Wacker Neuson RD 27-100, RD 27-120 Operator's Manual

Operator’s Manual

Roller

RD 27-100

RD 27-120

0171754en 003 1109

0171754EN

Copyright
notice

© Copyright 2009 by Wacker Neuson Corporation.
All rights, including copying and distribution rights, are reserved.
This publication may be photocopied by the original purchaser of the machine. Any

other type of reproduction is prohibited without express written permission from
Wacker Neuson Corporation.

Any type of reproduction or distribution not authorized by Wacker Neuson Corporation
represents an infringement of valid copyrights. Violators will be prosecuted.

Trademarks

Manufacturer

Translated
instructions

All trademarks referenced in this manual are the property of their respective owners.

Wacker Neuson Corporation
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: [phone] · Fax: [phone] · Tel: [phone]

www.wackerneuson.com

This Operator’s Manual presents a translation of the original instructions. The original
language of this Operator’s Manual is American English.

RD 27 Foreword

Foreword

Machines
covered in
this manual

Machine Item Number

RD 27-100 0620393

0620395
0620508
0620510
0620512

RD 27-120 0620396

0620394
0620509
0620511
0620513

Machine
documentation

Expectations
for
information in
this manual

 Keep a copy of the Operator’s Manual with the machine at all times.
 Use the separate Parts Book supplied with the machine to order replacement

parts.

 Refer to the separate Repair Manual for detailed instructions on servicing and

repairing the machine.

 If you are missing any of these documents, please contact Wacker Neuson

Corporation to order a replacement or visit www.wackerneuson.com.

 When ordering parts or requesting service information, be prepared to provide

the machine model number, item number, revision number, and serial number.

 This manual provides information and procedures to safely operate and main-

tain the above Wacker Neuson model(s). For your own safety and to reduce the
risk of injury, carefully read, understand, and observe all instructions described
in this manual.

 Wacker Neuson Corporation expressly reserves the right to make technical

modifications, even without notice, which improve the performance or safety
standards of its machines.

 The information contained in this manual is based on machines manufactured

up until the time of publication. Wacker Neuson Corporation reserves the right
to change any portion of this information without notice.

Copyright
notice

 All rights, especially copying and distribution rights, are reserved.
 Copyright 2009 by Wacker Neuson Corporation.
 This publication may be reproduced through photocopying by the original pur-

chaser of the machine. Any other type of reproduction is prohibited without
express written permission from Wacker Neuson Corporation.

 Any type of reproduction or distribution not authorized by Wacker Neuson Cor-

poration represents an infringement of valid copyrights, and violators will be
prosecuted.

wc_tx000836gb.fm 3

Foreword RD 27

CALIFORNIA
Proposition
65 Warning:

Laws
pertaining to
spark
arresters

Trademarks

Engine exhaust, some of its constituents, and certain vehicle components, contain
or emit chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.

NOTICE: State Health Safety Codes and Public Resources Codes specify that in
certain locations spark arresters be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed to prevent accidental dis­charge of sparks or flames from the engine exhaust. Spark arresters are qualified
and rated by the United States Forest Service for this purpose. In order to comply
with local laws regarding spark arresters, consult the engine distributor or the local
Health and Safety Administrator.

All trademarks referenced in this manual are the property of their respective own­ers.

4 wc_tx000836gb.fm

RD 27 Table of Contents

Foreword 3

1 Safety Information 9

1.1 Signal Words Found in this Manual ...................................................... 9

1.2 Machine Description and Intended Use ............................................. 10

1.3 Safety Guidelines for Operating the Machine ..................................... 11

1.4 Safety Guidelines while Using Internal Combustion Engines ............. 13

1.5 Guidelines for Service Safety ............................................................. 14

2 Labels 16

2.1 Label Locations .................................................................................. 16

2.2 Safety and Warning Labels ................................................................ 17

2.3 Informational Labels ........................................................................... 20

3 Lifting and Transporting 23

3.1 Lifting the Machine ............................................................................. 23

3.2 Tying Down/Transporting the Machine ............................................... 24

4 Operation 25

4.1 Preparing the Machine for First Use ................................................... 25

4.2 Position of the Operator ..................................................................... 25

4.3 Operation & Maintenance Locations .................................................. 26

4.4 Unlocking/Locking the Articulated Joint .............................................. 28

4.5 Using the Roll Over Protection Structure (ROPS) .............................. 29

4.6 Installing the Rotating Beacon ............................................................ 30

4.7 Using the Seat Belt ............................................................................. 31

4.8 Adjusting the Seat .............................................................................. 32

4.9 Adjusting the Steering Column ........................................................... 33

4.10 Positioning the Scraper Bars .............................................................. 33

4.11 Using the Anti-Vandalism Protection Devices .................................... 34

4.12 Using the Water Spray System .......................................................... 35

4.13 Using the Forward/Reverse Lever ...................................................... 36

4.14 Backup Alarm ..................................................................................... 37

4.15 Using the Flow Divider (if equipped) .................................................. 38

4.16 Using the Vibration System ................................................................ 39

4.17 Using the Parking Brakes ................................................................... 40

4.18 Warning Lights ................................................................................... 41

4.19 Using the Lights and Horn .................................................................. 42

4.20 Machine Stability ................................................................................ 43

4.21 Operating on Slopes ........................................................................... 44

wc_bo0171754en_003TOC.fm 5

Table of Contents RD 27

4.22 Preliminary Checks .............................................................................45

4.23 Mounting and Dismounting the Machine .............................................45

4.24 Starting the Engine ..............................................................................46

4.25 Stopping the Engine ............................................................................47

4.26 Understanding the Operator Present System .....................................48

4.27 Emergency Shutdown Procedure ........................................................48

5 Maintenance 50

5.1 Periodic Maintenance Schedule ..........................................................50

5.2 Major Component Locations ...............................................................52

5.3 Major Components ..............................................................................53

5.4 Safety-Related Spare Parts .................................................................54

5.5 Maintaining the Seat and Seat Belt .....................................................59

5.6 Checking the Air Filter Indicator ..........................................................60

5.7 Cleaning the Air Cleaner and Primary Air Filter Element ....................61

5.8 Changing the Air Filter Elements .........................................................62

5.9 Testing the Backup Alarm ...................................................................63

5.10 Checking the Engine Coolant Level ....................................................64

5.11 Checking the Engine Oil ......................................................................65

5.12 Checking Hydraulic Oil Level ..............................................................66

5.13 Checking the Neutral Switch ...............................................................67

5.14 Adjusting the Scraper Bars ..................................................................68

5.15 Inspecting the Seat Belt ......................................................................69

5.16 Cleaning the Water Spray Nozzles .....................................................70

5.17 Cleaning the Water Spray System Filter .............................................71

5.18 Cleaning and Changing the Fuel Filter/Water Separator ....................72

5.19 Priming the Fuel System .....................................................................73

5.20 Draining Water and Sediment from the Fuel Tank ..............................74

5.21 Cleaning the Water Tank Strainer .......................................................75

5.22 Adjusting Alternator Belt Tension ........................................................76

5.23 Lubricating the Articulated Steering Joint ............................................77

5.24 Lubricating the Steering Cylinder ........................................................78

5.25 Testing the Brake System ...................................................................79

5.26 Changing the Engine Oil and Filter .....................................................80

5.27 Cleaning the Fuel Tank Cap and Fuel Strainer ...................................81

5.28 Changing the Hydraulic Oil Filter .........................................................82

5.29 Cleaning the Hydraulic Oil Cooler .......................................................83

5.30 Disconnecting/Connecting the Battery ................................................84

5.31 Adjusting the Forward/Reverse Lever .................................................85

5.32 Changing the Hydraulic Oil ..................................................................86

5.33 Checking and Cleaning the Hydraulic Tank Breather .........................87

6 wc_bo0171754en_003TOC.fm

RD 27 Table of Contents

5.34 Cleaning the Hydraulic Oil Strainer .................................................... 88

5.35 Cleaning the Radiator Filler Cap ........................................................ 89

5.36 Checking the Engine Water Pump ..................................................... 90

5.37 Changing the Cooling System Coolant .............................................. 91

5.38 Replacing the Water Temperature Regulator ..................................... 93

5.39 Draining the Water Spray System ...................................................... 94

5.40 Towing the Machine ........................................................................... 95

5.41 Manually Releasing the Parking Brakes ............................................. 97

5.42 Troubleshooting .................................................................................. 98

6 Schematics 100

6.1 Electrical Schematic ......................................................................... 100

6.2 Hydraulic Schematic ......................................................................... 106

7 Technical Data 110

7.1 Engine .............................................................................................. 110

7.2 Roller ................................................................................................ 111

7.3 Lubrication ........................................................................................ 111

7.4 Sound Measurements ...................................................................... 112

7.5 Measurements of Operator Exposure to Vibration ........................... 112

7.6 Dimensions ....................................................................................... 113

wc_bo0171754en_003TOC.fm 7

Table of Contents RD 27

8 wc_bo0171754en_003TOC.fm

RD 27 Safety Information

1 Safety Information

1.1 Signal Words Found in this Manual

This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE
callouts which must be followed to reduce the possibility of personal injury, damage
to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potential personal hazards.
f Obey all safety messages that follow this symbol.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.

f To avoid death or serious injury from this type of hazard, obey all safety mes-

sages that follow this signal word.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

f To avoid possible death or serious injury from this type of hazard, obey all safety

messages that follow this signal word.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.

f To avoid possible minor or moderate injury from this type of hazard, obey all

safety messages that follow this signal word.

NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.

Note: A Note contains additional information important to a procedure.

wc_si000247gb.fm 9

Safety Information RD 27

1.2 Machine Description and Intended Use

This machine is a dual drum, ride-on roller. The Wacker Neuson Ride-On Roller
consists of an articulated frame onto which is mounted a gasoline or diesel engine,
a fuel tank, a hydraulic tank, a water tank, a hydrostatic drive system, two steel
drums containing internal eccentric weights, and an operator’s platform with a
ROPS (Roll Over Protective Structure). The engine powers the hydraulic systems
that provide machine movement and drum vibration. The vibrating drums smooth
and compact the work surface as the machine moves. Machine speed, direction,
and vibration are controlled by the operator from the operator’s seat on the platform.

The machine is designed as a lightweight roller to be used in the compaction of
sublayers and finish layers of asphalt on roads, driveways, parking lots, and other
types of asphalt-covered surfaces.

This machine has been designed and built strictly for the intended use described
above. Using the machine for any other purpose could permanently damage the
machine or seriously injure the operator or other persons in the area. Machine
damage caused by misuse is not covered under warranty.

The following are some examples of misuse:

 Using the machine as a ladder, support, or work surface
 Using the machine to carry or transport passengers or equipment
 Using the machine to tow other machines
 Using the machine to spray liquids other than water (i.e., diesel fuel on asphalt)
 Operating the machine outside of factory specifications.
 Operating the machine in a manner inconsistent with all warnings found on the

machine and in the Operator’s Manual.

