Repair Manual Roller RD 27-100 RD 27-120 0175061en 0 1 7 5 002 0 6 0909 1 E N
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.
RD 27 Foreword Foreword Machines covered by this manual Machine documentation Expectations for information in this manual Copyright notice Machine Item Number Machine Item Number RD 27-100 0620393 RD 27-120 0620394 RD 27-100 0620395 RD 27-120 0620396 RD 27-100 0620508 RD 27-120 0620509 RD 27-100 0620510 RD 27-120 0620511 RD 27-100 0620512 RD 27-120 0620513 Keep a copy of the Operator’s Manual with the machine at all times.
Foreword RD 27 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. Trademarks wc_tx000946gb.fm All trademarks referenced in this manual are the property of their respective owners.
RD 27 1 Foreword 3 Safety Information 9 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 Signal Words Found in this Manual ...................................................... 9 Safety Guidelines for Operating the Machine ..................................... 10 Safety Guidelines while Using Internal Combustion Engines ............. 11 Guidelines for Service Safety ............................................................. 12 Label Locations ........................................................................
Table of Contents 3.12 3.13 4 65 Determining Where to Begin ...............................................................66 Checking the Vibration Fuse ...............................................................67 Checking the Vibration ON/OFF Solenoid ...........................................68 Checking the Neutral Switch ...............................................................70 Checking the Neutral Relay .................................................................
RD 27 7 Troubleshooting the Water Spray System 7.1 7.2 7.3 7.4 7.5 7.6 8 Table of Contents Determining Where to Begin .............................................................. 85 Checking the Water Spray Fuse ........................................................ 86 Checking Power to the Spray Pump Motor ........................................ 87 Checking the Spray Switch ................................................................ 88 Checking the Timer Module ...............................
Table of Contents 9 RD 27 Schematics 9.1 9.2 162 Electrical Schematics ........................................................................162 Hydraulic Schematics ........................................................................167 10 Technical Data 10.1 10.2 10.3 10.4 10.5 10.6 169 Engine ...............................................................................................169 Roller ................................................................................................
RD 27 1 1.1 Safety Information Safety Information Signal Words Found in this Manual 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 messages that follow this signal word.
Safety Information 1.2 RD 27 Safety Guidelines for Operating the Machine Operator training 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. When operating this machine: Do not allow improperly trained people to operate the machine.
RD 27 1.3 Safety Information Safety Guidelines while Using Internal Combustion Engines Running the engine 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: DANGER Exhaust gas from the engine contains carbon monoxide, a deadly poison.
Safety Information 1.4 RD 27 Guidelines for Service Safety Precautions Accessories, safety devices, and modifications Replacing parts and labels Lifting and transporting 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.
RD 27 Cleaning and servicing the machine Safety Information 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 attempt to open the radiator cap while the machine is running or before the engine has cooled down.
Safety Information 1.5 RD 27 Label Locations v n x v q n s p g w d a o k i g k f d u b g c g h r m f l j d t g f wc_gr005053 wc_si000247gb.
RD 27 1.6 Safety Information Safety and Warning Labels Ref. Label Definition DANGER! b 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.
Safety Information Ref. RD 27 Label Definition f h WARNING! Avoid crushing area. 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. WARNING l WARNING! Pinching hazard. Rotating machinery. m wc_si000247gb.fm WARNING! Pressurized contents.
RD 27 Safety Information Ref. Label Definition n WARNING! Avoid crushing area. s WARNING! Do not drill or weld the ROPS. Read the Operator’s Manual. ADVERTENCIA 162789 t WARNING! WARNING Avoid crushing area. Articulated steering joint locking location. Lock the articulated steering joint before servicing the machine. Read Repair Manual. UNG 162788 wc_si000247gb.
Safety Information Informational Labels Ref. a Label O P E S T O R E P M A N T H R D IS T D IE A N W E E R S IC Ö R R A T R E D L A C U A L O U G R IB Definition O R 'S O N M E M E N C A N H Y O U T O R B E T R IE B S D E R M A S C R D E N . Z U R S A T Z B Ü C H H B IT T E A N T L IC H E N W M A A C T O B E U R . N U A L H IN E .
RD 27 Safety Information Ref. Label Definition k Water tank fill. o Engine oil drain. ENGINE OIL MOTOROEL ACEITE DE MOTOR HUILE À MOTEURS p Key switch positions. Power to glowplugs. Engine stopped (OFF). Engine ON. Power to starter motor. STOP q wc_si000247gb.fm Throttle lever positions. High speed. Low speed.
Safety Information Ref. RD 27 Label Definition r Vibration activation and deactivation switch. Forward/reverse lever positions. u Fuse identifications. v Tighten screw to reduce vibration. Read Operator’s Manual. 1 2 wc_gr002757 wc_si000247gb.fm w Guaranteed sound power level in dB(A).
RD 27 2 2.1 Operation Operation Operation & Maintenance Locations Ref.
Operation v RD 27 w r q u i s e d o c h p n l g j b k a 9 t 1 m 11 12 6 5 10 7 f 4 3 10 wc_tx000947gb.
RD 27 2.2 Operation Using the Forward/Reverse Lever Background 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. Travel direction Move the forward/reverse lever into FORWARD (f) or REVERSE (r) according to the direction of travel desired.
Operation 2.3 RD 27 Using the Flow Divider (if equipped) Background 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.
RD 27 2.4 Operation Using the Vibration System Background Vibration mode 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. Vibration ON-OFF switch To start vibration, press button (m).
Operation 2.5 RD 27 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.
RD 27 2.6 Operation 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. Turn off the engine immediately if this light illuminates when the engine is running. This light (o) illuminates when the engine is overheating. Turn off the engine immediately if this light illuminates.
Operation 2.7 RD 27 Using the Lights and Horn Background The rotary switch on the control panel controls power to the machine’s lights.
RD 27 2.
Operation 2.9 RD 27 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.
RD 27 2.10 Operation Stopping the Engine Prerequisites Flat surface with a suitable load-bearing capacity Procedure 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.
Troubleshooting the Engine Start System 3 RD 27 Troubleshooting the Engine Start System Best practice The best practice when troubleshooting this system is to: 1. Isolate and check each component of this system individually. 2. When a malfunctioning component is found, repair or replace it. 3. After replacing a malfunctioning component, retry system operation. This chapter provides procedures to check the components. 3.
RD 27 3.2 Troubleshooting the Engine Start System Checking the Fuses Prerequisites Machine shut down Procedure There are several fuses that affect the engine start system. Follow the procedure below to check them. 1. Remove the fuse box cover. 2. Remove and check the following fuses: key switch (a) brake/neutral (b) vibration (c) Is each fuse OK? Yes ____ No ____ Re-install each fuse. Replace the faulty fuse with one of like size and rating. The fuses have now been checked. wc_tx000948gb.
Troubleshooting the Engine Start System 3.3 RD 27 Checking the Wiring/Voltage to the Starter Solenoid Prerequisites Procedure Charged battery Multimeter Follow the procedure below to check the voltage to the starter solenoid. 1. Locate the starter solenoid. Check the connection of the white wire (a). It must be clean and tight. If it is not, clean it and try starting the engine again. If the engine does not start, continue. 2. Disconnect the white wire. 3.
RD 27 3.4 Troubleshooting the Engine Start System Checking the Key Switch Prerequisites Procedure Fully-charged battery Multimeter Follow the procedure below to check the key switch. 1. Remove the control panel (a) from the steering column. 2. Locate the key switch. Note it’s terminals are labeled: BAT, START, CONTROL, AID, and RELAY. 3. Measure the voltage between terminal BAT (brown wire) of the key switch and ground. Is 10–12.5 VDC measured? Yes ____ No ____ Continue.
Troubleshooting the Engine Start System 3.5 RD 27 Checking the Start 2 Relay Prerequisites Procedure Fully-charged battery Functioning key switch Follow the procedure below to check the start 2 relay. 1. Place the FWD/REV control in the NEUTRAL position. 2. Remove the control panel (a) from the steering column. 3. Locate the start 2 relay (b) and disconnect the connector. 4. Measure the voltage between wire 307-OR-16 at the connector and ground. Is 10.0–12.
