en Roller RD 27 REPAIR MANUAL

Transcription

1 en Roller RD 27 REPAIR MANUAL E N

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3 Foreword This manual covers machines with Item Number: , , , Operating / Parts Information You must be familiar with the operation of this machine before you attempt to troubleshoot or make any repairs to it. Basic operating and maintenance procedures are described in the Operator s Manual supplied with the machine. Keep a copy of it with the machine at all times. Use the separate Parts Book supplied with the machine to order replacement parts. If either of the documents becomes lost, please contact Wacker Corporation to order a replacement. Damage caused by misuse or neglect of the unit should be brought to the attention of the operator, to prevent similar occurrences from happening in the future. This manual provides information and procedures to safely repair and maintain the above Wacker model(s). For your own safety and protection from injury, carefully read, understand, and observe all instructions described in this manual. THE INFORMATION CONTAINED IN THIS MANUAL IS BASED ON MACHINES MANUFACTURED UP TO THE TIME OF PUBLICATION. WACKER CORPORATION RESERVES THE RIGHT TO CHANGE ANY PORTION OF THIS INFORMATION WITHOUT NOTICE. wc_tx000458gb.fm i

4 Foreword WARNING 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 to cause cancer and birth defects or other reproductive harm. Laws Pertaining to Spark Arresters Notice: State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust. Spark arresters are qualified and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator. All rights, especially copying and distribution rights, are reserved. Copyright 2005 by Wacker Corporation. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission from Wacker Corporation. Any type of reproduction or distribution not authorized by Wacker Corporation represents an infringement of valid copyrights and will be prosecuted. We expressly reserve the right to make technical modifications, even without due notice, which aim at improving our machines or their safety standards. wc_tx000458gb.fm ii

5 RD 27 Repair Table of Contents 1. Safety Information Operating Safety Operator Safety while using Internal Combustion Engines Service Safety Label Locations Warning & Informational Labels Technical Data Engine Roller Lubrication Sound Measurements Measurements of Operator Exposure to Vibration Dimensions Maintenance Maintenance Schedule Recommended Products and Amounts Oil/Temperature Table Battery Inspecting the ROPS Lifting the Machine Tying Down the Machine Engine Oil Testing Backup Alarm Engine Air Filter Fuel System Water Separator Hydraulic Oil Engine Cooling System Cleaning Radiator Core Sprinkler Efficiency Inspecting and Adjusting Belts Fuses Shockmounts Scraper Wear Lubricating Articulated Steering Joint wc_br en_000toc.fm 1

6 Table of Contents RD 27 Repair 3.21 Lubricating Steering Cylinder Lubricating Throttle Control General Cleaning Cleaning the Fuel Tank Towing Manually Releasing Parking Brakes Exhaust System and Engine Air Intake System Storage Electrical Schematics Hydraulic Schematic Engine Starting Troubleshooting Starting System Component Locations Troubleshooting Flowcharts Engine Does Not Crank Checking Power at Starter Motor Solenoid Checking Neutral/Brake Fuse Checking Power to/from Starter Relay Checking Power to/from Starter Relay Checking Key Switch Checking Power to/from Neutral Switch Relay Checking Neutral Switch Checking Fuses Checking 60A Circuit Breaker Checking Power to/from Main Power Relay Engine Cranks but does not Start Checking Fuel Flow Checking Power to Fuel Shutoff Solenoid Checking Power to/from Glow Plug Relay Checking Glow Plugs Drive System Electricals Drive System Electrical Overview Drive System Component Locations Troubleshooting Flowcharts Machine does not Drive (Propel) Troubleshooting Checking Neutral/Brake Solenoid...95 wc_br en_000toc.fm 2

7 RD 27 Repair Table of Contents 5.6 Checking Seat Switch Solenoid Checking Power to Brake Switch Checking Power to/from Brake 1 Relay Checking Power to/from Interlock 1 Relay Checking Function of Seat Switch Vibration System Electrics Vibration System Electrical Overview Vibration System Electrical Component Locations Checking the Vibration System Fuse Checking Power to the Vibration Solenoids Checking Drum Selector Switch Spray System Electrics Spray System Electrical Overview Spray System Troubleshooting Checking the Spray System Fuse Checking the Spray System Switch Checking Power to/from Spray System Relay Checking Power to the Spray System Pump Hydraulic Cooler Fan Motor System Checking Fan Motor Operation Hydraulic System Basics Hydraulic System Precautions Hydraulic System Service Basics Relieving Pressure in Hydraulic Tank Component Locations Analyzing Hydraulic Oil Contamination wc_br en_000toc.fm 3

8 Table of Contents RD 27 Repair 10. Drive System Hydraulics Drive System Hydraulic Overview Drive System Hydraulic Diagram Troubleshooting Drive System Checking/Adjusting Charge Pressure Checking Main Relief Valve Checking and Adjusting Drive Pump Neutral Setting Testing the Parking Brake Testing Motor Case Drain Flow Vibration System Hydraulics Vibration System Overview Vibration System Hydraulic Diagram Vibration System Electrical Diagram Troubleshooting Vibration System Testing Vibration Pump Flow Testing and Adjusting Vibration Valve Main Relief Testing and Adjusting Vibration Valve Intercircuit Relief Testing and Adjusting Vibration Valve Anti-Lope Relief Testing Vibration Motor Case Drain Flow Testing Vibration Frequency Steering System Hydraulics Steering System Overview Steering System Hydraulic Diagram Steering System Troubleshooting Testing Steering Pump Flow Testing Steering Unit Relief Valve Checking Steering Time Disassembly/Reassembly Procedures Tools Ordering Parts Reference Numbers ( ) wc_br en_000toc.fm 4

9 RD 27 Repair Table of Contents 13.4 Weight Block Removing and Installing Steering Servo Valve Removing and Installing Drive Motors Removing and Installing Exciter Motor Removing Drum Disassembling Drum Exciter Shaft Bearings Drum Shock Mounts Reassembling Drum Remounting Drum Removing and Installing Fuel Tank Removing and Installing Radiator Removing and Installing Vibration Pump Belts Removing and Installing Steering Cylinder Removing and Installing Articulated Steering Joint Articulated Steering Joint Exploded View Articulated Steering Joint Components Rebuilding Articulated Steering Joint Removing and Installing Spray System Water Pump Removing and Installing Water Tank Removing and Installing Hydraulic Oil Cooler Removing and Installing Drive Pump Removing Engine Installing the Engine Removing and Installing the Hydraulic Oil Tank Removing and Installing Vibration Pump Removing and Installing Steering Pump wc_br en_000toc.fm 5

10 Table of Contents RD 27 Repair wc_br en_000toc.fm 6

11 RD 27 1.Safety Information 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 DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. CAUTION: Used without the safety alert symbol, CAUTION indicates a potentially hazardous situation which, if not avoided, may result in property damage. Note: Contains additional information important to a procedure. wc_si000147gb.fm 7

12 Safety Information RD Operating Safety 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. Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate the machine ALWAYS wear protective clothing appropriate to the job site when operating equipment ALWAYS remain aware of moving parts and keep hands, feet, and loose clothing away from moving parts of equipment ALWAYS read, understand, and follow procedures in Operator's Manual before attempting to operate equipment ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children ALWAYS check that all controls are functioning properly immediately after start-up! DO NOT operate machine unless all controls operate correctly ALWAYS operate machine with all safety devices and guards in place and in working order ALWAYS remain aware of changing positions and movement of other equipment and personnel on the job site ALWAYS remain aware of changing surface conditions and use extra care when operating over uneven ground, on hills, or over soft or coarse material. The machine could shift or slide unexpectedly ALWAYS use caution when operating near the edges of pits, trenches or platforms. Check to be sure ground surface is stable enough to support the weight of the machine and there is no danger of the machine sliding, falling or tipping ALWAYS be sure that all other persons are at a safe distance from the machine. Stop the machine if people step into the working area of the machine ALWAYS disengage and stow locking bar for the articulated steering joint before operating machine. The machine cannot be steered when the locking bar is engaged DO NOT attempt to start the machine when standing alongside it. Only start the engine when seated in the driver's seat and with the forwardreverse lever in the neutral position. WARNING wc_si000147gb.fm 8

13 RD 27 Safety Information 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 NEVER carry passengers. Danger of crushing keep clear of the articulated steering joint between the front and rear frames NEVER use or attempt to repair damaged safety belts or ROPS. Replace only with Wacker spare parts NEVER touch the engine or muffler while the engine is on or immediately after it has been turned off. These areas get hot and may cause burns NEVER use accessories or attachments that are not recommended by Wacker. Damage to equipment and injury to the user may result NEVER leave machine running unattended NEVER start a defective unit in need of service or repair. 1.2 Operator Safety while using Internal Combustion Engines Internal combustion engines present special hazards during operation and fueling! Read and follow warning instructions in engine owner's manual and safety guidelines below. Failure to follow warnings and DANGER safety guidelines could result in severe injury or death DO NOT run machine indoors or in an enclosed area such as a deep trench unless adequate ventilation, through such items as exhaust fans or hoses, is provided. Exhaust gas from the engine contains poisonous carbon monoxide gas; exposure to carbon monoxide can cause loss of consciousness and may lead to death DO NOT smoke while operating machine DO NOT smoke when refueling engine DO NOT refuel hot or running engine DO NOT refuel engine near open flame DO NOT spill fuel when refueling engine DO NOT run engine near open flames ALWAYS refill fuel tank in well-ventilated area ALWAYS replace fuel tank cap after refueling ALWAYS check fuel lines and fuel tank for leaks and cracks before starting engine. Do not run machine if fuel leaks are present or fuel lines are loose ALWAYS keep area around hot exhaust pipes free of debris to reduce the chance of an accidental fire DO NOT remove radiator cap when engine is hot. Contents are hot and under pressure. wc_si000147gb.fm 9

14 Safety Information RD 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 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 DO NOT stand under the machine while it is being hoisted or moved DO NOT get onto the machine while it is being hoisted or moved DO NOT use the machine as a ladder. Use safe ladders and platforms designed for this purpose DO NOT modify, weld or drill safety frames (ROPS) fitted as original equipment. DO NOT loosen or remove bolts. DO NOT weld, drill or modify a broken safety frame DO NOT attempt to open the radiator cap while the unit is running or before the engine has cooled down. Severe burns may result! DO NOT modify the equipment without express written approval of the manufacturer DO NOT attempt to clean or service machine while it is running. Rotating parts can cause severe injury DO NOT use gasoline or other types of fuels or flammable solvents to clean parts, especially in enclosed areas. Fumes from fuels and solvents can become explosive ALWAYS keep area around muffler free of debris such as leaves, paper, cartons, etc. A hot muffler could ignite them, starting a fire ALWAYS replace worn or damaged components with spare parts designed and recommended by Wacker ALWAYS keep machine clean and labels legible. Replace all missing and hard-to-read labels. Labels provide important operating instructions and warn of dangers and hazards ALWAYS check and tighten all external fasteners at regular intervals ALWAYS turn engine off before performing maintenance or making repairs 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 ALWAYS keep hands, feet and loose clothing away from moving parts. wc_si000147gb.fm 10

15 RD 27 Safety Information ALWAYS make sure slings, chains, hooks, ramps, jacks and other types of lifting devices are attached securely and have enough weightbearing capacity to lift or hold the machine safely. Always remain aware of the position of other people around you when lifting the machine Before you start the machine, ensure that all tools have been removed from the machine and that replacement parts and adjusters are firmly tightened Do not open hydraulic lines or loosen hydraulic connections while engine is running! Before dismantling hydraulic connectors or hoses, ensure that all pressure has been bled from the circuit. Hydraulic fluid under pressure can penetrate the skin, cause burns, blind, or create other potentially dangerous hazards. Set all controls in neutral and turn engine off before loosening hydraulic fittings or attaching test gauges Fluid leaks from small holes are often practically invisible. DO NOT use your bare hands to check for leaks. Check for leaks using a piece of cardboard or wood. wc_si000147gb.fm 11

16 Safety Information RD Label Locations H M L R U P N C N K N S N V A Q B G G J I O F E, T D D G wc_gr wc_si000147gb.fm 12

17 RD Warning & Informational Labels Safety Information Ref. Label Meaning A 2-4 ) ) 7 ) * , ) ) ) ) 7 ) + ) * - 4, - 4 -, / 0 ; ) 9 ) + - 4, * 7 6 4, 1- * * ), - 4 ) ) 7 * - 9 ) , * / ) 6 * , * ) ) , ) 7 ), ) + 1, - * , - ) ) ) + 6 ) ) 5 7, * 7 1, 4 9 ) ) ) 2 ) 4 ) 2 -, ) 4 ), 1+ 1 ) ) , - 2 1, ) ) ) , * ) ), : - 2 ) ) 14 - # ' $ Operator's Manual must be stored on machine. Replacement Operator's Manual can be ordered through your local Wacker distributor. B DANGER! Read and understand the supplied Operator's Manuals before operating this machine. Failure to do so increases the risk of injury to yourself and others. D EMPLOI Engines emit carbon monoxide; operate machine in well-ventilated area. To reduce the risk of hearing loss, wear hearing protection when operating this machine. Always wear seat belt when operating roller. Never operate the machine sideways on slopes. C DANGER! Asphyxiation hazard. Read the Operator s Manual for instructions. No sparks, flames, or burning objects near machine. Stop the engine before adding fuel. Use only diesel fuel. D CAUTION! Lifting point. wc_si000147gb.fm 13

18 Safety Information RD 27 Ref. Label Meaning E Model Item Number kg MADE IN ITALY lbs max.kg Rev. kw max.lbs Wacker Corporation Menomonee Falls, WI USA Serial Number hp Manuf. Yr. db(a) A nameplate listing the Model Number, Item Number, Revision, and Serial Number is attached to each unit. Please record the information found on this plate so it will be available should the nameplate become lost or damaged. When ordering parts or requesting service information, you will always be asked to specify the model, item number, revision number, and serial number of the unit. F WARNING! Avoid crushing area. G Tie-down point. H WARNING 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. I HYDRAULIC OIL HYDRAULIKÖL ACEITE HIDRÁULICO HUILE HYDRAULIQUE Hydraulic oil drain. J Hydraulic oil reservoir fill. wc_si000147gb.fm 14

19 RD 27 Safety Information Ref. 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.fm 15

20 Safety Information RD 27 Ref. Label 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 wc_si000147gb.fm 16

21 RD 27 Safety Information Ref. Label Meaning T WARNING UNG WARNING! Avoid crushing area. Articulated steering joint locking location. Lock the articulated steering joint before servicing the machine. Read Repair Manual U Fuse identifications. 15A 10A 10A 10A 10A 10A 10A V 10A 1 10A wc_gr Tighten screw to reduce vibration. Read operator s manual. 2 wc_gr Guaranteed sound power level in db(a). wc_si000147gb.fm 17