This machine has been designed and built in accordance with the latest global
safety standards. It has been carefully engineered to eliminate hazards as far as
practicable and to increase operator safety through protective guards and labeling.
However, some risks may remain even after protective measures have been taken.
They are called residual risks. On this machine, they may include exposure to:

 Heat, noise, exhaust, and carbon monoxide from the engine
 Burns from hot hydraulic fluid
 Fire hazards from improper refueling techniques
 Fuel and its fumes
 Personal injury from improper lifting techniques
 Crushing hazards from improper operation (feet, legs, or arms extending

outside of the operator work station) and for other persons in the work zone

 Line of sight blockage by the ROPS

To protect yourself and others, make sure you thoroughly read and understand the
safety information presented in this manual before operating the machine.

10 wc_si000247gb.fm

RD 27 Safety Information

1.3 Safety Guidelines for Operating the Machine

Operator
qualifications

Personal
Protective
Equipment
(PPE)

Operator
training

Only trained personnel are permitted to start, operate, and shut down the machine.
They also must meet the following qualifications:

 have received instruction on how to properly use the machine
 are familiar with required safety devices

The machine must not be accessed or operated by:

 children
 people impaired by alcohol or drugs

Wear the following Personal Protective Equipment (PPE) while operating this
machine:

 Close-fitting work clothes that do not hinder movement
 Safety glasses with side shields
 Hearing protection
 Safety-toed footwear

Before operating the machine:

 Read and understand the operating instructions contained in all manuals

delivered with the machine.

 Familiarize yourself with the location and proper use of all controls and safety

devices.

 Contact Wacker Neuson Corporation for additional training if necessary.

Machine’s
safety devices

When operating this machine:

 Do not allow improperly trained people to operate the machine. People

operating the machine must be familiar with the potential risks and hazards
associated with it.

 Disengage and stow the locking bar for the articulated steering joint before

operating the machine. The machine cannot be steered when the locking bar is
engaged.

 Check that all controls are functioning properly immediately after start-up!

To ensure safe operation of the machine:

 Do not operate the machine if any safety devices or guards are missing or

inoperative.

 Do not operate the machine unless all controls operate correctly.
 Do not modify or defeat safety devices.
 Do not use accessories or attachments that are not recommended by Wacker

Neuson. Damage to equipment and injury to the user or others may result.

wc_si000247gb.fm 11

Safety Information RD 27

Safe
operating
practices

When operating this machine:

 Always remain seated and wear the seat belt at all times while operating the

machine.

 Remain aware of changing positions and the movement of other equipment and

personnel on the job site.

 Be sure that all other persons are at a safe distance from the machine. Stop the

machine if people step into the working area of the machine.

 Remain aware of changing surface conditions, for example, uneven ground,

hills, trench edges, soft or coarse material. Be sure that the surface is stable
enough to support the weight of the machine and that there is no chance of the
machine sliding, falling, or tipping.

 Remain aware of the machine’s moving parts. Keep hands, feet, and loose

clothing away from the machine’s moving parts.

 Wear protective clothing appropriate to the job site when operating the machine.
 Wear safety glasses when operating this machine.
 Store the machine properly when it is not being used. The machine should be

stored in a clean, dry location out of the reach of children.

When operating this machine:

 Do not drive off curbs or other uneven surfaces that will result in jarring impacts

to the machine and operator.

 Do not touch the engine or muffler while the engine is on or immediately after it

has been turned off. These areas get hot and may cause burns.

 Do not allow anyone to ride on any part of the machine. Passengers can be

seriously injured or killed from falls, tip-overs, or roll-over incidents.

 Do not leave the machine running unattended.
 Do not operate a machine in need of repair.
 Do not attempt to start the machine while standing alongside it. Only start the

engine when seated in the driver’s seat and with the forward/reverse control in
the neutral position.

 Do not operate a machine when its fuel cap is loose or missing.
 Do not use a cellphone or send text messages while operating this machine.
 Do not operate the machine with unapproved accessories or attachments.
 Do not transport the machine while it is running.

12 wc_si000247gb.fm

RD 27 Safety Information

1.4 Safety Guidelines while Using Internal Combustion Engines

WARNING

Internal combustion engines present special hazards during operation and fueling.
Failure to follow the warnings and safety standards could result in severe injury or death.
f Read and follow the warning instructions in the engine owner’s manual and the

safety guidelines below.

DANGER

Exhaust gas from the engine contains carbon monoxide, a deadly poison.
Exposure to carbon monoxide can kill you in minutes.

f NEVER operate the machine inside an enclosed area, such as a tunnel, unless

adequate ventilation is provided through such items as exhaust fans or hoses.

Operating
safety

Refueling
safety

When running the engine:



Keep the area around exhaust pipe free of flammable materials.



Check the fuel lines and the fuel tank for leaks and cracks before starting the engine.
Do not run the machine if fuel leaks are present or the fuel lines are loose.

When running the engine:



Do not smoke while operating the machine.



Do not run the engine near sparks or open flames.



Do not touch the engine or muffler while the engine is running or immediately after it
has been turned off.



Do not operate a machine when its fuel cap is loose or missing.



Do not start the engine if fuel has spilled or a fuel odor is present. Move the machine
away from the spill and wipe the machine dry before starting.

 Do not remove the radiator cap when the engine is running or hot. The radiator

fluid is hot and under pressure and may cause severe burns!

When refueling the engine:



Clean up any spilled fuel immediately.



Refill the fuel tank in a well-ventilated area.



Replace the fuel tank cap after refueling.



Do not smoke.



Do not refuel a hot or running engine.



Do not refuel the engine near sparks or open flames.



Do not refuel if the machine is positioned in a truck fitted with a plastic bed liner.
Static electricity can ignite the fuel or fuel vapors.

wc_si000247gb.fm 13

Safety Information RD 27

1.5 Guidelines for Service Safety

WARNING

A poorly maintained ained machine can become a safety hazard! In order for the
machine to operate safely and properly over a long period of time, periodic
maintenance and occasional repairs are necessary.

f ALWAYS do periodic maintenance as recommended in the Operator’s Manual.

Personal
Protective
Equipment
(PPE)

Precautions

Wear the following Personal Protective Equipment (PPE) while servicing or
maintaining this machine:

 Close-fitting work clothes that do not hinder movement
 Safety glasses with side shields
 Hearing protection
 Safety-toed footwear

In addition, before servicing or maintaining the machine:

 Tie back long hair.
 Remove all jewelry (including rings).

 To reduce the risk of personal injury, read and understand the service

procedures before performing any service to the machine.

 Some service procedures require that the machine’s battery be disconnected.
 All adjustments and repairs MUST be completed before operation. NEVER

operate the machine with a known problem or deficiency! All repairs and
adjustments should be completed by a qualified technician.

 Stop the engine before servicing the machine. If the engine has electric start,

disconnect the negative terminal on the battery.

 Secure the articulated steering joint using the locking bar before lifting, jacking,

and servicing the machine. Machine halves could swing together unexpectedly
and cause a serious injury.

Accessories,
safety
devices, and
modifications

Replacing
parts and
labels



Do not modify, weld, or drill safety frames (ROPS) fitted as original equipment.



Do not loosen or remove bolts.



Do not weld, drill, or modify a broken safety frame.



Do not modify the machine without the express written approval of the manufacturer.

 Replace worn or damaged components.
 When replacement parts are required for this machine, use only Wacker

Neuson replacement parts or those parts equivalent to the original in all types of
specifications, such as physical dimensions, type, strength, and material.

 Never use or attempt to repair a damaged safety belt or ROPS. Replace these

components before operating the machine.

 Replace all missing and hard-to-read labels. Labels provide important operating

instructions and warn of dangers and hazards.

 Check all external fasteners at regular intervals.

14 wc_si000247gb.fm

RD 27 Safety Information

Lifting and
transporting

Cleaning and
servicing the
machine

When lifting the machine:

 Make sure slings, chains, hooks, ramps, jacks and other types of lifting devices

are attached securely and have enough weight-bearing capacity to lift or hold
the machine safely.

 Remain aware of the location of other people when lifting the machine.

To reduce the possibility of injury:

 Do not stand under the machine while it is being hoisted or moved.
 Do not get onto the machine while it is being hoisted or moved.

While cleaning or servicing the machine:

 Keep the area around the muffler free of debris such as leaves, paper, cartons,

etc. A hot muffler could ignite the debris and start a fire.

 Keep the machine clean and labels legible.
 Keep hands, feet, and loose clothing away from moving parts.

While cleaning or servicing the machine:

 Do not remove air cleaner cover, paper element, or precleaner while engine is

running.

 Do not attempt to open the radiator cap while the machine is running or before

the engine has cooled down. Severe burns may result!

 Do not attempt to clean or service the machine while it is running. Rotating parts

can cause severe injury.

 Do not use gasoline or other types of fuels or flammable solvents to clean parts,

especially in enclosed areas. Fumes from fuels and solvents can become
explosive.

 Do not tip the machine for cleaning or for any other reason.

WARNING

Possibility of injury. Hydraulic fluid under pressure can penetrate the skin, cause
burns, blind, or create other potentially dangerous hazards.
f Set all controls to neutral, turn the engine off, and allow fluids to cool before

loosening hydraulic fittings or attaching test gauges.

f Do not open hydraulic lines or loosen hydraulic connections when the engine is

running.

f Before dismantling hydraulic connectors or hoses, ensure that all pressure has

been bled from the circuit.

f Fluid leaks from small holes are often practically invisible. DO NOT use your

bare hands to check for leaks. Check for leaks using a piece of cardboard or
wood.

f Always make sure hose connections have been reconnected back to the cor-

rect fitting. Failure to do so may result in damage to the machine and/or injury to
person on or near the machine.

 Always replace safety devices and guards after completing repairs and

maintenance.

 Before you start the machine, ensure that all tools have been removed from the

machine and that replacement parts and adjusters are firmly tightened.

wc_si000247gb.fm 15

Labels RD 27

2 Labels

2.1 Label Locations

v

n

q

g

o

i

g

k

b

x

v

n

s

p

w

d

u

a

k

f

d

c

g

g

h

r

m

j

f

t

l

d

g

f

wc_gr005053

16 wc_si000393gb.fm

RD 27 Labels

STOP

2.2 Safety and Warning Labels

Ref. Label Definition

b DANGER!

Read and understand the supplied
Operator's Manuals before operating this
machine. Failure to do so increases the risk
of injury to yourself and others.

Do not run the machine indoors or in an
enclosed area without adequate ventilation.
Engine exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
Exposure to carbon monoxide can cause
loss of consciousness and CAN KILL YOU IN
MINUTES.

To reduce the risk of hearing loss, wear hear­ing protection when operating this machine.

Always wear seat belt when operating the
machine.

Never operate the machine sideways on
slopes.

c DANGER!

Asphyxiation hazard. Do not run the machine
indoors or in an enclosed area without ade­quate ventilation. Read the Operator’s Man­ual for instructions. No sparks, flames, or
burning objects near machine. Stop the
engine before adding fuel. Use only diesel
fuel.

0178715

dCAUTION

Lifting point.

wc_si000393gb.fm 17

Labels RD 27

Ref. Label Definition

f WARNING!

Avoid crushing area.

h WARNING!

Disconnect battery before servicing.
Read Repair Manual.
Explosion hazard. Batteries can emit explo­sive hydrogen gas. Keep all sparks and
flames away from the battery.

lWARNING!

Pinching hazard. Rotating machinery.

m WARNING!

Pressurized contents. Do not open when hot!

18 wc_si000393gb.fm

RD 27 Labels

Ref. Label Definition

n WARNING!

