bearing (11) from the centrifugal clutch (13) with a 2-arm puller.

17. The pins (7) can be pressed out of the clutch drum (10) with an arbor using a hand press.

18. The DU-bushings (6) are pressed out of the V-belt pulley (5) with jig bolt 0048585 (see chapter 5 "Jigs") under a hand press.

23

V-belt/clutch

6 Disassembly

0206600

20

b 19. The bushing (20) is also pressed out of the V-belt pulley (5) under the hand press with die 0206600 (see chapter 5 "Jigs") and base (b).

20. The drawing shows the entire clutch.

24

V-belt/clutch

6 Disassembly 6.3

Bowden cable 1 2 3

4 5

7

6

8

9 13 12

10

14 11 Item

Designation

Item

Designation

Item

Designation

1

Pipe clamp

6

Cheese head screw

11

Hexagonal nut

2

Disc

7

Actuator (Bowden cable)

12

Cheese head screw

3

Cheese head screw

8

Angle joint

13

Hexagonal nut

4

Transmitter

9

Lever

14

Pipe lead-through

5

Ball-shaped button

10

Angle joint

25

Bowden cable

6 Disassembly

12

1. Unscrew and remove the cheese head screw (12) from the lower angle joint (10) with a 5 mm Allen wrench.

9

2. Separate the upper angle joint (8) with an 8 mm open-end wrench and a 10 mm ring wrench. Remove the hexagonal nut (13). The hexagonal nut (13) is a locknut. Remove the handle (9).

26

Bowden cable

6 Disassembly

3. Loosen the adjusting nut with a 17 mm open-end wrench and remove the actuator (7) from the angle plate.

b a

4. Loosen and unscrew the adjusting nut on the angle joint (8) with a 10 mm openend wrench and pliers. Turn and remove the angle joint (8).

5. Unscrew and remove the black dust cap (a) by hand. Unscrew both of the adjusting nuts (b) from the actuator (7). The actuator (7) is now free from all attachment parts.

27

Bowden cable

6 Disassembly

6. Loosen 3 pipe clamps (1) with a 10 mm ring wrench and remove, along with the cheese head screw (3) and the disc (2), from the guide handle. If necessary, slightly bend the pipe clamps (1) open.

4 6

7. Unscrew 2 cheese head screws (6) with a 5 mm Allen wrench and disconnect the transmitter (4) from the guide handle.

CAUTION f The transmitter (4) may fall. f Hold the transmitter (4) securely.

28

Bowden cable

6 Disassembly

14

8. Loosen the 2 pipe lead-throughs (14) on the upper mass with a screwdriver and remove from the actuator (7).

c 9. As a fit-up aid for the installation of a new Bowden cable, knot a tear-resistant cord (c) (approx. 1 m in length) on the thread of the actuator (7), secure with electrical tape if necessary. Clean the actuator (7).

10. Remove the actuator (7) from the upper mass. Both sides of the cord must protrude out of the upper mass openings.

29

Bowden cable

6 Disassembly

30

Bowden cable

6 Disassembly 6.4

Diesel engine

1

11

10 9

2 8 7

3

4 6

12 13

5

Item

Designation

Item

Designation

1

Diesel engine

6

Disc

11

Seal

2

Cheese head screw

7

Hexagonal nut

12

Angle joint

3

Lock washer

8

Bracket

13

Hexagonal nut

4

Lever

9

Cheese head screw

5

Button head screw

10

Disc

31

Item

Designation

Diesel engine

6 Disassembly

First detach the covers. See chapter 6.1 "Disassembling covers and the crank protector". Complete all steps.

Completely dismantle the clutch. See chapter 6.2 "Disassembling the Vbelt/clutch". Complete all steps.

Remove the Bowden cable. See chapter 6.3 "Disassembling the Bowden cable". If the actuator (Bowden cable) is intact, remove only the actuator from the engine.

Note:

Only complete steps 1- 3 if these parts are defective or should be mounted on a new engine.

10,9 8

1. Unscrew and remove 2 cheese head screws (9) with discs (10). Remove the bracket (8).

5

4

6,7

2. Unscrew the hexagonal nut (7) with disc (6) using a 10 mm open end wrench and remove them along with the button head screw (5). Remove the lever (4) from the shaft.

32

Diesel engine

6 Disassembly

12

13 3. Unscrew the hexagonal nut (13) with a 13 mm and 11 mm open-end wrench and remove the angle joint (12) from the level.

2,3

4. Unscrew and remove the 4 cheese head screws (2) with lock washers (3) from the engine mount.

WARNING Danger due to the machine falling!

If the engine falls, it can cause severe injury such as crushing. f Only use suitable and tested hoisting gear and lifting tackle of sufficient lifting capacity. f Attach the engine firmly to the hoisting gear.

Leave the danger area.

5. Lift the diesel engine (1) from the upper mass.

6. When the engine has been disassembled, the seal (11) can be removed. Simply pull the defective seal off the diesel engine (1). Remove the seal residue.

33

Diesel engine

6 Disassembly

34

Diesel engine

6 Disassembly 6.5

Apron 1 2

3 4 5

6

7

8

Item

Designation

Item

Designation

Item

Designation

1

Hexagonal bolt

4

Fitting

7

Fitting

2

Plate

5

Cover

8

Apron

3

Cheese head screw

6

Cheese head screw

35

Apron

6 Disassembly

1 2

1. Unscrew the 2 hexagonal bolts (1) with a 24 mm ring wrench and remove them together with the plate (2).

2. Depending on the other types of procedures, it is not always necessary to completely remove the apron.

3 4 5

3. Unscrew the 2 cheese head screws (3) with a 5 mm Allen wrench and remove them together with the fitting (4) and the cover (5).

36

Apron

6 Disassembly

7 6

8

4. Loosen the 6 cheese head screws (6) with a 5 mm Allen wrench, do not remove them. Leave the fitting (7) on the machine if it does not need to be replaced.

Open the apron (8) and pull it out. Only partially pull the apron out.

37

Apron

6 Disassembly

38

Apron

6 Disassembly 6.6

Upper mass

8

7

1

3 4

2

Item

Designation

6

Item

Designation

5

Item

Designation

1

Cheese head screw

4

Seal

7

Pipe clamp

2

Lock washer

5

Hose pipe

8

Upper mass

3

Hollow screw

6

Cheese head screw

39

Upper mass

6 Disassembly

Disassemble the apron. See chapter 6.5 "Disassembling the apron".

First detach the covers. See chapter 6.1 "Disassembling covers and the crank protector". The protective frame can remain on the machine.

Disassemble the clutch. See chapter 6.2 "Disassembling the V-belt/clutch".

Disassemble the clutch to the extent that the V-belt can be removed.

1,2

1,2

1. Unscrew the cheese head screws (1) with a 10 mm Allen wrench and remove them together with the lock washers (2). 8 cheese head screws (1) need to be unscrewed, 4 at the front and 4 at the rear.

Note:

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

This connection must be severed before the upper mass is removed.

40

Upper mass

6 Disassembly

WARNING Danger due to the machine falling!

If the upper mass falls, it can cause severe injury such as crushing. f Only use suitable and tested hoisting gear and lifting tackle of sufficient lifting capacity. f Attach the upper mass firmly to the hoisting gear.

Insert a spacer, e.g. wood, between the upper mass and the base plate.

2. With a crane and suitable lifting gear, lift the upper mass (8) approx. 100 mm.

3. In order to loosen the hose, the workspace must be secured, for example, with wood between the upper mass and the base plate (assembly safety mechanism).

5 7

6

41

Upper mass

6 Disassembly 4. Unscrew the hollow screw (3) with a 19 mm ring wrench and remove it together with the hose pipe (5). The hose pipe (5) has 2 seals (4). Unscrew the cheese head screw (6) with a 5 mm Allen wrench and remove it together with the pipe clamp (7).

NOTICE Oil leaks out when the hose pipe (5) is loosened. Do not allow the oil to enter the base. f Please observe the environmental regulations in effect when you dispose of the used oil.

5. Remove the upper mass (8).

42

Upper mass

6 Disassembly 6.7

Guide handle 12

10

13

9

14 15

8 7

11

6

17 18

4 3 1

16

19 20 21

5

2

22 23 24

Item

Designation

Item

Designation

Item

Designation

1

Hose pipe

9

Disc

17

Threaded spindle compl.

2

Holder compl.

10

Button

18

Cheese head screw

3

Hexagonal bolt

11

Guide handle

19

Bracket

4

Worm drive hose clip

12

Washer

20

Disc

5

Bellows

13

Rubber element

21

Vibration dampers

6

Locking pin

14

Handle

22

Cheese head screw

7

Compression spring

15

Mushroom washer

23

Disc

8

Setscrew

16

Cheese head screw

24

Holder

43

Guide handle

6 Disassembly

Disassemble the apron. See chapter 6.5 "Disassembling the apron".

