) (IRATE! Iz G REPAIR INSTRUCTIONS Repair work of drum with vibrator HD 10-12 H200 0001 sete 01.03.2014 2291223 en roe manber arava HAMM AG 2015 Version 01® Publisher Name of the document Date of first issue Date of change Copyright HAMM AG. Postfach 1160 195633 Tirschenreuth Germany Phone: +49 (0) 96 31 / 80-0 http:/Avww hamm.eu 2291228_01_REP_Repait_\V-drum_H200_en Original repair instructions 01.03.2014 01.03.2015 HAMM AG 2015, The disclosure as well as the duplication of this document, the use and the forwarding of its contents, are forbidden as far as not expressively permitted. Violations will cause indemnities. With respect to patent, utility ‘sample or design patent registration all rights reserved, erz01 -2281223_01_V-drum_H200_en (© HAMM AG 2015aan ae ‘These repair instructions are applicable to: ‘Assembly Rollertype [Series _| Series number Drum with vibrator HD 10 200 from 0001 Drum with vibrator HD 12 H200 from 0001 © HAMM AG 2015 2201223_01_V-drum_H200_ena © ma mis @ TABLE OF CONTENTS 3 3.00 Tools needed.. 3.01 Work equipment, jointing medium, securing devices, lubricants... 3.02 Starting torques, general. 3.03 4 4.00 4.01 4.02 —_ Horizontal installation using special tools. 5 Dismantling, 5.00 —_Preparating the roller drum disassembly.. 5.00.01 Parking and securing the roller. 12 5.00.02 Removing the scraper. 12 5.00.03, Blanking plugs for hydraulic hoses... 5.01 Roller drum disassembly.. 5.01.01 Removing the right-hand side plate.. - B 5.01.02, Removing the left-hand side plate. 14 5.02 Removing the roller drum. 6.00.01 Travel drive side, . 7 6.00.02 Unbalanced shaft. 18 6.00.03 Vibration side. 19 6.01 _ Installing the drum. 7 Inspection and maintenance... 4 -2281223_01_V-drum_H200_en (© HAMM AG 2015aan ae 1 OVERVIEW @ HAMM AG 2015 2291223_01_V-drum_H200_eniy — @ 2 FOREWORD ‘This document provides the repair and maintenance instructions for the ‘drums with vibrator of H200 series. 7 | T2alow ts maintenance or repair the drum does not necessarily need to be disassembled completely (e.g., no complete disassembly is required to replace the buffer elements). 6 -2281223_01_V-drum_H200_en (© HAMM AG 2015Preparation ‘Tools needed 3.01 3.02 3.03 PREPARATION Tools needed ‘© 2iacks (each with a minimum load-carrying capacity of half the machine weight) ‘+ Crane (minimum liting capacity: 3.5 t) with chain, gripping jaw and round sling «+ Lift truck /forkift (iting capacity at least 2.5t) «+ Wheel chooks «+ Set of open-jawed spanners / socket spanners + Allen key set «+ Extractor for bearing inner rings ‘Blanking plug (2278286) Work equipment, jointing medium, securing devices, lubricants ‘+ Liquid plastic / screw locking paste @ ‘+ WIRTGEN GROUP high-performance grease @ (pressure and temperature-stable) ‘* WIRTGEN GROUP hydraulic oil] * WIRTGEN GROUP vibrator ot > When a repair kt is used, liquid plastic @ has already been applied to Secure all screws the kit contains. Starting torques, general For the tightening torque values to be applied to serew connections, please refer to the operating instructions belonging to your roller. Specific tightening torque values are indicated separately. oA. so2 01 General instructions 7 | Before starting any activity, please be sure to also observe the |_| instructions provided in the assembly safety manual, inthe general safety manual and in the operating instructions. ‘Mon oon. ‘These instructions may be applicable to several types of a given series of machines or to machines which present diflerent configurations. Accordingly, these instructions include descriptions of components or configurations not installed on. your machine. ‘MOn_po0-03 @ HAMM AG 2015 2291223_01_V-drum_H200_en 7‘Safety Instructions, a coe 4 SAFETY INSTRUCTIONS Ps