www.wackergroup.
RD 27 Table of Contents 1. Foreword 3 2. Safety Information 4 2.1 2.2 2.3 2.4 2.5 3. Technical Data 3.1 3.2 3.3 3.4 3.5 3.6 4. Operating Safety .................................................................................. 5 Operator Safety while using Internal Combustion Engines .................. 7 Service Safety ...................................................................................... 8 Label Locations ..........................................................................
Table of Contents 4.19 4.20 4.21 4.22 4.23 5. RD 27 Locking/Unlocking Articulated Steering Joint ......................................37 Operating on Slopes ............................................................................38 Preliminary Checks .............................................................................39 Starting the Engine ..............................................................................40 Stopping the Engine ....................................................
CALIFORNIA Proposition 65 Warning: Diesel engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California WARNING to cause cancer and birth defects or other reproductive harm. 1. Foreword This manual provides information and procedures to safely operate and maintain this Wacker model. For your own safety and protection from injury, carefully read, understand and observe the safety instructions described in this manual.
Safety Information RD 27 2.Safety Information This manual contains DANGER, WARNING, CAUTION, 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 injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
RD 27 2.1 Safety Information Operating Safety WARNING wc_si000147gb.fm Familiarity and proper training are required for the safe operation of equipment. Equipment operated improperly or by untrained personnel can be dangerous. Read the operating instructions contained in both this manual and the engine manual and familiarize yourself with the location and proper use of all controls.
Safety Information RD 27 2.1.13 NEVER allow improperly trained people to operate this equipment. People operating this equipment must be familiar with the potential risks and hazards associated with it. 2.1.14 NEVER carry passengers. Danger of crushing — keep clear of the articulated steering joint between the front and rear frames. 2.1.15 NEVER use or attempt to repair damaged safety belts or ROPS. Replace only with Wacker spare parts. 2.1.
RD 27 2.2 Safety Information Operator Safety while using Internal Combustion Engines DANGER wc_si000147gb.fm Internal combustion engines present special hazards during operation and fueling. Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. Failure to follow the warnings and safety guidelines could result in severe injury or death. 2.2.
Safety Information 2.3 RD 27 Service Safety WARNING Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. 2.3.1 Some service procedures require that the machine’s battery be disconnected. To reduce the risk of personal injury, read and understand the service procedures before performing any service to the machine. 2.3.
RD 27 wc_si000147gb.fm Safety Information 2.3.16 ALWAYS 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. 2.3.17 ALWAYS keep hands, feet and loose clothing away from moving parts. 2.3.
Safety Information 2.4 RD 27 Label Locations N R H M L C S N U P K N N V A Q B G G D O J I F E, T D G wc_gr002236 wc_si000147gb.
RD 27 Safety Information 2.5 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 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 Meaning M A A C T O B E U R . N U A L H IN E .
Safety Information Ref. RD 27 Label Meaning E Wacker Corporation Menomonee Falls, WI 53051 USA Model Item Number Rev. Serial Number kg lbs kW hp max.kg max.lbs Manuf. Yr. 112232 MADE IN ITALY dB(A) 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.
RD 27 Ref. Safety Information Label Meaning K Water tank fill. L WARNING! Pinching hazard. Rotating machinery. M WARNING! Pressurized contents. Do not open when hot! N WARNING! Avoid crushing area. O Engine oil drain. ENGINE OIL MOTOROEL ACEITE DE MOTOR HUILE À MOTEURS wc_si000147gb.
Safety Information Ref. Label RD 27 Meaning P STOP Key switch positions. Power to glowplugs. Engine stopped (OFF). Engine ON. Power to starter motor. Q Throttle lever positions. Idle. Low speed. High speed. R Vibration activation and deactivation switch. Forward/reverse lever positions. S WARNING! Do not drill or weld the ROPS. Read the Operator’s Manual. ADVERTENCIA 162789 wc_si000147gb.
RD 27 Ref. Safety Information Label T Meaning WARNING! WARNING Avoid crushing area. Articulated steering joint locking location. Lock the articulated steering joint before servicing the machine. Read Repair Manual. UNG 162788 U Fuse identifications. 15A 10A 10A 10A 10A 10A 10A 10A 10A 162921 wc_gr002659 V Tighten screw to reduce vibration. Read operator’s manual. 1 2 wc_gr002757 Guaranteed sound power level in dB(A) wc_si000147gb.
Technical Data 3. RD 27 Technical Data 3.1 Engine Item No. RD 27 0009469, 0620007, 0620037, 0620038 Engine Engine Make Perkins Engine Model 403C-15 Engine Type Liquid-cooled diesel Rated Power @ 2450/3000 rpm kW (Hp) 23.3 (31.3)/25.1 (33.7) Displacement cm³ (in³) 1496 (91.3) Starter type/V/kW Electric / 12 / 2.7 Alternator Volts/Amp 12V / 55A rpm 2450/3000 mm (in.) 0.2 (0.