RD 27 Troubleshooting the Engine Start System Continued from the previous page. 7. Locate the brake 3 relay (c) and disconnect it. 8. Measure the voltage between wire C907-WH-16 and ground. Is 10.0–12.5 VDC measured? Yes ____ No ____ Continue. The start 2 relay has failed; replace it. 9. Locate the start 1 relay (d) and disconnect it. You may need to remove the battery to access the start 1 relay. If so, reconnect the battery with auxiliary cables. 10.
Troubleshooting the Engine Start System 3.6 Checking the Neutral Relay Prerequisites Procedure Fully-charged battery Functioning vibration fuse Follow the procedure below to check the neutral relay. 1. Remove the control panel (a) from the steering column. 2. Locate the neutral relay (b) and disconnect it. 3. Place the FWD/REV control in the NEUTRAL position. 4. Measure the voltage between wire 374-PK-16 and ground. Is 10.0–12.5 VDC measured? Yes ____ No ____ Continue.
RD 27 Troubleshooting the Engine Start System Continued from the previous page. 6. Check the continuity between wire 200-BK-16 and ground. Does the wire have continuity to ground? Yes ____ No ____ Continue. Repair wire 200-BK-16. 7. Reconnect the neutral relay. 8. Locate the start 2 relay and disconnect it. 9. Measure the voltage between wire 307-OR-16 at the connector and ground. Is 10.0–12.5 VDC measured? Yes ____ No ____ The neutral relay is OK. The neutral relay has failed; replace it.
Troubleshooting the Engine Start System 3.7 RD 27 Checking the Neutral Switch Prerequisites Procedure Fully-charged battery Multimeter Follow the procedure below to check the neutral switch. 1. Roll up the boot (c) from the FWD/REV lever. 2. Remove the wires from the neutral switch (d). 3. Check for continuity between the NC terminal and the COM terminal of the neutral switch in each position of the FWD/REV control lever. See chart.
RD 27 3.8 Troubleshooting the Engine Start System Checking the Brake 3 Relay Prerequisites Procedure Fully-charged battery Functioning start 2 relay Follow the procedure below to check the brake 3 relay. 1. Remove the control panel (a) from the steering column. 2. Locate the brake 3 relay (c) and disconnect it. 3. Place the brake switch in the activated (down) position. 4. With the starter key in the START position, measure the voltage between wire 419-YL-16 and ground. Is 10.0–12.
Troubleshooting the Engine Start System RD 27 Continued from the previous page. 7. Insert the meter probe (b) into the connector at terminal 87. 8. With the starter key in the START position, check for continuity between wire terminal 87 and ground. Is there continuity to ground? Yes ____ No ____ The brake 3 relay is OK. The brake 3 relay has failed; replace it. The brake 3 relay has now been checked. If the problem has not been resolved, continue with Checking the Brake Switch. wc_tx000948gb.
RD 27 3.9 Troubleshooting the Engine Start System Checking the Brake Switch Prerequisites Procedure Key in OFF position Multimeter Follow the procedure below to check the brake switch. 1. Remove the control panel (a) from the steering column. 2. Locate the brake switch (b). 3. Disconnect the wires from the brake switch. 4. Place the brake switch in the disengaged position (up). 5. Check the continuity between terminal 1 and terminal 2 of the brake switch.
Troubleshooting the Engine Start System RD 27 Continued from the previous page. 7. Place the brake switch in the engaged position (down). 8. Check the continuity between terminal 1 and terminal 2 of the brake switch. Note: Terminal 1 is on the opposite side of the brake switch as terminal 2. Is there continuity between terminal 1 and terminal 2? Yes ____ No ____ The brake switch has failed; replace it. Continue. 9. Check the continuity between terminal 3 and terminal 4 of the brake switch.
RD 27 3.10 Troubleshooting the Engine Start System Checking Start 1 Relay Prerequisites Procedure Fully-charged battery Functioning start 2 relay Follow the procedure below to check the start 1 relay. 1. Locate the start 1 relay (b) and disconnect it. You may need to remove the battery to access the start 1 relay. If so, reconnect the battery with auxiliary cables. 2. Measure the voltage between wire 109-RD-10 and ground. Is 10.0–12.5 VDC measured? Yes ____ No ____ Continue.
Troubleshooting the Engine Start System RD 27 Continued from the previous page. 4. Reconnect the start 1 relay. 5. Locate the starter solenoid. 6. Disconnect the white wire (a). 7. Place the key switch in the START position, measure the voltage between the white wire and ground. Is 10.0–12.5 VDC measured? Yes ____ No ____ The start 1 relay is OK. The start 1 relay has failed; replace it. The start 1 relay has now been checked. wc_tx000948gb.
RD 27 3.11 Troubleshooting the Engine Start System Checking the Fuel Flow Prerequisites Procedure Fully-charged battery Container to catch fuel Follow the procedure below to check the fuel flow. 1. Open the hood. 2. Disconnect the fuel hose (a). 3. Place the fuel hose in a suitable container to catch the fuel. 4. Turn the key to the START position. Does fuel flow from the fuel hose while the engine cranks? Yes ____ No ____ The fuel flow is OK.
Troubleshooting the Engine Start System 3.12 RD 27 Checking the Fuel Shutoff Solenoid Prerequisites Procedure Fully-charged battery Functioning key switch Follow the procedure below to check the fuel shutoff solenoid. 1. Open the hood and locate the fuel shutoff solenoid (a) and disconnect it. 2. Turn the key to the ON position and measure the voltage between wire 308-YL-16 and ground. Is 10.0–12.5 VDC measured? Yes ____ No ____ Continue.
RD 27 3.13 Troubleshooting the Engine Start System Checking the Start Aid Relay Prerequisites Procedure Fully-charged battery Functioning key switch Follow the procedure below to check the start aid relay. 1. Open the hood and locate the start aid relay (a) and disconnect it. 2. With the key in the preheat position, measure the voltage between wire 310-PU16 and ground. Is 10.0–12.5 VDC measured? Yes ____ No ____ Continue. Check/repair wire 310-PU-16. 3.
Troubleshooting the Engine Start System RD 27 Continued from the previous page. 6. Disconnect the wire from the glow plugs (b). 7. With the key switch in the preheat position, measure the voltage between wire 304-BU-8 and ground. Is 10.0–12.5 VDC measured? Yes ____ No ____ The start aid relay is OK. The start aid relay has failed. Replace it. The start aid relay has now been checked. Reconnect the wire to the glow plugs. wc_tx000948gb.
RD 27 4 Troubleshooting the Drive System Troubleshooting the Drive System Best practice The best practice when troubleshooting this system is to: 1. Isolate and check each component of this system individually. 2. When a malfunctioning component is found, repair or replace it. 3. After replacing a malfunctioning component, retry system operation. This chapter provides procedures to check the components. 4.
Troubleshooting the Drive System RD 27 Neutral brake solenoid The neutral brake solenoid is part of the drive pump. It controls oil flow to the brakes and to the control group. When the neutral brake solenoid is de-energized (parking brake ON, operator off seat, or engine OFF), oil is diverted from the control group and from the brakes back to the tank. In this state, the SAHR-type brakes engage and the machine stops.
RD 27 4.2 Troubleshooting the Drive System Determining Where to Begin Prerequisites Procedure Engine must be able to start Multimeter Follow the procedure below to determine where to begin and the sequence of checking the drive system. 1. Disconnect the seat switch solenoid (a). 2. With the engine running, measure the voltage between wire 307-OR-16 and ground. f If 10–12.5 VDC is not measured, the problem is within the electrical components.
Troubleshooting the Drive System 4.3 RD 27 Checking the Interlock Relay Prerequisites Procedure Fully-charged battery Functioning key switch Follow the procedure below to check the interlock relay. 1. Place the brake switch in the disengaged position (up). 2. Remove the control panel (a) from the steering column. 3. Locate the interlock relay (b) and disconnect the connector. 4. With the key in the ON position, measure the voltage between wire F765-BR-16 at the connector and ground. Is 10.0–12.
RD 27 Troubleshooting the Drive System Continued from the previous page. 5. Place the FWD/REV lever in the NEUTRAL position. 6. With the starter key in the ON position, measure the voltage between wire 307OR-16 of the connector and ground. Is 10.0–12.5 VDC measured? Yes ____ No ____ Continue. Repair wire 307-OR-16. 7. With an assistant sitting in the operator’s seat, check the continuity of wire C906-PU-16 of the connector to ground. Is there continuity to ground? Yes ____ No ____ Continue.