Avoid crushing area.

s WARNING!

Do not drill or weld the ROPS.
Read the Operator’s Manual.

t WARNING!

Avoid crushing area.
Articulated steering joint locking location.
Lock the articulated steering joint before ser­vicing the machine.
Read Repair Manual.

wc_si000393gb.fm 19

Labels RD 27

2.3 Informational Labels

Ref. Label Definition

a Operator’s Manual must be stored on

O P E R A T O R ' S M A N U A L M U S T B E
S T O R E D O N M A C H I N E .
R E P L A C E M E N T O P E R A T O R ' S
M A N U A L C A N B E O R D E R E D

L O C A L W A C K E R

T H R O U G H Y O U R
D I S T R I B U T O R .

D I E B E T R I E B S V O R S C H R I F T M U S S
A N D E R M A S C H I N E A U F B E W A H R T
W E R D E N . Z U R B E S T E L L U
E R S A T Z B Ü C H E R N W E N D E N S I E
S I C H B I T T E A N I H R E N
Ö R T L I C H E N W A C K E R H Ä N D L E R .

N G V O N

E L M A N U A L D E O P E R A C I O N D E B E
S E R R E T E N I D O E N L A M A Q U I N A .
C O N T A C T E A S U D I S T R I B U I D O R
W A C K E R M A S C E R C A N O P
P E D I R U N E J E M P L A R
A D I C I O N A L .

L A N O T I C E D ' E M P L O I D O I T
E T R E M U N I E S U R L A M A C H I N E .
C O N T A C T E R L E D I S T R I
W A C K E R L E P L U S P R O C H E
P O U R C O M M A N D E R U N
E X E M P L A I R E S U P P L E M E N T A I R E .

B U T E U R

A R A

machine. Replacement Operator’s Manual
can be ordered through your local Wacker
Neuson distributor.

1 1 5 0 9 6

e A nameplate listing the model number, item

number, revision number, and serial number
is attached to each unit. Please record the
information found on this plate so it will be
available should the nameplate become lost
or damaged. When ordering parts or
requesting service information, you will
always be asked to specify the model num­ber, item number, revision number, and serial
number of the unit.

g Tie-down point.

i Hydraulic oil drain.

HYDRAULIC OIL
HYDRAULIKÖL
ACEITE HIDRÁULICO
HUILE HYDRAULIQUE

j Hydraulic oil reservoir fill.

20 wc_si000393gb.fm

RD 27 Labels

Ref. Label Definition

k Water tank fill.

o Engine oil drain.

ENGINE OIL
MOTOROEL
ACEITE DE MOTOR
HUILE À MOTEURS

p Key switch positions.

STOP

Power to glowplugs.
Engine stopped (OFF).
Engine ON.
Power to starter motor.

q Throttle lever positions.

High speed.
Low speed.

wc_si000393gb.fm 21

Labels RD 27

Ref. Label Definition

r Vibration activation and deactivation switch.

Forward/reverse lever positions.

u Fuse identifications.

v Tighten screw to reduce vibration.

1

2

Read Operator’s Manual.

wc_gr002757

w Guaranteed sound power level in dB(A).

x ROPS certification label

y Biodegradable hydraulic oil reservoir fill

(if equipped)

22 wc_si000393gb.fm

RD 27 Lifting and Transporting

3 Lifting and Transporting

3.1 Lifting the Machine

Prerequisites

Procedure

 Lifting equipment (crane or hoist) capable of supporting 2722 kgs. (6000 lbs.)
 Four lifting hooks and chains capable of supporting 2722 kgs. (6000 lbs.)

WARNING

Crushing hazard. You may be crushed if the lifting devices fail.

f Never stand under, or get onto, the machine while it is being lifted or moved.
f Use only the designated lifting points to lift the machine.

Follow the procedure below to lift the machine.

1. Stop the engine.

2. Engage the parking brake.

3. Lock the articulated steering joint (a).

4. Attach one lifting chain to each of the four lifting eyes (b) on the machine (two
per side) using hooks or shackles.

5. Attach the other end of the chains to the lifting equipment.

6. Lift the machine as necessary.

CAUTION

Crushing / machine damage hazards. The Roll Over Protection Structure (ROPS)
(c) is intended strictly to protect the operator during a rollover or tip-over incident.
The ROPS must not be used to lift the machine.
f Use only the designated lifting eyes to lift the machine.

wc_tx001351gb.fm 23

Lifting and Transporting RD 27

3.2 Tying Down/Transporting the Machine

Prerequisites

Procedure

 Engine shut down
 Parking brake ON

Follow the procedure below to tie down the machine.

1. Make sure that the transport vehicle is capable of handling the weight and size
of the machine. See Technical Data for dimensions and operating weight.

2. Lock the articulated steering joint (a).

c

wc_gr004992

3. Attach steel ropes or chains to each of the four tie down eyes (b) on the
machine (two per side) and the two tie down bars (c) on the front and rear of the
machine.

c

4. Attach the other end of the chains to an appropriate vehicle capable of handling
the weight of the machine.

Note: The transmission is normally braked when the diesel engine is off, or when
the hydraulic system is not functioning, unless there is a fault and/or the parking
brakes have been manually disabled.

NOTICE: Do not position ropes or chains across the machine frame or the articu­lated joint when tying down the machine. Damage to the machine may occur.

NOTICE: Do not completely compress the shock mounts when tying down the
machine. Damage to the shock mounts may occur.

NOTICE: Do not leave the machine tied down for extended periods of time (except
when transporting). Damage to the shock mounts may occur.

24 wc_tx001351gb.fm

RD 27 Operation

4 Operation

4.1 Preparing the Machine for First Use

Preparing for
first use

To prepare your machine for first use:

1. Make sure all loose packaging materials have been removed from the machine.

2. Check the machine and its components for damage. If there is visible damage,
do not operate the machine! Contact your Wacker Neuson dealer immediately
for assistance.

3. Take inventory of all items included with the machine and verify that all loose
components and fasteners are accounted for.

4. Attach component parts not already attached.

5. Add fluids as needed, including fuel, engine oil, and battery acid.

6. Move the machine to its operating location.

4.2 Position of the Operator

Safe and efficient use of this machine is the operator’s responsibility. Full control of
the machine is not possible unless the operator maintains the proper working
position at all times.

While operating this machine, the operator must:

 be seated in the operator’s seat facing forward
 wear the seat belt, properly adjusted and latched
 have both feet on the control deck
 have one hand on the steering wheel at all times
 have the other hand free to operate the controls as needed

wc_tx000814gb.fm 25

Operation RD 27

4.3 Operation & Maintenance Locations

Ref. Description Ref. Description

a Throttle lever l Vibration mode switch

b Ignition key block m Vibration ON/OFF switch

c Alternator warning light n Water pump switch

d Engine oil pressure warning light o Engine temperature warning light

e Hydraulic oil temperature warn-

ing light

f Forward-reverse lever q Turn signal switch

g Horn r Flashers ON warning light

h Parking brake warning light and

control

i Vibration-on warning light t Flow divider switch (if equipped)

j Light switch u Turn signal indicator

k Fuse box v Lights ON indicator

-- -- w Light switch

p Hour meter

s Flasher activation switch

Ref. Description Ref. Description

1 Diesel engine 7 Front exciter hydraulic motor

2 Hydraulic transmission pump 8 Rear hydraulic transmission

motor

3 Front hydraulic transmission

motor

4 Rear exciter hydraulic motor 10 Brake

5 Exciter hydraulic pump 11 Oil cooler

6 Steering hydraulic pump 12 Electric water pump

9 Servo steering

26 wc_tx000814gb.fm

RD 27 Operation

v

rwq iu s c hode

p

n l g j

b

a

9

t

1

11

7

10

3 10

2

k

m

12

6

5

10

f

4

10

8

wc_gr005016

wc_tx000814gb.fm 27

Operation RD 27

4.4 Unlocking/Locking the Articulated Joint

Locking

Unlocking

Install the articulated steering joint pin in the LOCKED position (a) before you lift
the machine, transport the machine, or perform maintenance near the center of the
machine.

Install the articulated steering joint pin in the UNLOCKED position (b) before you
operate the machine.

NOTICE: Attempting to steer the machine with the articulated steering joint pin in
the locked position may destroy the steering cylinder and locking mechanism.

28 wc_tx000814gb.fm

RD 27 Operation

4.5 Using the Roll Over Protection Structure (ROPS)

Background

Positioning

The machine is equipped with a Roll Over Protection Structure (ROPS). The ROPS
is designed to protect the operator in a rollover accident.

WARNING

Crushing hazard. You may be crushed if the machine rolls over.
f Never use the machine without the ROPS in place.

Follow the procedure below to position the ROPS in the upright position.

1. Support the ROPS (a) using a crane and suitable rigging capable of supporting
70 kg (155 lbs.).

2. Remove the safety pin (b) and pull out the locking pin (c).

3. Lift the ROPS into the upright position.

4. Insert the locking pin and secure it with the safety pin.

5. Tighten the adjusting screw (d) as needed to reduce vibration.

Keep the ROPS in the extended (upright) position when using the roller.

WARNING

Crushing / machine damage hazards. The ROPS is intended strictly to protect the
operator during a rollover or tip-over incident and must not be used to lift the
machine.

f Use only the designated lifting eyes to lift the machine. See Lifting the Machine.

WARNING

Personal injury hazard. The ROPS is not a handhold for passengers. Passengers
can be seriously injured or killed from falls, tip-overs, or roll-over incidents.

f Do not allow anyone to ride on any part of the machine.

wc_tx000814gb.fm 29

Operation RD 27

Checking

Rules for re­installing

Each month, check:

 the torque on all of the screws holding the ROPS in place
 the ROPS frame for rust, cracks, and any other damage

When reinstalling the ROPS:

 Use the original nuts and bolts.
 Use oil to lubricate the bolts before installing the ROPS.
 Tighten the bolts to the specified torques.

NOTICE: Do not weld or drill into the ROPS. Drilling or welding on the ROPS will
nullify the ROPS certification.

4.6 Installing the Rotating Beacon

Background

The rotating beacon illuminates and rotates when the key switch is in the ON
position.

Procedure

Follow the procedure below to install the beacon.

1. Thread the power wire (c) through the light staff and fix it to the upper connector.

a

d

b

c

wc_gr004731

2. Insert the connector into the light staff.

3. Insert the light staff assembly (a) into the left side of the machine ROPS and
tighten the set screw (b).

4. Slide the rotating beacon (d) onto the light staff.

30 wc_tx000814gb.fm

RD 27 Operation

4.7 Using the Seat Belt

Precaution

To use

Always use the seat belt when operating the machine.

To use the seat belt:

1. Pull seat belt (c) out of the retractor in a continuous motion.

c

d

b

a

wc_gr002238

2. Fasten seat belt catch (b) into buckle (a).

3. Position the seat belt low across the lap of the operator. The retractor will adjust
the belt length and the retractor will lock in place.

4. Push the release button (d) on the buckle in order to release the seat belt. The
seat belt will automatically retract into the retractor.

wc_tx000814gb.fm 31

Operation RD 27

4.8 Adjusting the Seat

Background

To adjust

Adjust the seat position and tension (firmness) according to working conditions and
operator’s weight.