22 Technical Data RD Technical Data 2.1 Engine Item No. RD , , , Engine Make Engine Perkins Engine Model 403C-15 Engine Type Liquid-cooled diesel Rated 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 Operating Speeds rpm 2450/3000 Valve Clearance (cold) intake / exhaust mm (in.) 0.2 (0.078) Air Cleaner type Dual element Battery V / rating CCA CA 12 / 100 Amp-hour -17 C (0 F) 0 C (32 F) Engine Oil Capacity l (qts.) 5.7 (6) Fuel type Clean, filtered diesel Fuel Tank Capacity l (gal.) 46.5 (12.3) Fuel 2450 rpm l (gal.)/hr. 7.1 (1.9)/7.7 (2.0) /3000 rpm Coolant Capacity l (gal.) 6.7 (1.8) wc_td000148gb.fm 18

23 RD Roller Technical Data Item No. RD , Overall Dimensions mm (in.) Roller 2428 x 1300 x 2775 (95.6 x 51.2 x 109.3) RD , x 1100 x 2775 (95.6 x 43.3 x 109.3) Operating Weight 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) Forward/Reverse Speed km/hr (mph) 2450 rpm 3000 rpm (0 5.0) (0 6.2) Vibration Frequency Hz (vpm) 55 or 66 (3300 or 3960) (0 5.0) (0 6.2) 55 or 66 (3300 or 3960) 2.3 Lubrication Item No. RD , , , Engine Crankcase Hydraulic System Articulated Steering Joint type l (qts.) type l (gal.) type quantity Lubrication API CH4 or ACEA E5 5.7 (6.0) Oil, Arnica (6.9) GR MU / EP shots with a hand-held grease gun wc_td000148gb.fm 19

24 Technical Data RD Sound Measurements The operating sound level, measured per the requirements of Appendix 1, Paragraph f of the EC-Machine Regulations, is: the guaranteed sound power level (L WA ) = 109 db(a). the sound pressure level at operator s location (L pa ) = 84 db(a). This sound value was determined according to ISO 3744 for the sound power level (L WA ). 2.5 Measurements of Operator Exposure to Vibration The operator of this machine should expect to be exposed to vibration levels listed below when using the machine in performance of its normally intended function: Hand/arm vibration levels do not exceed 2.5 m/s 2. This is the representative value of the weighted root mean square (rms) acceleration to which the hands and arms are subjected. The weighted rms value measured according to ISO is 1.89 m/s 2. Whole body vibration levels do not exceed 0.5 m/s 2. This is the representative value of the root mean square (rms) acceleration to which the whole body is subjected. The weighted rms value measured according to ISO is m/s 2. The results are compliant to the limit and action vibration values (hand/ arm and whole body) as specified in European directive 2002/44/EC. wc_td000148gb.fm 20

25 RD Dimensions See Graphic: wc_gr Technical Data 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 a e c f b wc_gr wc_td000148gb.fm 21

26 Maintenance RD Maintenance 3.1 Maintenance Schedule Daily or every 10 hours Every 50 hours Every 250 hours Every 500 hrs. Every 1000 hrs. 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. Drain fuel system water separator. Check battery. Check and tighten external hardware. Lubricate throttle control. Lubricate steering cylinder ends. Inspect shockmounts. Clean engine cooling system and hydraulic oil cooler. Replace fuel system water separator element. Inspect belts. Change engine oil and replace filter. Replace hydraulic fluid filter. Lubricate articulated steering joint. Replace hydraulic tank breather. Clean/replace cooling system pressure cap. Change hydraulic fluid. wc_tx000495gb.fm 22

27 RD 27 Maintenance 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. wc_tx000495gb.fm 23

28 Maintenance RD 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. Part Type Quantity Engine OIL, Diesel Gamma liters gallons (summer or winter grade) Exciter bearings #2 lithium-based grease per bearing 60 grams (2 oz.) Hydraulic oil tank OIL, Arnica Fuel tank Diesel fuel, clean and filtered Water tank Soft water Lubricant specifications For oils of other brands call Wacker Service. Part AGIP code/name Code/name Diesel Engine Diesel Gamma API CC - 4/SG MIL - L E ACEA E3-96 MIL - L E Hydraulic system Arnica 46 DIN Pt. 3 - Cat. HV wc_tx000495gb.fm 24

29 RD Oil/Temperature Table Maintenance Diesel engine oil F SAE 5 W/30 SAE 10 W SAE 10 W/40 SAE 15 W/40 SAE 20 W/20 SAE 30 SAE C Comparative table of oils AGIP Diesel Gamma 15W/40 ARNICA 46 Rotra MP80W/90 Grease MU EP2 BP Vanellus 15W/40 SHF 46 Hypogear 80W/90 Grease LT2 ELF Elf HD 15W/40 Elf 46 Trans Elf BO 80W/90 Elf Epexa 2 ESSO Lube HDX 15W/40 Invarol EP 46 Gear Oil GX 80W/90 Mulitpurpose Grease H MOBIL Delvac W/40 Mobil DTE 15 Mobilube HD 80W/90 Mobilgrease MP SHELL Rotella SX 15W/40 Tellus T46 Spirax HD 80W/90 Alvania EP2 AGIP Hydraulic oil Cold climates: Below -10 C ARNICA 22 Temperate climates: From -15 C to +30 C ARNICA 46 Tropical climates: Above +30 C ARNICA 68 wc_tx000495gb.fm 25

30 Maintenance RD 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. Do not touch the machine frame or the negative terminal of the battery when working on the positive terminal. WARNING Battery fluid is poisonous and corrosive. In the event of ingestion or contact with skin or eyes seek medical attention immediately. Dispose of dead batteries in accordance with local environmental regulations. To disconnect the battery: Stop the machine and shut down the engine Place all electrical switches in the OFF position Disconnect the negative battery cable from the battery Disconnect the positive battery cable from the battery. To connect the battery: Connect the positive battery cable to the battery Connect the negative battery cable to the battery wc_gr wc_tx000495gb.fm 26

31 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. When necessary, tighten the cables and grease the cable clamps with petroleum jelly. Maintain the battery at full charge to improve cold weather starting. Dispose of dead batteries in accordance with local environmental regulations. CAUTION: Observe the following to prevent serious damage to the machine s electrical system: Never disconnect the battery with the machine running. Never attempt to run the machine without a battery. Never attempt to jump-start a machine. In the event that the machine has a dead battery, either replace the battery with a fully charged battery or charge the battery using an appropriate battery charger. 3.5 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_tx000495gb.fm 27

32 Maintenance RD Lifting the Machine See Graphic: wc_gr 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. Attach the hoisting ropes to the lifting eyes (b) on the machine using hooks or shackles. Attach the other end of the ropes to the hook of the hoisting equipment. The hook must have a lifting capacity which will support the weight of the machine which is 2630 Kg (5797 lbs.). Lift the machine using four ropes, one rope attached to each lifting eye and a spreader bar that prevents the ropes from contacting the machine. Use only steel ropes or chains for hoisting. Ropes or chains must have the suitable specified lifting capacity and must be at least 2000 mm (6.5 ft.) long. Do not use improvised ropes or chains. Do not stand under, or get onto, the machine while it is being hoisted or moved. WARNING b b a wc_gr wc_tx000495gb.fm 28

33 RD Tying Down the Machine Maintenance See Graphic: wc_gr 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. CAUTION: Do not position ropes or chains across the machine frame or the articulated joint when tying down the machine. Damage to the machine may occur. CAUTION: Do not use complete deflection of shockmounts when tying down the machine. Damage to the shockmounts may occur. CAUTION: Do not leave the machine tied down for extended periods of time (except for cases of transporting). Damage to the shockmounts may occur. b b a wc_gr wc_tx000495gb.fm 29

34 Maintenance RD Engine Oil See Graphic: wc_gr 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 Clean around the dipstick 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. CAUTION: Only use oil which meets the standards specified in the table of recommended lubricants. Oil consumption in the first 100 hours is higher than normal. During this period it is therefore advisable to check the oil level at least twice daily and top up when necessary. Engine oil and filter change Stop the machine, apply the parking brake and switch off the engine. The machine must be level. Change the oil when the engine is still warm. Warm oil drains more easily. WARNING Danger of burns! Care must be taken when draining hot engine oil. Hot oil can burn! Open the engine hood Detach the drain hose (c) from the frame Drain off the used oil into a suitable container. Note: Collect, store and dispose of all old oil in accordance with current environmental protection regulations Refit the drain hose to the frame Unscrew the filter cartridge (d) and remove it. Note: Dispose of used filters in accordance with environmental protection regulations Clean the filter housing base and apply a thin coat of engine oil to the seal of the new oil filter Install the new filter and tighten by hand. When the seal contacts the base, tighten the filter an additional 3/4 turn Remove the oil filler cap (b) and pour in the required amount of oil. Clean the oil filler cap and replace. wc_tx000495gb.fm 30

35 RD 27 Maintenance CAUTION: Always use the correct oil type. Do not use oil brands or grades which are not recommended Start and run the engine for a few minutes. Check the oil pressure and the filter seal 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 a wc_gr Testing Backup Alarm The backup alarm is located at the rear of the machine Engage the parking brake Start the engine 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 If the backup alarm does not sound, make the necessary repairs. wc_tx000495gb.fm 31

36 Maintenance RD Engine Air Filter See Graphic: wc_gr 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. Replace main paper filter element if it appears heavily soiled and/or when yellow plunger of indicator appears in or near the red line. Push and hold in the yellow rubber button on top of indicator to reset it after replacing main paper filter element. Stop the machine, apply the parking brake and switch off the engine. Replace main filter element The main air filter element can be used up to six times; after that it must be replaced Remove cover (b) for the air filter housing Remove main filter element (c) from the air filter housing Clean inside of the air filter housing Install new main filter element and replace the cover Replace cover (b) and reset the filter indicator (a). Clean main filter element Remove cover (b) for the air filter housing Remove main filter element (c) from the air filter housing Clean inside of the air filter housing Clean the filter element with a compressed air gun fitted with a straight or bent nozzle. CAUTION: Only use filtered, dry compressed air. Do not exceed an air pressure of 30 psi Blow through the filter from the inside to the outside along the folds of the filter. Continue until all dust has been removed Hold the element up to the light or pass a lamp through the middle to check the condition of the element folds Check that the sealed surface is in good condition Install main filter element and replace the cover. wc_tx000495gb.fm 32

37 RD 27 Maintenance CAUTION: Do not re-use damaged filters. Replace damaged filters even though the damage may be very slight Reassemble cover (b) and reset the filter indicator (a). Replace secondary filter element Remove cover (b) for the air filter housing Remove main filter element (c) from the air filter housing Remove the secondary filter element Cover the intake port (d) and clean inside of the air filter housing. CAUTION: Do not allow dirt to get into the engine intake port while cleaning - damage to engine will result Remove the cover from the intake port and install new secondary filter element Install main filter element and replace the cover Reassemble cover (b) and reset the filter indicator (a). Note: Change the secondary element (e) every third time the main element is changed. CAUTION: Do not use air filter as ether starting aid intake. a b c e d wc_gr wc_tx000495gb.fm 33

38 Maintenance RD Fuel System Water Separator See Graphic: wc_gr Drain fuel system water separator (f) Open the engine hood Attach a rubber drain tube to the valve (e) Turn valve (e) counterclockwise in order to open the valve 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 Close valve (e) Remove the rubber drain tube. Fuel system water separator element Open the engine hood Turn valve (e) in a counterclockwise direction in order to drain the fuel. Drain the fuel into a suitable container. Note: Collect, store and dispose of all old fuel in accordance with current environmental protection regulations Close valve (e) Hold bowl (d) while you loosen the collar (c). Remove the bowl (d) and the collar (c) Loosen the collar (a). Remove the element (b). Note: Dispose of used filters in accordance with environmental protection legislation Clean the parts. Inspect the parts for damage. Replace the damaged parts or replace the worn parts Clean the filter mounting base. All of the old seal must be removed Apply a light coat of diesel fuel to the seal of the new filter Install the new filter and tighten by hand. Tighten the collar (a) Install the bowl (d) and tighten the collar (c) Start the engine and check the fuel system for leaks Close the engine compartment. wc_tx000495gb.fm 34

39 RD 27 Maintenance a b c f d e wc_gr wc_tx000495gb.fm 35

40 Maintenance RD Hydraulic Oil See Graphic: wc_gr Hydraulic oil level Stop the machine, apply the parking brake and switch off the engine 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 If the level is low, top up through the filler (c). CAUTION: Only use oil which meets the standards specified in the table of recommended lubricants. Hydraulic oil cooler Stop the machine, apply the parking brake and switch off the engine Open the engine hood Clean the hydraulic oil cooler (e) Clean the oil cooler fins using compressed air, high pressure water or steam. Do not knock the fins. Knocking will bend the fins. Hydraulic oil change Stop the machine, apply the parking brake and switch off the engine Open the engine hood Remove hydraulic tank filler cap (c) Remove the screen from the filler tube of the tank Wash the screen and filler cap in clean, nonflammable solvent Check the vent (d) for the hydraulic tank. Wash with a clean, nonflammable solvent Open the drain for the tank (b) and drain into a suitable container (g). Note: Collect, store and dispose of all used oil in accordance with current environmental protection regulations Remove the suction strainer inside the hydraulic tank. The strainer is removed by unscrewing the large coupling on the outside lower left corner of the tank. Using Loctite 575 or equivalent on threads, install a new suction strainer in the hydraulic tank Close the drain for the tank (b) Install the screen into the filler tube of the tank Refill the tank with clean, filtered hydraulic oil. Check the oil level in the sight gauge. Maintain the oil level to the mark on the sight gauge. CAUTION: The hydraulic system is not designed to accommodate biodegradeable oil. wc_tx000495gb.fm 36

41 RD 27 Maintenance Install hydraulic tank filler cap (c). Hydraulic oil filter change Stop the machine, apply the parking brake and switch off the engine Open the engine hood Unscrew the old filter cartridge (f) keeping a plastic bag over the cartridge to contain any oil loss Oil the seal of the new filter Install the new filter and tighten by hand. When the seal contacts the base, tighten the filter an additional 3/4 turn Check the hydraulic oil tank level. Add oil if needed. Note: In the interests of environmental protection, place impermeable sheeting and a container under the machine to collect the liquid which drains off. Dispose of this liquid in accordance with environmental protection legislation. a b c d e f g wc_gr wc_tx000495gb.fm 37