Uncontrolled movements! Risk of fatal injury due to unintentional roling away of the machine. Before starting any repair or retrofiting work * Park the machine on firm and flat ground. * Secure machine against rolling away. ; | : Inadmissable engine start! Rsk of injury due to starting engine during repair and retrofitting work. Prior to start of repair and retrofiting work + Affix a warning notice at the driver's position, + Pulloff the key from the battery disconnector (if existing) + fno battery isolating switch exist, remove the ground strap from the | x 2 & Hot surface, not ulus! Risk of bums due to hot surfaces and fluids. + Prior to repair and retrofiting work, allow the machine to cool down below a temperature of 30 °C (86 “F). + Do not touch hot machine parts. MOA_02-10 Fluids under pressure! Risk of injury due to fuids spurting out under pressure. + Carry out repair and retrofiting work only with depressurized hydraulic systems. + Lower any lifted appliance, e.g., the Edge Pressing and Cutting Device (KAG) down to the ground. + Wait atleast 1 minute after you switched off the motor until the pressure is relieved, MOA_o02-12 -2281223_01_V-drum_H200_en (© HAMM AG 2015aan ae @ HAMM AG 2015 ‘Safety Instructions, During assembly or repair work, it may be necessary to heat |} component parts in order to shrink them onto other components MOA_799-01, Hot surface! Bum hazard by hot surfaces. ‘+ Wear appropriate safety clothing, ‘+ Wear appropriate safety gloves. | a 8 Slippery surfaces! Risk of falling and injury by slipping on spilled fuel or lubricants, ‘+ Clean any spifed or leaked fuel or lubricant from both the machine Parts and the workplace. MOA 003.02 NOTICE Wear or damage of screws and nuts may cause material damage. ‘Threads may be damaged when reusing sorews or nuts already used beforehand. Itis hard to unscrew worn sorew heads «Dispose of used old screws and nuts during disassembly. + Always use new screws and nuts for installation. MOA 004-18 Before starting any activity, please be sure to also observe the instructions provided in the assembly safety manual, in the ‘general safety manual and in the operating instructions. ‘MOA_p00-02 2291223_01_V-drum_H200_en2 @ ‘Safety instructions Use of hydraulic jacks 4.00 Use of hydraulic jacks 1. Position 2 jacks [5] (each with a minimum load- carrying capacity of haf the machine weight) Under the chassis [A] on both sides as shown in the photograph. 2. Jack up the roller about 2 em until the load i relieved from the buffer elements. NOTICE Jacks may cause material damage if positioned wrongly! ‘jack may damage the bottom plate of the roller, * Do not position the jack unless under supporting structural elements of the chassis. MOA _004-16 4.01 Rotating the drum ‘The drum [A] needs to be tured several times during repair work. Use suitable ling {gear (crane) with a sufficient lifting capacity. “The gripping jaw [R] provides far eacy drum [A] handling ‘When selecting the gripping jaw, please its use for lifting bent material. Pea Uncontrolled drum movement! Uncontrolled movement is possible when turning the drum. + Make certain that there is nobody in the danger zone when the drum is being turned. MOA_001 10 -2281223_01_V-drum_H200_en (© HAMM AG 2015ae Safety Instructions, Horizontal instalation using special tools 4.02 Horizontal installation using special tools When using HAMM special tools for roller drum assembly, the roller drum does not need to be tured. ‘A crane [C] is used to move the special tool [A] together with the part [B] to be installed to the roller drum [0] which is supported safely ina horizontal position. The work steps described in the instructions are identical apart from the fact that the roller drum does nct need to be put into an. upright position and turned. A 8 sete @ HAMM AG 2015 2291223_01_V-drum_H200_en "4 Ge oer “) Ema Preparatng the roler drum disassembly 5 DISMANTLING 5.00 Preparating the roller drum disassembly 5.00.01 Parking and securing the roller |. Park the roller on flat and firm ground. ‘Switch off diesel engine and remove ignition key. ‘Secure roller against rong away. Battery isolating witch on position 0. 