RD 27 3.2 Technical Data Roller Item No. RD 27 0009469, 0620038 RD 27 0620007, 0620037 Roller Overall Dimensions 2428 x 1300 x 2775 (95.6 x 51.2 x 109.3) 2428 x 1100 x 2775 (95.6 x 43.3 x 109.3) kg (lb.) 2750 (6063) 2550 (5622) Drum Width mm (in.) 1200 (47.2) 1000 (39.4) Drum Diameter mm (in.) 700 (27.6) 700 (27.6) Water Tank Capacity l (gal) 150 (39.6) 150 (39.6) Outside Turning Radius m (ft.) 3.6 (11.8) 3.5 (11.5) Operating Weight Forward/Reverse Speed mm (in.
Technical Data 3.4 RD 27 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) = 84 dB(A). This sound value was determined according to ISO 3744 for the sound power level (LWA). 3.
RD 27 Technical Data 3.6 Dimensions See Graphic: wc_gr002221 Ref. Dimension mm (inches) Ref. Dimension mm (inches) a 2428 (95.6) g 2589 (102.0) b 1000 (39.4)/1200 (47.2) h 938 (37.0) c 700 (27.6) i 1541 (60.7) d 2775 (109.3) j 1801 (71.0) e 1728 (68.0) k 256 (10.0) f 1101 (43.3)/1301 (51.2) l 1801 (70.9) d g j l i h k b e c f a wc_gr002221 wc_td000148gb.
Operation 4. RD 27 Operation 4.1 Application This 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. Do not use this machine for any other purpose. 4.2 Operation and Service Locations See Graphic: wc_gr002228, wc_gr002229, wc_gr002235 Ref. Description Ref.
RD 27 Operation q j r i s e d o c h p g n l b a k wc_gr002228 1 9 11 12 5, 6 7 4 8, 10 3,10 wc_tx000425gb.
Operation 4.3 RD 27 Roll Over Protection Structure (ROPS) See Graphic: wc_gr002233 The machine is equipped with a Roll Over Protection Structure (ROPS). Do not use the machine without the ROPS in place. The ROPS is designed to protect the operator in a rollover accident. WARNING The machine is normally delivered to the customer with the ROPS folded forward to facilitate transport. Before using the machine, position the ROPS in the fully upright position as follows: 4.3.
RD 27 Operation a d b c wc_gr002233 wc_tx000425gb.
Operation 4.4 RD 27 Rotating Beacon (if equipped) See Graphic: wc_gr002304 The rotating beacon illuminates and rotates when the key switch is in the ON position. To install the beacon: 4.5 4.4.1 Thread the power wire (c) through the light staff and fix it to the upper connector. Insert the connector into the light staff. 4.4.2 Insert the light staff assembly (a) into the left side of the machine ROPS and tighten the set screw (b). 4.4.3 Slide the rotating beacon (d) onto the light staff.
RD 27 4.6 Operation Lighting Equipment (if equipped) See Graphic: wc_gr002237 and wc_gr002313 • Headlights (a). • Working light (b). • Front turn signal lights/roading lights (c). • Rear turn signal lights/roading lights (d). WARNING When working in the dark or in bad visibility, use all the lights available. Replace broken bulbs immediately. Only replace bulbs when machined is turned off.
Operation 4.7 RD 27 Seat Belt See Graphic: wc_gr002238 Pull seat belt (c) out of the retractor in a continuous motion. Fasten seat belt catch (b) into buckle (a). Make sure that the seat belt is placed low across the lap of the operator. The retractor will adjust the belt length and the retractor will lock in place. Push the release button (d) on the buckle in order to release the seat belt. The seat belt will automatically retract into the retractor. Replace the seat belt every three years.
RD 27 4.8 Operation Seat Adjustment See graphic: wc_gr002234 The machine is equipped with an operator present system. This system is part of the driver's seat and senses the weight of an operator in the seat. If the operator is not sitting in the driver's seat, movement of the roller stops. Machine movement cannot be restored until the Forward/Reverse lever is returned to the neutral position. The seat can be adjusted in three ways: tension, front to back, and side to side (optional).
Operation 4.9 RD 27 Scraper Adjustment See Graphic: wc_gr002305 Each drum has two scrapers (a, b). The scrapers are spring-loaded. They may be set in the travel position (1) or the scraping position (2). The scraper distance from the drum may also be adjusted. To adjust the distance: wc_tx000425gb.fm 4.9.1 Loosen the retaining nuts (c). 4.9.2 Adjust the scraper to the desired distance from the drum and retighten the retaining nuts.
RD 27 Operation 4.10 Anti-Vandalism Protection and Machine Access See Graphic: wc_gr002230 Parts of the machine which may be subject to theft or vandalism when the vehicle is parked unattended can be padlocked to prevent unauthorized access or use. Lockable parts are: • Engine cover. • Control console cover. • Operator’s manual holder. To lock the engine cover, close the cover and attach a padlock to the fastener (a). The control console cover is usually open during operation and service.
Operation RD 27 4.11 Water Spray System 1 See Graphic: wc_gr002306 and wc_gr002307 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 0 - water spray system OFF Position 1 activates intermittent water spray system 0 Position 2 - activates continuous water spray system When using the water spray system: 2 wc_gr002306 • Check that the tank is full of water.
RD 27 Operation 4.12 Transmission See Graphic: wc_gr002308 Both roller drums are driven. An infinitely variable displacement pump and hydrostatic transmission drive the hydraulic motors fitted to each drum. Forward and reverse travel are selected using a forward-reverse lever located to the side of the driver’s seat. In order to comply with safety standards, the machine has a device which only enables starting of the diesel engine when the forward-reverse lever is in the neutral position.