The seat can be adjusted in three ways:

Tension Use knob (a) for adjusting seat tension. Turn from a minimum of

60 kg to a maximum of 120 kg (132 lb–264 lb).

Front to back Use lever

controls.

Side to side (optional) Use pin

ment holes (if so equipped).

(b) to adjust the front-to-back distance from the driving

(c) to set one of the three side-to-side position place-

32 wc_tx000814gb.fm

RD 27 Operation

4.9 Adjusting the Steering Column

Background

To adjust

Adjust the angle of the steering column according to working conditions and the
operator’s height and personal preference.

The angle of the steering column can be adjusted as follows:

1. Loosen the four mounting bolts (a) at the base of the steering column.

2. Pivot the steering column forward or backward as desired.

3. Once the desired angle has been reached, re-tighten the mounting bolts.

4.10 Positioning the Scraper Bars

Prerequisites

Positions

 Machine shut down
 Parking brake engaged

Each drum has two scrapers (a, b). They may be set in the travel position (1) or the
scraping position (2).

wc_tx000814gb.fm 33

Operation RD 27

4.11 Using the Anti-Vandalism Protection Devices

Background

Procedure

Parts of the machine may be subject to theft or vandalism when the machine is
unattended. These parts can be locked to prevent unauthorized access or use.

Lockable parts include:

 Engine cover
 Control console cover
 Operator’s Manual holder

Follow the procedure below to lock the machine.

1. Close the engine cover and attach a padlock to the fastener (a).

wc_gr004735

2. Slide the control console cover over the console and attach a padlock to the
fastener (b).

3. Close the Operator’s Manual holder lid and attach a padlock to the fastener (c).

Note: Padlocks are supplied with the machine as standard.

34 wc_tx000814gb.fm

RD 27 Operation

4.12 Using the Water Spray System

Switch
positions

Guidelines
when using

Water from the tank is fed to the spray nozzles by an electric pump. The switch
controls the water pump motor. The switch has three positions:

Position 1: activates the
intermittent water spray

Mid position (0): turns
off the water spray

0

system

Position 2: activates the
continuous water spray

When using the water spray system:

 Check that the tank is full of water.
 Use only clean water. Dirty water, even when filtered, can clog the system.
 Keep the water system clean and well maintained. See Maintenance Section.
 If spray does not begin immediately when the system is turned on, it may be

necessary to bleed air from the water lines. Opening the diaphragm valve (a)
while the system is running will force air out of the lines. Close the diaphragm
valve when water begins to spray through the nozzles.

Adjusting

To adjust the angle of spray:

Insert a screwdriver into the nozzle (b) and adjust the angle as desired.

Note: Ensure that water spray covers entire length of drum.

Draining

During winter, or when temperatures drop below 0°C (32°F), drain the water spray
system. See section Draining the Water Spray System.

wc_tx000814gb.fm 35

Operation RD 27

4.13 Using the Forward/Reverse Lever

Background

Travel
direction

Both roller drums are driven. An infinitely variable displacement pump and
hydrostatic transmission drive the hydraulic motors fitted to each drum. The
machine moves forward or reverse by using the forward/reverse lever located to
the side of the driver’s seat.

Move the forward/reverse lever into FORWARD (f) or REVERSE (r) according to
the direction of travel desired.

To change direction of travel from FORWARD to REVERSE or vice versa:

Travel speed

Braking

Operator
present
system

1. Move the forward/reverse lever to the “N” NEUTRAL position (n).

2. Allow the machine to come to a complete stop.

3. Move the forward/reverse lever in the direction desired.

Note: In order to comply with safety standards, the machine has a device which
only enables starting of the engine when the forward/reverse lever is in the neutral
position.

 Travel speed varies from “ZERO” to a permitted maximum of 10 kph (6.2 mph).
 The farther forward or reverse the forward/reverse lever is positioned, the faster

the roller will travel.

 Travel speed is the same in both FORWARD and REVERSE.

Note: When negotiating slopes, keep the forward/reverse lever at minimum travel
speed.

The forward/reverse lever can be used as an engine brake. Shifting the forward/
reverse lever to the neutral position stops the machine.

The machine is equipped with an operator present system. The system prevents
the machine from moving forward or reverse unless the operator is seated. The
operator should remain seated at all times.

36 wc_tx000814gb.fm

RD 27 Operation

4.14 Backup Alarm

Location

Operation

The backup alarm (e) is located on the rear of the machine.

Start the engine and move the forward-reverse lever to the reverse position. The
backup alarm should sound immediately. The backup alarm will continue to sound
until the forward-reverse lever is moved to the neutral position or to the forward
position.

If the backup alarm does not sound, make the necessary repairs before using the
roller.

e

wc_gr005034

wc_tx000814gb.fm 37

Operation RD 27

4.15 Using the Flow Divider (if equipped)

Background

Flow divider
switch

This machine may be equipped with an optional flow divider. Non-uniform soil
conditions, such as a combination of loose sandy material and large particles, may
cause the drums to rotate at unequal speeds. This may impede machine
movement. When activated, the flow divider equalizes the flow of hydraulic oil
traveling to each drive motor so that movement can be re-established.

The activation switch for the flow divider is foot-operated. Follow the procedure
below to activate the flow divider.

1. Locate the activation switch (a) on the operator’s platform to the right of the
steering column.

a

wc_gr005009

2. Press the activation switch once to turn the flow divider system on.

3. Press the activation switch again to turn the flow divider off.

NOTICE: The flow divider is designed for intermittent use only. Continuous use of
the flow divider will cause the hydraulic oil to become overheated, possibly
damaging the hydraulic system. Only use the flow divider if necessary to re­establish machine movement.

38 wc_tx000814gb.fm

RD 27 Operation

4.16 Using the Vibration System

Background

Vibration
mode switch

Vibration
ON-OFF
switch

The machine has an exciter on each drum. The exciters are driven by gear-type
hydraulic motors. The exciter motors are fed by a fixed-displacement, gear-type
hydraulic pump.

Position 1: vibration of front drum
only.

Position 2: vibration of both drums.

When the switch is activated in
Position 1 or Position 2, the light (i)
on the control panel illuminates.

To start vibration, press button (m).

To stop vibration, press button (m)
again.

Frequency

NOTICE: Do not leave the vibration
running when the vehicle is to remain
stationary for some time. Leaving the
exciter on for a prolonged period
when the machine is stationary may
damage the exciter.

Note: Vibration will not run when the
forward/reverse control is in NEU­TRAL.

Position 1: Use when starting or
shutting down the engine.

Position 2: Use for approximately 55
Hz of vibration.

Position 3: Use for approximately 66
Hz of vibration.

Note: Always use Position 2 or Posi­tion 3 when operating the machine.

wc_tx000814gb.fm 39

Operation RD 27

4.17 Using the Parking Brakes

Background

To aid in holding the machine in a stopped position (parked), there is a mechanical
parking brake on each drum drive motor. The mechanical parking brakes are
spring-activated and hydraulically released (SAHR) type brakes.

The parking brakes are applied when any of the following conditions exist:

 The parking brake push button (h) is pressed.
 The engine is switched off.
 The operator leaves the seat.
 There is a fault in the hydraulic system.

h

wc_gr005010

Engaging and
releasing

Emergency
use

Pushing the button engages the parking brakes.

The “Brakes On” warning light illuminates when the button is pressed.

Pulling the button up allows the release of the parking brakes.

Note: All of the following conditions must be met for the parking brakes to release:

 The engine must be running.
 The forward/reverse lever must be in the neutral position.
 The operator must be seated.

NOTICE: Do not use the parking brakes to stop the machine during normal
operating conditions. Using the parking brake while the machine is moving may
damage the drive motors.

Only use the parking brakes to stop the machine during an emergency condition.
For example:

 During failure of the main hydraulic braking system (no braking action when the

forward/reverse lever is moved to the neutral position)

 During a runaway condition traveling down a slope

40 wc_tx000814gb.fm

RD 27 Operation

4.18 Warning Lights

Warning light Description Action Required

Engine oil pressure This light (d) illuminates

when the key switch is in
the ON position; it goes out
once the engine has
started, if engine oil pres­sure is OK.

Engine high temperature This light (o) illuminates

when the engine is over­heating.

Alternator This light (c) illuminates

when the key switch is in
the ON position; it goes out
once the engine has
started, if the charging sys­tem is OK.

Hydraulic oil temperature This light (e) illuminates

when the hydraulic oil is too
hot.

Turn off the engine immedi­ately if this light illuminates
when the engine is running.

Check:
Engine oil level
Engine oil viscosity

Turn off the engine immedi­ately if this light illuminates.

Check:
Engine coolant level

Turn off the engine immedi­ately if this light illuminates
while the engine is running.

Check:
Alternator belt

Turn off the engine immedi­ately if this light illuminates.

Check:
Hydraulic oil level
Hydraulic oil viscosity

wc_tx000814gb.fm 41

d

o

c

e

wc_gr005012

Operation RD 27

4.19 Using the Lights and Horn

Background

Identifying the
lights

Operating the
lights and
horn

The rotary switch on the control panel controls power to the machine’s lights.

 Headlights (a)
 Working light (b)
 Front turn signal lights / roading lights (c)
 Rear turn signal lights / roading lights (d)

dc a c d b

wc_gr005035

 Position 0: all lights off
 Position 1: headlights and roading lights ON
 Position 2: headlights, roading lights, and work lights ON
 Press the center of the switch to sound the horn.

0

1

2

wc_gr005032

WARNING

Collision hazard. Failure to use all available lights when working in the dark or in
bad visibility may increase the possibility of colliding with nearby people, vehicles,
or stationary objects.

f Use all available lights when working in the dark or in bad visibility.
f Replace broken lamps immediately.

42 wc_tx000814gb.fm

RD 27 Operation

2

4.20 Machine Stability

WARNING

Crushing hazards. Certain job site conditions or operating practices may adversely
affect machine stability.

f

Follow the instructions below to reduce the risk of tipping or falling incidents.

Surface
conditions

Steering angle

Pay attention to changing surface conditions while operating the machine. Adjust
speed and travel direction as necessary to maintain safe operation.

 Machine stability and traction may be severely reduced when operating on

uneven or rough terrain, rocky soils, or wet or loosely packed surface material.

 The machine may suddenly tip, sink, or fall when moved onto surfaces that have

been newly filled with earth.

An articulated roller is more likely to tip when moving off an elevated surface if the
machine is turned away from the edge.

 As shown in the illustration on the right, always turn the machine toward the

edge when moving off an elevated surface.

Travel speed

A fast moving machine is more likely to tip or fall over while making turns or
changing direction.

 Reduce travel speed before turning the machine.

Drum
overhang

The machine can tip suddenly if more than half of the drum width extends beyond
the edge of the elevated surface.

 Reduce travel speed and watch the drum position carefully when operating

along the edge of an elevated surface.

 Keep as much of the drum on the elevated surface as possible.

Vibrating on a
compacted
surface

Activating the vibratory system on a fully compacted surface may cause the drums
to rebound and momentarily lose contact with the ground. If this occurs while the
machine is on an incline, the machine may slide.

 If the drums rebound on the compacted surface, reduce vibration speed or stop

vibration entirely.

wc_tx000814gb.fm 43

wc_gr00704

Operation RD 27

4.21 Operating on Slopes

Background

Procedure

When operating on slopes or hills, special care must be taken to reduce the risk of
personal injury or damage to the machine.