42 Maintenance RD Engine Cooling System See Graphic: wc_gr WARNING Danger of burns. Only clean the engine cooling system when the engine is cold Stop the machine, apply the parking brake and switch off the engine. Allow the cooling system to cool completely Open the engine hood Slowly loosen the cooling system pressure cap in order to relieve system pressure. Remove cap (a) Remove the lower hose that is connected to the radiator. Allow the coolant to drain into a suitable container (b). Note: In the interests of environmental protection, place impermeable sheeting and a container under the machine to collect the liquid which drains off. Dispose of this liquid in accordance with environmental protection legislation Replace the lower drain hose. Fill the cooling system with clean water and with a 6 to 10% concentration of cooling system cleaner Install the cooling system pressure cap Close the engine compartment Start the engine and let it run for 90 minutes Stop the engine and allow the cooling system to completely cool Remove the cooling system pressure cap Remove the lower drain hose from the radiator. Drain the cleaning solution Flush the cooling system with water until the draining water is transparent Replace the lower drain hose Using long life, premix coolant, fill the coolant level to 1 cm of the bottom of the fill pipe Start the engine and let run. Leave the cap off until the thermostat opens and the coolant level stabilizes Inspect the gasket on the cooling system pressure cap. Replace the cooling system pressure cap if the gasket is damaged Install the cooling system pressure cap. wc_tx000495gb.fm 38

43 RD 27 Maintenance a b wc_gr Cleaning Radiator Core See graphic: wc_gr Stop the machine, apply the parking brake, switch off the engine, and disconnect the battery While wearing gloves, remove large pieces of debris by hand 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_gr wc_tx000495gb.fm 39

44 Maintenance RD Sprinkler Efficiency See Graphic: wc_gr Clean water spray nozzles Remove cap (c). Remove spray nozzle (d). Remove screen (e) 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 Install screen (e) and nozzle (d). Note: Use only Wacker nozzles. Using other nozzles may modify spray pattern and endurance Install cap (c). Note: Rotation of the nozzle may be required in order to establish a correct spray pattern. Drain water spray system Remove drain plug (b) and drain the main water tank Open drain valve (h) and drain the lines for the spray bar Remove the housing for the water filter (g) Remove the strainer from the housing Drain the water from the housing. Allow the water in the water line to drain Clean the strainer. Install the strainer into the housing for the water filter Install water filter (g). Clean water spray system filter Remove water filter (g) Remove filter bowl (j). Remove screen (k) Clean filter bowl (j) and screen (k) with water or compressed air Install screen (k) into filter bowl (j) Install water filter (g). Clean water tank strainer Remove the filler cap (l) Remove the strainer Clean the filler cap and strainer with water or compressed air Install the strainer Fill tank with clean water. Note: The sprinkler system is not compatible with the use of fuel/water mix or non-stick chemicals. wc_tx000495gb.fm 40

45 RD Install the filler cap (l). Maintenance c d e f a b g g h j l k wc_gr wc_tx000495gb.fm 41

46 Maintenance RD Inspecting and Adjusting Belts See Graphic: wc_gr 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. Belt slippage will also cause poor performance. Improper tightening of belts will generate an increase in noise level. Alternator and Water Pump Belt Open the engine compartment To check belt tension, apply 110N (25 lbs.) of force midway between the pulleys. A correctly adjusted belt will deflect 13 to 19 mm (1/2 to 3/ 4 inch) In order to adjust the alternator belt(a), loosen the mounting nuts (b and c) To achieve the correct adjustment, move the alternator inward or move the alternator outward, as required TIghten mounting bolts (b and c). Note: The alternator shaft nut must be tightened to a torque of 50±5Nm (37±4 ft.lbs.) When new belts are installed, recheck the belt adjustment after 30 minutes of operation. Vibratory belts Open the engine compartment To check belt tension, apply 430±20N (97±5 lbs.) of force midway between the pulleys. A correctly adjusted belt will deflect 5 to 6 mm (0.2 to 0.24 inch) In order to adjust the vibratory pump belts (d), loosen the three mounting bolts (e) In order to tighten the belts, turn the adjusting screw (f) clockwise. In order to loosen the belts, turn the adjusting bolt counterclockwise Tighten the three mounting bolts (e) Close the engine compartment. wc_tx000495gb.fm 42

47 RD 27 Maintenance c f e b a d wc_gr wc_tx000495gb.fm 43

48 Maintenance RD Fuses See Graphic: wc_gr 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. (a) Fan motor 15 Amp (b) Brake and neutralizer 10 Amp (c) Gauges and horn 10 Amp (d) Vibration system 10 Amp (e) Backup alarm and beacon 10 Amp (f) Hour meter 10 Amp (g) Water spray system 10 Amp (h) Flasher 10 Amp (i) Keyswitch 10 Amp a h i b c d g f e wc_gr wc_tx000495gb.fm 44

49 RD Shockmounts Maintenance 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 Stop the machine, apply the parking brake and switch off the engine, and allow engine to cool Open the engine hood and fix it in the raised position with the rod Check the wear of the diesel engine shockmounts. The rubber should not be broken nor should it show any signs of having lost its resilience. The shockmounts prevent excessive vibrations from reaching the frame and thus also protect the other components mounted on the engine from damage and faulty operation. Exciter drum shockmounts Stop the machine, apply the parking brake and switch off the engine Check the wear of the exciter drum shockmounts. The rubber should not be broken nor should it show any signs of having lost its resilience. The shockmounts prevent excessive vibration from reaching the frame and thus also protect the other components from damage and faulty operation. wc_tx000495gb.fm 45

50 Maintenance RD Scraper Wear See Graphic: wc_gr Stop the machine, apply the parking brake, and switch off the engine Remove dirt and debris from scrapers 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. The tension on the spring mounts should be adjusted in order to prevent bouncing of the scraper when the vibration system is active Scraper bar pivots are protected with special, auto-lube plastic sleeves. Check the pivots for wear and replace when necessary. a wc_gr wc_tx000495gb.fm 46

51 RD Lubricating Articulated Steering Joint Maintenance See Graphic: wc_gr Stop the machine, apply the parking brake, and switch off the engine Lock the articulated steering joint before servicing. See section Locking/Unlocking Articulated Steering Joint Clean all fittings before servicing Clean all caps before servicing Lubricate the fittings (c) for the articulation bearing. Note: Use a small amount of grease (see section Lubrication). Excess grease can cause seal damage Install all caps after servicing. Note: Lubricate pins of locking mechanism with a film of grease as needed. c c wc_gr wc_tx000495gb.fm 47

52 Maintenance RD Lubricating Steering Cylinder See Graphic: wc_gr Stop the machine, apply the parking brake and switch off the engine Lock the articulated joint before servicing. See section Locking/ Unlocking Articulated Joint 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. Note: Clean the fittings before lubricating the steering cylinder. a b wc_gr wc_tx000495gb.fm 48

53 RD Lubricating Throttle Control Maintenance See Graphic: wc_gr Stop the machine, apply the parking brake, switch off the engine, and disconnect the battery Clean the throttle control linkage (a) with a clean rag Lubricate the throttle control linkage with engine oil. wc_gr a wc_tx000495gb.fm 49

54 Maintenance RD 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. Note: Do not spray the backup alarm directly with the high-pressure water. Cleaning the vehicle thoroughly will show any oil leaks, loose nuts, or other faults. Particular attention should be paid to the following: Vent cap on the hydraulic oil tank. Fuel filler cap on the diesel oil tank. Engine compartment. Exciter drum shockmounts. After washing, dry the machine with a jet of compressed air and then remove the protective covers and tape. wc_tx000495gb.fm 50

55 RD Cleaning the Fuel Tank Maintenance See Graphic: wc_gr 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 Open engine hood Remove fuel tank cap (a) Remove the filler screen and wash in a clean, nonflammable solvent. Dry with pressure air Inspect cap and filler screen. Replace if damaged Install filler screen Apply a thin film of fuel to the gasket of the fuel tank cap Install fuel tank cap (a). CAUTION: Only use clean and filtered fuel. Always use the correct type of fuel for the time of year: either normal diesel or winter diesel. Drain fuel tank and sediment Remove the drain plug (b) and allow the water and sediment to drain into a suitable container. Note: In the interests of environmental protection, place impermeable sheeting and a container under the machine to collect the liquid which drains off. Dispose of this liquid in accordance with environmental protection legislation Install the drain plug (b). CAUTION: The tank must be cleaned more frequently if the vehicle is being used in very humid or dusty conditions. a b wc_gr wc_tx000495gb.fm 51

56 Maintenance RD Towing See Graphic: wc_gr 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 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. WARNING These towing instructions are for moving a disabled machine for a short distance at a low speed. Move the machine at a speed of 2 km/ h (1.2 mph) or less to a convenient location for repair. These instructions are only for emergencies. Always haul the machine if long distance moving is required. Shielding must be provided on both machines. This will protect the operator if the tow line or the tow bar breaks. Do not allow an operator to be on the machine that is being towed unless the operator can control the steering and/or the braking. Before towing, make sure that the tow line or the tow bar is in good condition. Make sure that the tow line or the tow bar has enough strength for the towing procedure that is involved. The strength of the towing line or the tow bar should be at least 150 percent of the gross weight of the towing machine. This is true for a disabled machine that is stuck in the mud and for towing on a grade. Keep the tow line angle to a minimum. Do not exceed a 30 degree angle from the straight ahead position. Quick machine movement could overload the tow line or the tow bar. This could cause the tow line or the tow bar to break. Gradual, steady machine movement will be more effective. Normally, the towing machine should be as large as the disabled machine. Make sure that the towing machine has enough brake capacity, enough weight, and enough power. The towing machine must be able to control both machines for the grade that is involved and for the distance that is involved. You must provide sufficient control and sufficient braking when you are moving a disabled machine downhill. This may require a large towing machine or additional machines that are connected to the rear. This will prevent the machine from rolling away out of control. wc_tx000495gb.fm 52

57 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. The operator must steer the machine that is towed in the direction of the tow line. Ensure that all instructions in this section are followed carefully. Ensure that all instructions in this section are followed exactly. WARNING If the engine is stopped: Shutting off the engine will result in the loss of machine steering. When the engine is stopped, additional steps may be required before the machine is towed. In order to avoid damaging the power train, the steering system, and the brakes, which may be inoperable, additional steps may be required Block the drums in order to prevent the movement of the machine. Do not remove the blocking until the tow vehicle has been positioned and the tow lines are in place Manually release the parking brake. This will prevent excessive wear and damage to the braking system when towing Turn the bypass valve (a) for two full turns in the counterclockwise direction. Note: Do not turn the bypass valve further than two turns. When the bypass valve is turned further than two turns, oil will leak past the bypass valve Attach the tow line to the machine at the tow points (b & c) Attach the tow line to the vehicle that is used to tow the disabled machine Remove the blocks from the drums Tow the disabled machine at a slow rate of speed to the desired location Once the machine is at the desired location, securely block the drums. This will prevent the movement of the machine Turn the bypass valve clockwise in order to tighten the bypass valve Manually re-engage the parking brake by fully releasing the two release screws. wc_tx000495gb.fm 53

58 Maintenance RD Detach the tow lines. a b c wc_gr wc_tx000495gb.fm 54

59 RD Manually Releasing Parking Brakes Maintenance See Graphic: wc_gr 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 Chock each drum to prevent the machine from moving Lock the articulated steering joint Remove the plugs (a) in order to access the release screws Press and turn each release screw in until its threads catch in the brake plate. Tighten each screw until the spring on each screw is fully compressed. You will feel a substantial difference in the amount of torque required to turn the screw once its spring is fully compressed. Then, continue to tighten (turn clockwise) the two release screws to compress the brake plate springs. Alternate back-and-forth between the two screws, turning approximately 45 at a time, until the drums are no longer held by the brake plate. The brake plate should release after turning each screw approximately 120 total. To test if the brake is free, manually turn the drum Replace the plugs (a). Note: After repair, ensure that the releasing screws are back in the normal operating position. Note: Replacement drive motors come with the brakes in the ON position. a wc_gr wc_tx000495gb.fm 55

60 Maintenance RD Exhaust System and Engine Air Intake System WARNING 3.28 Storage 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. If the vehicle is to remain idle for an extended period, the following operations should be carried out: Clean the machine. Grease all grease fittings. Change engine oil. Follow the instructions in the diesel engine Instruction and Maintenance manual. If the vehicle will be parked outside: Cover the machine or put the machine under shelter. Remove the battery and protect it from freezing conditions. Completely drain the diesel fuel tank and fuel hoses. Completely drain the water tank, water filter, and the roller sprinkling equipment. If the vehicle will be parked inside in a controlled environment: Completely drain the water tank, water filter, and the roller sprinkling equipment. Completely fill the fuel tank. Check all fluid levels. Periodically check battery charge. The vehicle should be started and driven a short distance at least once a month so that a thin layer of oil is maintained on the various hydraulic and mechanical components; this ensures adequate protection of transmission parts. CAUTION: After a prolonged period of idleness, all filters must be changed before the machine is returned to service. wc_tx000495gb.fm 56

61 RD Electrical Schematics Maintenance 384-BU OR YL GN GY PU PU-16 A990-BU-16 C924-YL RD-6 A990-BU BK BU-8 VIB ON/OFF SOLENOID 406-PU GY YL-16 FUEL SHUTOFF SOLENOID GLOW PLUGS RD WH RD BK-16 STARTER 304-WH-16 RD-2 CABLE AS. BK-00 BATTERY CABLE AS. SHEET 2 /ZONE A-6 SHEET 2 /ZONE A-5 ALTERNATOR B+ C GND SHEET 2 /ZONE A4 403-GN-16 GROUND HARNESS AS.-ENGINE RD-2 RD-6 STRAP AS. CHASSIS GROUND STRAP AS. FRONT CHASSIS GROUND ENGINE GROUND REAR CHASSIS GROUND C924-YL BK PU BK OR BK-16 DRUM VIB SOLENOID 1 NEUTRAL/BRAKE SOLENOID SEAT SWITCH SOLENOID COOL TEMP SWITCH 200-BK-16 OIL PRESSURE SWITCH 200-BK BK T PLUG PLUG PLUG PLUG CHASSIS GROUND G S MTR BAT MOTOR NEG POS wc_gr wc_tx000495gb.fm 57

