WTC Machinery Corp WTC-250 Track press.

Date: 10-18-23

Model# D1413 Ser# 1877

Initial inspection results recorded after testing. [ In preparation of Rebuild/upgrade]

Hyd Pump tests results:

1. 6,200 psi +/_ 300 psi. Dead Head High Psi hyd pump
2. 3,000 psi max set point of Adjustable Pressure Control valve. [can be set to Dead head pump.
3. 465 psi Min set point of Adjustable Pressure control valve.

Factory recommended pressure settings below:

Force MAX. WTC250/360 pressures.
a. Cat D10 -270,000 2,390
b. Cat D9 -250,000 2,210
c. Cat D8, -200,000 1,770
d. Cat D6 -120,000 1,060
e. Cat D 5- 100,000 885
f. Cat D3, 4 -72,000 635

Ram cycle times: for Left & Right sides Viewed from Operators position.

LEFT RAM RIGHT RAM

IN OUT IN OUT [ measured in Seconds]

8 33 @ 3,000PSI. w/HPP 8 12 @ 3,000PSI W/LPP w/stick

16 To Slow 95* @ 30PSI W/LPP 15 18 @ 30psi W/LPP W/stick

9 OK 10* @ 30psi W/LPP 10 10 @ 30psi. W/LPP *This

resulted in operating valve w/cable disconnected & manual operating valve [ valve full travel was not
being achieved w/cable operation] in conclusion Both Left & right Rams are operating at same cycle
times. cables replacement and adjustment needed.

Also, we had to remove wire loom & a wire tie from Left Hand Ram Joystick, which was causing some of
the cycle times to be slow as well.

Diagnosis:

The track press cycle times are the same and the original complaint of it being slow was the result of
control valve cables out of adjustment and the modified joystick handle controls electrical harness was
interfering with the travel as well. Once we rebuild machine w/o flow modifications the Ram cycle times
should average 10 sec in or out. This will be the same with either the Low-Pressure pump [ LPP] or the
High- Pressure Pump [HPP] .
Note: the cycle times of the GR Ais track press model; TM200 has cycle times tha Ave;3.5 sec in and 3.5
sec out.

Other Issues we have found wrong, that need to be repaired.

1. Electronic Control Module BAD [ internal battery failure] basically an ECM.

This is outdated and no longer available controller. Even a used one would have to be
programmed w/window 95 software and after talking to the track mfg & controller Mfg we
won’t be able to program it. [outdated]
a. WTC is working on an updated model for a replacement we can use.
They will quote us the cost. They will also help with any issues we may have during the
Install.
2. Main Motor Controller [ Mag switch] Making a loud Buzzing sound randomly during testing.
a. Have a few options. New diff type from Grainger $830.00 [ old style we have no longer sold]
or E-Bay Good used like ours $250.00.
3. Hyd Oil; filter was cut open and inspected for contamination, filter looked like new.
Note: filter was dated 2006.

4. Mult hyd hoses,

5. Reseal all items [ we are finding many small leaks.
6. Cable controls
7. Lexon windows
8. Add restriction gage @ filter.
9. Reseal HYD Ram cyls
10. Rework Ram Bed [ shim & square up bed ways etc]
11. New joystick controls & cables.
12. Fix door for fast easy operation.
13. Fix door safety switch.
14. Add LED shock proof work lights over work area.
15. Paint w/ hardener for long wear life. [ est 1,500 paint Emron]
16. Clean electric motor.

Once apart we will have more items to add.

Conclusion:

Machine works pretty good as it is, and many parts we should be able to Reuse.

I would test cylinders for leaks once out, we can’t see them good when installed. Possibly ok to reuse?