Troubleshooting the Drive System RD 27 Continued from the previous page. 13.Move the FWD/REV lever out of the NEUTRAL position and into full FORWARD or full REVERSE. 14.With the key in the ON position and an assistant seated in the operator’s seat, measure the voltage between wire 307-OR-16 of the seat switch solenoid and ground. Is 10.0–12.5 VDC measured? Result wc_tx000949gb.fm Yes ____ No ____ The interlock relay is OK. The interlock relay has failed; replace it.
RD 27 4.4 Troubleshooting the Drive System Checking the Seat Switch Prerequisites Machine shut down An assistant Background There are two seat switches. If one fails, the other will allow machine operation. The procedure to check either seat switch is the same. Procedure Follow the procedure below to check the seat switch. 1. Check that the wiring to each seat switch is secure. If it is not, reconnect the wiring and retry drive system operation. If the wiring is secure, continue. 2.
Troubleshooting the Drive System 4.5 RD 27 Checking the Seat Switch Solenoid Valve Prerequisites Procedure Engine must be able to start Multimeter Follow the procedure below to check the seat switch solenoid valve. 1. Disconnect the wiring from the seat switch solenoid valve (a). 2. Measure the resistance of the coil (b). Does the coil measure 8.0–11.0 ohms? Yes ____ No ____ Continue. The solenoid has failed; replace it. 3. Reconnect the connector. 4.
RD 27 4.6 Troubleshooting the Drive System Checking the Neutral/Brake Solenoid Valve Prerequisites Procedure Engine must be able to start Multimeter Follow the procedure below to check the neutral/brake solenoid valve. 1. Disconnect the wiring from the neutral/brake solenoid valve (a). 2. Measure the resistance of the coil (b). Does the coil measure 7.0–8.0 ohms? Yes ____ No ____ Continue. The solenoid has failed; replace it. 3. Reconnect the wiring and coil. 4.
Troubleshooting the Drive System 4.7 RD 27 Checking the Drive System Operating Pressure Prerequisites Machine on a firm, level surface 350-bar (5000-psi) pressure gauge Hydraulic oil warm Background Failure of the drive circuit to reach operating pressures is normally caused by a worn or damaged drive pump; however, the problem could also be the result of a badly worn motor. Procedure Follow the procedure below to test the drive system operating pressure. 1.
RD 27 4.8 Troubleshooting the Drive System Testing Drive Motor Integrity Prerequisites Hydraulic oil must be warm 207 bar (3000 psi) pressure gauge Graduated container and tubing Background By checking the drive motor case drain flow, the integrity of the drive motor can be determined. Test both drive motors, one at a time, as described below. Procedure Follow the procedure below to test the drive motor integrity. 1.
Troubleshooting the Drive System RD 27 Continued from the previous page. 7. Have an assistant start the engine and move the FWD/REV control to the forward position until 80 bar (1166 psi) is read on the 207 bar (3000 psi) pressure gauge. Leave the FWD/REV control in the position that produces 80 bar (1166 psi). 8. With the engine running and the brake disengaged, collect hydraulic oil from the case drain during a 1-minute period. Make note of the amount of hydraulic oil collected.
RD 27 4.9 Troubleshooting the Drive System Testing the Parking Brakes Prerequisites Hydraulic oil must be warm Background The brakes on this machine are spring-activated and hydraulically released. By removing the hydraulic supply hose from the brakes, the spring and mechanical portion of the brakes may be tested. Procedure Follow the procedure below to test the parking brakes. 1. Start the engine and operate the machine at high idle until the hydraulic oil temperature reaches 43±5.6°C (110±10°F).
Troubleshooting the Drive System 4.10 RD 27 Checking the Backup Alarm Switch Prerequisites Procedure Machine shut down Multimeter Follow the procedure below to check the backup alarm switch. 1. Peel back the boot (c) from the FWD/REV control lever to reveal the switches. 2. Remove the wires from the backup alarm switch (a). 3. Check for continuity between the NO terminal and the COM terminal of the neutral switch in each position of the FWD/REV control lever. See chart.
RD 27 5 Troubleshooting the Vibration System Troubleshooting the Vibration System Best practice The best practice when troubleshooting this system is to: 1. Isolate and check each component of this system individually. 2. When a malfunctioning component is found, repair or replace it. 3. After replacing a malfunctioning component, retry system operation. This chapter provides procedures to check the components. wc_tx000953gb.
Troubleshooting the Vibration System 5.1 RD 27 Determining Where to Begin See the chart below to determine where to begin: If Then The problem is that the vibration does not function, or functions only on one drum, follow the sequence for electrical problems. The problem is that the vibration system performs poorly, follow the sequence for hydraulic problems. Electrical problems: Step Task See Topic 1. Check the vibration fuse. 5.2 2. Check the vibration ON/OFF solenoid. 5.3 3.
RD 27 5.2 Troubleshooting the Vibration System Checking the Vibration Fuse Prerequisites Machine is shut down Procedure To check the vibration fuse: 1. Remove the fuse box cover plate. 2. Remove the vibration fuse (a) and inspect it. 3. If necessary, replace the fuse with one of equivalent size and rating. 4. Re-install the fuse box cover plate. Result wc_tx000953gb.fm The vibration fuse has now been checked. If the problem has not been resolved, continue with the next topic.
Troubleshooting the Vibration System 5.3 RD 27 Checking the Vibration ON/OFF Solenoid Prerequisites Procedure Fully-charged battery Functioning vibration ON/OFF switch Perform the procedure below to check the vibration ON/OFF solenoid. 1. Move the key switch to the ON position. 2. Move the forward/reverse lever slightly out of neutral (in either direction). With the vibration ON/OFF switch in the ON position (activated), 10–13 VDC should be measured. 3.
RD 27 Troubleshooting the Vibration System Continued from the previous page. 6. Measure the voltage at the electrical connector. Does the voltage measure 10–13 VDC? Yes ____ Continue. No ____ Repair the wiring between the vibration ON/OFF switch and the vibration ON/OFF solenoid. 7. Measure the resistance at the connector pins. Does the resistance measure 5–10 Ohms? Result wc_tx000953gb.fm Yes ____ No ____ The vibration ON/OFF solenoid is OK. The vibration ON/OFF solenoid has failed; replace it.
Troubleshooting the Vibration System 5.4 RD 27 Checking the Neutral Switch Prerequisites Procedure Machine is shut down Multimeter Follow the procedure below to check the neutral switch. 1. Remove the retaining ring from the rubber boot at the base of the FWD/REV control (joystick). 2. Roll up the rubber boot to expose the neutral switch (a). 3. Disconnect one or both of the wires from the neutral switch. 4.
RD 27 Troubleshooting the Vibration System Continued from the previous page. 5. Keeping the multimeter’s probes in place, move the joystick backward and forward. Is there continuity when the joystick is in the backward and forward positions? Result Yes ____ No ____ The neutral switch has failed; replace it. The neutral switch is OK. The neutral switch has now been checked. Reassemble the machine. If the problem has not been resolved, continue with the next topic. wc_tx000953gb.
Troubleshooting the Vibration System 5.5 RD 27 Checking the Neutral Relay Prerequisites Procedure Multimeter Functioning starter relay 2 Follow the procedure below to check the neutral relay. 1. Place the FWD/REV control in the NEUTRAL position. 2. Remove the control panel cover. 3. Locate the neutral relay (a) and disconnect the connector. 4. With the starter key in the START position, measure the voltage between wire 125-OR-16 at the connector and ground.
RD 27 5.6 Troubleshooting the Vibration System Checking the Vibration Switch Prerequisite Procedure Machine shut down Multimeter Perform the procedure below to check the vibration switch. 1. Shut down the machine. 2. Remove the access panel (a). 3. Locate the vibration switch and disconnect the connector (b). 4. Probe the two pins (c and d) of the connector with a multimeter. (These are the pins that connect to wires A990 and C720 of the main wiring harness.) d c wc_gr006499 5.