Operation RD 27 4.13 Exciter System See Graphic: wc_gr002309 The machine has exciters on each drum. The exciters are driven by gear-type hydraulic motors. The exciter motors are fed by a fixeddisplacement, gear-type hydraulic pump. The exciters are electrically controlled. A switch (l) on the control console is used to select between no vibration, front drum only vibration, or both drum vibration. When activated, a light (i) on the control panel illuminates.
RD 27 Operation 4.14 Braking System See Graphic: wc_gr002310 The machine’s hydraulic system is the main source of movement and braking. Moving the forward-reverse lever to either the forward or reverse position causes hydraulic oil to flow through the drive motors. Hydraulic oil flow causes the motors to turn and thus the machine to move. When no hydraulic oil flow is delivered to the drive motors, the machine does not move.
Operation RD 27 4.15 Throttle Lever See Graphic: wc_gr002311 The throttle lever has three positions which allow the operator to adjust the speed of the engine and thus the frequency of vibration in the drums. Use the idle position (1), when starting or shutting down the engine. Use the medium position (2), for approximately 55 Hz of vibration. Use the high position (3), for approximately 66 Hz of vibration. Note: Always use the medium or high position when operating the machine. 4.
RD 27 Operation 4.17 Turn Signal Indicator (if equipped) See Graphic: wc_gr0002314 Use the turn signal switch (q) to activate the desired turn signal. The flasher light (r) will illuminate when the turn signal switch is used. r q wc_gr002314 wc_tx000425gb.
Operation RD 27 4.18 Panel Indicator Lights See Graphic: wc_gr002315 Engine oil pressure warning light This warning light (d) illuminates when the key switch is in the ON position; it goes out once the engine has started. CAUTION: If the light remains off with the key switch in the ON position, check the bulb. Replace the bulb before using the machine. If the light illuminates when the engine is running, it indicates that the oil pressure is too low.
RD 27 Operation 4.19 Locking/Unlocking Articulated Steering Joint See Graphic: wc_gr002232 Install the articulated steering joint pin in the LOCKED position (a) before you lift, transport, 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. CAUTION: Attempting to steer the machine with the articulated steering joint pin in the locked position may destroy the steering cylinder and locking mechanism.
Operation RD 27 4.20 Operating on Slopes See Graphic: wc_gr002529 When operating on slopes or hills, special care must be taken to reduce the risk of personal injury or damage to the equipment. Always operate the machine up and down hills rather than from side to side. For safe operation and for protection of the engine, continuous duty use should be restricted to front/rear slopes of 19° (35% grade) or less. NEVER operate machine sideways on slopes. The machine may roll over, even on stable ground.
RD 27 Operation 4.21 Preliminary Checks Before starting the machine, check the following items: • Check the machine for obstructions and remove all obstructions before operating. • Place the articulated steering joint locking pin in the unlocked position. • Remove locks fom vandalism guard and hood. • With the machine on a flat surface, open the hood, place retaining bar in place to hold hood, and check the following items: • Engine coolant level. • Engine oil level. • Hydraulic oil level.
Operation RD 27 4.22 Starting the Engine See graphic: wc_gr002312, wc_gr002311, wc_gr002229, and wc_gr002582 Exhaust gases are toxic. Do not start the engine in enclosed spaces. WARNING 4.22.1 Sit down in the operator’s seat and fasten seat belt. 4.22.2 Move forward-reverse (f) lever to neutral position. 4.22.3 Push parking brake knob (h) downward to engage parking brake. 4.22.4 Move throttle to the LOW position (1). 4.22.5 Insert the ignition key into the ignition switch in “Position 0”. 4.22.
RD 27 wc_tx000425gb.
Operation RD 27 4.23 Stopping the Engine See graphic: wc_gr002312, wc_gr002311, wc_gr002229, and wc_gr002582 When you finish using the machine: 4.23.1 Stop the machine on a flat surface with a suitable load bearing capacity. 4.23.2 Move the forward-reverse (f) lever to the neutral position. 4.23.3 Move the throttle lever to the low position (1). CAUTION: Never stop the engine suddenly after a lengthy period of running under heavy loading.
RD 27 5. Maintenance Maintenance 5.1 Maintenance Schedule Daily or every 10 hours Check level of engine oil. Check level of hydraulic fluid. Check and clean spray system. Check and clean scrapers. Check fuel level. Check engine coolant level. Check air cleaner; replace filters as needed. Clean sediment cup on engine fuel system. Test back-up alarm. Test neutral switch. Inspect seat belt. Every 50 hours Drain fuel system water separator. Check battery.
Maintenance RD 27 Daily or every 10 hours Every 50 hours Every 250 hours Every 500 hrs. Every 1000 hrs. Inspect engine: mounting bolts, valve lash, cylinder head bolts, exhaust system. Clean control lever with compressed air and adjust. Inspect ROPS and torque mounting hardware. 5.2 Recommended Products and Amounts The amounts shown in liters are approximate and are provided as a guide only. To establish an oil level accurately, use the appropriate level plug, dipstick, etc.
RD 27 Maintenance 5.