62 Maintenance RD BR YL OR-16 A990-BU PK GN PU RD RD OR YL GN BK BK GY PU YL OR GN PK GN YL GY PU GN-16 PLUG 605-YL GY PU GN PU-16 G736-PK-16 G797-BU-16 A893-OR-16 A990-BU-16 C906-PU-16 C922-BR-16 C924-YL-16 C927-PU BK-16 PLUG PLUG PLUG PLUG PLUG PLUG BK PU GY BK GN RD-12 20A LIGHT CIRCUIT BREAKER CABLE AS. 101-RD RD RD-6 60A 101-RD-6 ALTERNATOR CIRCUIT BREAKER 109-RD WH-10 START RELAY 109-RD BU-8 START AID RELAY MAIN POWER RELAY 109-RD PU-6 P GN BK-16 P PU BK BK YL RD RD RD RD GN BK BK YL PU-16 ARC-SUPPRESSOR VIB SW REVERSE NEUTRAL SEAT SWITCH C906-PU BK-16 C906-PU BK-16 HARNESS AS.-PLATFORM 614-PU GY BK-16 RH REAR TURN LIGHT 321-BR BK-16 BACKUP ALARM C922-BR BK-16 MOTOR WATER SPRAY PUMP A893-OR BK-16 G736-PK BK-16 MOTOR OIL COOLER FAN MOTOR G797-BU BK-16 BK-16 BK-16 T RH FRONT TURN LIGHT RH FRONT ROADING LIGHT WORKING LIGHT HORN LH FRONT ROADING LIGHT WORKING LIGHT LH FRONT TURN LIGHT 322-GY BK-16 G798-PU BK-16 G798-PU OR-16 OIL COOLER TEMP SWITCH (110 C) 404-YL BK-16 BK-16 BK-16 HYD OIL TEMP SWITCH FRAME GROUND 121-YL-16 BEACON 681-OR BK-16 WORKING LIGHT 605-YL PU-16 LH REAR TURN LIGHT 204-BK T PLUG 307-OR YL GN GY PU PU-16 A990-BU-16 C924-YL OR-16 PLUG 469-GN BK-16 SHEET 1 /ZONE F-4 C927-PU BK A990-BU-16 PLUG BK-18 BK-18 BK-18 BK-18 SHEET 3 / ZONE A-6 SHEET 3 / ZONE A-4 HARNESS AS - MAIN wc_gr wc_tx000495gb.fm 58

63 RD 27 Maintenance WARNING LIGHTS ENG OIL PRESS ENG TEMP X1 X2 1 2 ALT HYD TEMP 307-OR YL-16 PLUG 306-GN BK-16 F765-BR YL PU-16 PLUG 201-BK-16 C720-BU YL-16 PLUG 419-YL BK-16 F765-BR OR-16 PLUG 307-OR-16 C906-PU-16 C935-PU-16 C935-PU-16 PLUG C922-BR-16 C937-WH BU BU-16 G736-PK-16 PLUG G797-BU-16 START RELAY A BRAKE 1 RELAY A BRAKE 2 RELAY A INTERLOCK 1 RELAY A SPRAY RELAY A FAN MOTOR RELAY A RD RD PU OR YL GN BK BK GY PU YL OR GN PK GN YL GY PU-16 PLUG PLUG PLUG 605-YL GY PU GN OR PU-16 G736-PK-16 G797-BU-16 PLUG A990-BU-16 C906-PU-16 C922-BR-16 C924-YL-16 PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG 405-GY WH GN YL PU-16 DRUM SELECT SWITCH HAZARD SWITCH TURNING SIGNAL INDICATOR VIB LAMP INDICATOR SWITCH-HORN 419-YL BK-16 BRAKE SWITCH GN GN YL-16 F765-BR A541-PU BK-16 A990-BU BK GY WH-16 TURN SIGNAL SWITCH OR-16 C924-YL GN GY YL GN GY YL-16 SHEET 2 /ZONE F-6 HOURMETER + - SIG SHEET 2 /ZONE F-4 HARNESS AS.-INSTRUMENT 308-YL-16 1 PLUG 330-YL RD PU-16 PLUG 110-GN PK-16 C720-BU OR BK-16 KEY SWITCH OFF ON ST NEUTRAL SWITCH RELAY A R A C S B 537-GN GN-16 WATER SPRAY SWITCH C922-BR-16 F427-PK BK-16 A990-BU-16 C935-PU GY-16 LIGHT SWITCH 102-RD PU GN OR-16 WATER TIMER C935-PU-16 + BATTERY 200-BK-16 GROUND C937-WH-16 OUTPUT FLASHER 201-BK-16 GROUND 537-GN-16 OUTPUT A541-PU-16 IND LAMP 108-BU-16 + BATTERY FLASHER FUSE HOURMETER FUSE 112-PU-10 10A 108-BU PU-10 10A F427-PK-16 WATER SPRAY FUSE 112-PU-10 10A 118-GY-16 BACKUP/BEACON FUSE 112-PU-10 10A 121-YL-16 CLUSTER/HORN FUSE 10A 123-WH PU-10 FAN MOTOR FUSE 15A 122-BU PU-10 VIB FUSE 10A 125-OR PU-10 BRAKE/NEUTRAL FUSE 10A 110-GN PU-10 KEY SWITCH FUSE 109-RD-10 10A 105-RD-16 wc_gr wc_tx000495gb.fm 59

64 Maintenance RD Hydraulic Schematic A B C -8 D L 130 BARS T R VIBRATION VALVE STEER CONTROL UNIT 100 cc 100 BARS P T STEER CYLINDER P FRONT MOTOR VIB. 8.4 cc REAR MOTOR VIB. 8.4 cc M 150 BARS 250 BARS -8 OIL COOLER M1 a b L1 M2 L2 S CHARGE FILTER 3.5 BARS STEER/CHARGE PUMP 8.1 cc 2370 RPM VIBRATION PUMP 10.8 cc 2950 RPM -6 A B Ø bars 350 bars 24 bars PROPEL PUMP 2800 RPM 22 cc CF -8-8 P NEUTRAL BRAKE SOLENOID CONTROL GP T P b SEAT SWITCH ATTACHMENT SEAT SWITCH SOLENOID 3B DRUM VIB. SOLENOID 1 3A VIB. ON/OFF SOLENOID 2A 2B FRONT PROPEL MOTOR 408 cc REAR PROPEL MOTOR 408 cc STRAINER a wc_gr wc_tx000495gb.fm 60

65 RD 27 Repair Engine Starting Troubleshooting 4. Engine Starting Troubleshooting 4.1 Starting System Component Locations a i b a g c d e f h wc_gr a Starter relay 2 f Main power relay b Neutral switch relay g Fuel shutoff solenoid c 60A circuit breaker h Glow plug d Starter relay 1 i Neutral switch e Glow plug relay wc_tx000455gb.fm 61

66 Engine Starting Troubleshooting 4.2 Troubleshooting Flowcharts RD 27 Repair The troubleshooting flowcharts are designed to step you through the process of determining the source of a problem with starting the engine should a problem exist. Many of the tests involve live voltages and therefore should only be attempted by qualified personnel. The procedures for carrying out the tests are included in this manual. Each flowchart includes references (by section number) to the location of the specific procedure(s) in the manual. wc_tx000455gb.fm 62

67 RD 27 Repair 4.3 Engine Does Not Crank Engine Starting Troubleshooting Check position of FWD/REV lever. Is lever in neutral position? Yes Check power at starter motor. Is battery voltage (12V) measured at starter motor? Yes Replace starter motor. See Perkins engine repair manual. No 4.4 No Reposition lever. Check neutral/brake fuse. Check power to starter relay 1. Is battery voltage (12V) measured at starter relay 1? Yes Check power from starter relay 2. Is battery voltage (12V) measured from starter relay 2? No Engine does not Crank Troubleshooting Flowchart 1A Control panel lights illuminate No Yes Repair or replace wiring between battery and starter relay 1. Replace starter relay 1. Repair or replace key switch. No Is battery voltage (12V) measured from key switch? Yes Replace starter relay 2. Check power to starter relay 2.. Is battery voltage (12V) measured at starter relay 2? Yes 4.7 Check power from key switch. No 4.8 Check power from neutral switch relay. Is battery voltage (12V) measured from neutral switch relay? No Replace starter relay Check function of neutral switch; adjust or replace neutral switch. Yes wc_gr wc_tx000455gb.fm 63

68 Engine Starting Troubleshooting 4.4 Checking Power at Starter Motor Solenoid RD 27 Repair See Graphic: wc_gr The starter motor solenoid receives power (battery voltage, approximately 12) directly from the battery through wire RD-2 (a). The coil of the solenoid is energized when it receives power through wire 304-WH-16 (b) When energized, the solenoid sends power to the stater motor which cranks the engine. To check power to the starter motor solenoid, carry out the following procedures: Check that the connections of wire RD-2 between the battery and the starter motor solenoid are clean and secure. Measure voltage between the BAT terminal of the starter motor solenoid and ground. If 12V (battery voltage) is not measured, check continuity of wire RD-2. If 12V is measured (battery voltage), continue Check power to the starter solenoid s coil. To do so, place the key switch in the START position (3) and measure voltage between wire 304-WH-16 and ground. If 12V is measured, reconnect wire 304-WH-16 and try starting the engine again. If the engine still won t crank, there is a problem with the starter solenoid or starter motor. See the Perkins engine repair manual. If 12V is not measured, check the continuity of wire 304-WH-16. Also check function of starter relay 1. 1 a 2 b wc_gr wc_tx000455gb.fm 64

69 RD 27 Repair Engine Starting Troubleshooting 4.5 Checking Neutral/Brake Fuse See graphic: wc_gr Remove the four screws (a) securing the fuse box cover Check condition of the 10A neutral/brake fuse (b); replace fuse if blown Replace fuse box cover. wc_tx000455gb.fm 65

70 Engine Starting Troubleshooting 4.6 Checking Power to/from Starter Relay 1 RD 27 Repair See Graphic: wc_gr Starter relay 1 receives power (battery voltage, approximately 12) through wire 109-RD-10 from starter relay 2. The coil of starter relay 1 is energized when it receives power from wire 306-GN-16. When energized, the starter relay 1 sends power to the starter motor solenoid through wire 304-WH-10. To check power to/from starter relay 1, carry out the following procedures: Open the hood. Starter relay 1 is mounted to the bulkhead near the battery Check power to starter relay 1 by measuring voltage between starter relay 1 at wire connection 109-RD-10 (a) and ground. If 12V is not measured, check continuity of wire 109-RD-10. Repair or replace wire as necessary. If 12V is measured, continue Check power from starter relay 1 by placing the key switch in the START position (3) and measuring voltage between starter relay 1 at wire connection 304-WH-10 (b) and ground. If 12V is measured, check the continuity of wire 304-WH-10. If there is continuity to the wire, there should be power to the starter motor. If 12 Volts is not measured, continue Check power to the relay s coil by placing the key switch in the START position (3) and measuring voltage across connector P (c), wires 306-GN-16 and 202-BK-16. If 12V is measured, replace starter relay 1. If 12V is not measured, check continuity of wires 306-GN-16 and 202-BK-16. Also check function of starter relay 2. wc_tx000455gb.fm 66

71 RD 27 Repair Engine Starting Troubleshooting b c a wc_gr wc_tx000455gb.fm 67

72 Engine Starting Troubleshooting 4.7 Checking Power to/from Starter Relay 2 RD 27 Repair See Graphic: wc_gr Starter relay 2 receives power (battery voltage, approximately 12) through wire 307-OR-16 from the neutral switch relay. The coil of starter relay 2 is energized when it receives 12V through wire 330-YL- 16 from the key switch. When starter relay 2 is engergized, it sends power to starter relay 1. To check power to/from starter relay 2, carry out the following procedures: Remove the control panel cover. Starter relay 2 (a) is mounted to the inside of the control panel cover Check power to starter relay 2 by removing the wiring connector to starter relay 2. Place the key switch in the ON position (1) and measure voltage across wire 307-OR-16 (b) and ground. If 12V is not measured, check continuity of wire 307-OR-16. Also check function of neutral switch relay. If 12V is measured, continue With the wiring connector still disconnected, check power to the relay s coil from the key switch. To do so, place the key switch in the START position (3) and measure voltage between wire 330-YL-16 (c) and ground. If 12V is not measured, check the continuity of wire 330-YL-16. Also check function of key switch. If 12V is measured, continue Re-install the wiring connector. Check power from starter relay 2 to starter relay 1. To do so, disconnect the wire connector (d) P21, at starter relay 1. Place the keyswitch in the START postion (3) and measure voltage across the connector wires 306-GN-16 and 202- BK-16. If 12V is not measured, confirm continuity of wires 306-GN-16 and 202-BK-16. If the wires have continuity, starter relay 2 is not sending power to starter relay 1 and thus is faulty; replace starter relay 2. If 12V is measured, starter relay 2 is functioning properly. wc_tx000455gb.fm 68

73 RD 27 Repair Engine Starting Troubleshooting 1 a 2 b c d wc_gr wc_tx000455gb.fm 69

74 Engine Starting Troubleshooting 4.8 Checking Key Switch RD 27 Repair See Graphic: wc_gr Remove the control console cover Unplug the key switch from the wiring harness The key switch may be left installed or removed. It is shown here removed from the control console Check the function of the key switch by checking for continuity between the switch s terminals as follows: Key Position Function Terminals 0 OFF C and B 1 ON S and R 2 GLOW PLUGS (start aid) B and A 3 START B and R If the key switch lacks continuity between any of the terminals listed in the chart above, replace the key switch. wc_tx000455gb.fm 70

75 RD 27 Repair Engine Starting Troubleshooting wc_tx000455gb.fm 71

76 Engine Starting Troubleshooting 4.9 Checking Power to/from Neutral Switch Relay RD 27 Repair See Graphic: wc_gr The neutral switch relay receives power (battery voltage, approximately 12) from the main power relay through the brake/neutral fuse through wire 110-GN-16. The coil of the neutral switch relay is energized when it receives power from the main power relay. The power first runs through the brake/neutral fuse and the neutral switch in the control lever before it arrives at the neutral switch relay through wire 374-PK-16. When energized, the neutral switch relay sends power to start relay 2. To check power to/from the neutral switch relay, carry out the following procedures: Remove the control panel cover. The neutral switch relay (a) is mounted to the inside of the control panel cover. Disconnect the wiring connector from the neutral switch relay Place the key switch in the START position (3), measure the voltage between wire 110-GN-16 (b) and ground. If 12V is not measured, check the continuity of 110-GN-16 between the brake/neutral fuse and the neutral switch relay. If 12V is measured, continue With the wiring connector still disconnected, check for power to the relay s coil. To do so, place the key switch in the START (3) position and measure the voltage between wire 374-PK-16 (c) and ground. If 12V is not measured, check the continuity of wires 374-PK-16 and 201-BK-16. Also check function of neutral switch in control lever. If 12V is measured, continue Re-install wiring connector. Check for power from the neutral switch relay. To do so, measure voltage between wire 307-OR-16 (d) and ground at starter relay 2. If 12V is not measured, confirm continuity of wire 307-OR-16. If the wire has continuity the neutral switch relay is not sending power to starter relay 2 and thus is faulty; replace the neutral switch relay. If 12V is measured, the neutral switch relay is functioning properly. wc_tx000455gb.fm 72