Troubleshooting the Vibration System 5.7 RD 27 Checking the Drum Vibration Solenoid Prerequisites Procedure Fully-charged battery Functioning vibration switch Perform the procedure below to check the drum vibration solenoid. 1. Move the key switch to the ON position. 2. Move the forward/reverse lever slightly out of neutral (in either direction). 3. Locate the drum vibration solenoid (a) inside the left corner of the frame. 4. Disconnect the electrical connector from the drum vibration solenoid.
RD 27 Troubleshooting the Vibration System Continued from the previous page. 8. Measure the resistance at the solenoid connector pins. Does the resistance measure 5 to 10 Ohms? Result wc_tx000953gb.fm Yes ____ No ____ The drum vibration solenoid is OK. The drum vibration solenoid has failed; replace it. The vibration solenoid has now been checked. If the problem has not been resolved, continue with the next topic.
Troubleshooting the Vibration System 5.8 RD 27 Checking Engine RPM and Drum VPM Prerequisites Procedure Vibrotach (P/N 53397) Vibration must turn on Follow the procedure below to check the engine rpm and drum vpm (vibrations per minute). 1. Start the engine and place the throttle switch in the 66 Hz (FAST) position. 2. Measure the engine rpm using a vibrotach. 3. Measure the vpm (vibrations per minute) by placing the vibrotach on the rim of the drum while vibration is on. 4.
RD 27 5.9 Troubleshooting the Vibration System Checking Vibration System Operating and Relief Pressure Prerequisites Procedure 350 bar (5000 psi) pressure gauge Functioning vibration switch Perform the procedure below to check the vibration system operating pressure. 1. Run the machine so that the hydraulic oil is at operating temperature; approximately 43±5°C (110±10°F). 2. Stop the engine. 3. Connect the 350 bar (5000 psi) gauge to the vibration manifold (a). 4. Start the engine.
Troubleshooting the Vibration System RD 27 Continued from the previous page. 8. Press the vibration ON/OFF switch to activate the vibration and measure the relief and operating pressures. The relief pressure is the pressure shown as soon as the vibration is turned on. The system will then settle into operating pressure. Record these two pressures. Is an operating pressure of 120–152 bar (1800–2200 psi) measured? Yes ____ No ____ The vibration system operating pressure is OK.
RD 27 5.10 Troubleshooting the Vibration System Checking the Vibration Motor for Binding Prerequisites Machine shut down Compactible surface Background By removing the exciter motor you’ll be able to check it along with the coupling and the exciter shaft for binding. Removal Perform the procedure below to remove and check the exciter motor for binding. 1. Remove the hose protector plate (a). 2. Loosen the hose clamps (b). 3. Disconnect the hoses (c) from the exciter motor (d).
Troubleshooting the Vibration System RD 27 Continued from the previous page. 5. Remove the screws and remove the exciter motor (d) from the drum. Inspection Perform the following procedure to inspect the exciter motor, coupling, and exciter shaft for binding. 1. Remove the coupling adapter (e) and inspect it. Replace the coupling if the coupling adapter is damaged. 2. Rotate the exciter shaft (f) by hand. If the exciter shaft binds, disassemble the drum and inspect the exciter shaft bearings. 3.
RD 27 Troubleshooting the Vibration System Continued from the previous page. 3. Remove the coupling adapter from the exciter motor. 4. Position the exciter motor (d) so that the coupling will not touch the machine or anything else when it is activated. 5. Start the engine. 6. If working on the rear exciter motor, park the machine on old tires or a suitable compactible surface. CAUTION Cutting hazard. The tines of the coupling present a cutting hazard when spinning.
Troubleshooting the Steering System 6 6.1 RD 27 Troubleshooting the Steering System Determining Where to Begin Prerequisites Before replacing any components or performing any troubleshooting procedures, be sure that: The correct hydraulic oil is being used The hydraulic reservoir is full The articulated steering joint is not locked If the above criteria are being met and there is still a problem, continue.
RD 27 6.2 Troubleshooting the Steering System Diagnosing the Steering System Prerequisites Procedure The hydraulic oil is warm 207 bar (3000 psi) pressure gauge Large container Perform the procedure below to diagnose the steering system. 1. Run the machine so that the hydraulic oil is at operating temperature, approximately 43±5°C (110±10°F). 2. Stop the engine. 3. Remove the control panel (a) from the steering column. 4. Disconnect the hose (b) from the steering unit (c). 5.
Troubleshooting the Steering System RD 27 Continued from the previous page. 7. Reconnect the hose to the steering servo. 8. Disconnect the two hoses (e) from the steering cylinder (h). Access the steering cylinder from underneath the frame. 9. Cap the two hoses and the fittings on the steering cylinder. 10.Connect the 207 bar (3000 psi) pressure gauge (f) to the test port (g) of the steering pump. 11.Start the engine and check the pressure.
RD 27 7 Troubleshooting the Water Spray System Troubleshooting the Water Spray System Best practice The best practice when troubleshooting this system is to: 1. Isolate and check each component of this system individually. 2. When a malfunctioning component is found, repair or replace it. 3. After replacing a malfunctioning component, retry system operation. This chapter provides procedures to check the components. 7.
Troubleshooting the Water Spray System 7.2 RD 27 Checking the Water Spray Fuse Prerequisites Machine shut down Procedure Follow the procedure below to check the water spray fuse. 1. Remove the fuse box cover. 2. Remove and check the water spray fuse (a). Is the fuse OK? Result wc_tx001224gb.fm Yes ____ No ____ Re-install the fuse. Replace the faulty fuse with one of like size and rating. The water spray fuse has now been checked. Re-install the fuse box cover.
RD 27 7.3 Troubleshooting the Water Spray System Checking Power to the Spray Pump Motor Prerequisite Procedure Fully-charged battery Machine shut down Perform the procedure below to check power to the spray pump motor. 1. Shut down the machine. 2. Remove the access panel (a). 3. Locate the wiring from the spray pump (c) and disconnect the connector (b). 4. Probe the connector with your multimeter. 5. Move the key switch to the ON position. 6. Move the spray switch to the continuous position. 7.
Troubleshooting the Water Spray System 7.4 RD 27 Checking the Spray Switch Prerequisite Procedure Fully-charged battery Machine shut down Perform the procedure below to check the spray switch. 1. Shut down the machine. 2. Remove the steering tower cover (a). 3. Locate the spray switch (b). 4. Move the key switch to the ON position. 5. Measure the voltage between terminal/wire 118-GY-16 of the spray switch and ground. Is at least 10 VDC measured? Yes ____ No ____ Continue.
RD 27 7.5 Troubleshooting the Water Spray System Checking the Timer Module Prerequisite Procedure Fully-charged battery Machine shut down Perform the procedure below to check the voltage to the timer module. 1. Shut down the machine. 2. Remove the steering tower cover (a). 3. Locate the timer module (b) and remove it. For easier access, disconnect the connector from the tower cover. 4. Move the key switch to the ON position. 5.
Troubleshooting the Water Spray System RD 27 Continued from the previous page. 6. Measure the voltage between wire C935-PU-16 at the connector and ground. Is at least 10 VDC measured? Yes ____ No ____ Continue. Repair wire C935-PU-16. 7. Check the continuity of wire 200-BK-16 to ground. Is there continuity? Yes ____ No ____ Continue. Repair wire 200-BK-16. 8. Locate the spray relay (c) and disconnect it. 9.
RD 27 7.6 Troubleshooting the Water Spray System Checking the Spray Relay Prerequisite Procedure Fully-charged battery Machine able to start Perform the procedure below to check the spray relay. 1. Shut down the machine. 2. Remove the steering tower cover (a). 3. Locate the spray relay (c) and disconnect it. 4. Turn the key switch to the ON position. 5. Move the spray switch to the intermittent position. 6. Move the forward/reverse lever (joystick) out of the neutral position. 7.
Troubleshooting the Water Spray System RD 27 Continued from the previous page. 8. Measure the voltage between wire C935-PU-16 at the spray relay connector and ground. Is at least 10 VDC measured? Yes ____ No ____ Continue. Repair wire C935-PU-16. 9. Reconnect the spray relay. 10.Remove the access panel (a). 11.Locate the wiring from the spray pump (c) and disconnect the connector (b). 12.Measure the voltage between wire 720-BU-16 at the connector and ground.