Always operate the machine up and down slopes rather than from side to side. For
safe operation and for protection of the engine, continuous duty use should be
restricted to slopes of 19° (35% grade) or less.

WARNING

Crushing hazard. Never operate the machine sideways on slopes. The machine
may tip or roll over even on stable ground.

f Operate the machine straight up and down slopes.

Surface
conditions

Pay attention to changing surface conditions while operating the machine. Adjust speed
and travel direction as necessary to maintain safe operation.



Machine stability and traction may be severely reduced when operating on uneven
or rough terrain, rocky soils, or wet or loosely packed surface material.



The machine may suddenly tip, sink, or fall when moved onto surfaces that have
been newly filled with earth.

44 wc_tx000814gb.fm

RD 27 Operation

4.22 Preliminary Checks

Prerequisites

Before
starting

Before
operating

Machine on a flat, level surface

Before starting the machine, check the following items:

 Engine coolant level
 Engine oil level
 Engine air filter indicator
 Hydraulic oil level
 Diesel fuel level
 Condition of oil cooler and radiator cooling fins
 Water level in tank

NOTICE: Top off the lubricating and hydraulic oil levels using products with the
grades and specifications shown in the “Lubricants” table found in the Technical
Data chapter of this Operator’s Manual. When doing so, use clean containers, fun­nels, etc., to avoid contamination.

Before operating the machine:

 Unlock the articulated joint.
 Adjust drum scraper position.
 Check the machine for fluid leaks. Repair them before operating.
 Check the work area for obstructions. Remove all obstructions.
 Check that all handles, steps, and platforms are free of dirt, snow, grease, fuel,

or anything else which might endanger operator safety.

 Allow the engine to warm up according to the following schedule:

Ambient Temperature Time (min.)

Above 0°C (32°F) 15

Below 0°C (32°F) 30*

* More time may be required if hydraulic controls are sluggish.

4.23 Mounting and Dismounting the Machine

When climbing on and off the machine, maintain a three-point contact with the
steps and the handholds.

Three-point contact can be:

 two feet and one hand
 one foot and two hands

wc_tx000814gb.fm 45

Operation RD 27

4.24 Starting the Engine

DANGER

Asphyxiation hazard. Engine exhaust contains carbon monoxide which CAN KILL
YOU IN MINUTES. This is a poison that you cannot see or smell.

f Do not start the engine in enclosed spaces.

Procedure

Follow the procedure below to start the engine.

1. Sit down in the operator’s seat and fasten the seat belt.

2. Move the forward/reverse (f) lever to the NEUTRAL position.

3. Push the parking brake push button (h) to engage the parking brake.

4. Move the throttle to the LOW position (1).

5. Turn the starting key to POSITION 1. Check for power to the control panel. The
oil pressure and alternator lights should illuminate.

6. Turn the starting key to POSITION 2 and hold it there for approximately 15
seconds to supply power to the glow plugs. In warmer weather the time period
may be reduced.

7. Immediately after powering the glow plugs, turn the key to POSITION 3 to crank
the engine. When the engine fires, release the starting key to avoid straining the
starter motor.

NOTICE: Do not crank the engine for periods longer than 30 seconds. Turn the
key back to OFF and wait 15 seconds before cranking the engine again.

46 wc_tx000814gb.fm

RD 27 Operation

4.25 Stopping the Engine

Prerequisites

Procedure

Flat surface with a suitable load-bearing capacity

Follow the procedure below to stop the engine.

1. Stop the machine on a flat surface with a suitable load bearing capacity.

2. Move the forward/reverse (f) lever to the NEUTRAL position.

3. Move the throttle lever to the LOW position (1).

NOTICE: Do not stop the engine suddenly after a lengthy period of running under
heavy loading. Allow the engine to run at low idling speed for a few minutes before
stopping it. This avoids a sudden drop in engine temperature when the engine is
stopped.

4. Push the parking brake push button (h).

5. Turn the key switch to POSITION 0 (OFF).

6. Remove the starting key before you leave the operator’s seat.

7. Chock the drums if the machine must be parked on a slope.

CAUTION

Obstruction hazard.
f Mark the machine with signs, lights, and other identification if the machine

poses an obstacle to traffic when parked.

wc_tx000814gb.fm 47

Operation RD 27

4.26 Understanding the Operator Present System

Background

Operation

The machine is equipped with an operator present system. This system prevents
machine movement if the operator is not seated in the operator’s seat. The system
includes the seat switch and the neutral switch.

If the machine stops during operation, take the following steps to resume operation:

1. Sit in the operator’s seat.

2. Return the forward/reverse lever to the NEUTRAL position.

3. Operate the machine as normal.

Note: The seat switch is activated by operator weight when seated. Adjust the seat
tension so that the operator’s weight activates the seat switch. See section “Adjust­ing the Seat.”

4.27 Emergency Shutdown Procedure

If a breakdown/accident occurs while the machine is operating, follow the
procedure below.

1. Stop the engine.

2. Allow the engine and exhaust system to cool.

3. Using appropriate equipment, return the machine to an upright position if tipped
over.

4. Contact rental yard or machine owner.

48 wc_tx000814gb.fm

RD 27 Operation

Notes:

wc_tx000814gb.fm 49

Maintenance RD 27

5 Maintenance

5.1 Periodic Maintenance Schedule

Tasks designated with check marks may be performed by the operator. Tasks
designated with square bullet points require special training and equipment.

Interval* (hours of service)

(10) (100) (250) (500) (1000) (3000) (12,000)

Item Task

Air cleaner Clean

Backup alarm Test

Engine coolant level Check

Engine oil level Check

Fuel level Check

Hydraulic oil level Check

Neutral switch Test

Scrapers Check

Seat belt Inspect

Spray nozzles Clean

Spray system filter Clean

External hardware Check

Daily 2

weeks3 months

3
3
3
3
3
3
3
3
3
3
3

3

Yearly Yearly 3

years

6

years

Fuel system water separa­tor

Fuel tank Drain

Throttle control Lubricate

Water tank strainer Clean

Alternator belt Check

Articulated steering joint Lubricate

Steering cylinder Lubricate

Braking system Test

Engine oil and filter Change

Clean/

Drain

water/

sediment

3

3

3
3

3
3
3

3
3

50 wc_tx000815gb.fm

RD 27 Maintenance

Interval* (hours of service)

(10) (100) (250) (500) (1000) (3000) (12,000)

Item Task

Exciter shaft bearings Re-pack

Fuel system water separa­tor element

Fuel tank cap and strainer Clean

Hydraulic oil filter Change

Radiator/hydraulic oil
cooler

Shock mounts Check

Battery Check

Control lever tension Adjust

Engine: mounting bolts,
valve lash, cylinder head
bolts, exhaust system

Hydraulic oil Change

Hydraulic tank breather Replace

Replace

Clean

Inspect

Daily 2

weeks3 months

Yearly Yearly 3



years

3

3
3

3

3

3
3

3

3
3

6

years

Hydraulic tank strainer Clean

Radiator filler cap Clean

ROPS and mounting hard­ware

Engine water pump Check

Fuel injector Test

Cooling system coolant Change

Temperature
regulator

* Use whichever comes first, calendar time or service hours.

Inspect/

torque

Replace

3
3

3

3
3





wc_tx000815gb.fm 51

Maintenance RD 27

5.2 Major Component Locations

1

5678

2

3

4

12

13

11

8

14

10 9

15

16

17

4

wc_gr005054

52 wc_tx000815gb.fm

RD 27 Maintenance

5.3 Major Components

Ref. Description Ref. Description

1 Forward/reverse lever 10 Seat switch solenoid

2 Hydraulic tank 11 Hydraulic oil filter

3 Oil cooler 12 Suction strainer

4 Front vibration motor 13 Suction strainer

5 Steering cylinder 14 Drive pump

6 Steering pump 15 Flow divider

7 Vibration pump 16 Flow divider solenoid

8 Hydraulic motor 17 Vibration manifold

9 Steering valve - ---

wc_tx000815gb.fm 53

Maintenance RD 27

3

5.4 Safety-Related Spare Parts

Overview

ROPS
diagram

This machine is equipped with several features to enhance operator safety. These
include the ROPS, the seat belt, and the Operator Presence switch. For your
convenience, we have provided the following diagrams and lists of replacement
parts for these safety-related features.

For a complete list of spare parts for this machine, contact your Wacker Neuson
dealer or visit www.wackerneuson.com.

wc_gr00704

54 wc_tx000815gb.fm

RD 27 Maintenance

ROPS parts
list

Ref. Part No. Qty. Description Measurement

1 0161542 4 Screw

2 0161617 2 Shim

4 0162243 2 Control lever

5 0174257 1 ROPS frame

7 0161769 1 Label—warning

8 0162357 2 Label

9 0162007 2 Nut M16 x 2

10 0162011 2 Bolt M16 x 2

11 0162017 4 Bolt M16 x 2 x 50

12 0162059 8 Washer

13 0161850 2 Cable

14 0161940 4 Pin

15 0162247 4 Clevis pin

wc_tx000815gb.fm 55

Maintenance RD 27

Seat
assembly
diagram

wc_gr007044

56 wc_tx000815gb.fm

RD 27 Maintenance

Seat
assembly
parts list

Ref. Part No. Qty. Description Measurement

1 0161620 1 Skirt replacement kit

2 0161621 1 Seat slide kit

3 0161622 1 Indicator kit

4 0161744 1 Adjustable seat kit

5 0161853 1 Seat switch kit

6 0161855 1 Seat

7 0161854 1 Arm rest kit

8 0161856 1 Seat belt kit

wc_tx000815gb.fm 57

Maintenance RD 27

Seat switch
diagram

wc_gr007045

58 wc_tx000815gb.fm

RD 27 Maintenance

Seat switch
parts list

Ref. Part No. Qty. Description Measurement

1 0162359 1 Wiring harness, seat

2 0161998 1 Seat assembly

3 0174165 2 Spacer

4 0174181 2 Bolt 7/16-20

5 0161879 4 Strap—mounting

6 0174353 1 Clip

7 0161903 2 Washer

8 0161925 1 Cable clip

9 0174405 1 Grommet

10 0174406 2 Lock nut 7/16-20

11 0162006 1 Washer

12 0162023 2 Washer

5.5 Maintaining the Seat and Seat Belt

Background

Maintaining
the seat and
seat belt

In order for the seat and seat belt to operate safely and properly over a long period
of time, periodic maintenance and occasional repairs are necessary. Poorly
maintained equipment can become a safety hazard!

 Keep the seat clean. Dirt, dust, or harsh chemicals can damage the upholstery.

Repair holes or tears immediately.

 If necessary, clean the seat belt with a mild soap solution. Do not use chemical

cleaners, as they will damage the fabric.

 Periodically test the operation of the seat tension knob and the front-to-back

lever. Repair or replace worn or malfunctioning components.

 If the seat does not move smoothly during adjustment, apply a small amount of

standard bearing grease (such as Shell Alvania

®

RL2 or equivalent) to the rails.

wc_tx000815gb.fm 59

Maintenance RD 27

5.6 Checking the Air Filter Indicator

Prerequisites

When

Procedure

 Engine running
 Parking brake on

Every 10 hours of service or daily

l

Follow the procedure below to check the air filter indicator.