77 RD 27 Repair Engine Starting Troubleshooting 1 2 b a c d wc_gr wc_tx000455gb.fm 73

78 Engine Starting Troubleshooting 4.10 Checking Neutral Switch RD 27 Repair See Graphic: wc_gr The neutral switch is located within the control lever assembly. To access the switch, remove the two retaining rings (a) and remove the protective boot (b). The neutral switch (c) is located on the outer side of the control lever assembly To test the neutral switch, place the control lever in the NEUTRAL position and test the neutral switch for continuity across terminals 1 and 3. Also test for continuity while in the FORWARD and the REVERSE positions. There should be continuity while in the NEUTRAL position and no continuity while in the FORWARD or the REVERSE position. If the neutral switch fails to function accordingly, replace it The neutral switch activation mechanism may be adjusted by loosening the socket head screw (d) and rotating the cam (e) so that it pushes the spring that activates the switch s plunger. Rotate the cam so that the plunger is fully extended (f) while the control lever is in the NEUTRAL position. The plunger should be fully retracted (g) while the control lever is in the FORWARD or REVERSE position. Retighten the screw once in position Replace the protective boot and retaining rings. wc_tx000455gb.fm 74

79 RD 27 Repair Engine Starting Troubleshooting a c b d e f g wc_gr wc_tx000455gb.fm 75

80 Engine Starting Troubleshooting Engine does not Crank Troubleshooting (continued) RD 27 Repair Engine does not Crank Troubleshooting Flowchart 1B Check condition of battery. Control panel lights do not illuminate Does the battery measure 11 13V? Yes No Recharge or replace battery. Check KEY SWITCH fuse. Check CLUSTER/HORN fuse. Check BRAKE/NEUTRAL fuse Are fuses blown? No Check condition of 60A circuit breaker Yes Is 60A circuit breaker OK? No Replace 60A circuit breaker. Replace blown fuses. Yes Check function of key switch. 4.8 Is key switch functioning? No Replace key switch. Yes Check function of main power relay Is main power relay functioning? 4.13 No Replace main power relay. Yes Call Wacker service. wc_gr wc_tx000455gb.fm 76

81 RD 27 Repair 4.11 Checking Fuses Engine Starting Troubleshooting See Graphic: wc_gr Remove the four screws (a) securing the fuse box cover Check the 10A key switch fuse (b); replace fuse if blown Check the 10A cluster/horn fuse (c); replace fuse if blown Check the 10A brake/neutral fuse (d); replace fuse if blown Replace fuse box cover Checking 60A Circuit Breaker See Graphic: wc_gr The 60A circuit breaker is located on the bulkhead near the battery Check the wiring to the circuit breaker (a). Make sure connections are tight and clean Check the circuit breaker for continuity. If the circuit breaker has no continuity, replace it. a wc_gr wc_tx000455gb.fm 77

82 Engine Starting Troubleshooting 4.13 Checking Power to/from Main Power Relay RD 27 Repair See Graphic: wc_gr The main power relay receives power (battery voltage, approximately 12) from the battery via the 60A circuit breaker through wire 109-RD- 6. The coil of the relay receives power via the key switch through wire 310-PU-16. When energized, the main power relay sends power to the fuse block where power is distributed throughout the machine. To check power to/from the main power relay, carry out the following procedures: Open the hood. The main power relay is mounted to the bulkhead near the battery Check power to the main power relay by measuring voltage between wire 109-RD-6 (a) at its connection point on the main power relay and ground. If 12V is not measured, check the continuity of wire 109-RD-6 between the 60A circuit breaker and the main power relay. Check the 60A circuit breaker for continuity and incoming voltage. There should be battery voltage on wire 101-RD-6. If not, check the continuity of wire 101-RD-6. If 12V is measured, continue Check the power from the main power relay by placing the key switch in the ON position (1) and measuring voltage between wire 112-PU-6 (b) at its connection point on main power relay and ground. If 12V is measured, check continuity of wire 112-PU-6 between the main power relay and the fuse block. If the wire has continuity, there should be power to the fuse block. If 12V is not measured, continue Check power to the main power relay s coil by placing the key switch in the ON position (1) and measuring voltage (c) between wires 308- YL-16 and 202-BK-16. If 12V is measured, the main power relay is malfunctioning; replace it. If 12V is not measured, check continuity of wires 308-YL-16 and 202-BK-16. Also check function of 60A circuit breaker. wc_tx000455gb.fm 78

83 RD 27 Repair Engine Starting Troubleshooting c a b wc_gr wc_tx000455gb.fm 79

84 Engine Starting Troubleshooting 4.14 Engine Cranks but does not Start RD 27 Repair Check fuel supply. Is tank filled with fresh fuel? No Drain tank of old fuel. Fill tank with fresh fuel. Yes Check condition of air filter. Is air filter condition OK? Yes Check engine oil. Is level adequate? Yes No No Check wire connection of engine oil pressure sensor. Is the sensor connected? Yes No Replace air filter. Fill engine with oil. Connect it. Engine Cranks but does not Start Troubleshooting Flowchart 2A Check glow plug relay. Is glow plug relay functioning properly? Yes Check condition of glow plugs. Are glow plug relays functioning properly? Yes Refer to Perkins repair manual for engine repairs No No Replace glow plug relay. Replace glow plugs. Remove fuel line at fuel rail. Does fuel squirt out during cranking? Yes 4.15 Check power to fuel solenoid. Is there power to fuel solenoid? Yes 4.16 No Check continuity of wiring between main power relay and fuel solenoid. Repair or replace wiring as needed. No Check condition of fuel filter, hoses, and clamps; replace if necessary. Replace fuel solenoid. See Perkins repair manual. wc_gr wc_tx000455gb.fm 80

85 RD 27 Repair 4.15 Checking Fuel Flow Engine Starting Troubleshooting See Graphic: wc_gr To check fuel flow: Disconnect the fuel hose (a) at the engine. Have a container ready to catch fuel Place the hose into the container and turn the key switch to the ON position for approximately one second. Fuel should flow from the hose. If fuel does not flow from the hose: Check the fuel filter (b) and fuel hoses (c) for clogs or leaks. Check the function of the fuel shutoff solenoid. If fuel flows from the hose, replace the hose and tighten the hose clamp. wc_tx000455gb.fm 81

86 Engine Starting Troubleshooting 4.16 Checking Power to Fuel Shutoff Solenoid RD 27 Repair See Graphic: wc_gr The fuel shutoff solenoid is fed power (battery voltage, approximately 12) via the key switch through wire 308-YL-16. When the key switch is in either the ON or START position, the solenoid is energized and fuel flows. When the key switch is in the OFF position or when power is cut to the fuel shutoff solenoid, the solenoid de-energizes and stops fuel flow. To check power to the fuel shutoff solenoid: Open the hood. The fuel shutoff solenoid (a) is located near the fuel injectors Disconnect the wiring connector (b) Place the key switch in the ON position and measure voltage across wires 308-YL-16 and 200-BK-16. If 12V is not measured, check the continuity of the wires. Also check function of key switch. If 12V is measured, the fuel shutoff solenoid should be functioning (fuel flowing). If it is not, replace the fuel shutoff solenoid. Note: The coil of a working solenoid will have resistance of approximately 11 Ohms. wc_tx000455gb.fm 82

87 RD 27 Repair Engine Starting Troubleshooting a b wc_gr wc_tx000455gb.fm 83

88 Engine Starting Troubleshooting 4.17 Checking Power to/from Glow Plug Relay RD 27 Repair See Graphic: wc_gr The glow plug relay (start aid relay) receives power (battery voltage, approximately 12) via the 60A circuit breaker through wire 109-RD-8. The relay s coil receives power via the key switch through wire 310- PU-16. When energized, the glow plug relay sends power to the glow plugs. To check power to and from the glow plug relay, carry out the following procedures: Open the hood. The glow plug relay is mounted to the bulkhead near the battery Check power to the glow plug relay by measuring voltage between wire 109-RD-8 (a) at its connection point on the glow plug relay and ground. If 12V is not measured, check the continuity of wire 109-RD-8 between the 60A circuit breaker and the glow plug relay. Check the 60A circuit breaker for continuity and incoming voltage. If 12V is measured, continue Check power from the glow plug relay by placing the key switch in the GLOW PLUG (preheat) position (2) and measuring voltage between wire 384-BU-8 (b) at its connection point on the glow plug relay and ground. If 12V is measured, check continuity of wire 384-BU-8. Also check glow plugs. If 12V is not measured, continue Check power to the glow plug relay s coil by placing the key switch in the GLOW PLUG (preheat) position (2) and measuring voltage between wires 310-PU-16 and 202-BK-16 at connector P20, (c). If 12V is measured, the glow plug relay is malfunctioning, replace it. If 12V is not measured, check continuity of each wire. Also check function of key switch. wc_tx000455gb.fm 84

89 RD 27 Repair Engine Starting Troubleshooting c b a wc_gr wc_tx000455gb.fm 85

90 Engine Starting Troubleshooting 4.18 Checking Glow Plugs RD 27 Repair See graphic: wc_gr The glow plugs receive power (battery voltage, approximately 12) via the glow plug relay through wire 384-BU-8. To check the glow plugs: Place the key switch in the GLOW PLUG position and check for 12V between wire 384-BU-8 (a) and ground. If 12V is not measured, check the continuity of wire 384-BU-8. Also check the glow plug relay. If 12V is measured, continue Remove the jumper (b) connecting the glow plugs Unscrew the glow plugs (c) from the engine. Burn hazard. Glow plugs can reach temperatures up to 1200 F (649 C). Do not touch the element of the glow plug. Be extremely careful when testing the glow plug. WARNING Using 10-gauge wire, apply 12VDC to the glow plug positive on the upper portion and ground the base. If the glow plug doesn t heat (glow) within five seconds, replace the glow plug. Note: If any one of the glow plugs needs replacing, replace all of them. wc_tx000455gb.fm 86

91 RD 27 Repair 5. Drive System Electricals Drive System Electricals 5.1 Drive System Electrical Overview See Graphic: wc_gr In order for the machine to drive (propel), both the neutral/brake solenoid and the seat switch solenoid must be energized. The main power relay delivers power to the fuse block when the key switch is in the ON position. Power is transferred to the brake switch via brake/neutral fuse (f) through wire 110-GN-16. With the brake switch (g) in the OFF position, power is transferred to brake 1 relay (k) through wire F765-BR-16. It is further transferred to the neutral/brake (m) solenoid, which energizes and disengages the brakes. In addition to the brake switch, the 110-GN-16 also transfers power to the neutral switch relay (i) at terminals 30 and 85 (coil) through wire 374-PK-16 via the neutral switch (n) in the control lever assembly. When energized, the neutral switch relay transfers power to both the seat switch solenoid (s) and to terminals 85 and 87 of the interlock relay (r). The seat switch solenoid energizes as long as the control lever is in the NEUTRAL position; when moved from the neutral position, the seat switch solenoid is no longer energized through the neutral switch relay. Instead, it is energized by power from the interlock relay. The interlock relay receives power at terminal 30 from the brake switch (in OFF position). Its coil (terminal 85) receives power via the neutral switch relay (as stated earlier). The coil of the interlock relay energizes when the seat switch (q) provides a path to ground (closes). When energized, the interlock relay provides power to the seat switch solenoid. As long as the operator is seated and the brake switch is in the OFF position, the electrical system is enabled for the machine to drive. When the brake switch is placed in the ON position, power is supplied to the parking brake indicator (g), terminal 85 (coil) of brake 1 relay, and terminals 85 (coil) and 87 of brake 2 relay (l). The parking brake indicator illuminates and the coils of the relays energize. When brake 1 relay is energized, the neutral/brake solenoid is de-energized, and the parking brake is engaged. Regardless of the position of the control lever, the parking brake remains engaged when the parking brake switch is ON. The parking brake will release when the brake switch is moved from the ON to the OFF position, provided the control lever is in the NEUTRAL position. In this condition, power transfers from the brake switch through wire F-765-BR-16 to terminal 30 of interlock relay and to terminal 30 of the brake 1 relay. Power travels through brake 1 relay to the neutral/brake solenoid via wire 777-PU-16. The neutral/brake solenoid energizes and the brakes release. wc_tx000494gb.fm 87

92 Drive System Electricals RD 27 Repair If the parking brake switch is moved from the ON to the OFF position, the parking brake will remain engaged if the control lever is out of NEUTRAL position. When the control lever is out of the neutral position, the neutral switch is open and the coil of the neutral switch relay is de-energized. When de-energized, there is no power transferred to the seat switch solenoid or to the interlock relay. Instead, power is transferred from wire 110-GN-16 to wire C720-BU-16. Wire C720-BU-16 provides power to terminal 30 of brake 2 relay. When the brake switch is in the ON position, the coils of the brake relays are energized, and the brakes are engaged. Moving the brake switch from the ON to the OFF position cuts power to wire 419-YL-16. Ordinarily, in this state, the brake relays coils de-energize, and the brakes disengage. However, since voltage is available at terminal 30 of the number 2 relay, the instant the brake switch is moved to the OFF position, power is transferred to wire 419-YL-16. The coils of the brake relays remain energized, the brakes remain engaged, and the parking brake indicator remains illuminated. The machine will remain in this state until the control lever is moved back to the NEUTRAL position. Similarly, when the operator leaves the seated position while driving (control lever out of NEUTRAL position, either forward or reverse), the seat switch opens, cutting the path to ground for power on wire C906- PU-16 to the interlock relay. With no path to ground, the interlock relay coil de-energizes and power is no longer available from wire 307-OR- 16 to the seat switch solenoid, thus the machine stops. When the operator returns to the seated position, the path to ground on wire C906-PU-16 is remade; however, power to the interlock relay through wire 307-OR-16 is unavailable because the control lever is out of the NEUTRAL position. The control lever must be placed back in the NEUTRAL position to restore power to the neutral switch relay s coil through wire 374-PK-16. This power can then be transferred to the interlock relay and on to the seat switch solenoid through wire 307-OR- 16. When the control lever is in the REVERSE position, the reverse switch (o) is closed; power is transferred to the backup alarm (a), and the alarm sounds. wc_tx000494gb.fm 88

93 RD 27 Repair Drive System Electricals e 200-BK-16 a 321-BR-16 p PU-10 b 121-YL-16 o n f 112-PU BK-16 g 419-YL BK GN GN-16 c X1 d A990-BU-16 X h OR-16 F765-BR YL BR OR PK GN-16 F765-BR OR-16 PLUG 307-OR-16 C906-PU OR BK C906-PU BK-16 87A r 1 2 s q 777-PU BK m 110-GN PK-16 C720-BU OR BK A i F765-BR YL PU-16 PLUG 201-BK A k C720-BU YL-16 PLUG 419-YL BK A l j wc_gr a Backup alarm k Brake 1 relay b Backup fuse l Brake 2 relay c Vibration fuse m Neutral/brake solenoid d Vibration indicator lamp n Neutral switch e B+ from power relay o Reverse switch f Brake/neutral fuse p Vibration ON/OFF switch g Parking brake indicator lamp q Seat switch h Brake switch r Interlock relay i Neutral switch relay s Seat switch solenoid j To starter relay wc_tx000494gb.fm 89