RD 27 8 8.1 Disassembly and Assembly Disassembly and Assembly Tools Required for Disassembly/Assembly 8.2 Information Regarding Replacement Parts 8.3 It is up to the mechanic to use common sense and good judgment in tool selection to reduce the risk of injury while repairing the machine. In cases where a special tool is required, the special tool is listed in the prerequisite section of the procedure.
Disassembly and Assembly 8.4 RD 27 Removing and Installing the Steering Servo Valve Prerequisites Removal Machine shut down Machine cool Perform the procedure below to remove the steering servo valve. 1. Disconnect the battery. 2. Open the hood and place the safety bar in position. 3. Remove the vandal cover. 4. Remove the control panel (a). 5. Label the four hydraulic hoses (c). 6. Remove the hydraulic hoses, one at a time, from the servo valve (f).
RD 27 Disassembly and Assembly Continued from the previous page. 7. Remove the three longer screws (d) securing the servo valve. 8. Remove the shorter screw (e) and remove the servo valve (f) from the control console. Installation Follow the procedure below to install the steering servo valve. 1. Install the shorter screw (e) to the secure servo valve (f) to the tower. 2. Install the three longer screws (d) to secure the servo valve. Torque all screws to 22.5±2.5Nm (17±2 ft.lbs.).
Disassembly and Assembly RD 27 Continued from the previous page. 3. Connect the hydraulic hoses (c) to the servo valve (f) starting with the rear hoses first. Be sure to connect the hoses in the correct locations. Do not connect a long hose where a short one should be connected. Torque the fittings to 40 Nm (29 ft.lbs.). 4. Inspect the seal around the control console and replace the seal if necessary. 5. Reattach the control console cover. 6. Reattach the vandal guard. Result wc_tx001221gb.
RD 27 8.5 Disassembly and Assembly Removing and Installing a Drive Motor Prerequisites Removal Two screw-type or hydraulic floor jacks Lifting device capable of lifting 226 kg (500 lb) Container to collect draining hydraulic oil Two M16x200 screws with head removed Perform the procedure below to remove the drive motor. 1. Position the machine by moving it forward or reverse as needed so that the shock mount screws (a) are accessible. 2. Remove the hose cover protective plate (b). 3.
Disassembly and Assembly RD 27 Continued from the previous page. 6. Using two screw-type or hydraulic floor jacks (d) mounted under the machine, jack up the machine slightly to relieve pressure on the shock mounts. 7. Remove the top three shock mount screws (a1, a2, a3). Jack up the machine slightly more to relieve pressure and remove the last two shock mount screws (a4, a5). 8. Connect an appropriate lift to the lifting point of the drum support. 9.
RD 27 Disassembly and Assembly Continued from the previous page. 11.Remove the five screws (h) securing the shock mount support plate (i) and remove the shock mount support plate. 12.Remove the fittings (j) from the motor (k). Reuse the fittings on the replacement motor. 13.Remove the seven screws (l) securing the motor (k) to the drum support (m) and remove the motor. Installation Perform the procedure below to remove the drive motor. 1.
Disassembly and Assembly RD 27 Continued from the previous page. 3. Using the five screws (h) install the shock mount support plate (i). 4. With the shims and spacer in place, slide the drum support over the pins installed during removal. Using screws (e) install the drum support to the frame. 5. Using screws (a1, a2, a3, a4, a5), install the shock mount to the machine. 6. Connect the hydraulic hoses. 7. Install the hose cover protective plate (b). I. Result wc_tx001221gb.
RD 27 8.6 Disassembly and Assembly Removing and Installing an Exciter Motor Prerequisites Removal Machine shut down Battery disconnected Perform the procedure below to remove the exciter motor. 1. Remove the screws securing the hose protective cover (a) and remove the hose protective cover. 2. Remove the hose clamps (b) securing the exciter motor to the drum support. 3. Have a container ready to collect any draining hydraulic oil. Remove the case drain hose (c) from the motor.
Disassembly and Assembly RD 27 Continued from the previous page. 5. Remove the two screws (h) and remove the exciter motor (i). i wc_gr006773 Installation Perform the procedure below to install the exciter motor. 1. Place the green adapter portion (j) of the coupling onto the end of the shaft. Insert the exciter motor, gear/shaft-side down. Make sure the gears of the exciter motor mesh with the green adapter. 2.
RD 27 Disassembly and Assembly Continued from the previous page. 3. Reattach the hydraulic fittings (f and g); however, at this time hand tighten the hydraulic fittings only. 4. Connect the two hydraulic hoses (d and e). 5. Connect the case drain hose (c). 6. Tighten all the hydraulic fittings. 7. Install the hose clamps (b). 8. Install the hose protective cover (a). Result wc_tx001221gb.fm The exciter motor has now been installed.
Disassembly and Assembly 8.7 RD 27 Removing a Drum Prerequisites Removal Machine shut down Battery disconnected Lifting crane and devices capable of lifting 910 kg (2000 lb) Perform the procedure below to remove a drum. 1. Support the machine with jacks from underneath and/or a crane at the towing point (a). 2. Remove the drive-side drum support. See section Removing and Installing a Drive Motor. 3. Remove the hydraulic hoses from the exciter motor.
RD 27 Disassembly and Assembly Continued from the previous page. 6. Remove the large spacer and the shims. 7. Lift the machine slightly if necessary to roll the drum (e) from underneath the machine. Result wc_tx001221gb.fm The drum has now been removed.
Disassembly and Assembly 8.8 RD 27 Disassembling a Drum Prerequisites Disassembly Drum removed Crane capable of lifting 450 kg (1000 lb) Perform the procedure below to disassemble the drum. 1. Remove the drum from the machine. See section Removing a Drum. 2. Using an appropriate lift or hoist, lift the drum into the vertical position resting on the side where the drive motor was mounted. 3. Remove the four screws (a) securing the exciter-motor-side drum support (b) and remove the drum support.
RD 27 Disassembly and Assembly Continued from the previous page. 8. Remove the seal (h). 9. Make a reference mark (i) on the bearing flange and clean out the drum so that no dirt will fall into the drum when the bearing flange is removed. 10.Remove the gear (j). Then, remove the inner four screws (k) and remove the exciter shaft coupling (l). 11.Remove the six screws securing the bearing flange/drum cover (m) and remove the bearing flange/drum cover.
Disassembly and Assembly RD 27 Continued from the previous page. 12.Attach a lifting eye to the exciter shaft (p) and lift the exciter shaft from the drum. 13.Inspect the interior of the drum and clean it if necessary. 14.Inspect the exciter shaft for wear and discoloration. 15.Replace the exciter shaft bearings. See Topic Exciter Shaft Bearings. wc_tx001221gb.
RD 27 8.9 Disassembly and Assembly Removing and Installing the Exciter Shaft Bearings Prerequisites Removal Drum removed Drum disassembled Arbor press Perform the procedure below to remove the exciter shaft bearings. 1. Remove the drum from the machine. See section Removing a Drum. 2. Disassemble the drum. See section Disassembling the Drum. 3. Remove the retaining ring (a), grease retainer (b), outer bearing race (c), and the grease seal (d) from the exciter-side bearing flange.
Disassembly and Assembly RD 27 Continued from the previous page. 5. Heat the inner bearing races (g and h) to remove them from the exciter shaft. 6. Remove the bearing (i) and the grease ring (j) from the support plate. Installation: Perform the procedure below to install the exciter shaft bearings. This procedure continues on the next page. wc_tx001221gb.
RD 27 Disassembly and Assembly Continued from the previous page. 1. Coat the grease ring (j) with a thin film of grease and install it into the support plate. 2. Pack the support plate bearing (i) with 60 grams (2 oz.) of grease. Insert the bearing into the support plate. If necessary, use the bearing cover as a pusher to install the bearing. Mount the bearing cover with two screws 180° from each other. Tighten the two screws evenly until the bearing is seated.
Disassembly and Assembly RD 27 Continued from the previous page. 4. Coat the grease seal (d) with a thin film of grease. Insert the seal, groove side first, into the exciter-side bearing flange. Press the outer bearing race (c) into the flange. Pack the bearing with 60 grams (2 oz.) of grease. Add the grease retainer (b) and the retaining ring (a). 5. Press the outer bearing race (f) into the drive-side bearing flange. Pack the bearing with 60 grams (2 oz.) of grease. 6.