9. If no battery isolating switch exists, remove the ground strap from the battery. 6. Lif the roller using jacks. 5.00.02 Removing the scraper 1, Unscrew 2 x2 screws [A] at the outer scraper (Bl. 2. Proceed likewise to unscrew 2x2 screws at the inner scraper. 7] The screws, nuts and washers can be 1) reused after cleaning in this case. 5.00.03 Blanking plugs for hydraulic hoses Insert blanking plugs [A] to blank off all hydraulic hoses after disassembly. Have a sufficient number of dummy plugs ready, 2 -2281223_01_V-drum_H200_en (© HAMM AG 2015Dismanting Roller drum disassembly 5.01 Roller drum disassembly 5.01.01 Removing the right-hand side plate 1, Fasten and tension the chain of the crane with a round sing to the holder lug [A] of the side piate. yyy 2, To unscrew the hose holder [B]: Loosen 2 screws [C], nuts and washers, Mark the ports of the hydraulic hoses at LJ the engines. This helps to avoid confusion during assembly later on. 3, To disassemble the flexible tube system of the \ipraton arive at the gear motor: Loosen the union nuts [D]. 4, Close all hoses using blanking plugs. @ HAMM AG 2015 -2281223_01_V-drum_H200_en 8Dismantiing Roller drum disassembly 5. Unscrew 4 locknuts [E] of the side plate. 6. Dispose of the locknuts. 7. Loosen the 4 screw connections [F] ofthe side plate at the chassis 8, Remove and put aside the side piate and the intermediate plat. 9. HD 10; Remove and put aside 4 spacers. HD 12: A single spacer piece remains on the chassis 5.01.02 Removing the left-hand side plate 11. Fasten and tension the chain ofthe crane with a round sling to the holder lug [A] of the side plate. 14 -2281223_01_V-drum_H200_en (© HAMM AG 2015‘Mark the ports of the hydraulic hoses at the engines. This helps to avoid confusion during assembly later on. 2, To disassemble the flexible tube system of the travel drive and brake at the gear hub motor: Loosen the 4 union nuts [B}. 3, Close all hoses using blanking plugs. 4, Unscrew the rear screw-in nozzles [C] from the gear hub motor. 5, Unscrew 7 screws [D] of the gear hub motor. 6, Loosen the 4 screw connections [E] of the side plate at the chassis. 7. Remove and put aside the side plate and the intermediate plate. Remove and put aside 4 spacers. ‘single spacer piece remains on the The roller drum can now move freely and can be pulled out to the side from under the roller using a pallet jack fork it. Dismanting Roller drum disassembly o 250 @ HAMM AG 2015 -2281223_01_V-drum_H200_en 15® Dismanting ‘Removing the roller drum 5.02 Removing the roller drum 1. Set the drum to an upright postion - vibration end up. 2. To remove the gear motor [27] from the driver [24 Loosen 4 cheese head screws [28] and washers [20], 3, Remove the coupling [13] 4. To remove the driver [24] from the flange [20]: Loosen 5 hexagon head serews [25] and washers [26]. 5. Remove the O-ing (23) 6. To remove the cover [17] from the bearing flange: Loosen 8 hexagon head screws [18] 7. Slide deep-groove ball bearing [16], Nios ring [21], flange [20] and seal ring [22] ftom the shatt ofthe bearing flange (5). 8. To remove the bearing flange [5] from the roller drum [1]: Loosen 12 hexagon head screws [6] and washers (7. 9. Lift the bearing flange [5] off the eccentric shaft [12 10.To remove the bearing cover [6] from the bearing flange [5]: Loosen 6 screws [10] nuts and washers [11]. 