Maintenance 5.4 RD 27 Battery Before servicing this machine, make sure the engine start switch is in the off “O” position and that the battery is disconnected. Attach a “DO NOT START” sign to the machine. This will notify other personnel that the unit is being serviced and will reduce the chance of someone inadvertently trying to start the unit. WARNING Explosion hazard. Batteries can emit explosive hydrogen gas. Keep all sparks and flames away from the battery. Do not short-circuit battery posts.
RD 27 Maintenance The battery supplied on this machine is constructed to resist vibration and provide long service life. CAUTION DO NOT use automotive-type batteries on this machine. Automotivetype batteries are not designed to withstand the heavy vibration produced by this machine. The case on automotive-type batteries could fail, causing battery acid to leak. Inspect battery periodically. Keep battery terminals clean and connections tight.
Maintenance 5.5 RD 27 Inspecting the ROPS Inspect the rollover protection structure (ROPS) for cracks. Inspect the ROPS for any loose bolts or damaged bolts. Replace the damaged bolts with original equipment parts only. Torque mounting bolts to 240Nm (177 ft.lbs.). Inspect the locking pins for wear or damage. Replace the ROPS if it is damaged. Do not straighten the ROPS or repair the ROPS by welding reinforcement plates to the ROPS. wc_tx000426gb.
RD 27 Maintenance 5.6 Lifting the Machine See Graphic: wc_gr002288 Stop the engine. Refer to Section Stopping the Engine for information. Locking the articulated steering joint (a) Before hoisting the machine, make sure the articulated steering joint is in the LOCKED position. Refer to section Locking/Unlocking Articulated Steering Joint for information. Hoisting Use hoisting ropes or chains with an appropriate amount of load bearing capacity.
Maintenance 5.7 RD 27 Tying Down the Machine See Graphic: wc_gr002287 Lock the articulated steering joint (a). Refer to section Locking/ Unlocking Articulated Steering Joint for information. Secure the machine by attaching steel ropes or chains to the tie down eyes (b). 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.
RD 27 5.8 Maintenance Engine Oil See Graphic: wc_gr002217 Engine oil level Stop the machine, apply the parking brake, and switch off the engine. Check the oil level with the machine standing on a level surface. 5.8.1 Clean around the dipstick. 5.8.2 Extract the dipstick (a) and check the oil level. The oil level should be between the two notches on the dipstick. Add oil through oil filler cap (b) if needed so that the oil reaches the maximum level mark.
Maintenance RD 27 CAUTION: Always use the correct oil type. Do not use oil brands or grades which are not recommended. 5.8.11 Start and run the engine for a few minutes. Check the oil pressure and the filter seal. 5.8.12 Stop the engine and make the following checks: • Check the oil level and top up if necessary. • Check the new filter for leaks. b c d wc_tx000426gb.
RD 27 5.9 Maintenance Testing Backup Alarm The backup alarm is located at the rear of the machine. wc_tx000426gb.fm 5.9.1 Engage the parking brake. 5.9.2 Start the engine. 5.9.3 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 or FORWARD position. 5.9.4 If the backup alarm does not sound, make the necessary repairs.
Maintenance RD 27 5.10 Engine Air Filter See Graphic: wc_gr002225 WARNING NEVER use gasoline or other types of low flash point solvents for cleaning the air filter. A fire or explosion could result. CAUTION: NEVER run engine without the air cleaner elements. Severe engine damage will occur. Filter Indicator The air intake system is equipped with a filter indicator (a), which indicates when a filter change is required.
RD 27 Maintenance CAUTION: Do not re-use damaged filters. Replace damaged filters even though the damage may be very slight. 5.10.15 Reassemble cover (b) and reset the filter indicator (a). Replace secondary filter element. 5.10.16 Remove cover (b) for the air filter housing. 5.10.17 Remove main filter element (c) from the air filter housing. 5.10.18 Remove the secondary filter element. 5.10.19 Cover the intake port (d) and clean inside of the air filter housing.
Maintenance RD 27 5.11 Fuel System Water Separator See Graphic: wc_gr002218 Drain fuel system water separator (f) 5.11.1 Open the engine hood. 5.11.2 Attach a rubber drain tube to the valve (e). 5.11.3 Turn valve (e) counterclockwise in order to open the valve. 5.11.4 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. 5.11.5 Close valve (e). 5.11.6 Remove the rubber drain tube.
RD 27 Maintenance a b c d f e wc_gr002218 wc_tx000426gb.
Maintenance RD 27 5.12 Hydraulic Oil See Graphic: wc_gr002219 Hydraulic oil level 5.12.1 Stop the machine, apply the parking brake and switch off the engine. 5.12.2 Check the level in the sight gauge (a) on the left side of the tank. Check the oil level with the machine standing on a level surface. Maintain the oil level to the mark on the sight gauge. 5.12.3 If the level is low, top up through the filler (c).
RD 27 Maintenance 5.12.19 Install hydraulic tank filler cap (c). Hydraulic oil filter change 5.12.20 Stop the machine, apply the parking brake and switch off the engine. 5.12.21 Open the engine hood. 5.12.22 Unscrew the old filter cartridge (f) keeping a plastic bag over the cartridge to contain any oil loss. 5.12.23 Oil the seal of the new filter. 5.12.24 Install the new filter and tighten by hand. When the seal contacts the base, tighten the filter an additional 3/4 turn. 5.12.