Remove the covers. See chapter 6.1 "Disassembling covers and the crank protector".

Remove the 3 pipe clamps, the actuator (Bowden cable), and the transmitter.

See chapter 6.3 "Disassembling the Bowden cable".

Dismantle the upper mass, but without removing it. See chapter 6.6 "Disassembling the upper mass".

1. Unscrew the 2 cheese head screws (22) with a 10 mm Allen wrench and remove them together with the discs (23) and the holder (24).

4

5

2. Open the worm drive hose clip (4) with a screwdriver and allow it to hang loosely.

3. Remove the bellows (5). If the bellows (5) is difficult to remove, apply a dull object to the edges. Do not destroy the bellows (5).

44

Guide handle

6 Disassembly

WARNING Danger due to the machine falling!

If the guide handle falls, it can cause severe injury, e.g. bruising and crushing. f Only use suitable and tested hoisting gear and lifting tackle of sufficient lifting capacity. f Attach the guide handle securely to the lifting gear.

2 3

11

4. On each side, unscrew 2 cheese head screws (3) with a 13 mm open-end wrench.

Note:

The guide handle (11) is mounted to the machine with these 4 cheese head screws (3). The guide handle (11) is heavy. Before disassembling, hang and secure the guide handle on the crane.

5. Remove the holder (2) along with the guide handle (11) from the machine. The hose pipe (1) remains hanging in the machine. Exercise caution when disassembling, so that the hose pipe (1) does not become jammed.

6. Disassemble the handle: Unscrew the cheese head screw (16) with a 12 mm Allen wrench and remove the entire handle (6-9) from the guide handle head.

This procedure applies to both sides.

Note:

The entire handle with all components can fall!

7. Disassemble the vibration damper: Unscrew the 4 cheese head screws (18) with an 8 mm Allen wrench and remove the bracket (19) along with the vibration damper (17-21).

8. The threaded spindle (17), together with the disc (20), is screwed in, bonded, and tightened in the vibration damper (21).

9. Loosen the button (10). Because the button (10) is bonded, the parts can be heated with an industrial air gun. Remove the button (10) along with the disc (9).

45

Guide handle

6 Disassembly 10. The locking pin (6) can be removed with a downwards motion. The compression spring (7) can be removed.

46

Guide handle

6 Disassembly 6.8

Guide handle head 8

7 3

1

2

6

4

9 10 11

5

12

Item

Designation

Item

Designation

Item

Designation

1

Cheese head screw

5

Control piston

9

Gear rack

2

O-ring

6

Compression spring

10

O-ring

3

Control piston compl.

7

Guide

11

Spacer

4

Piston sealing ring

8

Guide handle head

12

O-ring

47

Guide handle head

6 Disassembly First disassemble the left handle: Unscrew the cheese head screw with a 12 mm Allen wrench and remove the entire handle from the guide handle head. This procedure applies to both sides. See chapter 6.7 "Disassembling the guide handle".

CAUTION The entire handle with all components can fall!

Note:

After disassembly, the gear rack (9) has the position shown in the figure. The gear rack may only be reinstalled in this position. The parallel part shows how the machined surfaces are positioned!

WARNING Danger due to spring-loaded control pistons!

If the control pistons shoot out, they can cause severe injury. f Always use the safety device. f Only release the spring under a press.

48

Guide handle head

6 Disassembly

8 0205327 a

1. The guide handle head (8) may only be removed with safety device 0205327 (see chapter 5 "Jigs"). Correctly attach the jig, firmly tighten the screw (a).

WARNING Danger due to the machine falling!

If the guide handle head falls, it can cause injury. f Hold the guide handle head firmly and secure it against falling.

2. Unscrew the 4 cheese head screws (1) with a 6 mm Allen wrench and remove them. Remove the O-ring (2) between the guide handle head (8) and the guide handle.

3. Release the compression spring (6) under a hand press and remove it along with the control piston (3). With the press in fitted position, the safety device 0205327 (see chapter 5 "Jigs") must be removed prior to releasing the spring (see figure).

4. If the piston sealing ring (4) is defective, it can be removed with a screwdriver.

New seals consist of 2 parts, older seals consist of one part. Disassemble all parts.

49

Guide handle head

6 Disassembly

5. Press out the gear rack (9) and the spacer (11) with the arbor.

Note:

The gear rack (9) and the spacer (11) fall.

6. In order to press out the second spacer (11), reinsert the gear rack (9) and press out with the arbor.

50

Guide handle head

6 Disassembly

7. The spacer (11) has an internal O-ring (12) and an external O-ring (10).

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

9. The guide (7) can be pressed out through the oil filler opening under a hand press.

51

Guide handle head

6 Disassembly

52

Guide handle head

6 Disassembly 6.9

Base plate and exciter

1 2

9

8

10 7 11

3

7

4 6 5 Item

Designation

Item

Designation

Item

Designation

1

Cheese head screw

5

Lock washer

9

Vibration dampers

2

Exciter compl.

6

Support plate

10

Shockmount support

3

Shock bushing

7

Conical spring washer

11

Cheese head screw

4

Hexagonal bolt

8

Hexagonal bolt

53

Base plate and exciter

6 Disassembly

First complete the steps from chapter 6.6 "Disassembling the upper mass".

1. If the vibration damper is defective, unscrew and remove the 10 mm cheese head screw (11). Secure the vibration damper (9) with the strap wrench 0094654 (see chapter 5 "Jigs"). Remove the cheese head screw (11), conical spring washer (7), and shockmount support (10).

54

Base plate and exciter

6 Disassembly

2. Unscrew the hexagonal bolt (8) using the 24 mm ring wrench. Secure the vibration damper (9) with the strap wrench 0094654 (see chapter 5 "Jigs"). Unscrew the hexagonal bolt (8), along with the conical spring washer (7), from the vibration damper (9) and remove the vibration damper (9).

3. In order to disassemble of one or more of the vibration damper (9), the corresponding support plate (6) must be removed.

4. Unscrew the 4 hexagonal bolts (4) in the support plate (6) using a 24 mm ring wrench (use an extension if the bolts are tight), and remove together with the lock washer (5).

CAUTION Danger due to the machine falling!

If the support plate falls, it can cause injury. f Position the base plate and the support plate in such a way, that the support plate cannot fall.

5. If the shock bushing (3) is defective, it can be removed by hand.

55

Base plate and exciter

6 Disassembly

Note:

Mark the location of the exciter (2) on the base plate.

6. Unscrew the binding screws from the base plate to the exciter (2). 12 cheese head screws (1) need to be unscrewed. Remove all of the screws.

WARNING Danger due to the machine falling!

If the exciter falls, it can cause severe injury. f Only use suitable and tested hoisting gear and lifting tackle of sufficient lifting capacity. f Attach the exciter firmly to the hoisting gear.

Leave the danger area.

7. Screw the M16 eye bolts into 2 opposing boreholes on the exciter (2) for transport. Connect both eye bolts with a suitable transport cable. Transport the exciter (2) to a workbench using a suitable means of transport.

56

Base plate and exciter

6 Disassembly 6.10

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

57

Exciter shafts

6 Disassembly

Item

Designation

Item

Designation

Item

Designation

1

Hexagonal bolt

11

Cylindrical roller bearing

21

Retaining clip

2

Body-plain washer

12

Bolt, cpl.

22

Retaining clip

3

Plate

13

Lip seal ring

23

Deep groove ball bearing

4

V-belt pulley

14

O-ring

24

Adjusting sleeve

5

Hexagonal bolt

15

Bolt

25

Shaft

6

Spring washer

16

Retaining clip

26

Tripping pin

7

Protection housing

17

Deep groove ball bearing

27

Eccentric weight

8

Rotary shaft seal

18

Spring washer

28

Lock washer

9

Cylinder cover

19

Hexagonal bolt

29

Cheese head screw

10

Cheese head screw

20

Control pin

58

Exciter shafts

6 Disassembly

31 10

6

32 30

6 10 40 28 33

39

28 34 11

37 35

35 11

38

36

Item

Designation

Item

Designation

Item

Designation

6

Spring washer

31

Exciter housing

36

Feather key

10

Cheese head screw

32

Cover

37

Gear

11

Cylindrical roller bearing

33

Cheese head screw

38

Shaft

28

Lock washer

34

Eccentric weight

39

Eccentric weight

30

Breather cover

35

Retaining clip

40

Cheese head screw

59

Exciter shafts

6 Disassembly

WARNING Danger of crushing.

The freely turnable shafts with the mounted eccentric weights can cause severe injuries to your hands. f Never reach into the open exciter if the shafts with the eccentric weights are not secured against independent rotation. f Follow the disassembly steps.