11.Press the outer ring ofthe cylindrical roller bearing [6 into the bearing fiange [5]. 12,Pull out the eccentric shaft [12] vertically. 418,Slide the inner rings of the cylindrical roller bearings [8] from both fends of the eccentric shaft [12] using an extractor. 14.Rotate the drum - travel drive side up. 18.To remove the driving star [D]: Unserew the 6 retaining nuts [E] ‘and washers [F. ‘16.Lif the driving star [D] out of the roller drum [1] using a crane. 117-To remove the gear hub motor [A] from the driving star [D]: ‘Loosen 5 cheese head screws [B] and washers [C]. 18.To remove the bearing lange [2] from the roller drum [1]: Loosen 12 serews [3] nuts and washers [4] 19:To remove the bearing cover [9] from the bearing flange [2 Loosen 6 screws [10] nuts and washers [11] 20-Press the outer ring ofthe cylindrical roller bearing [8] into the bearing fiange [5] Al parts, surfaces and boreholes need to be cleaned after disassembly. No rests of adhesive or locking fluid must remain ‘on the components, All screws, nuts and sealing tings must be replaced 16 -2281223_01_V-drum_H200_en (© HAMM AG 2015aan ‘Assembly Fiting the drum 6 ASSEMBLY 6.00 Fitting the drum 6.00.01 Travel drive side Sires Residual lubricant may reduce frictional connection. Reduced frictional connection may cause damage to material. ‘+ Remove residual lubricant from flange surfaces before starting assembly. + Thoroughly clean the flange surface. MOA, 00415 1. Set the drum to an upright position - drive end 31,92, 480 Up (smaller opening) ge) 2. Apply 70 g of high-performance grease @ to x, * lubricate the outer ring ofthe cylindrical roller == 3.4L bearing [8.2]. 3, Press the outer ring of the cylindrical roller bearing [8.2] into the bearing flange [2] 4, Fasten the bearing cover [0] to the bearing flange [2] using 6 eerewe [10] and wachers [11] each. 5. Screw the bearing flange [2] to the drive end of the roller drum each with 12 screws [3] and washers [4] 6, Fasten the 6 anti-vibration mounts [30] to the roller drum [1] using 2 hexagon bolts [31] and washers [32] each 7. Fasten the gear hub motor [A] to the driving star [DJ each with 5 cheese head screws [B] and ‘washers [C]. 8, Lift the driving star [D] into the roller drum [1] using a crane, and place it on the screws of the ant-vibration buffers [30]. 8. Fasten the driving star [D] using 6 retaining nuts. [Cand washers [F] each, 10.Tum the roller drum - vibration end upwards (larger opening). AE F D 30 soe @ HAMM AG 2015 2291223_01_V-drum_H200_en "7) J ‘Assembly Fiting the drum 6.00.02 Unbalanced shaft ‘1. Heat the inner rings of the cylindrical roller bearings [8.1] to 80 °C (176 “F) and shrink one each on every end of the eccentric shaft [12] 2. Screw the shaft piece of the coupling [13] to the eccentric shaft [12] using 3 screws [14] to be tightened to 55 Nm (end having 3 boreholes). NOTICE Damage to the cylindrical roller bearing! ‘There is a risk of damaging the cylincrical-roller bearing when the eccentric shaft is inserted wrongly. ‘+ Lower the ecoentne shatt vertically and in a straight direction into the bearing flange with the i ‘outer ring ofthe cylindrical-oller bearing. + Donot it, 3. To lower the eccentric shat [12] into the roller rum [1] with the coupling at the upper end: Allow the inner ring of the cylindrical roller = bearing [8.1] to slide into the outer ring [8.2] on - 200 the travel drive end, 18 -2281223_01_V-drum_H200_en (© HAMM AG 2015aan ae ‘Assembly Fitting the drum 6.00.03 Vibration side NOTICE Residual lubricant may reduce frictional connection. Reduced frictional connection may cause damage to material ‘= Remove residual lubricant from flange surfaces before starting assembly. + Thoroughly clean the flange surface. 