94 Drive System Electricals 5.2 Drive System Component Locations RD 27 Repair a b c d e f h g wc_gr a Interlock relay e Seat switch b Brake 2 relay f Neutral switch c Brake 1 relay g Neutral/brake solenoid d Neutral switch relay h Seat switch solenoid wc_tx000494gb.fm 90

95 RD 27 Repair 5.3 Troubleshooting Flowcharts Drive System Electricals The troubleshooting flowcharts are designed to step you through the process of determining the source of a problem with starting the engine should a problem exist. Many of the tests involve live voltages and therefore should only be attempted by qualified personnel. The procedures for carrying out the tests are included in this manual. Each flowchart includes references (by section number) to the location of the specific procedure(s) in the manual. wc_tx000494gb.fm 91

96 Drive System Electricals 5.4 Machine does not Drive (Propel) Troubleshooting RD 27 Repair Check position of brake switch. Machine does not Drive (Propel) Troubleshooting Flowchart 3A Is brake switch in OFF position? Yes No Place brake switch in OFF position. Place control lever in NEUTRAL position, then try driving again. Will machine now drive? No Yes Use machine as normal. Check condition of brake/neutral fuse. Is fuse OK? No Replace fuse. Yes Check wiring connection at neutral/brake solenoid. Will machine now drive? Yes 5.5 Use machine as normal. No Check wiring connection at seat switch solenoid. Will machine now drive? Yes 5.6 Use machine as normal. No See Flowchart 3B wc_gr wc_tx000494gb.fm 92

97 RD 27 Repair Drive System Electricals Continued from Flowchart 3A Machine does not Drive (Propel) Troubleshooting Flowchart 3B Check power to brake switch. Is 12V measured at brake switch? Yes No 5.7 Check wire 110-GN-10. Repair or replace wire as needed. Check power to brake 1 relay. Is 12V measured at brake 1 relay? No 5.8 Check wire F765-BR-16. Repair or replace wire as needed. Yes Check power to neutral/brake solenoid. Is 12V measured at neutral/brake solenoid? Yes No 5.5 Check wire 777-PU-16. If wire 777-PU-16 is OK, replace brake 1 relay. If not, repair or replace wire as needed. Check power to neutral switch relay. 4.9 Is 12V measured to neutral switch relay? Yes No Check wire 110-GN-16. Repair or replace wire as needed. See Flowchart 3C wc_gr wc_tx000494gb.fm 93

98 Drive System Electricals RD 27 Repair Machine does not Drive (Propel) Troubleshooting Flowchart 3C Continued from Flowchart 3B Check power to interlock 1 relay. Is 12V measured to interlock 1 relay? No 5.9 Check wires F765-BR-16 and 307-OR-16. If wire 307-OR-16 is OK, replace neutral switch relay. If not, repair or replace wires as needed. Yes Check wiring to and function of neutral switch. Is the neutral switch and wiring functioning properly? Yes 4.9 No Repair wires 110-GN-16 and 374-PK-16 and/or neutral switch as needed. Check wiring to and function of seat switch. Is the seat switch and wiring functioning properly? Yes 5.10 No Repair wire C906-PU-16 and/or seat switch as needed. Check hydraulic system. wc_gr wc_tx000494gb.fm 94

99 RD 27 Repair 5.5 Checking Neutral/Brake Solenoid Drive System Electricals See graphic: wc_gr The neutral/brake solenoid is fed power (battery voltage, approximately 12) via the brake 1 relay through wire 777-PU-16. To check power to the neutral/brake solenoid: Open the hood. The neutral/brake solenoid (a) is mounted to the drive pump Disconnect the wiring connector (b) Place the key switch in the ON position and measure voltage across wires 777-PU-16 and 200-BK-16. If 12V is not measured, check the continuity of the wires. Also check function of brake 1 relay. If 12V is measured, the neutral/brake solenoid should be functioning. If it is not, replace the neutral/brake solenoid. wc_tx000494gb.fm 95

100 Drive System Electricals 5.6 Checking Seat Switch Solenoid RD 27 Repair See Graphic wc_gr The seat switch solenoid is fed power (battery voltage, approximately 12) via the neutral switch relay and/or the interlock relay through wire 307-OR-16. To check power to the seat switch solenoid: Open the hood. The seat switch solenoid (a) is mounted near the drive pump Disconnect the wiring connector (b) With the brake switch in the OFF position, and the control lever in the NEUTRAL position, place the key switch in the ON position and measure voltage across wires 307-OR-16 and 200-BK-16. If 12V is not measured, check the continuity of the wires. Also check function of neutral switch relay and the interlock relay. If 12V is measured, the seat switch solenoid should be functioning; continue Swap out the coil of the seat switch solenoid with a known-to-beworking coil like that of the vibration ON/OFF solenoid (c). If the machine now drives, the seat switch solenoid is faulty; replace it. If the machine still won t drive, there is a problem with the hydraulics. See section Hydraulic System. wc_tx000494gb.fm 96

101 RD 27 Repair Drive System Electricals wc_tx000494gb.fm 97

102 Drive System Electricals 5.7 Checking Power to Brake Switch RD 27 Repair See Graphic: wc_gr The brake switch receives power (battery voltage, approximately 12) via the brake/neutral fuse through wire 110-GN-16. To check power to the brake switch, carry out the following procedure: Remove the screws securing the control console cover Place the key switch in the ON position Measure the voltage between wire 110-GN-16 (a) and ground. If 12V is not measured, check continuity of wire 110-GN-16. If 12V is measured, check the continuity of the brake switch, power to brake relay 1, and power to the interlock relay. wc_tx000494gb.fm 98

103 RD 27 Repair Drive System Electricals wc_tx000494gb.fm 99

104 Drive System Electricals 5.8 Checking Power to/from Brake 1 Relay RD 27 Repair See Graphic: wc_gr Brake 1 relay receives power (battery voltage, approximately 12) via the brake switch when it is in the OFF position through wire F765-BR- 16. The coil of brake 1 relay receives power from the brake switch when it is in the ON position. When energized, the brake 1 relay sends power to the neutral/brake solenoid. To check power to brake 1 relay, carry out the following procedure: Remove the screws securing the control console cover. Brake 1 relay (a) is located on the inside of the control console cover Disconnect the brake 1 relay. Place the key switch in the ON position. Place the brake switch in the OFF position Measure the voltage between wire F765-BR-16 (b) and ground. If 12V is not measured, check continuity of wire F765-BR-16. If 12V is measured, continue Place the brake switch in the ON position. Measure the voltage between wire 419-YL-16 (c) and ground. If 12V is not measured, check the continuity of wire 419-YL-16. If 12V is measured, continue Reconnect the brake 1 relay. Disconnect the wiring connector at the neutral/brake solenoid. Measure the voltage between wire 777-PU-16 and wire 200-BK-16. If 12V is not measured, brake 1 is malfunctioning; replace it. If 12V is measured, check the neutral brake solenoid. wc_tx000494gb.fm 100

105 RD 27 Repair Drive System Electricals a a c b wc_gr wc_tx000494gb.fm 101

106 Drive System Electricals 5.9 Checking Power to/from Interlock 1 Relay RD 27 Repair See Graphic: wc_gr Interlock 1 relay receives power (battery voltage, approximately 12) via the brake switch when it is in the OFF position through wire F765-BR- 16. The coil of interlock 1 relay receives power from the neutral switch. When energized, the interlock 1 relay sends power to the seat switch solenoid. To check power to interlock 1 relay, carry out the following procedure: Remove the screws securing the control console cover. Interlock 1 relay (a) is located on the inside of the control console cover Disconnect the Interlock 1 relay. Place the key switch in the ON position. Place the brake switch in the OFF position Measure the voltage between wire F765-BR-16 (b) and ground. If 12V is not measured, check continuity of wire F765-BR-16. If 12V is measured, continue Measure the voltage between each 307-OR-16 wire (c) and ground. If 12V is not measured, check continuity of each 307-OR-16 wire. Also check function of neutral switch relay. If 12V is measured, continue Reconnect the interlock 1 relay. Place the key switch in the ON position. Place the brake switch in the OFF position. Have an assistant sit in the operator s seat. Place the control lever in the NEUTRAL position, then move it from the NEUTRAL position (n) to either FORWARD (f) or REVERSE. Disconnect the seat switch solenoid (d) and measure the voltage between wire 307-OR-16 and ground. If 12V is not measured, check the continuity of wire 307-OR-16. Also check function and continuity of seat switch. If the wiring and the seat switch are OK, replace the interlock 1 relay. If 12V is measured, the interlock 1 relay is functioning. wc_tx000494gb.fm 102

107 RD 27 Repair Drive System Electricals a c b n f d wc_gr wc_tx000494gb.fm 103

108 Drive System Electricals 5.10 Checking Function of Seat Switch RD 27 Repair See Graphic: wc_gr When the operator leaves the seated position while driving (control lever out of NEUTRAL position, either forward or reverse), the seat switch opens cutting the path to ground for power on wire C906-PU-16 to the interlock relay. With no path to ground, the interlock relay coil deenergizes and power is no longer available from wire 307-OR-16 to the seat switch solenoid; thus the machine stops. When the operator returns to the seated position, the path to ground on wire C906-PU-16 is remade. But, power only returns to the seat switch solenoid when the control lever is replaced in the NEUTRAL position. To check the function of the seat switch, carry out the following procedures: Testing the seat switch requires that interlock 1 relay be working. Check the function of the interlock 1 relay. See section Checking Power to/from Interlock 1 Relay Remove the wiring connector (a) from the seat switch solenoid Have an assistant sit in the operator s seat and place the control lever in the NEUTRAL position (n) Place the key switch in the ON position (1) Measure the voltage to the seat switch solenoid across wires 307-OR- 16 and 200-BK-16. Battery voltage (approximately 12) should be measured. If 12V is not measure, there is a problem in the circuit. Troubleshoot the neutral switch relay and the interlock 1 relay. If 12V is measured, continue Have an assistant move the control lever to the FORWARD position (f). Once the lever is in the FORWARD position, have the assistant leave the seated position (stand up). Once again, check the voltage across wires 307-OR-16 and 200-BK-16. Note: Retry the test several times. Notice that the control lever must be replaced into the NEUTRAL position, then moved to the FORWARD position with each test. If 12V is not measure, the seat switch is working properly. If 12V is measured, the seat switch is not working; replace it Reconnect the wiring connector to the seat switch solenoid. wc_tx000494gb.fm 104

109 RD 27 Repair Drive System Electricals n f a wc_gr wc_tx000494gb.fm 105

110 Vibration System Electrics 6. Vibration System Electrics RD 27 Repair 6.1 Vibration System Electrical Overview See Graphic: wc_gr The main power relay distributes power to the vibration system fuse (h) through wire 112-PU-10. Power transfers from the vibration system fuse to the vibration control switch (a) in the control lever. When the vibration control switch is in the ON position, power transfers into wire A990-BU-16. This wire delivers power to the drum selector switch (f), the vibration indicator (g), and the solenoid (e) for the front drum. The vibration indicator illuminates, and the solenoid for the front drum energizes. When the drum selector switch is in the FRONT DRUM position, contacts for the rear drum are open, and the solenoid (d) for the rear drum is de-energized. When the drum selector switch is in the BOTH DRUMS position, contacts for the rear drum are closed. In this condition, power transfers to the solenoid for the rear drum through wire C924-YL-16, and the solenoid for the rear drum energizes. wc_tx000494gb.fm 106

111 RD 27 Repair Vibration System Electrics i a 4 1 b c 112-PU-10 h 125-OR BK-16 g A990-BU BR YL OR PK GN OR-16 2 f 1 3 C924-YL-16 C924-YL BK-16 d A990-BU BK-16 e wc_gr a Vibration control (ON/OFF) switch f Drum selector switch b Reverse switch g Vibration indicator lamp c Neutral switch h Vibration system fuse d e Drum vibration solenoid valve (rear) Drum vibration solenoid valve (ON/OFF) i B+ from power relay wc_tx000494gb.fm 107

112 Vibration System Electrics 6.2 Vibration System Electrical Component Locations RD 27 Repair a Drum vibration solenoid valve (rear) c Exciter selector switch b Drum vibration solenoid valve (ON/OFF) d Exciter ON/OFF switch wc_tx000494gb.fm 108

113 RD 27 Repair Vibration System Electrics 6.3 Checking the Vibration System Fuse See Graphic: wc_gr Remove the four screws (a) securing the fuse box cover Check condition of the 10A vibration system fuse (b); replace it if it is blown Replace the fuse box cover. wc_tx000494gb.fm 109

114 Vibration System Electrics 6.4 Checking Power to the Vibration Solenoids RD 27 Repair See Graphic: wc_gr The vibration solenoids are mounted to the vibration valve. The front drum solenoid (a) is fed power by wire A990-BU-16. The rear drum solenoid (b) is fed power by wire C924-YL-16. To check the power to the solenoids, carry out the following procedures. First, check the front drum solenoid Place the drum selector switch in the FRONT DRUM position Unplug the wiring connector to the front drum solenoid Place the key switch in the ON position and press the vibration control switch. Measure the voltage across wires A990-BU-16 and 200-BK- 16. If 12V is not measured, check the continuity of the wires and function of the vibration control switch. If 12V is measured, the front drum solenoid should be working. If there is doubt, check the hydraulic function of the valve Reconnect the wiring and turn the key switch to the OFF position. Next, check the rear drum solenoid Place the drum selector switch in the BOTH DRUMS position Unplug the wiring connector to the rear drum solenoid Place the key switch in the ON position and press the vibration control switch. Measure the voltage across wires C924-YL-16 and 200-BK-16. If 12V is not measured, check the continuity of the wires and function of the vibration control switch. If 12V is measured, the rear drum solenoid should be working. If there is doubt, check the hydraulic function of the valve Reconnect the wiring and turn the key switch to the OFF position. wc_tx000494gb.fm 110

115 RD 27 Repair Vibration System Electrics wc_tx000494gb.fm 111

116 Vibration System Electrics 6.5 Checking Drum Selector Switch RD 27 Repair See Graphic: wc_gr Remove the screws securing the control console cover Disconnect the wiring from the drum selector switch (a) Place the switch in the BOTH drums position and check for continuity across the terminals. There should be continuity Place the switch in the FRONT DRUM position and check for continuity across the terminals. There should be no continuity Replace the switch if it fails the above tests Reassemble the wiring and the control console cover. wc_tx000494gb.fm 112