Maintenance RD 27 5.13 Engine Cooling System See Graphic: wc_gr002226 Danger of burns. Only clean the engine cooling system when the engine is cold. WARNING 5.13.1 Stop the machine, apply the parking brake and switch off the engine. Allow the cooling system to cool completely. 5.13.2 Open the engine hood. 5.13.3 Slowly loosen the cooling system pressure cap in order to relieve system pressure. Remove cap (a). 5.13.4 Remove the lower hose that is connected to the radiator.
RD 27 Maintenance a b wc_gr002226 5.14 Cleaning Radiator Core See graphic: wc_gr002578 5.14.1 Stop the machine, apply the parking brake, switch off the engine, and disconnect the battery. 5.14.2 While wearing gloves, remove large pieces of debris by hand. 5.14.3 Use compressed air to remove smaller debris and dust from radiator fins. Note: High-pressure water is not recommended. High-pressure water may bend the radiator fins. wc_gr002578 wc_tx000426gb.
Maintenance RD 27 5.15 Sprinkler Efficiency See Graphic: wc_gr002220 Clean water spray nozzles 5.15.1 Remove cap (c). Remove spray nozzle (d). Remove screen (e). 5.15.2 Wash nozzle (d) and screen (e) in a clean, nonflammable solvent. Note: Use only Wacker nozzles. Using other nozzles may modify spray pattern and endurance. 5.15.3 Install screen (e) and nozzle (d). Note: Use only Wacker nozzles. Using other nozzles may modify spray pattern and endurance. 5.15.4 Install cap (c).
RD 27 Maintenance 5.15.22 Install the filler cap (l). c a e d f b g g h j l k wc_gr002220 wc_tx000426gb.
Maintenance RD 27 5.16 Inspecting and Adjusting Belts See Graphic: wc_gr002583 The machine is equipped with a belt that operates the fan, the alternator, and the water pump. It is also equipped with a second belt that operates the vibratory pump. For maximum engine performance and maximum utilization of the engine, inspect the belts for wear and cracking. Check the tension of the belts. Adjust the tension of the belts in order to minimize belt slippage. Belt slippage will decrease the belt life.
RD 27 Maintenance c f e b d a wc_gr002583 wc_tx000426gb.
Maintenance RD 27 5.17 Fuses See Graphic: wc_gr002291 The fuses protect the electrical system from damage due to overloaded circuits. If a fuse blows, replace it. If a newly replaced fuse blows, check the circuit and repair the problem before you operate the machine. The fuse compartment is located on the right side of the control console. To access the compartment, remove the four screws and the compartment cover.
RD 27 Maintenance 5.18 Shockmounts CAUTION: Fuel and hydraulic oils deteriorate the rubber of the shockmounts. The engine compartment should therefore be thoroughly cleaned at regular intervals. CAUTION: Shockmounts are not designed to absorb drops of over 8 cm (3 in.). Should it be necessary to replace one or more of the shockmounts, it is recommended to change all the other shockmounts at the same time. Engine shockmounts 5.18.
Maintenance RD 27 5.19 Scraper Wear See Graphic: wc_gr002566 5.19.1 Stop the machine, apply the parking brake, and switch off the engine. 5.19.2 Remove dirt and debris from scrapers. 5.19.3 Check the wear of the scraper (a). The scrapers should be adjusted vertical to the ground and to touch the width of the drums. The inner scrapers can be adjusted with the adjustable spring mounts which are located inside the front and rear frames.
RD 27 Maintenance 5.20 Lubricating Articulated Steering Joint See Graphic: wc_gr002223 Stop the machine, apply the parking brake, and switch off the engine. 5.20.1 Lock the articulated steering joint before servicing. See section Locking/Unlocking Articulated Steering Joint. 5.20.2 Clean all fittings before servicing. 5.20.3 Clean all caps before servicing. 5.20.4 Lubricate the fittings (c) for the articulation bearing. Note: Use a small amount of grease (see section Lubrication).
Maintenance RD 27 5.21 Lubricating Steering Cylinder See Graphic: wc_gr002576 Stop the machine, apply the parking brake and switch off the engine. 5.21.1 Lock the articulated joint before servicing. See section Locking/ Unlocking Articulated Joint. 5.21.2 The steering cylinder is located in the pivot area of the machine. It is on the right side of the engine compartment. Lubricate the steering cylinder via fittings (a & b). See Tech Data for type and amount of grease.
RD 27 Maintenance 5.22 Lubricating Throttle Control See Graphic: wc_gr002577 5.22.1 Stop the machine, apply the parking brake, switch off the engine, and disconnect the battery. 5.22.2 Clean the throttle control linkage (a) with a clean rag. 5.22.3 Lubricate the throttle control linkage with engine oil. a wc_gr002577 wc_tx000426gb.
Maintenance RD 27 5.23 General Cleaning Stop the machine, apply the parking brake and switch off the engine. Remove the ignition key and close the protective cover over the key switch. Protect the following parts with covers and adhesive tape: • Engine cooling louvers. • Exhaust pipe. • Dashboard. • Forward-reverse lever. • Backup alarm. Clean the roller thoroughly with high-pressure water jet and a strong brush. Remove all dirt, mud, and tar from the drums and bodywork.