1. Apply 70 g of high-performance grease @ to lubricate the outer ring of the eylindsical roller bearing 8.2) 2. Press the outer ring ofthe eyindrcal roller bearing [8.2] into the bearing flange [5] 3. Fasten the bearing cover [9] to the bearing flange [5] using 6 sorews [10] and washers [11] each. 4, Slide the bearing flange [5] over than eccentric shaft [12] so as fo ensure that the inner ring of the cylindrical-raller bearing [8.1] slides into the ‘outer ring [8.2] 6. Fasten the bearing flange [5] o the roller drum [1] using 12 hexagon bolts (6] and washers [7] each. 6. Lubricate the deep-groove ball bearing [16] and the Nios ing [21], apply 30 g of high- performance grease @ each. 7. Slide sealing ring [22], flange [20], Nios ting 21} and deep-arcove ball bearing [16] onto the shaft of the bearing flange (5) 8. Screw the cover [17] onto the shaft ofthe bearing flange [5] using & hexagon bolts [18 9. Pull the O-ring [23] onto the flange [20} 410.Connect the driver [24] tothe flange [20] each with 5 hexagon bolts [25] and washers [26] @ HAMM AG 2015 2291223_01_V-drum_H200_en 19‘Assembly Fiting the drum 11.Fasten the motor piece of the coupling [13] to the gear motor [27] using a hexagon nul to be tightened to 55 Nm. 12.Siipon the connecting piece ofthe coupling [13} 13.Put on the gear motor [27], connecting the coupling parts [12] to it 14.Mount the gear motor [27] using 4 cheese head screws [28] and washers [23] tothe driver [24], 415.Fasten the 4 ant-vibraton buffers [20] to the driver [24] using 2 hexagon bolts [31] and washers [22] each, 24 13 13 13 13 20 -2281223_01_V-drum_H200_en (© HAMM AG 2015aan Saou Assembly {nstaling the drum 6.01 Installing the drum 4. Position the roller drum under the roller using a pallet jack / fork tin. 7 ] To Position the roller drum: Vibration drive on the right, hydraulic connections up; Left- hand drive. 2. Locate the right-hand side plate at the screws of the antjvibration: buffers. 3. HD 10: Screw the right-hand side plate, intermediate plate and the ‘spacer pieces to the chassis using 4 screws and washers. HD 12: Screw the right-hand side plate and the intermediate plate to the chassis through the spacer piece, using 4 screws and washers, 4, ‘Screw the right-hand side plate to the ant-vibration buffers using 4 retaining nuts and washers. Carefully slide the left-hand side plate over the gear hub motor. HD 10: Screw the left-hand side plate, the intermediate plate and the spacer pieces to the chassis using 4 screws and washers. HD 12: Sorew the left-hand side plate and the intermediate plate to the chassis through the spacer piece, using 4 screws and. washers. 7. Tum the gear hub motor until the ports of the hydraulic system are at the upper side. 8. Screw the left-hand side plate to the gear hub moter at seven, positions. 8, Screw the hose bracket to the right-hand side plate. 10.Install the right-hand hydraulic flexible tube system to the gear ‘motor using 3 union nuts. 11. Screw the rear screw-in nozzles into the gear hub moter. ‘12 Install the lef-hand hydraulic flexible tube system to the gear hub ‘motor using 4 union nuts. 13.To install the scraper: Fasten 2x 2 screw connections each. @ HAMM AG 2015 2291223_01_V-drum_H200_en aran iin indie ara 7 INSPECTION AND MAINTENANCE 1. Inspect alll lines, hoses and screw connections for leaks and damage. 2. Reparany leis or darages. A CCheck the hycrauli oi level [—] andthe vibrator cil level <>. ‘Top up oil if the oil level is low (see the operating manual). ‘The hydraulic system is vented automatically during operation. Check the hydraulic oll level and top up again if necessary after running the machine for a short tme. 22 -2281223_01_V-drum_H200_en (© HAMM AG 2015