First complete the steps from chapter 6.9 "Disassembling the base plate and exciter".

2,1 3

1. Unscrew the 6 hexagonal bolts (1) with a 10 mm wrench and remove them together with the body-plain washers (2). The bolts are glued on and thus may be difficult to unscrew.

2. The plate (3) is sealed onto the protection housing (7) with a sealant. Remove the plate (3) by tapping it lightly with a plastic mallet.

4

3. Remove the V-belt pulley (4) using a taper punch and a hammer.

60

Exciter shafts

6 Disassembly

Note:

The V-belt pulley (4) has a left-hand thread. Follow the correct direction of rotation (clockwise) when disassembling!

7

4. Unscrew the 9 hexagonal bolts (5) with a 5 mm Allen wrench and remove them together with the spring washer (6). The bolts are glued on and thus may be difficult to unscrew.

CAUTION The protection housing (7) may fall.

5. Remove the protection housing (7). The protection housing (7) is installed with a sealant. If it is tight, remove the protection housing (7) from the exciter housing (31) by tapping it lightly with a plastic mallet.

6. Lever the rotary shaft seal (8) out of the bore using a screwdriver. Dispose of the defective rotary shaft seal (8), the rotary shaft seal (8) can be used only once.

10,6

9

7. Prior to disassembly, mark all 4 openings in the exciter housing (31) and the corresponding covers, in order to avoid an interchange during assembly.

61

Exciter shafts

6 Disassembly 8. Unscrew the 5 cheese head screws (10) with the spring washer (6) from the cylinder cover (9) with a 5 mm Allen wrench, and remove them. The bolts are glued on and thus may be difficult to unscrew.

9. Axially remove the cylinder cover (9) by hand. The cylinder cover (9) must be removed against the seal of the control piston. Do not use a plastic mallet or similar tool!

32

10,6

10. Unscrew the 4 cheese head screws (10) from the cover (32) with a 5 mm Allen wrench and remove them together with the spring washer (6). The bolts are glued on and thus may be difficult to unscrew.

11. Remove the cover (32). A bore is open. A hose clamp is mounted in this location during assembly. The cover (32) is sealed, carefully remove it with a screwdriver if it is tight.

30

10,6

12. Unscrew the 5 cheese head screws (10) from the breather cover (30) with a 5 mm Allen wrench and remove them together with the spring washer (6). The bolts are glued on and thus may be difficult to unscrew.

13. Take off the breather cover (30). If it is tight, carefully remove it with a screwdriver.

62

Exciter shafts

6 Disassembly

a

14. Set the exciter upright, and secure it with a screw clamp (a) on the right side.

WARNING Danger due to the machine falling.

If the eccentric weights fall, they can cause injury. f Hold the eccentric weights firmly when removing the screws.

15. Unscrew the 5 cheese head screws (29, 33, 40) with a 14 mm Allen wrench and remove them together with the lock washer (28). Remove the corresponding eccentric weights (27, 34, 39) in the process.

16. An eccentric weight (27) cannot be upgraded in this condition. Place the exciter on a workbench, lightly drive the shaft (25) in several millimeters with a plastic mallet, remove the eccentric weight (27).

17. Both of the shafts can be pressed out with the bearings. If the bearings need to be reinstalled, they must be installed in the same position in the exciter housing - therefore, mark the position. Set up the exciter under a hand press. In doing so, the bearing and the shaft to be pressed out must be open. This means that the exciter must be positioned on a jig which allows both parts to be pressed out.

63

Exciter shafts

6 Disassembly

0047380

0047380

18. With the jig pressing tool 0047380 (see chapter 5 "Jigs"), press out the bearings.

Note:

Mark the outer and inner bearing rings, as they must not be interchanged if reused.

64

Exciter shafts

6 Disassembly

19. In order to remove the shafts (25, 38) from the exciter housing (31), the outer rings of the cylindrical roller bearings (11) must be removed. Then, remove the shafts (25, 38) from the exciter housing (31).

20. Disassemble the shaft (38). Remove the inner rings of the cylindrical roller bearings (11) with a 2-arm extractor.

65

Exciter shafts

6 Disassembly

35

21. Remove retaining clips (35) with pliers.

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

23. Detach the shaft (25). Remove the inner rings of the cylindrical roller bearings (11) with a 2-arm extractor.

66

Exciter shafts

6 Disassembly

24. Remove the two retaining clips (21, 22) with pliers. The adjusting sleeve (24) then falls down. Remove the shaft (25) from the adjusting sleeve (24).

25. Remove the deep groove ball bearing (23) from the adjusting sleeve (24).

26. Remove the tripping pin (26).

20

27. Remove retaining clip (16) with pliers. Remove the control pin (20).

67

Exciter shafts

6 Disassembly

28. Unscrew the hexagonal bolt (19) with a 10 mm Allen wrench and remove it together with the spring washer (18). The bolt is glued on and thus may be difficult to unscrew.

29. Remove both of the deep groove ball bearings (17) from the bolt (15) with a 2-arm extractor.

30. Remove the lip seal ring (13) and the O-ring (14) if necessary.

68

Exciter shafts

6 Disassembly 6.11

Hydraulic line 1

2

3

4

6

5

Item

Designation

Item

Designation

Item

Designation

1

Screwed socket

3

Guide handle

5

Screw

2

Connection flange

4

Pipe clamp

6

Hose pipe

69

Hydraulic line

6 Disassembly

Unscrew the hydraulic line (6) from the exciter. See chapter 6.6 "Disassembling the upper mass". Catch the oil in the container, do not allow it to enter the base.

1. Unscrew the screw (5) from the pipe clamp (4) with a 6 mm Allen wrench and remove it.

2. Unscrew the jam nut from the screwed socket (1) with 2 open end wrenches (19, 22 mm) and remove it. If necessary, the screwed socket (1) can be separated from the intermediate flange (2).

3. Remove the hose pipe (6) from the guide handle (3).

70

Hydraulic line

7 Assembly 7

Assembly 7.1

Covers and crank protector 31

1

14

30

2 15

29

3

13

16 17

4

12

5 11 28 6 15

7

27 25

24

23

18

25 24

10

98

26 19

22 20

21 Item

Designation

Item

Designation

Item

Designation

1

Handle

6

Cushion

11

Strap hinge

2

Cover

7

Bottom plate

12

Cheese head screw

3

Bolt

8

Bracket

13

Cushion

4

Rubber profile

9

Disc

14

Belt guard

5

Crank protection

10

Cheese head screw

15

Cheese head screw

71

Covers and crank protector

7 Assembly

31

1

14

30

2 15

29

3

13

16 17

4

12

5 11 28 6 15

7

27 25

24

23

18

25 24

98

10

26 19

22 20

21 Item

Designation

Item

Designation

Item

Designation

16

Disc

22

Protective hood

28

Protective frame

17

Bracket

23

Protective side plate

29

Belt guard

18

Disc

24

Disc

30

Cheese head screw

19

Cheese head screw

25

Cheese head screw

31

Disc

20

Cheese head screw

26

Oil drain compl.

21

Disc

27

Lock washer

72

Covers and crank protector

7 Assembly

1

2

c b

d

a 1. Set the handle (1) on the cover (2). Apply Omnifit 100M to the hexagonal nut (c), screw in the nut and tighten it. The torque is 15 Nm. 2. Place the lock (b) on the bottom part of the handle (d). Apply Omnifit 100M to the screw (a), screw it in and tighten it. The torque is 10 Nm.

73

Covers and crank protector

7 Assembly

2

3 11 12

5

3. Place the strap hinge (11) on the crank protection (5) and attach it with cheese head screws (12).

4. Hold the cover (2) next to the strap hinge (11), insert the bolt (3).

13 5 4 6 e

5. Remove the protective film from both of the self-adhesive cushions (13, 6), and affix them to the cleaned surfaces.

6. Apply Sicomet to the edge (e) of the crank protection (5), which has been cleaned of adhesive residuals, and affix the rubber profile (4).

74

Covers and crank protector

7 Assembly

7 9,10 8

82 mm

7. Hold the bracket (8) on the front side of the bottom plate (7), secure it in the slot along with the discs (9) and the cheese head screws (10).

8. Adjust the bracket (8) to 82 mm to the upper edge of the bracket (8) and tighten the cheese head screws (10).

75

Covers and crank protector

7 Assembly

17 15

16

9. Mount both of the brackets (17). Tighten the cheese head screws (15) along with the discs (16) with a 10 mm Allen wrench.

28

15,27

26,15 15,27

10. Mount the protective frame (28). Mount the cheese head screws (15) along with the lock washer (27) using a 10 mm Allen wrench. The torque is 86 Nm.