RD 27 8.10 Disassembly and Assembly Removing and Installing Drum Shock Mounts Prerequisites Drum removed from machine Special shock mount removal tool Loctite® 243 or equivalent Background Inspect the shockmounts on both sides of the drum (drive-side and exciter-side). If one shockmount needs replacing, replace all the shockmounts on that side. The procedure for removing drive-side shock mounts (a) is the same for removing exciter-side shock mounts (b).
Disassembly and Assembly 8.11 RD 27 Assembling the Drum Prerequisites Procedure Loctite® 243 or equivalent Repacked exciter shaft bearings Crane and lifting devices capable of lifting 450 kg (1000 lb) Perform the procedure below to assemble the drum. 1. Using Loctite 243 or equivalent on six M10 screws, secure the drive-side bearing flange/drum cover (a) (with outer bearing race installed) to the drum. Torque the screws to 50 Nm (37 ft.lbs.). 2.
RD 27 Disassembly and Assembly Continued from the previous page. 5. Install the outer seal (e), lip-side up, to the exciter-side bearing flange. 6. Using Loctite 243 or equivalent on the four M8 screws (k), secure the coupling (l) to the exciter shaft. Torque the screws to 30 Nm (22 ft.lbs.). Install the coupling gear (j). 7. Install the shock mounts. See section Removing and Installing Shock Mounts. 8.
Disassembly and Assembly 8.12 RD 27 Re-installing the Drum Prerequisites Procedure Loctite® 243 or equivalent Crane and lifting devices capable of lifting 450 kg (1000 lb) Perform the procedure below to re-install a drum. 1. Using Loctite 243 or equivalent on four screws, secure the exciter-side drum support (a) to the drum. Torque the screws to 240 Nm (148 ft.lbs.). a wc_gr006800 2. Assemble the drive motor to the drive-side drum support.
RD 27 Disassembly and Assembly Continued from the previous page. 7. After the shim arrangement has been determined, route the hydraulic hoses (h and i) through the drum supports. 8. Using Loctite 243 or equivalent on the screws (c), secure the drum supports, large spacers, and shims to the machine frame. Torque the screws to 240 Nm (148 ft.lbs.). 9. Reattach the hydraulic hoses to either the drive motor or the exciter motor. 10.
Disassembly and Assembly 8.13 RD 27 Removing and Installing the Fuel Tank Prerequisites Removal Machine shut down Fuel tank drained Perform the procedure below to remove the fuel tank. Note: This procedure is best accomplished with very little fuel in the fuel tank or with the fuel tank drained. 1. Disconnect the supply and return hoses (a). 2. Remove the fasteners (b) that secure the strap (c). 3. Position the strap (c) so it does not interfere with lifting the fuel tank. 4.
RD 27 Disassembly and Assembly Continued from the previous page. 2. Secure the fuel tank to the machine using the strap (c) and fasteners (b). 3. Reconnect the supply and return hoses (a). Result wc_tx001221gb.fm The procedures to remove and install the fuel tank are now complete.
Disassembly and Assembly 8.14 RD 27 Removing and Installing the Radiator Prerequisites Removal Engine cool Machine shut down Container to collect coolant Perform the procedure below to remove the radiator. 4. Open the drain valve and drain (a) the coolant from the radiator. 5. Disconnect the upper hose (b). 6. Remove the screws (c and d). 7. Remove the guard (e). This procedure continues on the next page. wc_tx001221gb.
RD 27 Disassembly and Assembly Continued from the previous page. 8. Remove the fasteners (f). 9. Split the shroud and remove each half (g). 10.Disconnect the lower hose (h). 11.Remove the fasteners (i) that secure the radiator and remove the radiator (j). Installation Perform the procedure below to install the radiator. 1. Position the radiator (j) into the machine and secure it with fasteners (i). 2. Connect the lower hose (h). This procedure continues on the next page. wc_tx001221gb.
Disassembly and Assembly RD 27 Continued from the previous page. 3. Re-install each half (g) of the shroud with fasteners (f). 4. Re-install the guard (e) with screws (c and d). 5. Reconnect the upper hose (b). 6. Refill the radiator with coolant. Result wc_tx001221gb.fm The radiator has now been installed.
RD 27 8.15 Disassembly and Assembly Removing and Installing the Steering Cylinder Prerequisites Removal Machine turned left Machine shut down Perform the procedure below to replace the steering cylinder. 1. Turn the steering wheel to the left. This will provide improved access to the steering cylinder (a). 2. Stop the machine and disconnect the battery. 3. Disconnect the hoses from the steering cylinder (a).
Disassembly and Assembly RD 27 Continued from the previous page. 5. Remove the two pins (c and d). 6. Remove the washer (e). 7. Push the piston (ram) into the cylinder. 8. Moving the cylinder toward the front of the machine, manuever the steering cylinder (a) out of the machine. Installation Perform the procedure below to install the steering cylinder. 1. Moving the steering cylinder from the front of the machine to the back of the machine, position the steering cylinder inside the machine frame.
RD 27 Disassembly and Assembly Continued from the previous page. 2. Install the washer (e). 3. Secure the steering cylinder to the machine with the pins (c and d). Use Loctite 243 or equivalent on the screws that hold the pins. 4. Re-install the hydraulic fitting. 5. Re-install the hydraulic hoses. Result wc_tx001221gb.fm The steering cylinder has now been replaced.
Disassembly and Assembly 8.16 RD 27 Removing and Installing the Articulated Steering Joint Prerequisites Drums/machine straight in-line Steering cylinder disconnected from articulated steering joint Four screw jacks or similar to hold machine frames Sling and crane to lift articulated steering joint Background The steering cylinder must be disconnected from the articulated steering joint before the articulated steering joint may be removed.
RD 27 Disassembly and Assembly Notes wc_tx001221gb.
Disassembly and Assembly 8.17 RD 27 Articulated Steering Joint Exploded View wc_tx001221gb.
RD 27 8.18 Disassembly and Assembly Articulated Steering Joint Components wc_tx001221gb.
Disassembly and Assembly 8.19 RD 27 Rebuilding the Articulated Steering Joint Prerequisites Articulated steering joint removed from machine Bearings (see Parts Book) Disassembly Perform the procedure below to rebuild the articulated steering joint. 1. Remove the screw (a) from the threaded hole of the axle. b c wc_gr006809 2. Remove the spacer (b) and the conical washer (c). 3. Insert a sacrificial screw (d) into the threaded hole of the axle.
RD 27 Disassembly and Assembly Continued from the previous page. 6. Invert the hitch and place it on a thick board. Using a punch (i), knock out the smaller bearing (h) and the inner seal. 7. To remove the larger bearing (j), remove the outer seal (k). Then, using a screwdriver, pry the bearing away from the flange. Once it is free from the flange, use a gear puller to pull the bearing from the axle. Assembly Perform the procedure below to assemble the articulated steering joint 1.
Disassembly and Assembly RD 27 Continued from the previous page. 3. Insert the outer race of the larger bearing into the hitch casting. Insert the outer race of the smaller bearing (d) inside the hitch casting (e). 4. Place the hitch casting over the axle. Fill the hitch casting with multipurpose grease. 5. Install the oil seal (f) as shown. 6. Align the conical washer (g) (apex side towards the spacer) with the spacer (h). Insert them into the hitch casting and secure with the bolt (i).
RD 27 Disassembly and Assembly Continued from the previous page. 7. Mount the two pillow block/bearing sets (j) to the hitch. Add the cover (k) to each pillow block/bearing. Fill them with multipurpose grease. Result wc_tx001221gb.fm The articulated joint has now been rebuilt.
Disassembly and Assembly 8.20 RD 27 Removing and Installing the Spray System Pump Prerequisites Removal Machine shut down Water system drained Perform the procedure below to remove the spray system pump. 1. Disconnect the electrical connector (a) from the harness. 2. Remove the screws (b) that hold the spray system pump (c) to the machine. 3. Disconnect the hoses from the spray system pump and pull the spray system pump from the machine.
RD 27 8.21 Disassembly and Assembly Removing and Installing the Water Tank Prerequisites Removal Machine shut down Crane capable of lifting 226 kg (500 lb) Perform the procedure below to remove the water tank. 1. Stop the engine and disconnect the battery. 2. Drain the water tank. 3. Make sure all four locking pins (a) of the ROPS are in good shape and securely held in place by the retaining pins (b). 4. Secure the ROPS with a suitable crane and sling. 5.