RD 27 Maintenance 5.24 Cleaning the Fuel Tank See Graphic: wc_gr002227 Danger of explosion. Diesel fuel is flammable and must be treated with the necessary caution. Do not smoke when handling fuel. Also, avoid sparks and open flames when handling fuel. WARNING Stop the machine, apply the parking brake, and switch off the engine. The machine should be level. Clean fuel tank cap and strainer 5.24.1 Open engine hood. 5.24.2 Remove fuel tank cap (a). 5.24.
Maintenance RD 27 5.25 Towing See Graphic: wc_gr002581 Improper hookup and towing is dangerous and could result in injury or death to yourself or others. The towing connection must be rigid, or towing must be done by two WARNING machines of the same size or larger than the towed machine. Connect a machine on each end of the towed machine. Be sure that all necessary repairs and adjustments have been made before a machine that has been towed to a service area, is put back into operation.
RD 27 Maintenance All situation requirements cannot be listed. Minimal towing machine capacity is required on smooth, level surfaces. On inclines in poor condition or on surfaces in poor condition, maximum towing capacity is required. Attach the towing device and machine before you release the brakes. If the engine is running: The machine can be towed for a short distance under certain conditions. The power train and steering system must be operable.
Maintenance RD 27 5.25.11 Detach the tow lines. a b c wc_gr002581 wc_tx000426gb.
RD 27 Maintenance 5.26 Manually Releasing Parking Brakes See Graphic: wc_gr002290 There are two drive motors on the roller—one on each drum. Each drive motor includes a parking brake that is spring activated and hydraulically released (SAHR). To manually release the brakes: Note: Carry out procedure on both drums. 5.26.1 Chock each drum to prevent the machine from moving. 5.26.2 Lock the articulated steering joint. 5.26.3 Remove the plugs (a) in order to access the release screws. 5.26.
Maintenance RD 27 5.27 Exhaust System and Engine Air Intake System WARNING Danger of burns. Only check the exhaust system when the engine is cold. • Open the engine hood. • Check the exhaust pipes for leaks and holes. • Check the seal of the exhaust system gaskets for leaks. • Check the tightness of all retaining bolts. • Check that the air intake manifold does not leak. 5.
RD 27 Maintenance 1 2 3 4 5 6 7 8 9 10 11 12 PLUG PLUG 307-OR-16 308-YL-16 PLUG 403-GN-16 405-GY-16 406-PU-16 777-PU-16 A990-BU-16 C924-YL-16 PLUG TO SHEET 2 1 TO SHEET 2 384-BU-8 101-RD-6 304-WH-10 109-RD-6 TO SHEET 2 5.
RD 27 Maintenance TO SHEET 3 Electrical Schematics Sheet 2 of 3 VIB SWITCH 110-GN-16 121-YL-16 125-OR-16 200-BK-16 201-BK-16 306-GN-16 307-OR-16 308-YL-16 310-PU-16 322-GY-16 374-PK-16 403-GN-16 404-YL-16 405-GY-16 406-PU-16 PLUG 469-GN-16 PLUG 605-YL-16 606-GY-16 614-PU-16 619-GN-16 681-OR-16 777-PU-16 G736-PK-16 G797-BU-16 A893-OR-16 A990-BU-16 A990-BU-16 C906-PU-16 C922-BR-16 C924-YL-16 C927-PU-16 200-BK-16 PLUG PLUG PLUG PLUG PLUG PLUG PLUG 112-PU-6 109-RD-10 102-RD-12 1 2 3 4 5 6 7 8 9 10 11 12
RD 27 Maintenance 4 3 2 405-GY-16 123-WH-16 403-GN-16 404-YL-16 1 LIGHT SWITCH 102-RD-12 6 Electrical Schematics Sheet 3 of 3 BRAKE SWITCH X1 1 2 3 4 419-YL-16 F765-BR-16 X2 110-GN-16 HYD TEMP 419-YL-16 200-BK-16 110-GN-16 ALT 123-WH-16 SIG 322-GY-16 - 200-BK-16 F427-PK-16 200-BK-16 A990-BU-16 6 + 200-BK-16 A541-PU-16 4 5 605-YL-16 3 SWITCH-HORN ENG TEMP ENG OIL PRESS KEY SWITCH 308-YL-16 PLUG 330-YL-16 105-RD-16 310-PU-16 PLUG 406-PU-16 HOURMETER 1 2 606-GY-16 60
RD 27 Maintenance L -6 -6 FRONT MOTOR VIB. 8.4 cc R 5.30 Hydraulic Schematic Sheet 1 of 1 REAR MOTOR VIB. 8.4 cc -4 -4 -8 -6 -8 -8 VIBRATION VALVE A -8 -8 B -8 -8 -8 C D DRUM VIB. SOLENOID 1 3B -6 3A STEER CYLINDER P -6 -6 2A 250 BARS T -8 P -8 -6 -6 SEAT SWITCH ATTACHMENT 150 BARS M STEER CONTROL UNIT 100 cc 130 BARS 100 BARS 2B VIB. ON/OFF SOLENOID T OIL COOLER -8 CHARGE FILTER -8 -12 -16 3.5 BARS SEAT SWITCH SOLENOID CF STEER/CHARGE PUMP 8.