76

Covers and crank protector

7 Assembly

14

31,30

11. Install the belt guard (14). From above, set the belt guard (14) on top. Mount both of the cheese head screws (30) along with the discs (31) using an 8 mm Allen wrench. The torque is 49 Nm. 26

25,24 23

12. Mount the protective side plate (23). Mount both of the lower cheese head screws (25) along with the discs (24) using a 6 mm Allen wrench. The torque is 25 Nm. NOTICE Motor oil can spill.

The environment can be contaminated. f Avoid spilling oil. f Remove any spilled oil immediately. f Do not disconnect the oil drain hose.

13. Attach the oil drain compl. (26) and mount both of the upper cheese head screws (25) along with the disc (24) using a 6 mm Allen wrench. The torque is 25 Nm.

77

Covers and crank protector

7 Assembly

18,19

21,20

22

14. Attach the lateral protection cover (22). Mount both of the upper cheese head screws (19) along with the discs (18) using a 10 mm Allen wrench. The torque is 86 Nm. 15. Mount both of the lower cheese head screws (20) along with the discs (21) using a 6 mm Allen wrench. The torque is 25 Nm.

78

Covers and crank protector

7 Assembly 7.2

V-belt/clutch

1

2 3

5

4

6

7 8

10 9 11

20

19 18

12

11

13

17

14

16

Item

Designation

Item

Designation

Item

15

Designation

1

Cheese head screw

8

Clamping sleeve

15

V-belt

2

Mushroom washer

9

Cheese head screw

16

Cheese head screw

3

Disc spring

10

Clutch drum

17

Retaining clip

4

Seal

11

Deep groove ball bearing

18

Disc

5

V-belt pulley

12

Retaining clip

19

Retaining clip

6

DU-bushing

13

Centrifugal clutch

20

Bushing

7

Pin

14

Flange

79

V-belt/clutch

7 Assembly 1. Once the defective parts have been replaced, assembly proceeds in the reverse order.

2. The wearing parts must be replaced if grooves are visible, circularity is not present, or material wear is visible. The automatic operation of the centrifugal clutch functions only if the wearing parts still have an adequate amount of material. The wearing parts are items 3, 6, 7, 15, 20.

3. Because of the automatic operation, the V-belt does not need to be retightened.

Problems in the exciter drive system indicate that the parts are worn. Also see chapter 9 "Maintenance".

Note:

Do not oil or grease clutch members! Oiling or greasing destroys the graphite components of the bushings.

4. Press pins (7) into the clutch drum (10) using a hand press. The pins (7) are flush with the rear side.

0206600 6 5

5. Press the bushing (20) into the V-belt pulley (5) using a hand press and die 0206600 (see chapter 5 "Jigs"). Likewise, press the DU-bushings (6) into the V-belt pulley (5) with the bolt 0058929 (see chapter 5 "Jigs").

80

V-belt/clutch

7 Assembly 6. Insert the deep groove ball bearing (11) into the clutch drum (10) by hand. On older parts, the bearings may need to be inserted with light pressure.

7. Press the second deep groove ball bearing (11) onto the shaft of the centrifugal clutch (13) using a hand press.

8. Remove both of the retaining clips (12) with pliers.

9. Install the centrifugal clutch (13) using a hand press. The centrifugal clutch (13) must be able to rotate easily in the clutch drum (10) after installation, the girders are equally spaced to the clutch drum (10) around the entire drum.

10. Turn over the clutch drum (10) and insert the retaining clip (17) with pliers. Press in the clamping sleeve (8). Always replace both of the clamping sleeves (8), even if only one is worn or defective.

c 11. Mount the flange (14) onto the disc flywheel of the motor with 4 cheese head screws (16). Lock the disc flywheel with a screw (c) or bolt when tightening the cheese head screws (16). The torque is 25 Nm. Tighten the screws crosswise.

81

V-belt/clutch

7 Assembly

a

12. Mount the assembled clutch onto the flange (14). The clutch sits on the flange shaft (14) and is held in place with the cheese head screw (9). Clean both conical surfaces (a) of all grease prior to installation.

c 13. During installation, the disc flywheel of the motor must be locked. Lock the disc flywheel with a screw (c) or bolt. Screw in the cheese head screw (9). The torque is 86 Nm. 14. Insert the disc (18) into the clutch drum (10). Install the retaining clip (19) with pliers.

Note:

The V-belt is a wearing part that must be monitored regularly and replaced if necessary. If the V-belt width should fall below the measurement of 15.5 mm, the V-belt must be replaced.

82

V-belt/clutch

7 Assembly

b

15. Install the V-belt (15). First install the V-belt (15) in the V-belt pulley (b) of the exciter in the base plate. Then, position the V-belt (15) on top of the clutch drum (10).

16. During disassembly of the V-belt pulley (5), the position on the clutch drum (10) was marked. Observe this mark and reassemble both parts in the same position.

17. Slide the V-belt pulley (5) onto the clutch drum (10). Keep the V-belt (15) under tension and ensure that it remains in the V-belt pulley (b) of the exciter.

83

V-belt/clutch

7 Assembly

c

18. Insert the seal (4) and disc springs (3) into the V-belt pulley (5). Observe the following:

The parts must rest exactly in the intended recess.

The flexible tongues (c) of both disc springs must not rest on top of each other, as shown in the figure. Instead, they should form a hole.

Note:

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

0094654 0094654

2

1

19. The parts are fixed with a mushroom washer (2) and cheese head screw (1).

Tighten the cheese head screw (1) with a torque wrench and 49 Nm. Hold the clutch in place with the strap wrench 0094654 (see chapter 5 "Jigs"). Complete the functional check by hand.

20. Reattach the belt guard. See chapter 7.1 "Assembling covers and the crank protector".

84

V-belt/clutch

7 Assembly 7.3

Bowden cable 1 2 3

4 5

7

6

8

9 13 12

10

14 11

Item

Designation

Item

Designation

Item

Designation

1

Pipe clamp

6

Cheese head screw

11

Hexagonal nut

2

Disc

7

Actuator (Bowden cable)

12

Cheese head screw

3

Cheese head screw

8

Angle joint

13

Hexagonal nut

4

Transmitter

9

Lever

14

Pipe lead-through

5

Ball-shaped button

10

Angle joint

85

Bowden cable

7 Assembly

Once the defective actuators (7) have been replaced, assembly proceeds in the reverse order.

1. Pull the pipe lead-through (14) onto the actuator (7) on the guide handle side.

2. On the guide handle side, attach the end of the cord (f) to the actuator (7) thread in order to pull the actuator (7) through the upper mass with the cord. Lightly lubricate the actuator (7).

f

3. From the guide handle side and with the thread facing forward, carefully lead the new actuator (7) into the upper mass. The cord facilitates the threading into the upper mass.

a

4. Pull the actuator (7) through the upper mass to the extent that the thread protrudes approx. 35 mm (a) over the edge of the upper mass. Remove the cord.

86

Bowden cable

7 Assembly Note:

In order to correctly install and position the actuator (7) in the following steps, the ball-shaped button (5) (throttle lever) on the guide handle must be in the stop position!

d

e 4 6 5. Hold the transmitter (4) on the guide handle and attach it with 2 cheese head screws (6) using a 5 mm Allen wrench, torque is 10 Nm. 6. Attach the 3 pipe clamps (1) onto the guide handle along with the cheese head screw (3) and the disc (2), torque is 10 Nm. 7. Hold the lever (d) securely with the ball-shaped button (5) as depicted. Tighten the middle adjusting nut (e) in the transmitter (4) with a 10 mm ring wrench, so that the lever (d) with the ball-shaped button (5) does not change its position.

8. Pull the pipe lead-through (14) onto the actuator (7) from the engine side and install it in the upper mass. Before installing in the upper mass, lightly lubricate the pipe lead-through (14) in order to facilitate installation.

9. Screw on both of the adjusting nuts. Screw in the rear nut up to approx. 50 mm.

87

Bowden cable

7 Assembly

10. Slide the black dust cap (b) as far as it will go. Screw the front jam nut (c) into the rear jam nut with clearance.

8

g c

b

7 h

11. Screw on the angle joint (8), as shown in the figure, in order to facilitate the installation.

12. Mount the actuator (7) in the elbow (g). The lower adjusting nut (b) is on the bracket, the upper adjusting nut (c) is tightened.

88

Bowden cable

7 Assembly

Note:

The actuator (7) should not rest on the upper mass (h) or the oil drain plug of the engine. If this is the case, check the settings. Do not the clamp control cable next to the actuator (7)!

8 9

9

13. Insert the level (9) into the angle joint (8) and screw in the new hexagonal nut (13). Tighten with an 8 mm ring wrench and a 10 mm open end wrench.