Disassembly and Assembly RD 27 Continued from the previous page. 6. Lift the ROPS slightly off the machine. Disconnect the wiring (x) from the rotating beacon, then lift the ROPS up and away from the machine. 7. Using the adjusting lever (z), adjust the seat towards the rear of the machine as far as possible. 8. Remove the five screws (e) securing the operator platform. 9. Rotate the operator platform towards the front of the machine. Secure the operator platform (f) in this position. 10.
RD 27 Disassembly and Assembly Continued from the previous page. Installation Perform the procedure below to install the water tank. 1. Position the tank (h) into the machine frame. 2. Reconnect the water line between the tank and the filter at the filter (g). 3. Secure the operator platform to the machine using five screws (e). WARNING Safety hazard. The ROPS is designed to protect the operator in a rollover accident. f Do not use the machine without the ROPS in place.
Disassembly and Assembly RD 27 Continued from the previous page. 4. Position the ROPS over the machine and reconnect the wiring (x) for the rotating beacon. 5. Using the same fasteners as removed and the shims (c), secure the ROPS to the machine frame. Torque the fasteners to 240 Nm (177 ft.lbs.). Result wc_tx001221gb.fm The water tank has now been installed.
RD 27 8.22 Disassembly and Assembly Removing and Installing the Hydraulic Oil Cooler Prerequisites Removal Machine shut down Hydraulic oil drained Perform the procedure below to remove the hydraulic oil cooler. 1. Drain the hydraulic reservoir. 2. Disconnect the wiring (a) to the fan. 3. Disconnect the upper (b) and lower (c) hydraulic hoses. 4. Remove the screws (d) that secure the hydraulic oil cooler and remove hydraulic oil cooler (e) from the machine.
Disassembly and Assembly 8.23 RD 27 Removing and Installing the Drive Pump Prerequisites Removal Machine shut down Hydraulic oil drained Perform the procedure below to remove the drive pump. 1. Drain the hydraulic oil from the hydraulic reservoir. 2. Label, then disconnect the hoses (a) from the drive pump (b). 3. Remove the coil (c) of the solenoid valve. 4. Remove the two screws (d). 5. Pull the drive pump (b) from the machine.
RD 27 Disassembly and Assembly Continued from the previous page. 1. Position the drive pump (b) onto the engine. 2. Apply Loctite 234 or equivalent to the screws (d) and secure the drive pump to the engine. 3. Re-install the coil (c) of the solenoid valve. 4. Reconnect the hydraulic hoses (a). 5. Refill the hydraulic reservoir. Result wc_tx001221gb.fm The drive pump has now been replaced.
Disassembly and Assembly 8.24 RD 27 Removing and Installing the Steering Pump Prerequisites Removal Machine turned to the left Machine shut down Perform the procedure below to replace the steering pump. 1. Turn the steering wheel to the left. This will provide improved access to the steering cylinder (a) and other components. 2. Stop the machine and disconnect the battery. 3. Remove the suction hose (b) from the steering pump (c).
RD 27 Disassembly and Assembly Continued from the previous page. 5. Remove the fittings from the steering pump in two phases. First, remove the fittings (e) up to the elbow. 6. Then, remove the elbow (f). 7. Remove the nuts (g) from the long bolts that also hold the vibration pump. 8. Pull the steering pump (c) from the machine. Installation Perform the procedure below to install the steering pump. 1. Position the steering pump (c) onto the engine. 2.
Disassembly and Assembly RD 27 Continued from the previous page. 3. Re-install the fittings. First install the elbow (f). 4. Then, install the rest of the fittings (e). 5. Re-install the output hose (d). 6. Re-install the suction hose (b). Result wc_tx001221gb.fm The steering pump has now been replaced.
RD 27 8.25 Disassembly and Assembly Removing and Installing the Vibration Pump Prerequisites Removal Machine shut down Steering pump removed Perform the procedure below to remove the vibration pump. 1. Remove the steering pump. See Topic Removing and Installing the Steering pump. 2. Remove the suction hose (a) from the vibration pump (b). 3. Remove the output hose (c). 4. Slide the vibration pump along the long screws and separate the vibration pump from the spacer (d) and the engine. 5.
Disassembly and Assembly RD 27 Continued from the previous page. 1. Position the vibration pump close to the spacer (d) and slide the upper long screw (e) through the vibration pump and the spacer, and into the engine. 2. Connect the output hose (c). 3. Connect the suction hose (a). Result wc_tx001221gb.fm The vibration pump (b) has now been installed. Re-install the steering pump.
RD 27 8.26 Disassembly and Assembly Removing and Installing the Hydraulic Reservoir Prerequisites Removal Machine shut down Fuel tank removed Perform the procedure below to remove the hydraulic oil tank. 1. Remove the fuel tank. See Topic Removing and Installing the Fuel Tank. 2. Remove the screw (z) and loosen the hose clamp (a). 3. Disconnect the air filter indicator (b) and remove the air cleaner assembly (c) from the machine. 4. Disconnect the wiring (d) for the low-level sensor. 5.
Disassembly and Assembly RD 27 Continued from the previous page. 6. Remove all the screws (g) that secure the hydraulic reservoir to the machine. 7. Tip the hydraulic reservoir to access the drain hose (f). Then, disconnect the drain hose. 8. Lift the hydraulic reservoir (h) from the machine. 9. Remove the various fittings from the hydraulic reservoir. Installation Perform the procedure below to install the hydraulic reservoir. 1. Connect the various fittings to the hydraulic reservoir. 2.
RD 27 Disassembly and Assembly Continued from the previous page. 3. Connect the drain hose (f). 4. Secure the hydraulic reservoir to the machine with the screws (g). 5. Reconnect all the hydraulic hoses (e). 6. Reconnect the wiring (d) for the low-level sensor. 7. Re-install the air cleaner assembly with screw (z) and tighten the hose clamp (a). 8. Re-install the air cleaner indicator (b). Result wc_tx001221gb.fm The removal and installation procedures are now complete.
Disassembly and Assembly 8.27 RD 27 Removing and Installing the Engine Prerequisites Removal The following components removed: Hydraulic reservoir Drive pump Radiator Crane and chains capable of lifting 450 kg (1000 lbs.) Perform the procedure below to remove the engine. 1. Remove the hydraulic reservoir, the drive pump, and the radiator. 2. Disconnect the exhaust pipe (a) and gasket (b) from the engine. 3. Study the routing of the wiring harness (c). 4.
RD 27 Disassembly and Assembly Continued from the previous page. 6. Cut the cable tie (i) near the air hose. 7. Disconnect the wiring harness from the sender (j). 8. Disconnect the wiring harness and the fuel line (k) from clamp on top of the engine. 9. Cut the cable tie (l). 10.Disconnect the wiring harness from the glow plug (m). 11.Free the wiring harness from any remaining cable clamps (n) and connections (o). This procedure continues on the next page. wc_tx001221gb.
Disassembly and Assembly RD 27 Continued from the previous page. 12.Cut the cable ties that secure the hose (p). 13.Remove the hydraulic oil filter (q) (with the hoses still attached) and set it aside. 14.Disconnect the throttle cable (s). 15.Remove the fasteners (t) that secure the engine assembly to the machine. 16.Connect an appropriate crane and chains to the lifting eyes (u) of the engine. WARNING Crushing hazard. The engine may crush you if the lifting devices fail.
RD 27 Disassembly and Assembly Continued from the previous page. 17.Lift the engine approximately 25 cm (10 in.) out of the machine. Then, cut the cable tie (v) that secures the hydraulic hose. 18.Also cut the cable ties that secure the engine oil drain hose (w). 19.Lift the engine (x) out of the machine. 20.Set the engine on a flat, clean, solid surface. Remove any needed components from the engine. Installation Perform the procedure below to install the engine. 1.
Disassembly and Assembly RD 27 Continued from the previous page. 2. Install shockmounts (y). WARNING Crushing hazard. The engine may crush you if the lifting devices fail. f Do not stand under or reach under the engine while it is being lifted. 3. Using an appropriate crane and chains, lift and position the engine into the machine approximately 25 cm (10 in.) out of the machine. Then, install the cable tie (v) that secures the hydraulic hose. 4.