KE40246P2 6/9/05 3:16 PM Page i SAFETY ALERT SYMBOL This Safety Alert Symbol means ATTENTION is involved! Why is SAFETY important to YOU? The Safety Alert Symbol identifies important safety messages on machines, safety signs, in manuals, or elsewhere.When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message.
WORD OF EXPLANATION................................................................................ 2 FOREWORD.......................................................................................................... 4 A WORD TO THE USER ...................................................................................... 5 FOLLOW A SAFETY PROGRAM ...................................................................... 6 PREPARE FOR SAFE OPERATION......................................................
WORD OF EXPLANATION This Safety Manual covers many different types of roller compactors … including steel wheel rollers, vibratory rollers, rubber-tired rollers, segmented pad/sheepsfoot soil compactors and landfill compactors.These may be either self-propelled ride-on, walk-behind or towed rollers.They may be used for the compaction of asphalt, soil, landfill or other materials. Excluded from coverage are vibratory plates and hand rammers.
A WORD TO THE USER It is your responsibility to read and understand this safety manual and the manufacturer's manual(s) before operating your machine.This safety manual takes you step-by-step through your working day. Remember that YOU are the key to safety. Good safety practices not only protect you but also protect the people around you. Study this manual and the manufacturer's manual(s) for your specific machine. Make them a working part of your safety program.
FOLLOW A SAFETY PROGRAM KNOW WHAT IT IS? Consult your supervisor for specific instructions on a job, and the personal safety equipment required. For instance, you may need: • Hard Hat • Safety Shoes • Eye Protection • Face Protection • Heavy Gloves • Reflector Vests • Hearing Protection • Respirators Do not wear loose clothing or any accessory — flopping cuffs, untied shoelaces, dangling neckties and scarves, rings, wrist watches, or other jewelry — that can catch on protruding or moving parts or controls.
PREPARE FOR SAFE OPERATION LEARN TO BE SAFE READ the operator’s manual. If one has not been provided, GET ONE AND STUDY IT BEFORE OPERATING THE MACHINE. If you have any questions contact the manufacturer. Know the positions and understand the functions of all controls before attempting to operate a machine. Know the meaning of all identification symbols on your controls and gauges. (FIG. 5) Know the location of the emergency shut-down control if the machine is so equipped.
PREPARE FOR SAFE OPERATION FIRE PREVENTION Never allow flammable fluids or materials to contact hot surfaces. Because ether or other starting fluids are flammable, do not smoke when using them. Always follow the instructions on the container and in the operator’s manual for your machine. (See page 19.) Never refuel: • When engine is running • While smoking • Near open flames or sparks • In poorly ventilated area Batteries produce explosive gases. Keep open flame or sparks away.
PREPARE FOR SAFE OPERATION Before starting, carefully inspect your machine for any evidence of physical damage such as cracking, bending or deformation of plates or welds. Check for cracking or flaking of paint, which may indicate an excessive strain or dangerous crack in the material below. Check for loose, broken or missing parts such as Roll-Over Protective Structure (ROPS) support brackets, vibration isolators, and nuts and bolts.
START SAFELY Walk around your machine once more just prior to mounting it – checking for people and objects that might be in the way – then MOUNT PROPERLY USING STEPS AND HANDHOLDS PROVIDED. Always use seat belts if your machine is equipped with a ROPS. Just before starting, check all controls … such as forward and reverse, steering, transmission and throttle to be sure they are in the correct start-up position. (FIG. 13) The parking brake should be applied during the start-up operation.
START SAFELY COLD WEATHER OPERATION BOOSTER CABLE INSTRUCTIONS Consult the engine manufacturer’s operation manual for proper cold weather starting procedure. 1. Connect positive (+) cable to positive post of discharged battery. When using cold weather starting aids, be sure to follow the engine manufacturer’s instructions. (FIG. 16) 2. Connect other end of same cable to same marked post of booster battery. After starting, operate all systems slowly and gently until properly warmed up. 3.
WORK SAFELY For maximum safety on machines with more than one operator’s position, operate from the position giving the greatest visibility of potential hazards. NEVER allow unqualified or unauthorized personnel to operate your machine. NEVER allow other personnel to ride on your machine unless appropriate seating is provided … and then only if authorized to do so. NEVER abuse your machine. Misuse or abuse can cause an accident.
WORK SAFELY Avoid operating your machine too close to an overhang, deep ditch or hole. If your machine inadvertently gets close to a tipping condition or drop-off, STOP and get off the machine after applying the parking brake … plan your moves carefully before proceeding. Reversal is often the best move. Be alert to potential caving edges, falling rocks and slides. Check for overhead obstacles that could be dangerous. LOOK UP AS WELL AS DOWN. (FIG. 21) Be alert to obstacles and excessively rough terrain.
PARK AND SHUT DOWN SAFELY PARK SAFELY Park in an off the road area, out of traffic, or as instructed. If necessary to park in a traffic lane, use the appropriate flags, barriers, flares, lights and warning signals. Provide advance warning signals in the traffic lane to warn approaching traffic. Park on level ground whenever possible. (FIG. 25) When not possible, position the machine at right KE40246P2 6/9/05 3:17 PM angles to the slope.