1. Open the engine compartment.

2. Start the engine.

3. Place the throttle lever in the HIGH idle position.

4. Locate the air filter indicator (a).

If the yellow piston in the air filter indicator enters the red zone, clean the air
cleaner/air filters.

5. Turn off the engine.

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RD 27 Maintenance

5.7 Cleaning the Air Cleaner and Primary Air Filter Element

Prerequisites

Background

Procedure

 Machine shut down
 Source of clean, dry, and low-pressure (less than 207 kpA (30 psi)) compressed

air

The air intake system is equipped with a filter indicator (a), which indicates when a
filter change is required. The primary air filter element can be cleaned and reused
up to six times; after that it must be replaced.

Follow the procedure below to clean the primary air filter element.

WARNING

Fire hazard.
f Never use gasoline or low flash-point solvents for cleaning the air filter.

1. Remove the cover (b) from the air filter housing.

2. Remove the primary air filter element (c) from the air filter housing.

3. Clean inside of the air filter housing.

4. Clean the primary air filter element with low-pressure (207 kpA (30 psi))
compressed air. Blow the air through the primary air filter element from the
inside to the outside.

5. Hold the primary air filter element up to the light or pass a lamp through the
middle to check the condition of the element.

NOTICE:

 Do not re-use a damaged primary air filter element. Replace it even if damage is

very slight.

 Do not tap or strike the primary air filter element to clean it.
 Do not wash the primary air filter element.

6. Re-install the primary air filter element (c).

7. Reassemble the cover (b), positioning the breather (d) so that it is not
obstructed.

8. Push the black rubber button (several times if need be) on top of the filter
indicator to reset it.

wc_tx000815gb.fm 61

Maintenance RD 27

5.8 Changing the Air Filter Elements

Prerequisites

Primary filter
element

 Machine shut down
 New primary air filter element
 New secondary air filter element if required

NOTICE: Do not use the air filters as a starting aid (e.g., ether) intake.

Follow the procedure below to change the primary air filter element.

1. Remove the cover (b) from the air filter housing.

Secondary
filter element

2. Remove the primary air filter element (c).

3. Clean the inside of the air filter housing.

4. Install the new primary air filter element.

5. Replace the cover. Position it so that the breather (d) is not obstructed.

6. Reset the filter indicator (a).

Follow the procedure below to change the secondary air filter element.

Note: Change the secondary air filter element (e) every third time the primary air
filter element is changed.

1. Remove the cover (b) from the air filter housing.

2. Remove the primary air filter element (c).

3. Remove the secondary air filter element.

4. Cover the intake port and clean inside of the air filter housing.

NOTICE: Do not allow dirt to get into the engine intake port. Damage to the engine
will result.

5. Remove the cover from the intake port and install the new secondary air filter
element.

NOTICE: The secondary filter element has two rubber seals—one wider than the
other. Make sure to insert the end with the narrow seal. Damage to the engine will
result if the filter element is inserted incorrectly.

This procedure continues on the next page.

62 wc_tx000815gb.fm

RD 27 Maintenance

Continued from the previous page.

6. Install the new primary air filter element.

7. Replace the cover (b). Position it so that the breather (d) is not obstructed.

8. Reset the filter indicator (a).

5.9 Testing the Backup Alarm

Background

When

Testing
Procedure

The backup alarm is located on the rear of the machine.

Every 10 hours of service or daily

Follow the procedure below to test the backup alarm.

1. Turn the starting key to POSITION 1.

2. Move the forward/reverse lever to the reverse position.

The backup alarm should sound immediately. The backup alarm will continue to
sound until the forward/reverse lever is moved to the NEUTRAL position or to the
FORWARD position.

NOTICE: If the backup alarm does not sound, make the necessary repairs before
using the machine.

wc_tx000815gb.fm 63

Maintenance RD 27

5.10 Checking the Engine Coolant Level

Prerequisites

When

Procedure

 Machine shut down
 Engine cool

Every 10 hours of service or daily

l

Follow the procedure below to check the engine coolant level.

WARNING

Burn hazard. Engine coolant is hot and under pressure at operating temperature. It
can cause severe personal injury.

f Check the coolant level only after the engine has been shut down and is cool.

1. Open the engine compartment.

2. Open the radiator filler cap (a) slowly in order to relieve the pressure. Remove
the filler cap after the pressure has been released.

CAUTION

Burn hazard. Coolant can contain alkali.
f Avoid coolant contact with skin and eyes.

3. Maintain the coolant level to 2.54 cm (1 in.) below the shoulder inside the fill
pipe.

4. Make sure that the coolant overflow hole (b) is clean and the overflow tube is
securely attached.

5. Inspect the radiator filler cap and filler cap seal for damage. Clean the radiator
filler cap or replace it if necessary.

6. Re-install the radiator filler cap.

64 wc_tx000815gb.fm

RD 27 Maintenance

5.11 Checking the Engine Oil

Prerequisites

When

Procedure

 Park the machine on a level surface
 Shut down the machine
 Apply the parking brake

Every 10 hours of service or daily

Follow the procedure below to check the engine oil.

1. Clean around the dipstick (a).

2. Extract the dipstick and check the oil level. Maintain the oil level between the
two notches on the dipstick. When full, the oil level will reach notch (c).

3. Remove the oil filler cap (b) and add oil as needed.

NOTICE: Do not overfill the machine with oil. Overfilling the engine with oil may
lead to excessively high operating temperatures.

wc_tx000815gb.fm 65

Maintenance RD 27

5.12 Checking Hydraulic Oil Level

Prerequisites

When

Procedure

 Machine shut down
 Hydraulic oil warm

Every 10 hours of service or daily

l

Follow the procedure below to check the hydraulic oil level.

1. Open the engine compartment.

b

2. Observe the hydraulic oil level through the sight gauge (a).

3. If the oil level is low, open the reservoir cap (b) and fill the hydraulic oil to the
mark on the sight gauge.

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RD 27 Maintenance

5.13 Checking the Neutral Switch

Prerequisites

When

Procedure

Parking brake engaged

Every 10 hours of service or daily

Follow the procedure below to check the neutral switch.

WARNING

Crush hazard. The machine may lurch forward if the neutral switch is out of adjust­ment while making this test.

f Be sure the area is clear of all personnel and equipment before making this test.

1. Turn off the engine.

2. Engage the parking brake.

3. Move the forward/reverse lever to the FORWARD position.

4. Hold the engine start switch in the START position.

5. Slowly move the forward/reverse lever toward the NEUTRAL position.

 If the engine starts before the forward/reverse lever reaches the NEUTRAL

position, the neutral switch must be adjusted. Refer to the Repair Manual.

 If the engine starts only when the forward/reverse lever is in the NEUTRAL posi-

tion, the neutral switch is OK.

wc_tx000815gb.fm 67

Maintenance RD 27

5.14 Adjusting the Scraper Bars

Prerequisites

When

Procedure

 Machine shut down
 Parking brake engaged

Every 10 hours of service or daily

l

Follow the procedure below to adjust the scraper bars.

1. Loosen the bolts (a).

wc_gr004773

2. Adjust the scraper so that it touches the drum along its entire length.

3. Tighten the bolts.

68 wc_tx000815gb.fm

RD 27 Maintenance

5.15 Inspecting the Seat Belt

Prerequisites

When

Procedure

 Machine shut down
 Parking brake engaged

Daily, before starting the machine.

l

Follow the procedure below to inspect the seat belt.

1. Check the seat belt mounting hardware (a) for wear and damage. Replace
damaged hardware.

2. Check the buckle (b) for wear and damage. Replace the seat belt if the buckle is
damaged.

3. Inspect the seat belt (c) for wear and damage. Replace the seat belt if it is
damaged.

Note: Replace the seat belt every three years even if none of the components
show visible wear or damage.

wc_tx000815gb.fm 69

Maintenance RD 27

5.16 Cleaning the Water Spray Nozzles

Prerequisites

When

Procedure

 Machine shut down
 Clean, nonflammable solvent

Every 10 hours of service or daily

l

Follow the procedure below to clean the water spray nozzles.

1. Locate the water spray nozzles.

2. Remove the cap (a).

3. Remove the nozzle (b).

4. Remove the rubber washer (c).

5. Remove the screen assembly (d).

6. Clean the nozzle (b) and the screen assembly (d) in a clean, nonflammable
solvent.

7. Reassemble the components.

70 wc_tx000815gb.fm

RD 27 Maintenance

5.17 Cleaning the Water Spray System Filter

Prerequisites

When

Procedure

 Machine shut down
 Water spray system shutoff valve in closed position

Every 10 hours of service or daily

l

Follow the procedure below to clean the water spray system filter.

1. Locate the water spray system filter assembly (a) inside the step on the right
side of the machine.

e

2. Open the drain valve (b).

3. Unscrew and remove the filter bowl (d).

4. Remove the filter (c).

5. Clean the filter with water or compressed air.

6. Clean the filter bowl with water or compressed air.

7. Check the condition of the sealing gasket (e) and replace it if necessary.

8. Re-install the filter into the filter bowl, pressing down firmly to seat it in place.

9. Re-install the filter bowl.

10.Close the drain valve.

wc_tx000815gb.fm 71

Maintenance RD 27

5.18 Cleaning and Changing the Fuel Filter/Water Separator

Prerequisites

When

Draining
water
separator

 Machine shut down
 New filter

Drain every 100 hours; change element every 500 hours

Follow the procedure below to drain the fuel/water separator.

1. Open the engine compartment.

2. Position the rubber drain tube (g) so that it will drain into a receptacle outside of
the engine compartment.

g

Changing
element

3. Turn valve (e) counterclockwise to open the valve, and drain the water and the
sediment into a suitable container.

Note: Collect, store and dispose of all used fluids in accordance with current
environmental protection regulations.

4. Close the valve.

To change the fuel filter element:

1. Drain the fuel filter/water separator as stated above.

2. Hold the bowl (d) while you loosen the collar (c). Remove the bowl and the
collar (c).

3. Loosen the collar (a) and remove the fuel filter element (b).

Note: Dispose of used filters according to environmental protection regulations.

4. Clean the parts. Inspect the parts for damage. Replace damaged parts.

5. Clean the filter mounting base. Remove all of the old seal.

6. Apply a light coat of diesel fuel to the seal of the new filter element.

7. Install the new filter element and tighten by hand. Tighten the collar (a).

8. Install the bowl (d) and tighten the collar (c).

9. Pump the plunger (f) approximately three times to fill the fuel filter/water
separator with fuel.

10.Start the engine and check the fuel system for leaks.

72 wc_tx000815gb.fm

RD 27 Maintenance

5.19 Priming the Fuel System

Prerequisites

Procedure

 Machine shut down
 Engine cool

l

Follow the procedure below to prime the fuel system.

1. Open the engine compartment.

2. Locate the fuel filter/water separator.

3. Push the plunger (a) to fill the filter element with fuel. Pump the plunger
approximately three times until resistance is felt. This indicates the filter element
is full of fuel.

4. Attempt to start the engine.

Continue priming if:

 The engine does not start.
 The engine starts but misfires.
 The engine starts but emits smoke.