14. Tighten the nut on the angle joint with a 10 mm open end wrench.

89

Bowden cable

7 Assembly

15. Connect the lever (9) with the lower angle joint (10) with the cheese head screw (12). The torque is 10 Nm. 16. The distance from the lever (9) to the diesel engine (adjusting screw) should be approx. 10 mm.

90

Bowden cable

7 Assembly 7.4

Diesel engine

1

11

10 9

2 8 7

3

4 6

12 13

5

Item

Designation

Item

Designation

1

Diesel engine

6

Disc

11

Seal

2

Cheese head screw

7

Hexagonal nut

12

Angle joint

3

Lock washer

8

Bracket

13

Hexagonal nut

4

Lever

9

Cheese head screw

5

Button head screw

10

Disc

91

Item

Designation

Diesel engine

7 Assembly

1 11

3,2

11

1. Before installing the diesel engine (1), glue on a new seal (11) if necessary. The surface must be free of grease and residue. Remove the film from the seal (11) and glue the seal (11) onto the diesel engine (1).

WARNING Danger due to the machine falling!

If the engine falls, it can cause severe injury such as crushing. f Only use suitable and tested hoisting gear and lifting tackle of sufficient lifting capacity. f Attach the engine firmly to the hoisting gear.

Leave the danger area.

2. Lift the diesel engine (1) onto the upper mass.

92

Diesel engine

7 Assembly

2,3

3. Tighten the cheese head screws (2) and the lock washers (3) with a 10 mm Allen wrench, torque is 86 Nm.

10,9

8

a

4. Screw on the bracket (8) along with 2 cheese head screws (9) and discs (10) using a 5 mm Allen wrench. The torque is 10 Nm. Note:

When tightening, press the bracket (8) upwards (a) and utilize the play in the bores.

93

Diesel engine

7 Assembly

5,6,7

b

4

5. Press the disc (b) on the diesel engine (1) to the right as far as it will go, see figure above.

6. Attach the lever (4) to the shaft.

7. Loosely screw in the button head screw (5) along with the disc (6) and the hexagonal nut (7).

Install the Bowden cable, see chapter 7.3 "Assembling the Bowden cable".

Note:

The gas adjusting lever on the guide handle must be in the stop position.

12 12

4

94

Diesel engine

7 Assembly

8. Connect the lever (4) with the lower angle joint (12). Tighten the hexagonal nut (13) with 11 mm and 13 mm open end wrenches. If all parts are installed correctly, the gas setting results automatically. The lever (4) can be axially moved on the shaft.

9. Tighten the button head screw (5) along with the disc (6) and the hexagonal nut (7) using a 10 mm open end wrench.

Completely install the clutch. See chapter 7.2 "Assembling the V-belt/clutch".

Install the covers and the crank protector. See chapter 7.1 "Assembling covers and the crank protector".

95

Diesel engine

7 Assembly

96

Diesel engine

7 Assembly 7.5

Upper mass

8

7

1

3 4

2

Item

Designation

6

Item

Designation

5

Item

Designation

1

Cheese head screw

4

Seal

7

Pipe clamp

2

Lock washer

5

Hose pipe

8

Upper mass

3

Hollow screw

6

Cheese head screw

97

Upper mass

7 Assembly

WARNING Danger due to the machine falling!

If the upper mass falls, it can cause severe injury such as crushing. f Only use suitable and tested hoisting gear and lifting tackle of sufficient lifting capacity. f Attach the upper mass firmly to the hoisting gear.

Insert a spacer, e.g. wood, between the upper mass and the base plate.

1. Lift the upper mass (8) onto the base plate using a crane and suitable lifting gear.

Secure the upper mass (8) from falling, for example, with wood between the upper mass and the base plate (assembly safety mechanism).

4

2. Screw in the hose pipe (5) along with 2 new seals (4) and the hollow screw (3), and tighten with a 19 mm ring wrench.

3. When tightening, rotate the hose pipe (5) approx. 10° towards the exciter, so that

98

Upper mass

7 Assembly the pipe clamp (7) does not bend the hose pipe (5).

5 7

6

4. Secure the pipe clamp (7) and the cheese head screw (6) with a 5 mm Allen wrench. The cheese head screw (6) is glued with adhesive Omnifit 50M. Note:

The cheese head screw (6) is screwed into synthetic material, do not overwind.

5. Remove the assembly safety mechanism and place the shockmount supports of the upper mass (8) on the base plate. The bores in the upper mass (8) do not automatically fit the threaded holes in the shockmount supports. Set the alignment of the threaded holes by moving the upper mass (8).

6. Screw in the 8 cheese head screws (1) along with a new lock washer (2) and tighten them. The torque is 86 Nm.

Install the clutch with the V-belt. See chapter 7.2 "Assembling the V-belt/ clutch".

Install the covers. See chapter 7.1 "Assembling covers and the crank protector".

99

Upper mass

7 Assembly

100

Upper mass

7 Assembly 7.6

Apron 1 2

3 4 5

6

7

8

Item

Designation

Item

Designation

Item

Designation

1

Hexagonal bolt

4

Fitting

7

Fitting

2

Plate

5

Cover

8

Apron

3

Cheese head screw

6

Cheese head screw

101

Apron

7 Assembly

1. Install the apron (8). It is advisable to start on the left side (hose connection on the exciter). Insert the apron (8) from below into the groove intended for this purpose.

102

Apron

7 Assembly

7 6

8

2. The fittings (7) are loosely screwed, the apron (8) can be easily inserted. Insert the apron (8) completely into the groove on the upper mass intended for this purpose. When finished, the ends overlap with the intended bores, which must correspond.

3. If this is not the case, pull the apron (8) in the desired direction around all corners, starting from the left.

4. Tighten the cheese head screws (6) on both of the fittings (7) with a 6 mm Allen wrench. The torque is 25 Nm. 3 4 5

5. Screw in both of the cheese head screws (3) along with the fitting (4) and the cover (5) and tighten them with a 5 mm Allen wrench. The torque is 10 Nm.

103

Apron

7 Assembly

1 2

6. Screw on the plate (2) with the hexagonal bolt (1). Tighten the hexagonal bolts with a 24 mm wrench. The torque is 210 Nm.

104

Apron

7 Assembly 7.7

Guide handle 12

10

13

9

14 15

8 7

11

6

17 18

4 3 1

16

19 20 21

5

2

22 23 24

Item

Designation

Item

Designation

Item

Designation

1

Hose pipe

9

Disc

17

Threaded spindle compl.

2

Holder compl.

10

Button

18

Cheese head screw

3

Hexagonal bolt

11

Guide handle

19

Bracket

4

Worm drive hose clip

12

Washer

20

Disc

5

Bellows

13

Rubber element

21

Vibration dampers

6

Locking pin

14

Handle

22

Cheese head screw

7

Compression spring

15

Mushroom washer

23

Disc

8

Setscrew

16

Cheese head screw

24

Holder

105

Guide handle

7 Assembly

WARNING Danger due to the machine falling!

If the guide handle falls, it can cause severe injury, e.g. bruising and crushing. f Only use suitable and tested hoisting gear and lifting tackle of sufficient lifting capacity. f Attach the guide handle securely to the lifting gear.

11 3

2

1. Mount the guide handle (11) on the upper mass along with both of the holders (2) and the corresponding hexagonal bolts (3). The torque is 25 Nm.

5

4

2. Draw the bellows (5) to the frame. Mount the worm drive hose clip (4) over the bellows (5) and tighten it firmly with a screwdriver.

106

Guide handle

7 Assembly

24

23,22

3. Screw the holder (24), along with the cheese head screw (22) and the disc (23), above the guide handle using a 10 mm Allen wrench. Ensure that the recess faces the guide handle. The torque is 86 Nm.

Place the guide handle (11) upright and engage the lock. Screw on the actuator (throttle lever). See chapter 7.3 "Assembling the Bowden cable".

Place the washer (12) on the guide handle head. Connect the rubber element (13), the handle (14), and the mushroom washer (15) with a cheese head screw (16). Screw in the cheese head screw with a 10 mm Allen wrench and tighten it. The torque is 86 Nm. Attach the hose pipe (1) to the exciter. See chapter 7.5 "Assembling the upper mass".

107

Guide handle

7 Assembly

18

19

17 20 21

4. Screw the 4 cheese head screws (18) along with the bracket (19) onto the guide handle using an 8 mm Allen wrench. The torque is 49 Nm. Apply OmniFit 100M adhesive to the lower part of the threaded spindle (17), screw the threaded spindle along with the disc (20) into the vibration damper (21) and tighten them. The position of the guide handle can be adjusted by screwing in the threaded spindle (17) more or less.