117 RD 27 Repair 7. Spray System Electrics Spray System Electrics 7.1 Spray System Electrical Overview See Graphic: wc_gr The 112-PU-16 wire transfers power from the main power relay to the water spray fuse (b). Power transfers from the water spray fuse through wire 118-GY-16 to contact 2 of the water spray switch (c). When the water spray switch is in the CONTINUOUS position, contacts 1 and 2 are closed. This transfers power directly to the water spray pump (d) through wire C922-BR-16, and the water spray pump operates. It will operate without interruption while the water spray switch is in the CONTINUOUS position. When the water spray switch is in the INTERMITTENT position, contacts 2 and 3 of the water spray switch are closed. The C935-PU wire transfers power to the battery contact of the timer (a), also to contact 30 and the coil of the water spray relay (e). The ground path of the water spray coil is through the timer. The timer completes the ground path to the coil in 15-second increments. When the ground path is complete, the water spray relay coil is energized, and power transfers across the relay to the water spray pump. The water spray operates until the ground path of the water spray relay coil is broken. C935-PU-16 a B+ + BATTERY GROUND OUTPUT C935-PU BK-16 C937-WH PU-10 b 118-GY-16 2 c 1 3 C922-BR-16 C935-PU-16 C935-PU-16 C935-PU-16 PLUG C922-BR-16 C937-WH e C922-BR BK C937-WH-16 d wc_gr wc_tx000494gb.fm 113

118 Spray System Electrics 7.2 Spray System Troubleshooting RD 27 Repair When troubleshooting the spray system, start by checking the physical condition of the system: Water in tank. Condition of hoses. Frozen water in system. Condition of water filter. Condition of spray nozzles. Then check the electrical portion of the system: Spray system fuse. Function of spray system switch. Function of spray system relay. Power to spray pump. wc_tx000494gb.fm 114

119 RD 27 Repair 7.3 Checking the Spray System Fuse Spray System Electrics See Graphic: wc_gr Remove the four screws (a) securing the fuse box cover Check condition of the 10A spray system fuse (b); replace fuse if blown Replace fuse box cover. a b wc_gr wc_tx000494gb.fm 115

120 Spray System Electrics 7.4 Checking the Spray System Switch RD 27 Repair See Graphic: wc_gr The spray system switch is fed power (battery voltage) by wire 118- GY-16. When troubleshooting problems with the spray system, first check the fuse, then check that power is being transferred to the switch through wire 118-GY-16. To check the switch: Remove the screws securing the control console cover Label, then disconnect the wiring from the switch Place the switch in the OFF position and check the switch for continuity across each combination of the three terminals. There should be no continuity between any of the three terminals in the OFF position Place the switch in the INTERMITTENT position. There should be continuity between contacts 2 and 3. These are the two terminals (a and b) where the grey and purple wires are connected Place the switch in the CONTINUOUS position. There should be continuity between contacts 2 and 1. These are the two terminals (a and c) where the grey and brown wires are connected If the switch fails any of the tests above, replace it. wc_tx000494gb.fm 116

121 RD 27 Repair Spray System Electrics 7.5 Checking Power to/from Spray System Relay See Graphic: wc_gr The spray relay receives power (battery voltage, approximately 12) via the water timer through wire C935-PU-16. The coil of the spray relay also receives power via the water timer through wire C935-PU-16. When energized, the spray relay sends power to the water spray pump. To check power to the spray relay, carry out the following procedure: Remove the screws securing the control console cover. The spray relay (a) is located on the inside of the control console cover Disconnect the spray relay. Place the key switch in the ON position. Place the spray switch in the CONTINUOUS position Measure the voltage between wires C935-PU-16 (b and c) and ground. If 12V is not measured, check continuity of wire C935-PU-16. If 12V is measured, continue To check power from the spray relay, reconnect the spray relay. Place the key switch in the ON position. Place the spray switch in the CONTINUOUS position. Check the voltage between wire C922-BR-16 and ground. See section Checking Power to Spray System Pump. If 12V is not measured, check the continuity of wire C922-BR-16. If the wiring and spray switch are OK, replace the spray relay. If 12V is measured, the spray relay is functioning. wc_tx000494gb.fm 117

122 Spray System Electrics 7.6 Checking Power to the Spray System Pump RD 27 Repair See Graphic: wc_gr The spray relay receives power (battery voltage, approximately 12) via the water timer through wire C935-PU-16. The coil of spray relay also receives power via the water timer through wire C935-PU-16. When energized, the spray relay sends power to the water spray pump. To check power to the spray pump, carry out the following procedure: Disconnect the spray pump at connector (a). Place the key switch in the ON position. Place the spray switch in the CONTINUOUS position Measure the voltage between wires C922-BR-16 and 202-BK-16 at connector. If 12V is not measured, check continuity of wires C922-BR-16 and 202-BK-16. If 12V is measured, the spray pump should be working. If it is not, replace it. wc_tx000494gb.fm 118

123 RD 27 Repair Spray System Electrics wc_tx000494gb.fm 119

124 Hydraulic Cooler Fan Motor System 8. Hydraulic Cooler Fan Motor System RD 27 Repair 8.1 Checking Fan Motor Operation See Graphic: wc_gr The fan relay receives power (battery voltage, approximately 12) from the fan fuse through wire 122-BU-16. The coil of the relay receives power through a second wire connected to wire 122-BU-16. The ground path for the relay s coil is across the oil cooler temperature switch. When the temperature switch is closed, the coil of the relay is energized, and no power is transferred to the fan motor. When the temperature of the coolant rises above 110 C, the temperature switch opens, and the relay coil is de-energized. In this condition, the relay sends power to the fan motor. To check power to the fan motor relay, carry out the following procedure: Remove the screws securing the control console cover. The fan motor relay (a) is located on the inside of the control console cover Disconnect the fan motor relay. Place the key switch in the ON position Measure the voltage between wire 122-BU-16 and ground. If 12V is not measured, check the continuity of wire 122-BU-16. If 12V is measured, the relay is receiving power. To check power from the relay, carry out the following procedure: Place the key switch in the OFF position. Reconnect the fan relay Disconnect the hydraulic oil temperature switch (b) Place the key switch in the ON position. If the fan motor runs, the relay is operating. If the fan motor does not run, check wiring continuity. Repair or replace wiring as needed. When wiring is OK, continue With the hydraulic oil temperature switch still disconnected, remove the connector (c) to the fan motor. Place the key switch in the ON position and measure voltage across the connector. If 12V is measured, the fan motor is malfunctioning; replace it. If 12V is not measured, check the continuity of wiring. Repair or replace wiring as needed. wc_tx000494gb.fm 120

125 RD 27 Repair Hydraulic Cooler Fan Motor System a b c wc_gr B+ 112-PU BU BK-16 G979-BU A 2 wc_gr T BK Fan motor fuse 3 Oil cooler temperature switch 2 Fan motor relay 4 Oil cooler fan motor wc_tx000494gb.fm 121

126 Hydraulic System Basics 9. Hydraulic System Basics RD 27 Repair 9.1 Hydraulic System Precautions Escaping hydraulic fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, you must be treated immediately by a WARNING doctor familiar with this kind of injury. Always use a board or cardboard when checking for hydraulic fluid leaks. Relieve hydraulic pressure before working on machine. WARNING Personal injury can result from contact with hot hydraulic oil. Use extreme care and wear appropriate clothing, such as gloves and safety glasses, when working with hot hydraulic oil. 9.2 Hydraulic System Service Basics Many hydraulic system problems may be rectified by basic service and maintenance tasks. Before attempting in-depth service procedures, carry out the basic hydraulic service procedures listed below. Top off the hydraulic oil supply with the correct type and grade of oil. Clean and tighten all hydraulic fittings. Check hoses for holes and/or leaks. Air within the hydraulic system can greatly affect machine performance. Check/change hydraulic filter. Particles and debris in the filter are signs of failing component(s). Change the hydraulic oil and clean all components if there is debris found in the filter. Locate and replace the failing component before operating the machine. Carry out hydraulic tests with machine/hydraulic oil warm. Start and operate the machine at high idle for several minutes before conducting troubleshooting procedures. The hydraulic oil should be between C ( F). wc_tx000456gb.fm 122

127 RD 27 Repair 9.3 Relieving Pressure in Hydraulic Tank Hydraulic System Basics See Graphic: wc_gr Park the machine on a smooth, horizontal surface Place the control lever in NEUTRAL Engage the parking brake Stop the engine Open the engine compartment Slowly open the hydraulic tank cap. Note: The hydraulic tank is not pressurized. However, cap (a) should be removed in case the breather (b) is malfunctioning. If there is pressure in the tank, replace the breather Replace the tank cap. a b wc_gr wc_tx000456gb.fm 123

128 Hydraulic System Basics 9.4 Component Locations RD 27 Repair a i j f b g c d e h wc_gr a Hydraulic tank f Charge filter b Drive pump g Control valve group c Front drive motor h Vibration pump d Rear exciter motor i Servo e Steering charge pump j Vibration manifold wc_tx000456gb.fm 124

129 RD 27 Repair 9.5 Analyzing Hydraulic Oil Contamination Hydraulic System Basics If the hydraulic oil becomes contaminated, premature component failure could occur. Contaminated oil can also contribute to overheating. When inspecting the hydraulic oil filter for contamination, the type of contamination can help determine the probable cause of problems. Bronze colored particles suggest a pump or motor port plate failure. Shiny steel particles suggest pump or motor piston failure. Rubber particles indicate a seal failure or a hose failure. Aluminum particles suggest a steering and/or charge pump failure. If any particles are found in the hydraulic filter element, all components of the hydraulic oil system must be cleaned. Do not use any damaged components. Remove damaged components and replace with new. wc_tx000456gb.fm 125

130 Drive System Hydraulics 10. Drive System Hydraulics RD 27 Repair 10.1 Drive System Hydraulic Overview See grahic wc_gr Wacker RD 27 rollers are hydrostatically driven. The drive system consists of one variable-displacement piston pump (m) and two radial piston motors (h & i) one for each drum. The drive motors are plumbed in parallel and include integral brakes that are springactivated and hydraulically released (SAHR-type). The control lever (j), through charge pressure provided by the steering pump, controls the hydrostatic system. Engine rotation turns the pump drive shaft which then rotates the pump s piston barrel assembly. The pump s internal slipper pads allow the pistons to follow the angle of the swashplate. The swashplate angle is determined by the pump s servo piston (k), its position is controlled by the forward/reverse control lever. The further from the neutral position the forward/reverse control lever is moved, the greater the angle of the swashplate, which in turn means greater flow from the pump thus, faster movement of the drive motors. The action is the same whether moving forward or reverse. Charge oil to the drive system is provided by the steering pump. Oil flows from the steering pump through the charge filter (g) and into the drive pump. The oil is then diverted to three internal subsystems: The charge relief valve (e) The charge relief valve provides relief of the charge system if pressure builds up to 2400±100 kpa (348±14 psi). The neutral brake solenoid (k) The neutral brake solenoid controls 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 there is no flow from the drive pump because the control lever provides no flow to the servo piston to change the angle of the drive pump s swashplate. The internal springs of the servo piston automatically center the piston. The relief valve cartridges (a, b, c, and d) The function of the relief valve cartridges is two-fold. First, the makeup relief valves (b & c) provide makeup oil supply to the drive system if any has been lost due to leakage or slippage of the drive motors. Secondly, the main relief valves (a & d) provide drive pump highpressure relief if pressure builds up to 35000±2500 kpa (5439±363 psi). Excess oil is directed back into the pump case and/or back to the tank. wc_tx000456gb.fm 126

131 RD 27 Repair 10.2 Drive System Hydraulic Diagram Drive System Hydraulics m l k j a b c d f e h i g wc_gr a Main relief valve h Front drive motor b Makeup valve i Rear drive motor c Makeup valve j Control lever/group d Main relief valve k Neutral brake switch e Charge relief valve l Drive pump servo piston f From steering hydraulic system m Drive pump g Charge filter wc_tx000456gb.fm 127

132 Drive System Hydraulics Drive System Electrical Diagram RD 27 Repair e 200-BK-16 a 321-BR-16 p PU-10 b 121-YL-16 o n f 112-PU BK-16 g 419-YL BK GN GN-16 c X1 d A990-BU-16 X h OR-16 F765-BR YL BR OR PK GN-16 F765-BR OR-16 PLUG 307-OR-16 C906-PU OR BK A C906-PU BK r 1 2 s q 777-PU BK m 110-GN PK-16 C720-BU OR BK A i F765-BR YL PU-16 PLUG 201-BK A k C720-BU YL-16 PLUG 419-YL BK A l j wc_gr a Backup alarm k Brake 1 relay b Backup fuse l Brake 2 relay c Vibration fuse m Neutral/brake solenoid d Vibration indicator lamp n Neutral switch e B+ from power relay o Reverse switch f Brake/neutral fuse p Vibration ON/OFF switch g Parking brake indicator lamp q Seat switch h Brake switch r Interlock relay i Neutral switch relay s Seat switch solenoid j To starter relay wc_tx000456gb.fm 128

133 RD 27 Repair 10.3 Troubleshooting Drive System Drive System Hydraulics Problem: The drive system engages very slowly. Probable Cause Low charge pressure. The oil is too viscous. There is air in the oil. The hydraulic oil is low. Solution Adjust charge pressure. Replace hydraulic oil with correct weight and type. Check for leaks. Tighten all fittings. Fill tank with correct oil weight and type. The control valve is malfunctioning. Problem: The drive system engages very suddenly. Repair or replace the control valve. Probable Cause There is air in the oil. The servo valve spool is sticking. The control valve is sticking. Solution Change the hydraulic oil. Repair or replace the drive pump. Repair or replace the control valve. The charge pressure is excessive. Problem: The drive system operates in one direction only. Adjust the charge pressure. Probable Cause The drive pump swashplate has failed. The servo valve has failed. One of the multifunction valves is damaged. Solution Repair or replace the drive pump. Repair or replace the drive pump. Repair or replace the drive pump. The control valve has failed. Repair or replace the drive pump. Problem: The drive system does not disengage when the control lever is returned to neutral. Probable Cause The drive pump servo valve has failed. The drive pump servo piston has failed. The rocker arm section of the drive pump swashplate assembly has failed. The neutral adjustment of the servo valve is incorrect. The linkage rod between the directional control valves is incorrect. Solution Repair or replace the drive pump. Repair or replace the drive pump. Repair or replace the drive pump. Readjust the neutral setting. Repair or replace the drive pump. The control lever neutral switch has failed. Replace the neutral switch. Problem: The parking brake does not release when the parking brake button is pulled out. wc_tx000456gb.fm 129