LOAD AND UNLOAD MACHINE SAFELY Loading and unloading machines always involves potential hazards. EXTREME CAUTION SHOULD BE USED. Know the correct loading and unloading procedures for your machine. All machines are not loaded and unloaded the same way.The procedures recommended by the manufacturer should always be followed. • The ramp surface must provide adequate traction. Be sure the surface is clean and free of grease, oil, ice, and loose material.
TRANSPORTING SAFELY TOWING ALWAYS use EXTRA care when towing a trailer or machine… when maneuvering in tight places, when backing (visibility is reduced, and jackknifing must be avoided), and when towing on steep grades. Know and obey all local, state and federal laws and regulations. NEVER travel at speeds above those recommended by the manufacturer. KE40246P3 6/9/05 3:19 PM NEVER allow anyone to ride on a trailer or towed machine. (FIG.
PERFORM MAINTENANCE SAFELY CLOTHING AND PERSONAL PROTECTIVE ITEMS machinery. (FIG. 31) Heavy gloves should be worn for many operations. Keep hands and clothing well away from engine fan and moving parts while engine is running. EXHAUST FUMES ALWAYS wear appropriate safety glasses, goggles or face shield when working. (FIG.
PERFORM MAINTENANCE SAFELY Before beginning welding or burning operations, drain fuel lines and tank and move all flammable material to a safe distance, and be certain a fire extinguisher is readily available.When welding fuel tanks, either gasoline OR diesel, ALWAYS drain the tank, fill with water, and leave cap off during the welding operation.
PERFORM MAINTENANCE SAFELY FIRE PREVENTION CHECKLIST (FIG. 36) • Remove debris such as rags, coal dust, oil, leaves, pine needles. • Check and repair fuel and hydraulic leaks. • Check and repair damaged wiring. • Prevent hose and electrical wire harness abrasion. • Tighten loose clamps and fittings. • Secure loose wiring. • Make sure guards and protective covers are in place. • Make sure fire extinguisher is available and operable.
PERFORM MAINTENANCE SAFELY SERVICING COOLING SYSTEM When checking coolant level: • Stop the engine and let the engine and radiator cool before checking. (FIG. 38) If an overheated engine requires a shutdown: • Wait for the radiator to cool. The hot pressurized coolant can cause burn injuries. Never add coolant to an overheated system. • Overheating is a symptom of trouble. Stop the engine and have the trouble corrected before serious damage occurs.
PERFORM MAINTENANCE SAFELY BATTERY SERVICING To prevent a battery explosion: (Fig. 40) • Maintain the electrolyte at the recommended level. Check level frequently. Add distilled water to batteries only before starting up, never when shutting down.With electrolyte at the proper level, less space is available for gases to accumulate in the battery. • Use a flashlight to check the electrolyte level. Never use a flame. (Fig. 41) • Do not short across the battery terminals. The spark could ignite the gases.
PERFORM MAINTENANCE SAFELY HYDRAULIC SYSTEMS (CONT’D) If you are struck by escaping hydraulic fluid under pressure, serious injury can occur if proper medical treatment is not administered immediately. During operation, hydraulic fluid and air in an unvented hydraulic tank becomes heated and will tend to expand.This will raise the pressure inside an unvented hydraulic tank. If the filler cap is removed rapidly, the pressure in the tank can force the oil out of the tank very rapidly.
PERFORM MAINTENANCE SAFELY TIRE PRESSURE Check tire pressure before starting operation. An air pressure rise during operation is normal and should NOT be reduced. Overloads or overspeeds may produce increased tire pressures due to heat. Never bleed tires. Reduce your load – or speed – or stop until tires cool. ADD AIR From a distance – with air chuck clipped on the tire valve – and with extension hose that permits you to stand behind tread. (FIG. 45) Always use a tire cage or equivalent for protection.
SPECIAL OPERATING AND MAINTENANCE PRECAUTIONS PARKING AND TRANSPORTING ALWAYS select a level area to park in and, if possible, one where children are unlikely to be present. ALWAYS chock the front AND rear of the roller … even if leaving the machine unattended for short periods. ALWAYS use EXTRA care when towing a roller … when maneuvering in tight places, when backing (visibility is reduced, and jackknifing must be avoided), and when operating on grades.
SPECIAL OPERATING AND MAINTENANCE PRECAUTIONS FOR LANDFILL COMPACTORS General Operators of landfill compactors should carefully handle fill materials that could be picked up and thrown by the wheels, become lodged in the machine, or that are highly flammable. Frequent checks should be made for wire, cable or other material wound around the axle members. Remove them immediately. Travel with the blade as low as possible.
TEST YOUR KNOWLEDGE Do you understand this AEM SAFETY MANUAL AND ITEMS SUCH AS … • Proper operating procedures? • Proper parking, shutdown, and dismounting • Your safety program? • Your machine manufacturer’s manual(s)? • Proper clothing and personal safety equipment? • Your machine’s controls, warning signs and devices, • Proper maintenance procedures? • Proper loading and unloading procedures for and safety equipment? • How to properly inspect, mount, and start your machine? • How to check your machin
KE40246P1 6/9/05 3:14 PM Page 1
EC DECLARATION OF CONFORMITY CE-KONFORMITÄTSERKLÄRUNG DECLARACIÓN DE CONFORMIDAD DE LA CE DÉCLARATION DE CONFORMITÉ C.E.
Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90 Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957 Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel.