11

6

8,9,10

7 5. Screw the setscrew (8) into the locking pin (6) with Omnifit 100M adhesive and tighten it. From below, install both parts into the holder of the guide handle (11) together with the compression spring (7). Screw the button (10) along with the disc (9) into the setscrew (8) and tighten them. Sprinkle the setscrew (8) with OmniFit 100M adhesive beforehand.

108

Guide handle

7 Assembly 7.8

Guide handle head 8

7 3

1

2

6

4

9 10 11

5

12

Item

Designation

Item

Designation

Item

Designation

1

Cheese head screw

5

Control piston

9

Gear rack

2

O-ring

6

Compression spring

10

O-ring

3

Control piston compl.

7

Guide

11

Spacer

4

Piston sealing ring

8

Guide handle head

12

O-ring

109

Guide handle head

7 Assembly

Once the defective parts have been replaced, assembly proceeds in the reverse order.

1. Using a hand press with arbor, press the guide (7) into the guide handle head until the stop position is reached.

Bottom part

Upper part

2. Apply the new 2-part piston sealing ring (4) onto the control piston (5). First install the black bottom part into the groove. Then install the blue upper part with the double lip.

10 12 b a 3. Both of the spacers (11) each have 2 seals. Carefully slide the O-ring (10) outside into the groove. There are 2 grooves inside. When assembled, both O-rings (10 and 12) are on one side, close to the gearing. The free groove is filled with grease (a).

110

Guide handle head

7 Assembly

4. Complete the pre-assembly of the guide handle head using a hand press.

5. Press the spacer (11) into the guide handle head (8) until the finished surface on the guide handle head and the (turned on a lathe) raised edge (b) on the spacer (11) are flush. Insert the gear rack (9) and press in a second spacer (11).

6. Using both of the press-fit pipes 0206626, 0206627 (see chapter 5 "Jigs") prevents the first spacer (11) from being pressed out again, while the second is being pressed in.

7. Insert the compression spring (6) onto the control piston (3) and lower it into the guide handle head (8). The gearing of the control piston (3) engages the gearing of the gear rack (9). If necessary, rotate both parts and apply light pressure with the hand press.

WARNING Danger due to spring-loaded control pistons!

If the control pistons shoot out, they can cause severe injury. f Always use the safety device. f Only release the spring under a press.

111

Guide handle head

7 Assembly

Note:

When the control piston and the guide handle head are almost flush, the gear rack must be in the position shown in the figure.

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

9. Extend the hand press until the compression spring (6) is released. Accordingly turn the gear rack (9) by hand. Move back the hand press with the control piston (3) and the compression spring (6). Repeat this procedure until the position shown is reached. The entire procedure for setting the gear rack (9) in the correct position must occur smoothly and without applying force.

10. Slightly move the gear rack (9) when immersing the control piston (3) so that the gears can engage.

11. Screw on the safety device 0205327 (see chapter 5 "Jigs") and leave it on the guide handle until installation. Mount the handle to the guide handle head.

12. Insert the O-ring (2) into the groove.

112

Guide handle head

7 Assembly 13. Place the entire guide handle head onto the guide handle and screw it in and tighten it with 4 cheese head screws (1). The torque is 25 Nm. Note:

Before screwing on the guide handle head, check the oil level in the guide handle (hose). If necessary, fill to the top in order to facilitate subsequent bleeding.

NOTICE f Do not squeeze or destroy the O-ring!

14. Unscrew the safety device 0205327 (see chapter 5 "Jigs") and install the second handle. Refill oil in the guide handle head. To do so, place the guide handle in vertical position and add oil (Fuchs Renolit MR 520), up to the mark, through the opening in the guide handle head. Then close the bore again. The bleeding of the hydraulic line is detailed in chapter 8.1.

113

Guide handle head

7 Assembly

114

Guide handle head

7 Assembly 7.9

Base plate and exciter

1 2

9

8

10

7 11

3

7

4 6 5 Item

Designation

Item

Designation

Item

Designation

1

Cheese head screw

5

Lock washer

9

Vibration dampers

2

Exciter compl.

6

Support plate

10

Shockmount support

3

Shock bushing

7

Conical spring washer

11

Cheese head screw

4

Hexagonal bolt

8

Hexagonal bolt

115

Base plate and exciter

7 Assembly

Once the defective parts have been replaced, assembly proceeds in the reverse order.

WARNING Danger due to the machine falling!

If the exciter falls, it can cause severe injury. f Only use suitable and tested hoisting gear and lifting tackle of sufficient lifting capacity. f Attach the exciter firmly to the hoisting gear.

Leave the danger area.

b

a

1. Before assembling the exciter (2), the seal face of the base plate must be cleaned. 0.75 liter MR 520, 10W40 oil (a) is added to the tray. Add the sealing compound Omnivisc 1002 (b) to the seal face as shown in the figure.

116

Base plate and exciter

7 Assembly 2. Screw the M16 eye bolts into 2 opposing boreholes on the exciter (2) for transport. Connect both eye bolts with a suitable transport cable. Transport the exciter to the base plate with a suitable means of transport. Observe the exciter position mark that was added during disassembly and set the exciter on this mark.

1 2

3. Screw in the binding screws from the base plate to the exciter (2). Tighten the 12 cheese head screws (1) with a torque of 120 Nm.

7,8 9

0094654

4. Screw the vibration damper (9) along with the conical spring washer (7) and the hexagonal bolt (8) onto the base plate. Use new conical spring washers (7). The torque is 86 Nm. Apply counter pressure with the strap wrench 0094654 (see chapter 5 "Jigs").

117

Base plate and exciter

7 Assembly

11,7 10 0094654

5. Screw the shockmount support (10) along with the conical spring washer (7) and the cheese head screw (11) onto the vibration damper (9). Use new conical spring washers (7). The torque is 86 Nm. Observe the horizontal position of the supporting surface of the shockmount support (10). Apply counter pressure with the strap wrench 0094654 (see chapter 5 "Jigs").

5 6 4

118

Base plate and exciter

7 Assembly 6. Attach the support plate (6) using the hexagonal bolts (4) and the lock washers (5). Use new lock washers (5). Clean the surfaces between the base plate and the support plate (6). The torque is 210 Nm. 7. Install the shock bushing (3) by hand.

119

Base plate and exciter

7 Assembly

120

Base plate and exciter

7 Assembly 7.10

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

121

Exciter shafts

7 Assembly

Item

Designation

Item

Designation

Item

Designation

1

Hexagonal bolt

11

Cylindrical roller bearing

21

Retaining clip

2

Body-plain washer

12

Bolt, cpl.

22

Retaining clip

3

Plate

13

Lip seal ring

23

Deep groove ball bearing

4

V-belt pulley

14

O-ring

24

Adjusting sleeve

5

Hexagonal bolt

15

Bolt

25

Shaft

6

Spring washer

16

Retaining clip

26

Tripping pin

7

Protection housing

17

Deep groove ball bearing

27

Eccentric weight

8

Rotary shaft seal

18

Spring washer

28

Lock washer

9

Cylinder cover

19

Hexagonal bolt

29

Cheese head screw

10

Cheese head screw

20

Control pin

122

Exciter shafts

7 Assembly

31 10

6

32 30

6 10 40 28 33

39

28 34 11

37 35

35 11

38

36 Item

Designation

Item

Designation

Item

Designation

6

Spring washer

31

Exciter housing

36

Feather key

10

Cheese head screw

32

Cover

37

Gear

11

Cylindrical roller bearing

33

Cheese head screw

38

Shaft

28

Lock washer

34

Eccentric weight

39

Eccentric weight

30

Breather cover

35

Retaining clip

40

Cheese head screw

123

Exciter shafts

7 Assembly

1. Slide the retaining clip (16) onto the bolt (15). Then press both of the deep groove ball bearings (17) onto the bolt using a hand press. Apply adhesive Omnifit 100M to the hexagonal bolt (19) along with the spring washer (18). Screw it into the bolt (15) and tighten to 10 Nm. Use soft, aluminum jaws in the vise.

20

2. Insert the bolt (15) into the control pin (20). Install the retaining clip (16) with pliers.

124

Exciter shafts

7 Assembly 3. Lubricate the O-ring (14) and pull it over the the bolt (15) by hand. Also lubricate the lip seal ring (13) and pull it over the bolt (15) by hand.

4. Insert the assembled parts (12, 20) into the shaft (25). Drive the tripping pin (26) through the shaft (25) and into the control pin (20). This can be done under a hand press or with a plastic mallet.

5. After installation, the tripping pin (26) must protrude approx. 4.2 mm from both ends of the shaft (25). If necessary, center by pressing.