If the engine runs roughly, continue to run the engine at low idle until the engine
runs smoothly.

wc_tx000815gb.fm 73

Maintenance RD 27

5.20 Draining Water and Sediment from the Fuel Tank

Prerequisites

When

Procedure

 Machine shut down
 Suitable container

Every 100 hours of service or every 2 weeks

l

Follow the procedure below to drain water and sediment from the fuel tank.

1. Locate the drain plug (a) under the front center of the machine.

2. Remove the drain plug and allow water and sediment to drain into a suitable
container.

Note: Collect, store and dispose of all used fluids in accordance with current envi­ronmental protection regulations.

3. Re-install the drain plug.

74 wc_tx000815gb.fm

RD 27 Maintenance

5.21 Cleaning the Water Tank Strainer

Prerequisites

When

Procedure

Machine shut down

Every 100 hours of service or every 2 weeks

l

Follow the procedure below to clean the water tank strainer.

1. Remove the filler cap (a).

b

2. Remove the water tank strainer (b).

3. Clean the filler cap with clean water or compressed air.

4. Clean the water tank strainer with clean water or compressed air.

5. Re-install the water tank strainer.

6. Re-install the filler cap.

wc_tx000815gb.fm 75

Maintenance RD 27

5.22 Adjusting Alternator Belt Tension

Prerequisites

When

Procedure

 Machine shut down
 Engine cool

Every 250 hours of service or every 3 months

l

Follow the procedure below to inspect the alternator belt.

1. Open the engine compartment.

2. Remove the fan guard and shroud.

3. Apply 110 N (25 lbs.) of force to the belt (c) midway between the pulleys.
Correctly adjusted belts will deflect 13–19 mm (1/2–3/4 in.).

4. To adjust the belt, loosen mounting bolts (a) and (b).

5. Move the alternator (d) to adjust the tension.

6. Tighten the mounting bolts (a) and (b) when the tension is correct. Torque
mounting bolt (b) to 45–55 Nm (33–41 ft.lbs.).

Note: When installing a new belt, check and adjust the belt tension after the first 30
minutes of operation.

7. Re-install the fan guard and shroud.

76 wc_tx000815gb.fm

RD 27 Maintenance

5.23 Lubricating the Articulated Steering Joint

Prerequisites

When

Procedure

 Grease gun
 Machine shut down

Every 250 hours of service or every 3 months

l

Follow the procedure below to lubricate the articulated steering joint.

1. Clean the fitting caps.

2. Clean the articulated steering joint fittings (a).

3. Lubricate the articulated steering joint fittings with ten strokes from a grease
gun.

4. Lubricate the oscillation bearing (b) until grease flows out of the casting.

5. Re-install the fitting caps.

wc_tx000815gb.fm 77

Maintenance RD 27

5.24 Lubricating the Steering Cylinder

Prerequisites

When

Procedure

 Machine shut down
 Grease gun

Every 250 hours of service or every 3 months

l

Follow the procedure below to lubricate the steering cylinder.

One end (a) of the steering cylinder is located in the pivot area. The other end (b) is
located on the right side of the engine compartment.

1. Clean the fittings.

2. Lubricate the fittings with a grease gun.

78 wc_tx000815gb.fm

RD 27 Maintenance

5.25 Testing the Brake System

Prerequisites

When

Precaution

Procedure

15° slope

Every 500 hours of service or yearly

l

Use this test to determine if the parking brake is functioning on the specified slope.
This test is not intended to measure the maximum brake holding effort.

Follow the procedure below to test the braking system.

1. Position the machine on a 15° slope as shown.

2. With the engine running, place the throttle control into the LOW IDLE position
and the forward/reverse control lever in the NEUTRAL position.

3. Engage the parking brake. The machine should not move.

If the machine moves, consult Wacker Neuson Service.

wc_tx000815gb.fm 79

Maintenance RD 27

5.26 Changing the Engine Oil and Filter

Prerequisites

When

Procedure

 Engine warm
 15W40 engine oil and new filter

Every 500 hours of service or yearly

Follow the procedure below to change the engine oil.

WARNING

Burn hazard. Hot oil draining from the engine can burn.
f Do not touch the hot oil.

1. Open the engine hood.

2. Locate the engine oil drain hose (c) below the frame and place a suitable
container beneath it.

3. Open the drain valve beneath the filter cartridge (d) and drain off the used oil.

Note: Collect, store and dispose of all used oil and filters in accordance with cur­rent environmental protection regulations.

4. Unscrew the filter cartridge (d) and remove it.

5. Clean the filter housing base.

6. Apply a thin coat of engine oil to the seal of the new oil filter.

7. Install the new filter cartridge and tighten by hand. When the seal contacts the
base, tighten the filter cartridge an additional 3/4 turn.

8. Remove the oil filler cap and pour in the required amount of oil.

NOTICE: Always use the correct oil type. Do not use oil brands or grades which
are not recommended.

9. Clean the oil filler cap, then re-install it.

10.Start and run the engine for a few minutes.

11.Check the oil pressure and the filter seal.

This procedure continues on the next page.

80 wc_tx000815gb.fm

RD 27 Maintenance

Continued from the previous page.

12.Stop the engine and make the following checks:

 Check the oil level and top off if necessary.
 Check the new filter for leaks.

5.27 Cleaning the Fuel Tank Cap and Fuel Strainer

Prerequisites

When

Procedure

 Machine shut down
 Clean, nonflammable solvent

Every 500 hours of service or yearly

l

Follow the procedure below to clean the fuel tank cap and fuel strainer.

1. Open the engine compartment.

2. Remove the fuel tank cap (a).

3. Remove the fuel strainer (b).

4. Wash the fuel strainer in nonflammable solvent. Dry it with compressed air.

5. Inspect both the fuel tank cap and the fuel strainer for damage. Replace the fuel
tank cap or the fuel strainer if either is damaged.

wc_tx000815gb.fm 81

Maintenance RD 27

5.28 Changing the Hydraulic Oil Filter

Prerequisites

When

Procedure

 Hydraulic oil filter
 Strap-type wrench
 Suitable container
 Machine parked on a flat, level surface

Every 500 hours of service or yearly

l

Follow the procedure below to change the hydraulic oil.

Note: Take care to keep the hydraulic oil and the hydraulic system clean. Dirty
hydraulic oil will reduce component performance and shorten component service
life.

1. Open the engine compartment.

2. Locate the hydraulic oil filter (a).

3. Clean the area around the hydraulic oil filter.

4. Remove the hydraulic oil filter with a strap-type wrench.

Note: Collect, store and dispose of all used oil and filters in accordance with cur­rent environmental protection regulations.

5. Clean the filter housing base. Remove any existing gasket material.

6. Apply a light coat of hydraulic oil to the gasket on the new hydraulic oil filter.

7. Screw the new hydraulic oil filter on by hand. When the seal contacts the base,
tighten the filter element an additional 3/4 turn.

8. Check the hydraulic oil level (b) and add hydraulic oil as needed.

9. Check the hydraulic oil level again the next day, or after the machine has been
run and allowed to cool down.

82 wc_tx000815gb.fm

RD 27 Maintenance

5.29 Cleaning the Hydraulic Oil Cooler

Prerequisites

When

Procedure

 Machine shut down
 Parking brake engaged

Every 500 hours of service or yearly

l

Follow the procedure below to clean the hydraulic oil cooler.

1. Open the engine compartment.

2. Locate the hydraulic oil cooler (a).

3. Clean the hydraulic oil cooler using compressed air.

4. Close the engine compartment.

wc_tx000815gb.fm 83

Maintenance RD 27

5.30 Disconnecting/Connecting the Battery

WARNING

Explosion hazard. Batteries can emit explosive hydrogen gas.

f Keep all sparks and flames away from the battery.

f Do not short-circuit battery posts.

WARNING

Battery fluid is poisonous and corrosive.
f In the event of ingestion or contact with skin or eyes, seek medical attention

immediately.

Dispose of dead batteries in accordance with local environmental regulations.

Disconnecting

Connecting

Maintaining

Precautions

To disconnect the battery:

1. Stop the machine and shut down the engine.

2. Place all electrical switches in the OFF position.

3. Disconnect the negative battery cable from the battery.

4. Disconnect the positive battery cable from the battery.

To connect the battery:

1. Connect the positive battery cable to the battery.

2. Connect the negative battery cable to the battery.

 Keep battery terminals clean and connections tight.
 When necessary, tighten the cables and grease the cable clamps with petro-

leum jelly.

 Maintain the battery at full charge to improve cold weather starting.

Observe the following precautions to prevent serious damage to the electrical
system:

 Do not disconnect the battery while the machine is running.
 Do not attempt to run the machine without a battery.
 Do not attempt to jump-start a machine.
 In the event that the machine has a dead battery, either replace the battery with

a fully charged battery or charge the battery using an appropriate battery
charger.

84 wc_tx000815gb.fm

RD 27 Maintenance

5.31 Adjusting the Forward/Reverse Lever

Prerequisites

When

Procedure

 Machine shut down
 Parking brake engaged

Every 1000 hours of service or yearly

Follow the procedure below to adjust the tension (i.e., the amount of force required
to move) of the forward/reverse lever.

1. Lift up the boot (a) of the forward/reverse lever to expose the mechanism.

2. Loosen the lock nut (b).

3. Adjust the Allen screw until the desired firmness of the forward/reverse lever is
reached, then tighten the lock nut.

4. Reposition the boot.

wc_tx000815gb.fm 85

Maintenance RD 27

5.32 Changing the Hydraulic Oil

Prerequisites

When

Draining

 Hydraulic oil
 Suitable container
 Machine parked on a flat, level surface

Every 1000 hours of service or yearly

l

Follow the procedure below to drain the hydraulic oil tank.

Note: Take care to keep the hydraulic oil and the hydraulic system clean. Dirty
hydraulic oil will reduce component performance and shorten component service
life.

1. Open the engine compartment.

2. Remove the hydraulic tank filler cap (b).

f

Filling

3. Remove the screen (e) from the hydraulic tank filler tube. Clean the screen with
clean, nonflammable solvent.

4. Wash the hydraulic tank filler cap and the hydraulic tank filler tube with clean,
nonflammable solvent.

5. Check the condition of the breather (a). See section Checking and Cleaning the
Hydraulic Tank Breather. If the O-ring is in good condition, clean and re-install
the breather.

6. Locate the hydraulic hose drain tube connected to the hydraulic drain valve (d).

7. Drain the hydraulic oil into a suitable container.

Note: Collect, store and dispose of all used oil and filters in accordance with cur­rent environmental protection regulations.

Follow the procedure below to fill the hydraulic oil tank.

1. Remove the two suction strainers (f) inside the hydraulic tank.

2. Install two new suction strainers into the hydraulic tank.

3. Close the hydraulic drain valve (d).

4. Install the screen (e) into the filler tube.

This procedure continues on the next page.

86 wc_tx000815gb.fm

RD 27 Maintenance

Continued from the previous page.

5. Refill the hydraulic tank with clean, filtered hydraulic oil.

6. Check the hydraulic oil level using the sight gauge (c).

7. Re-install the hydraulic tank filler cap (b).

5.33 Checking and Cleaning the Hydraulic Tank Breather

Prerequisites

When

Procedure

 Machine shut down
 Clean, nonflammable solvent

Every 1000 hours of service or yearly

l

Follow the procedure below to clean the hydraulic tank breather (a).