RD 27 Disassembly and Assembly Continued from the previous page. 5. Install the fasteners (t) that secure the engine assembly to the machine. 6. Install the throttle cable (s). Use Loctite® 243 or equivalent on the small screw. 7. Re-install the hydraulic oil filter (q). 8. Install the cable ties that secure the hose (p). 9. Study the routing of the wiring harness (c). wc_gr006714 This procedure continues on the next page. wc_tx001221gb.
Disassembly and Assembly RD 27 Continued from the previous page. 10.Reconnect the wiring harness with cable clamp (n) and connector (o). 11.Reconnect the wiring harness to the glow plug (m). 12.Connect the cable tie (l). 13.Reconnect the wiring harness and the fuel line (k) with clamp on top of the engine. 14.Connect the wiring harness to the sender (j). 15.Connect the cable tie (i) near the air hose. This procedure continues on the next page. wc_tx001221gb.
RD 27 Disassembly and Assembly Continued from the previous page. 16.Reconnect the wiring harness to the starter solenoid (e). Also reconnect the ground strap (f), the red wire (g), and install the clamp (h). 17.Reconnect the wires (d and e) to the alternator. 18.Reconnect the exhaust pipe (a) and gasket (b) to the engine. 19.Re-install the hydraulic reservoir, the drive pump, and the radiator. Result wc_tx001221gb.fm The engine has now been installed.
Disassembly and Assembly 8.28 RD 27 Removing and Installing the Forward/Reverse Control (Joystick) Prerequisites Removal Machine shut down Soldering iron and solder Perform the procedure below to replace the forward/reverse control (joystick). 1. Remove the screws (a). 2. Lift the assembly (b) from the machine to gain access to the hydraulic fittings. 3. Label, then remove the hydraulic hoses (c). 4. Remove the fittings (d). 5. Remove the boot (e) from the end of the joystick. 6.
RD 27 Disassembly and Assembly Continued from the previous page. 7. Cut the wires and remove the vibration switch (g). 8. Disconnect the wiring (h) from the switches and pull the wires from the joystick. 9. Remove the screws and pull the joystick (i) from the machine. 10.Remove the switches (j). Installation Perform the procedure below to install the joystick. 1. Re-install the switches (j). 2. Secure the joystick (i) to the support plate. This procedure continues on the next page. wc_tx001221gb.
Disassembly and Assembly RD 27 Continued from the previous page. 3. Thread the wiring (h) to the switches. 4. Solder the wiring to the vibration switch (g). 5. Install the holders (f). 6. Re-install the boot (e). 7. Re-install the fittings (d). 8. Re-install the hydraulic hoses (c). 9. Secure the joystick assembly to the machine. Result wc_tx001221gb.fm The forward/reverse control (joystick) has now been replaced.
RD 27 8.29 Disassembly and Assembly Removing and Installing the Hydraulic Manifold Prerequisites Removal Machine shut down Hydraulic oil cool Perform the procedure below to remove the hydraulic manifold. Use the following graphic as reference. 1. Remove the cover from underneath the hydraulic manifold. 2. Disconnect the wiring to the solenoids. 3. Mark, then disconnect, all hoses from the hydraulic manifold (a). 4. Remove fittings from the hydraulic manifold if necessary. 5.
Schematics 9 9.1 RD 27 Schematics Electrical Schematics wc_tx000863gb-en_only.
RD 27 Schematics Electrical Schematics Sheet 1 of 3 163
RD 27 Schematics Electrical Schematics Sheet 2 of 3 164
RD 27 Schematics Electrical Schematics Sheet 3 of 3 165
Schematics RD27 Notes 166
RD 27 Schematics 9.2 Hydraulic Schematics STEERING VALVE Hydraulic Schematic With Flow Divider NEUTRAL BRAKE SOLENOID R P T P1 DRIVE PUMP 24 bars L2 170 bars 125 cc 170 bars L L1 P STEERING CYLINDER S FWD/REV CONTROL 105 BARS B VIBRATORY VALVE P a T a1 a2 100 bars T D A b1 A S 350 bars 350 bars 350 bars B 350 bars b2 OIL COOLER REAR VIBE MOTOR MF 8.4cc PV 22 cc b 2800 RPM 61.6 L/min A DRUM VIB. SOLENOID M1 1.
Schematics RD27 Hydraulic Schematic Without Flow Divider R T 170 bars NEUTRAL BRAKE SOLENOID 125 cc 170 bars P 105 BARS DRIVE PUMP 24 bars L P STEERING CYLINDER L2 FWD/REV CONTROL STEERING VALVE VIBRATORY VALVE T D L1 P b M1 OIL COOLER 22 cc b1 a1 A DRUM VIB . SOLENOID 1 2800 RPM 61.6 L/mi PV a T REAR VIBE MOTOR S B 100 bars MF 8.4cc P1 350 bars b2 a2 1.7 bars 150 bars A CHARGE FILTER C M2 VIB.
RD 27 Technical Data 10 Technical Data 10.1 Engine Engine Power Rating Engine power rating per ISO/TR 14396. Actual power output may vary due to conditions of specific use. RD 27-100 RD 27-120 Item No. Engine Engine make Perkins Engine model 403D-15 Engine type Liquid-cooled diesel Max. rated power @ 2800 rpm kW (Hp) 24.4 (32.7) Displacement cm³ (in³) 1500 (91.5) Starter type/V/kW Electric / 12 / 2.7 Alternator Volts/Amp 12V / 55A rpm 2470/2800 mm (in.) 0.2 (0.
Technical Data 10.2 RD 27 Roller Item No. RD 27-100 RD 27-120 Roller Operating weight kg (lb) 2617 (5770) 2824 (6226) Dry weight kg (lb) 2375 (5236) 2582 (5692) Drum width mm (in.) 1000 (39.4) 1200 (47.2) Drum diameter mm (in.) 700 (27.6) 700 (27.6) L (gal) 150 (39.6) 150 (39.6) Outside turning radius m (ft) 3.6 (11.8) 3.5 (11.5) Speed .....@ 2470 rpm .....@ 2800 rpm km/hr (mph) 0–8.1 (0–5.0) 0–10.0 (0–6.2) 0–8.1 (0–5.0) 0–10.0 (0–6.
RD 27 10.4 Technical Data Sound Measurements The operating sound level, measured per the requirements of Appendix 1, Paragraph 1.7.4.f of the EC-Machine Regulations, is: the guaranteed sound power level (LWA) = 106 dB(A). the sound pressure level at operator’s location (LpA) = 88.0 dB (A). This sound value was determined according to ISO 6394:1998 for the sound power level (LWA). 10.
Technical Data 10.6 RD 27 Dimensions See graphic: wc_gr004619 RD 27-100 RD 27-120 RD 27-100 RD 27-120 Ref. Dimension mm (inches) Ref. Dimension mm (inches) a 2500 (98.4) j 1801 (71.0) k 262 (10.3) b 1000 (39.4) 1200 (47.2) c Ø700 (27.5) l 863 (34) d 2775 (109.3) m 1488 (58.6) with sliding seat 1438 (56.6) without sliding seat e 1800 (70.9) n 175 (6.9) o 150 (5.9) f 1105 (43.5) 1305 (51.4) g 2700 (106.3) p 172 (6.8) h 938 (37.0) q 546 (21.5) i 1541 (60.7) r 910.
Threadlockers and Sealants Threadlockers and Sealants Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container.
Threadlockers and Sealants Threadlockers and Sealants (continued) Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container.
Torque Values Torque Values Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) 8.8 10.9 WRENCH SIZE 12.9 Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch M3 1.2 *11 1.6 *14 2.1 *19 5.5 7/32 2.5 – M4 2.9 *26 4.1 *36 4.9 *43 7 9/32 3 – M5 6.0 *53 8.
Torque Values Torque Values (continued) Inch Fasteners (SAE) Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch No.4 0.7 *6 1.0 *14 1.4 *12 5.5 1/4 – 3/32 No.6 1.4 *12 1.9 *17 2.4 *21 8 5/16 – 7/64 No.8 2.5 *22 3.5 *31 4.7 *42 9 11/32 – 9/64 No.10 3.6 *32 5.1 *45 6.8 *60 – 3/8 – 5/32 1/4 8.
Wacker Neuson SE · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02-0 · Fax: +49 - (0)89-3 54 02-390 Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