125

Exciter shafts

7 Assembly

23 22

6. Install the retaining clip (22) with pliers. This is the lower retaining clip (22), as the deep groove ball bearing (23) is later pressed in. Press the deep groove ball bearing (23) onto the shaft (25) using a hand press with pipe 0095512 (see chapter 5 "Jigs").

22 23

7. Install the retaining clip (22) above the deep groove ball bearing (23) with pliers.

126

Exciter shafts

7 Assembly

24

a

b

8. Assemble the adjusting sleeve (24) with the shaft (25). It must be ensured that the punch mark (a) on the gear wheel and the bore (b) in the shaft face one another, as shown in the figure.

Bore M16 and gear wheel mark on one level

Tripping pin top

24

25 12

9. Check: Check the shaft (25) and the adjusting sleeve (24) after they have been assembled. To do this, completely slide in the bolt, cpl. (12) as shown in the figure. The mark and the bore must be on one level.

Note:

Non-compliance of this setting can cause malfunction (reverse travel instead of forward travel). It can only be corrected by carrying out a new and complete disassembly and assembly.

127

Exciter shafts

7 Assembly

10. Install the retaining clip (21) with pliers.

11. The shaft (25) is now assembled. The function can be tested. If the shaft (25) in the adjusting sleeve (24) is turned upwards, the bolt, cpl. (12) comes out. If the shaft (25) in the adjusting sleeve (24) is released, the shaft (25) must turn downwards on its own accord and the bolt, cpl. (12) must reimmerse. The free movement of this function facilitates the change of direction of the machine.

35

38

12. Install the first retaining clip (35) onto the shaft (38) with pliers. Install the feather key (36) in the shaft (38).

128

Exciter shafts

7 Assembly

38 c

37 d 13. Press the gear wheel (37) onto the shaft (38) using a hand press. The raised edge (c) of the gear wheel (37) must point towards both bores (d) for the eccentric weights (34, 39).

e 14. Install the second retaining clip (35) with pliers. Press on both inner rings of the cylindrical roller bearings (11) using a hand press. The bearing shelf (e) of the inner rings must point inwards.

Note:

The outer rings of the bearings must be matched to the correct inner ring.

129

Exciter shafts

7 Assembly 15. After the assembly of the shafts (38, 25) the fitting of the exciter housing (31) follows.

16. Press the two bearing outer rings of the cylindrical roller bearings (11) into the exciter housing (31) using a hand press with the pressing tool 0047380 (see chapter 5 "Jigs"). Make sure the base is even. Leave the bearing outer rings of the cylindrical roller bearing (11) flush with the exciter housing (31). The exact fitted position is adjusted later.

Note:

The inscription on the bearing must point to the exciter housing! If the bearing is marked, observe the installation position in the exciter housing.

f

f

17. Insert both of the shafts (38, 25) into the cylindrical roller bearing (11). Both of the gear wheels have punch marks (f). Both must point to each other.

130

Exciter shafts

7 Assembly

18. Press in both of the remaining bearing outer rings of the cylindrical roller bearings (11) flush with the exciter housing (31) using a hand press and the pressing tool 0047380 (see chapter 5 "Jigs"). Make sure the base is even. The marks must point to each other, check again.

31

10,6

19. Install the cover (32). Hold the cover (32) against the exciter housing (31), apply the adhesive Omnifit 100M to the cheese head screws (10) and screw them in along with the spring washers (6), torque is 10 Nm. This moves the cylindrical roller bearing (11) to its final position. Apply the sealant Omnivisc 1002 to the seal face. The order in which the 3 covers (9, 30, 32) are installed is not specified.

131

Exciter shafts

7 Assembly

9

20. When installing the cylinder cover (9), oil must be applied to the bore because the cylinder cover (9) must be moved axially over the lip seal ring (13). Also apply the sealant Omnivisc 1002 to the seal face on the cylinder cover (9). Screw in the cheese head screws (10) along with the spring washer (6), torque is 10 Nm. Apply the adhesive Omnifit 100M to the thread.

Note:

Check that the shafts move freely.

WARNING Danger due to the machine falling.

If the eccentric weights fall, they can cause injury. f Hold the eccentric weights firmly when removing the screws.

WARNING Danger of crushing.

The freely turnable shafts with the mounted eccentric weights can cause severe injuries to your hands. f Never reach into the open exciter if the shafts with the eccentric weights are not secured against independent rotation. f Follow the disassembly steps.

132

Exciter shafts

7 Assembly

29,28 27

21. Install the eccentric weights (27). Install the eccentric weights (27) on the shaft (25), along with the cheese head screw (29) and the lock washer (28), using a 14 mm Allen wrench. The torque is 295 Nm. 22. To avoid injuries, it is recommended to place the exciter housing (31) upright on the workbench and to secure it with a screw clamp.

28,40 39 40

28,33

23. Install the eccentric weights of the shaft (38) in the same manner. The large eccentric weight (34) is installed in the middle of the shaft (38), the two smaller eccentric weights (39) above and below, respectively. The screwed in raised edges prevent an interchange. Screw in and tighten the cheese head screws (33 and 40) along with the lock washer (28).

133

Exciter shafts

7 Assembly

24. The torque is 295 Nm. Secure the exciter housing on the workbench with a screw clamp.

25. After installation, the function of the exciter can be tested. To do this, the exciter must be placed on the workbench.

CAUTION Pay attention to the eccentric weights, danger of injury. Both of the shafts with the eccentric weights must be free and easily turnable. If the shaft (25) is jammed, check the bolt, cpl. (12) in the cylinder cover (9).

134

Exciter shafts

7 Assembly

26. Press the rotary shaft seal (8) into the protection housing (7) using a jig and a hand press. Apply oil to the outside of the rotary shaft seal (8) to facilitate the fitting.

Note:

The rotary shaft seal (8) is a sensitive spare part. You may only apply pressure on the horizontal ring surface!

27. Fill the space between the dust lip and the seal lip with Alvania R 2 grease.

135

Exciter shafts

7 Assembly

7

5,6

28. Attach the protection housing (7), along with the hexagonal bolt (5) and the spring washer (6), to the exciter. Make sure that the parts are properly positioned. Apply the adhesive Omnifit 100M to the hexagonal bolts (5). Seal the seal face with Omnivisc 1002. The torque is 10 Nm. .

4

29. Install the V-belt pulley (4). The V-belt pulley (4) has a left-hand thread. Follow the correct direction of rotation (counterclockwise) when assembling! Tightening by hand is sufficient. Seal the thread with Omnivisc 1002.

136

Exciter shafts

7 Assembly

30. Apply the sealant Omnivisc 1002 to the outside of the plate (3) and attach it. Apply the adhesive Omnifit 100M to the hexagonal bolt (1) and mount them along with the body-plain washer (2) onto the protection housing (7). Tighten the screws with a 10 mm wrench. The torque is 10 Nm.

Attach the entire exciter to the base plate. See chapter 7.9 "Assembling the base plate and the exciter".

137

Exciter shafts

7 Assembly

138

Exciter shafts

7 Assembly 7.11

Hydraulic line 1

2

3

4

6

5

Item

Designation

Item

Designation

Item

Designation

1

Screwed socket

3

Guide handle

5

Screw

2

Connection flange

4

Pipe clamp

6

Hose pipe

139

Hydraulic line

7 Assembly

3

6

1. Insert the hose pipe (6) into the guide handle (3). Ensure that the hose pipe is only inserted below the notch of the guide handle (3) which is designed for this purpose.

2. Bolt the hose pipe (6) to the screwed socket (1). The jam nut must be screwed on and the screwed socket (1) must be held in place. Wrenches 19 and 22 mm in size must be used. The screwed socket (1) is screwed on in the intermediate flange (2).

140

Hydraulic line

7 Assembly

3. Fasten the pipe clamp (4) to the guide handle (3) with the screw (5).

Mount the hose pipe (6) to the exciter. See chapter 7.5 "Assembling the upper mass".

Refill oil in the hose pipe up to the screwed socket.

After attaching the guide handle head, bleed the hydraulic line. See chapter 8.1 "Bleeding the hydraulic line".

141

Hydraulic line

7 Assembly

142

Hydraulic line

8 Hydraulic line 8

Hydraulic line 8.1

Bleeding the hydraulic line

a

1. The machine must be operationally assembled in order to bleed the hydraulic line.

2. Place the guide handle upright, allow it to engage in the detent.

3. The control handles are in the "forward travel" position.

4. Unscrew the oil fill screw (a) in the guide handle head with a 22 mm wrench and remove it.

5. Pour in approx. 0.4 l hydraulic oil (MR 520). Pour in the oil to approx. 1 cm below the screw thread in the guide handle head. The oil stands slightly over the oil level mark located on the outer surface.

6. Place both of the control handles in the "forward travel" and "reverse travel" position. The oil is pumped into the line and the control piston chamber. Monitor the oil level and fill the oil as necessary.