1. Open the engine compartment.

2. Remove the breather from the hydraulic tank.

3. Clean the breather with clean, nonflammable solvent.

4. Check the condition of the O-ring (b). If the O-ring is deteriorated, replace the
breather.

5. If the O-ring is in good condition, dry the breather with compressed air.

6. Re-install the breather.

wc_tx000815gb.fm 87

Maintenance RD 27

5.34 Cleaning the Hydraulic Oil Strainer

Prerequisites

When

Procedure

 Machine shut down
 Clean, nonflammable solvent

Every 1000 hours of service or yearly

l

Follow the procedure below to clean the hydraulic oil strainer.

1. Open the engine compartment.

2. Remove the hydraulic tank filler cap (a).

3. Remove the hydraulic oil strainer (b).

4. Wash the hydraulic oil strainer in nonflammable solvent. Dry it with compressed
air.

5. Re-install the hydraulic oil strainer and the hydraulic tank filler cap.

88 wc_tx000815gb.fm

RD 27 Maintenance

5.35 Cleaning the Radiator Filler Cap

Prerequisites

When

Procedure

 Machine shut down
 Engine cool

Every 1000 hours of service or yearly

Follow the procedure below to clean the radiator filler cap.

WARNING

Burn hazard. At operating temperature engine coolant is hot and under pressure. It
can cause severe personal injury.

f Remove the radiator filler cap only after the engine has been shut down and is

cool.

1. Open the engine compartment.

2. Remove the radiator filler cap (a) slowly to relieve pressure.

CAUTION

Burn hazard. Coolant can contain alkali.
f Avoid coolant contact with skin and eyes.

3. Clean the radiator filler cap with a clean cloth.

4. Inspect the radiator filler cap for damage. Replace it if it is damaged.

5. Re-install the radiator filler cap.

wc_tx000815gb.fm 89

Maintenance RD 27

5.36 Checking the Engine Water Pump

Prerequisites

When

Background

Procedure

 Machine shut down
 Engine cool

Every 3000 hours of service or 2 years

l

If the water pump fails, the engine will overheat which can cause:

 Cracks in the cylinder head
 Piston seizure

Follow the procedure below to check the engine water pump.

1. Open the engine compartment.

2. Remove the fan guard and shroud.

3. Locate the water pump (a).

4. Visually inspect the water pump for leaks.

If Then

Leaks are found, replace all seals.

There is an excessive leakage of coolant, replace the engine water pump.

5. Replace the fan cover and shroud.

90 wc_tx000815gb.fm

RD 27 Maintenance

5.37 Changing the Cooling System Coolant

Prerequisites

When

Draining

 Machine shut down
 Engine cool

Every 12,000 hours of service or 6 years

l

Follow the procedure below to drain the cooling system coolant.

WARNING

Burn hazard. At operating temperature, engine coolant is hot and under pressure. It
can cause severe personal injury.

f Check the coolant level only after the engine has been shut down and is cool.

1. Open the engine compartment.

2. Open the radiator filler cap (a) slowly in order to relieve the pressure. Remove
the filler cap after the pressure has been released.

3. Place a suitable container underneath the machine.

4. Open the drain valve (b) on the bottom of the radiator and allow the coolant to
drain through the attached hose into a suitable container.

Cleaning

Follow the procedure below to clean the cooling system.

1. Close the radiator drain valve.

2. Fill the coolant system with clean water and 6–10% coolant system cleaner.

3. Install the radiator filler cap.

4. Start the engine. Run the engine for 90 minutes.

5. Stop the engine. Allow the cooling system to completely cool.

6. Open the radiator filler cap.

7. Place a suitable container underneath the machine.

8. Open the drain valve (b) on the bottom of the radiator and allow the cleaner to
drain into a suitable container.

Note: Collect, store and dispose of all used coolant in accordance with current
environmental protection regulations.

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Maintenance RD 27

9. Flush the cooling system with water until the draining water is transparent.

Filling

Follow the procedure below to fill the cooling system.

1. Close the radiator drain valve.

2. Add the recommended amount of coolant to the radiator.

3. Start the engine.

4. Leave the radiator fill cap off until the thermostat opens and the coolant level
stabilizes.

5. Maintain the coolant level to 2.54 cm (1 in.) below the shoulder of the fill pipe.

6. Inspect the radiator filler cap and filler cap seal for damage. Clean the radiator
filler cap or replace it if necessary.

7. Re-install the radiator filler cap.

92 wc_tx000815gb.fm

RD 27 Maintenance

5.38 Replacing the Water Temperature Regulator

Prerequisites

When

Procedure

Removal

 Machine shut down
 Engine cool

Every 3000 hours of service or every 2 years

l

Follow the procedure below to replace the water temperature regulator.

WARNING

Burn hazard. At operating temperature, engine coolant is hot and under pressure. It
can cause severe personal injury.

f Check the coolant level only after the engine has been shut down and is cool.

Follow the procedure below to remove the water temperature regulator.

1. Open the engine compartment.

2. Drain and clean the engine cooling system. See section Changing the Cooling
System Coolant. The water temperature regulator should be replaced while the
coolant system is completely drained.

3. Remove the housing (a) for the water temperature regulator.

4. Remove the gasket and remove the water temperature regulator.

Installation

Follow the procedure below to install the water temperature regulator.

Note: Water temperature regulators may be reused if they are within test specifica­tions, are not damaged, and are free of excessive deposit buildup.

1. Install a new water temperature regulator and install a new gasket.

NOTICE: If the water temperature regulator is installed incorrectly, it will cause the
engine to overheat.

2. Install the housing for the water temperature regulator.

3. Add coolant to the radiator. See section Changing the Cooling System Coolant.

4. Install the radiator filler cap.

wc_tx000815gb.fm 93

Maintenance RD 27

5.39 Draining the Water Spray System

Prerequisites

When

Procedure

 Machine shut down
 Parking brake engaged

Prior to working in or experiencing freezing conditions.

l

Follow the procedure below to drain the water tank.

1. Remove the water tank filler cap.

2. Remove the water tank drain plug (a) and drain the water.

3. Open the drain valves (b and c) located within the machine frame to drain the
water.

4. When the water is drained, turn on the water pump for 30 seconds to drain the
water pump.

5. Remove the cap (d) and diaphragm (e) from the diaphragm valve.

6. Remove the caps from the ends of the spray bars to drain the spray bars. If
desired, blow compressed air through the bars to dry them.

7. Re-install the caps to the spray bars.

8. Re-assemble the diaphragm valve.

9. Close the drain valves.

10.Re-install the water tank drain plug.

94 wc_tx000815gb.fm

RD 27 Maintenance

5.40 Towing the Machine

Prerequisites

Limitations

Procedure

 Second machine of greater size and rigid towing equipment, or
 Two machines of equal size to towed machine if non-rigid towing equipment is

being used

 Shielding for all machines being used

Note: The strength of the towing line or the tow bar should be at least 150 percent
of the gross weight of the towing machine.

l

The following limitations must be followed:

 Limit towing to emergency situations only
 Limit towing to short distances
 Limit towing speed to 2 km/h (1.2 mph)
 Limit tow line angle to 30°

Follow the procedure below to tow the machine.

Note: If the engine runs and the steering system and/or braking system functions,
an operator may be allowed to ride on and steer the machine being towed. In all
other cases, do not ride on the machine when it is being towed.

1. Attach shielding to the machines to protect the operators if the towing
equipment breaks.

2. Block the drums so that the machine cannot move.

3. Open the engine compartment.

4. Release the parking brakes. See section Manually Releasing the Parking
Brakes.

5. Turn the bypass valve (a) two full turns in the counterclockwise direction.

Note: Do not turn the bypass valve farther than two turns. When the bypass valve
is turned farther than two turns, oil will leak past the bypass valve.

This procedure continues on the next page.

wc_tx000815gb.fm 95

Maintenance RD 27

Continued from the previous page.

6. Connect the tow lines at the tie down bars (b and c).

7. Attach tow lines to the towing machine.

8. Remove the blocks from the drums.

9. Tow the machine as needed.

10.Once the machine is at the desired location, block the drums.

11.Close the bypass valve by turning it two full turns in the clockwise direction.

12.Disconnect the tow lines.

96 wc_tx000815gb.fm

RD 27 Maintenance

5.41 Manually Releasing the Parking Brakes

Prerequisites

Procedure

 Machine shut down
 Blocks

Follow the procedure below to manually release the parking brakes.

1. Block the drums to prevent the machine from moving.

2. Remove the two plugs from each drive motor.

3. Insert an Allen wrench into the drive motor and engage the screw. Depress the
spring inside the drive motor with the screw and turn the screw until it catches.
Repeat for the second screw of the drive motor.

NOTICE: Do not use power tools to turn the screws. Damage to the drive motor
may result.

4. Turn the screws in equal amounts until the springs are fully depressed.

5. Turn the screws approximately an additional 120° until the brakes are released.

6. Repeat the procedure for the opposite drive motor.

wc_tx000815gb.fm 97

Maintenance RD 27

5.42 Troubleshooting

Problem / Symptom Reason Remedy

Engine does not start Empty fuel tank Refill fuel tank.

Wrong type of fuel Drain tank, change fuel fil-

ter, and refill with the proper
fuel.

Old fuel Drain tank, change fuel fil-

ter, and refill with fresh fuel.

Fuel system not primed Prime the fuel system.

Fuel filter restricted or
plugged

Battery connections are
loose or corroded, or bat­tery is dead.

Plugged air cleaner or filter
elements

Defective starter motor Repair or replace.

Inoperative fuel solenoids
on engine

Inoperative starter relay Repair or replace.

Loose or broken electrical
connections

Engine stops by itself Empty fuel tank Refill fuel tank.

Clogged fuel filter Clean or replace.

Loose or broken fuel lines Check connections and

No vibration Defective switch or poor

connection

Replace fuel filter.

Check battery connections
or replace battery as
needed.

Clean air cleaner or replace
filter elements.

Repair or replace.

Check connections and
tighten or repair as needed.

tighten or repair as needed.

Check components and
tighten or repair as needed.

Damaged or disconnected
solenoid on vibration valve

Damaged exciter assembly Repair the assembly.

Damaged or broken exciter
motor coupling

Damaged exciter motor Repair or replace.

Damaged exciter pump Repair or replace.

Damaged exciter bearings Repair or replace.

Reconnect or repair sole­noid.

Repair or replace.

98 wc_tx000815gb.fm

RD 27 Maintenance

Problem / Symptom Reason Remedy

No travel, or travel only in
one direction

No steering Damaged steering cylinder Repair or replace.

Water leaking from spray
nozzles when machine is
shut off

Sheared pin on forward/
reverse control

Loose or broken control
cable

Damaged drive motor Repair or replace.

Damaged drive pump Repair or replace.

Defective relief valve(s) Repair or replace.

Damaged steering unit Repair or replace.

Stuck or damaged steering
relief valve

Articulating joint pin is in the
LOCKED position.

One or both of the dia­phragm valves is not com­pletely closed.

The diaphragm is worn.

Replace pin.

Tighten or replace.

Repair or replace.

Install the articulating joint
pin in the UNLOCKED posi­tion.

Close the diaphragm
valve(s) completely.

Replace the diaphragm.

wc_tx000815gb.fm 99

Schematics RD 27

6 Schematics

6.1 Electrical Schematic

100 wc_tx000863gb.fm