143

Bleeding the hydraulic line

8 Hydraulic line 7. After 6 to 8 such surges, a counterpressure builds and the control handles travel only halfway forwards in the "forward travel" position. The position is approx. 45 degrees.

8. Leave the control handles in the "forward travel" position, monitor the oil and screw the oil fill screw (a) back in.

Note:

Do not move the control handle until the engine is running!

a

b

9. Place the machine on a soft surface.

10. Start the engine and allow it to warm up for approx. 5 minutes. Apply full throttle and first pull the control handles backwards in the "reverse travel" position and then push them forwards in the "forward travel" position. Repeat this procedure 2 to 3 times. When doing so, the machine must run forwards and backwards.

11. Turn off the engine, place the guide handle upright and lock it. Open the oil fill screw (a) in the guide handle head with a 22 mm wrench and check the oil level.

Refill the oil up to the outer mark (b) if necessary. Lock the screw again.

Note:

Never start the engine if the screw in the guide handle head is still open. Complete all procedures on the guide handle and the guide handle head only with the guide handle in vertical position.

144

Bleeding the hydraulic line

9 Maintenance 9

Maintenance 9.1

Maintenance schedule

Component

Maintenance work

Drive motor

First replacement of oil and oil filter.

Valve clearance

Cold engine: Check the valve clearance and adjust as needed.

Inlet valve 0.1 mm - outlet valve 0.2 mm

Air cleaner

Check dry-type air cleaner - if necessary, clean or replace filter element (observe maintenance indicator).

Drive motor

Check oil level, refill oil if necessary.

Center pole height adjustment, Transport retainer

Relubricate.

V-belt

Check the V-belt and replace if necessary.

Protective frame Central suspension

Maintenance interval

25 hrs. after initial operation

Daily

Weekly

Check that the fastening screws are tight.

Guide handle head

Check the oil level - add oil as needed.

Drive motor

Replace oil, oil filter.

Keep cooling fins free of dirt, dry clean.

Tighten all accessible screw connections.

Exciter

Change the oil.

Fuel filter

Replace filter.

145

Monthly

Every 250 h Every 500 h

Maintenance schedule

9 Maintenance 9.2

Engine oil 1. Checking the oil level: f Check the oil level with the dipstick (21). f If the oil level is too low, replenish the oil by pouring Fuchs Titan Unic 10W40 MC through the filler neck (19).

2. Changing the oil: f Allow the engine to warm up. f Loosen the drain plug. f Loosen the fastening screws and hang the holder above the oil collection container. f Completely unscrew the drain plug and catch the used oil with the container. f Screw in the drain plug and secure the holder again. f Replenish 1.0 l oil via the filler neck (19).

Note:

Please make sure that you observe the environmental regulations in effect when you dispose of the used oil. We recommend that you take the oil in an enclosed container to a waste-oil collection point. Do not dispose of the used oil as household waste or pour it into the sewer system, down a drain or into the ground.

146

Engine oil

9 Maintenance 9.3

Hydraulic control 1. Checking the oil level: f Set the guide handle in the vertical position. f Open the filler hole (26). f The oil level must be at fill level mark, add Fuchs Renolin MR 520 hydraulic oil if necessary. f Close the filler hole (26).

2. Bleeding the hydraulic control: f Remove the apron (28) by unscrewing the screws (29). f Place the guide handle in vertical position, bring the control handle (6) completely into reverse position, open the filler hole (26). f Loosen the hollow screw (27). f Slowly press the control handle (6) into advance position until the hydraulic oil starts to leak bubble-free at the hollow screw. f Tighten the hollow screw (27), mount the apron (28). f Add Fuchs Renolin MR 520 hydraulic oil if necessary, close the filler hole (26).

Oil

147

Hydraulic control

9 Maintenance 9.4

Exciter oil 1. Checking the oil level: f Put the vibrating plate in the horizontal position. f Open the filler hole (30). f The oil level must reach the start of the thread of the filler hole. f If required, pour Fuchs Titan Unic 10W40 MC into filler hole (max. 0.75 l); use a funnel. f Tightly close the filler hole (torque 100 mm).

2. Changing the oil: f Open the filler hole (30). f Tilt the vibrating plate and hold it in a tilted position until the oil has been completely drained. f Put the vibrating plate in the horizontal position. f Pour 0.75 l of Fuchs Titan Unic 10W40 MC into filler hole. f Tightly close the filler hole (torque 100 mm).

Note:

Do not overfill!

Note:

Please make sure that you observe the environmental regulations in effect when you dispose of the used oil. We recommend that you take the oil in an enclosed container to a waste-oil collection point. Do not dispose of the used oil as household waste or pour it into the sewer system, down a drain or into the ground.

148

Exciter oil

9 Maintenance 9.5

Exciter V-belt

By applying the automatic centrifugal clutch, the V-belt does not need to be retightened.

If the V-belt width should fall below the measurement of 15.5 mm, the V-belt must be replaced.

1. Changing exciter V-belt: f Remove the belt guard (31). f Loosen the screw (32). f Remove the mushroom washer (33), the disc spring (34), the seal (35) and the front segment of the V-belt pulley (10). f Change exciter V-belt (12). f Assemble the parts in reverse order and ensure that the color mark on the pin (36) corresponds to the mark on the V-belt pulley (10).

Note:

Do not oil or grease clutch members (destruction of the graphite bushings).

149

Exciter V-belt

9 Maintenance

150

Exciter V-belt

10 Malfunction 10 Malfunction Malfunction

Cause

Remedy

Reverse travel speed too low

Too much hydraulic oil in the guide handle head

Add hydraulic oil.

Advance travel speed too low

Insufficient amount of oil in the guide handle head

Adjust oil level according to the fill level mark.

Air in the hydraulic control

Bleed.

No reverse travel

Mechanical malfunction

Contact Wacker Service.

Loss of hydraulic oil

Leaks, hydraulic hose is defective

Contact Wacker Service.

Replace defective parts.

Note: Bleed after every disassembly

Engine will not start

Insufficient oil

Refill the oil and actuate the valve lever at the oil filter housing once.

Shift the throttle lever to the start position.

Throttle level is in the stop or idle position No fuel at the injection pump

Fill the tank with fuel. Check the entire fuel system.

Check the supply line to the engine and fuel filter.

No vibration while engine is running

Valve clearance is incorrectly set

Check the valve clearance and adjust as needed.

Valves are worn

Contact Wacker Service.

Cylinder and/or piston ring wear

Contact Wacker Service.

Injector is not functioning properly

Contact Wacker Service.

V-belt is worn out

Replace V-belt.

Clutch linings are worn out

Replace the clutch linings.

151

10 Malfunction

152

11 Torque values 11 Torque values Type

ft lb

Nm

ft lb

Nm

ft lb

Nm

inch

Met.

inch

Met.

M3

*11

1.2

*14

1.6

*19

2.1

7/32

5.5

-

2.5

M4

*26

2.9

*36

4.1

*43

4.9

9/32

7

-

3

M5

*53

6.0

6

8.5

7

10

5/16

8

-

4

M6

7

10

10

14

13

17

-

10

-

5

M8

18

25

26

35

30

41

1/2

13

-

6

M10

36

49

51

69

61

83

11/16

17

-

8

M12

63

86

88

120

107

145

3/4

19

-

10

M14

99

135

140

190

169

230

7/8

22

-

12

M16

155

210

217

295

262

355

15/16

24

-

14

M18

214

290

298

405

357

485

1-1/16

27

-

14

M20

302

410

427

580

508

690

1-1/4

30

-

17

* = in lb Type

ft lb

Nm

ft lb

Nm

inch

Met.

ft lb

Nm

inch

Met.

No. 4

*6

0.7

*9

1.0

1/4

-

*12

1.4

3/32

-

No. 6

*12

1.4

*17

1.9

5/16

8

*21

2.4

7/64

-

No. 8

*22

2.5

*31

3.5

11/32

9

*42

4.7

9/64

-

No. 10

*32

3.6

*45

5.1

3/8

-

*60

6.8

5/32

-

1/4

6

8

9

12

7/16

-

12

16

3/16

-

5/16

13

18

19

26

1/2

13

24

33

1/4

-

3/8

23

31

33

45

9/16

-

43

58

5/16

-

7/16

37

50

52

71

5/8

16

69

94

3/8

-

1/2

57

77

80

109

3/4

19

105

142

3/8

-

9/16

82

111

115

156

13/16

-

158

214

-

-

5/8

112

152

159

216

15/16

24

195

265

1/2

-

3/4

200

271

282

383

1-1/8

-

353

479

5/8

-

1 ft lb = 1.357 Nm

1 inch = 25.4 mm

153

11 Torque values

154