134 Drive System Hydraulics RD 27 Repair Probable Cause The parking brake button has failed. The neutral/brake solenoid valve has failed. The neutral switch has failed. The neutral switch relay has failed. Low charge pressure. The brake relay(s) has failed. The brake group is sticking or damaged. There is a brake line that is pinched. Solution Replace the parking brake switch. Replace the neutral/brake solenoid valve. Replace the neutral switch. Replace the neutral switch. Adjust the charge pressure. Replace the brake relay(s). Repair or replace the drive motor. Repair or replace damaged lines. The steering/charge pump has failed. Repair or replace the steering/charge pump. Problem: The parking brake does not engage when the parking brake button is pushed down. Probable Cause The parking brake switch has failed. The brake relay(s) has failed. There is a pinched brake line. The neutral/brake solenoid valve has failed. Solution Replace the parking brake switch. Replace the brake relay(s). Repair or replace damaged lines. Replace the neutral/brake solenoid valve. There is a fault in the electrical circuit. Problem: There are external leaks from either drive motor. Repair or replace malfunctioning wiring and/or components. Probable Cause Motor case pressure is too high. There is a restriction in the oil return line to the hydraulic oil tank. There are damaged seals due to pressure peaks, use of unapproved hydraulic oil, or an incorrect tightening torque. The charge pump has failed. Problem: The oil in the drive system overheats. Probable Cause An incorrect type of oil is being used in the hydraulic circuit. The oil cooler is internally restricted. The radiator and/or the oil cooler is externally restricted. Solution Adjust charge pressure. Repair or replace damaged lines. Change the hydraulic oil and check all fittings for proper torques. Repair/replace the steering/charge pump. Solution Change the hydraulic oil. Flush the oil cooler. Replace the cooler if it is damaged. Clean the radiator and oil cooler. wc_tx000456gb.fm 130

135 RD 27 Repair There is a low charge line pressure that is caused by excessive internal leakage in the circuit. The charge pressure is low. Drive System Hydraulics Check the filter for contamination and repair/replace the worn component(s) as necessary. Adjust the charge pressure. wc_tx000456gb.fm 131

136 Drive System Hydraulics 10.4 Checking/Adjusting Charge Pressure RD 27 Repair See Graphic: wc_gr Park the machine on a smooth, horizontal surface Place the control lever in NEUTRAL Engage the parking brake Stop the engine Connect a kpa ( psi) pressure gauge to the pressure tap (a) on the charge filter base Start and operate the machine at high idle for several minutes so that hydraulic oil warms up. The hydraulic oil should be between C ( F) Observe the reading on the pressure gauge. The pressure should be 2400±150 kpa (350±22 psi). If necessary, adjust the adjusting screw as described below until the pressure is within range Locate the charge relief valve on the bottom face of the drive pump. Loosen the locknut (b) on the charge relief valve, and rotate the adjustment screw clockwise to increase charge pressure or counterclockwise to decrease charge pressure. Retighten locknut. wc_tx000456gb.fm 132

137 RD 27 Repair Drive System Hydraulics a b wc_gr wc_tx000456gb.fm 133

138 Drive System Hydraulics 10.5 Checking Main Relief Valve RD 27 Repair See Graphic: wc_gr Place the machine on a smooth, horizontal surface Place the control lever in the NEUTRAL position Block the drums with appropriate devices so that the machine cannot move Engage the parking brake Stop the engine Disconnect the brake supply line (a) from the front brake. Cap the lines as soon as they are disconnected Disconnect the brake supply line (b) from the rear brake. Cap the lines as soon as they are disconnected Connect a kpa (0 870 psi) pressure gauge to the forward pressure gauge fitting (c) of the hydraulic pump Connect a kpa (0 870 psi) pressure gauge to the reverse pressure gauge fitting (d) of the hydraulic pump Start the engine and operate the machine at high idle until the oil temperature reaches 43±5.6 C (110±10 F) Move the parking brake switch to the OFF position Move the control lever forward. Observe the reading on the pressure gauge. The reading should be 37500±2500 kpa (5440±360 psi) Move the control lever to the rear. Observe the reading on the pressure gauge. The reading should be 37500±2500 kpa (5440±360 psi) Stop the engine. If the pressures are within the specification, remove the gauges and reconnect the lines If the pressures are not within the specifications, have a certified hydraulic shop replace the forward (e) and/or reverse (f) relief valve cartridges as needed. wc_tx000456gb.fm 134

139 RD 27 Repair Drive System Hydraulics a b c e f d wc_gr wc_tx000456gb.fm 135

140 Drive System Hydraulics 10.6 Checking and Adjusting Drive Pump Neutral Setting RD 27 Repair See Graphic: wc_gr Place the machine on a smooth, horizontal surface Place the control lever in the NEUTRAL position Block the drums with appropriate devices so that the machine cannot move Engage the parking brake Stop the engine Connect a kpa ( psi) test gauge to the forward port (a) on the drive pump. Also connect a kpa ( psi) test gauge to the reverse port (b) on the drive pump Start the engine and operate the machine at high idle until the hydraulic oil temperature reaches 43±5.6 C (110±10 F) Read the pressure on both gauges. If the pressure is equal, shut down the machine and remove the gauges. If the pressure on both gauges is not equal, continue. The adjustment mechanism for the pump is located on the rear face of the pump close to the input shaft Place the speed control lever in the idle position Loosen the locknut on the adjustment mechanism for the pump. Turn the adjustment screw clockwise in order to increase the pressure on the forward port to 3450 kpa (500 psi). Note the angular position of the wrench Rotate the adjustment screw counterclockwise until pressure on the gauge in the reverse port shows 3450 kpa (500 psi). Note the angular position of the wrench Rotate the adjustment screw to the halfway point between the angular position from step 10 and the angular position from step 11. Hold the adjustment screw in place and tighten the locknut Recheck the pressures at high idle as in step 8. wc_tx000456gb.fm 136

141 RD 27 Repair 10.7 Testing the Parking Brake Drive System Hydraulics See Graphic: wc_gr Place the machine on a smooth, horizontal surface Place the control lever in the NEUTRAL position Block the drums with appropriate devices so that the machine cannot move Engage the parking brake Stop the engine Disconnect the oil supply lines for the front and rear brakes (a and b). To reduce hydraulic system contamination, cap the lines and motor fittings immediately after disconnecting them Start the engine and operate the machine at high idle until the hydraulic oil temperature reaches 43±5.6 C (110±10 F) Move the parking brake to the OFF position Move the control lever fully forward. Then, move the control lever fully backward. If the machine moves in either direction, repair the brakes Stop the engine and remove the caps from hydraulic lines and fittings. Reconnect the hydraulic lines to the motors. wc_tx000456gb.fm 137

142 Drive System Hydraulics 10.8 Testing Motor Case Drain Flow RD 27 Repair See Graphic: wc_gr Check the function of the parking brake before carrying out this test. Check both front and rear drive motors in this fashion Place the machine on a smooth, horizontal surface Place the control lever in the NEUTRAL position Block the drums with appropriate devices so that the machine cannot move Engage the parking brake Stop the engine Start the engine and operate it at high idle until the hydraulic oil is 43±5.6 C (110±10 F) Disconnect the case drain line (a) from the drive motor. Place the hose into a graduated container Run the engine for 30 seconds and collect the hydraulic oil. CAUTION: To prevent overheating of the hydraulic oil and possible damage to hydraulic components, do not run the test longer than 30 seconds Stop the engine. Check the amount of hydraulic oil in the graduated container. Determine the flow rate. The flow should be less than 3.8l/ min (1 US gal/min). If the flow is greater than this specification, repair or replace the motor. wc_tx000456gb.fm 138

143 RD 27 Repair Drive System Hydraulics wc_tx000456gb.fm 139

144 Vibration System Hydraulics 11. Vibration System Hydraulics RD 27 Repair 11.1 Vibration System Overview See Graphic: wc_gr The vibration system consists of a fixed-displacement, gear-type pump (i); a manifold (m); two fixed-displacement, gear-type motors (a & b) one mounted to each drum; and two exciters one inside each drum. Control for the vibration system comes via the exciter-mode selector toggle switch, the control lever pushbutton, and the vibratory manifold. The pushbutton on the control lever activates the exciter circuit while the exciter-mode selector toggle switch controls, through solenoid valves (d & k), which exciters will be rotating front drum only or both front and rear drum exciters. The vibratory manifold contains three relief valves: The main relief valve (j) This relief valve limits the maximum pressure in the system to a pressure differential of kpa (3630 psi). The anti-lope relief valve (e) This relief valve stops the eccentric weights from spinning after the vibration system is disengaged. The valve is set a pressure differential of kpa (1450 psi). The inter circuit line relief valve (g) This relief valve vents pressure spikes that are created in the line to the rear vibratory motor if the vibration mode is changed. The valve is set at a pressure differential across the motor of kpa (2180 psi). When the engine is running, the vibratory pump (i) draws oil from the hydraulic tank (c) through the strainer (h). Supply oil flows to port P of the vibratory manifold. When the vibration control switch is OFF, the front drum solenoid (k) is not energized, and the anti-lope relief valve (e) is closed. The front drum solenoid opens a passage which allows pump supply oil to flow through the oil cooler (f) to the hydraulic tank (c). The anti-lope relief valve and the check valve (l) prevent flow to the motors (a & b), and the motors do not turn. wc_tx000456gb.fm 140

145 RD 27 Repair Vibration System Hydraulics When the vibration control switch is ON and the drum selector switch is in the FRONT DRUM mode, the front drum solenoid is energized, and the rear drum solenoid valve (d) is de-energized. The check valve in the front drum solenoid valve blocks the passage for pump supply oil to flow to the oil cooler. When the front drum solenoid is energized, pilot oil acts against the anti-lope relief valve, and pump supply oil flows to the inlet side of the front drum motor (a). The pilot oil causes the anti-lope relief valve to open. The open valve creates a passage between the outlet port of the front drum motor and the oil cooler (f). The pressure differential across the front drum motor causes the exciter motor to rotate thus; the front drum vibrates. Return oil from the front drum motor flows across the rear drum solenoid valve. The oil bypasses the rear drum motor. The return oil goes through the anti-lope relief valve and the oil cooler and back into the tank. When the vibration control switch is moved to the OFF position, the front drum solenoid de-energizes. This opens a passage that allows the supply oil from the pump to flow through the oil cooler. This action discontinues the pilot signal to the anti-lope relief valve and the supply flow to the inlet side of the front drum motor. The spring which acts against the anti-lope relief valve closes the valve. The closed valve blocks the return passage from the outlet side of the front drum motor. The momentum of the exciter in the front drum attempts to continue rotating the vibratory motor. This rotation causes pressure in the return line of the front motor to increase. The increased pressure acts against the anti-lope relief valve. When the pressure which acts against the anti-lope relief valve reaches a pressure differential of kpa (1450 psi), the relief valve opens. The open relief valve vents the excess pressure into the line to the oil cooler. The anti-lope relief valve vents excess pressure from the system. The anti-lope relief valve also creates back pressure on the outlet side of the front drum motor. The back pressure provides a braking effect on the front drum motor, which stops the rotation of the exciter. wc_tx000456gb.fm 141

146 Vibration System Hydraulics RD 27 Repair When the vibration control switch is in the ON position, and the vibration selector switch is in BOTH DRUMS mode, the front and the rear drum solenoids are energized. The front drum solenoid forces the pilot oil to act against the anti-lope relief valve. The solenoid forces the supply oil from the pump to flow to the inlet side of the front drum motor. This causes the front drum to vibrate. The rear drum solenoid blocks the passage between the outlet side of the front drum motor and the oil cooler. The return oil from the front drum motor is forced to flow to the inlet side of the rear drum motor, The return oil acts against the rear inter circuit line relief valve. The pilot oil which acts against the anti-lope relief valve causes the valve to open a passage between the outlet side of the rear drum motor and the oil cooler. The pressure differential across the rear drum motor causes the motor to rotate, thus the rear drum vibrates. The inter circuit line relief valve limits the maximum pressure at the inlet side of the rear drum motor. The inter circuit relief valve protects the vibration system from pressure spikes. When the vibration system is ON, pressure spikes are created when the drum selector switch is moved from the FRONT DRUM position to the BOTH DRUMS position. wc_tx000456gb.fm 142

147 RD 27 Repair 11.2 Vibration System Hydraulic Diagram Vibration System Hydraulics a Front drum vibratory motor h Strainer b Rear drum vibratory motor i Vibratory pump c Hydraulic tank j Main relief valve d Drum vibration solenoid valve (rear) e Anti-lope relief valve l Check valve k Drum vibration solenoid valve (ON/OFF) f Oil cooler m Vibratory manifold g Inter circuit line relief valve wc_tx000456gb.fm 143

148 Vibration System Hydraulics 11.3 Vibration System Electrical Diagram RD 27 Repair i a 4 1 b c 112-PU-10 h 125-OR BK-16 g A990-BU BR YL OR PK GN OR-16 2 f 1 3 C924-YL-16 C924-YL BK-16 d A990-BU BK-16 e wc_gr a Vibration control (ON/OFF) switch f Drum selector switch b Reverse switch g Vibration indicator lamp c Neutral switch h Vibration system fuse d e Drum vibration solenoid valve (rear) Drum vibration solenoid valve (ON/OFF) i B+ from power relay wc_tx000456gb.fm 144

149 RD 27 Repair 11.4 Troubleshooting Vibration System Vibration System Hydraulics Problem: The vibration system does not work in forward or reverse travel. Probable Cause Low hydraulic oil level. There is a restriction in the oil strainer. Low charge oil pressure. The vibratory manifold is not functioning properly. The vibration solenoid valves are not functioning properly. The vibratory pump is not functioning properly. The vibratory motors are not functioning properly. The vibration ON/OFF switch is not functioning properly. There is a fault in the electrical wiring. Problem: There is periodic loss of vibration. Probable Cause There is a loose connection in the electric circuit wiring. Solution Replace hydraulic oil with correct weight and type. Clean/replace the suction strainer. See Checking/Adjusting Charge Pressure. Clean/rebuild vibratory manifold. Test/replace vibration solenoid valves. Clean/rebuild vibratory pump. Clean/rebuild vibratory motors. Replace the vibration ON/OFF switch. Trace circuits. Repair or replace wiring as needed. Solution Trace circuits. Repair or replace wiring as needed. The vibration ON/OFF switch is not functioning properly. Problem: The engagement of the vibration systems harsh. Replace the vibration ON/OFF switch. Probable Cause The relief valve for the vibration manifold is set too high. Problem: The start of vibration is slow. Probable Cause The solenoid valves are not functioning properly. The main relief on the vibratory manifold is set too low. The engine speed is too low. Problem: Slow stop of vibration. Probable Cause The solenoid valves are not functioning properly. The vibration ON/OFF switch is not functioning properly. The relief valve does not close completely on the return side circuit. Solution Reset the relief valve. Solution Test and replace faulty solenoid valves. Reset the relief valve. Reset/adjust engine speed. Solution Test and replace faulty solenoid valves. Replace the vibration ON/OFF switch. Replace the relief valve. wc_tx000456gb.fm 145

150 Vibration System Hydraulics RD 27 Repair Problem: The machine will not reach maximum vibration frequency. Probable Cause The engine high idle is not correctly adjusted. The pressure for the main relief valve is set too low. The vibratory motor is not functioning properly. The vibratory pump is not functioning properly. The exciter bearings have failed. Solution Readjust high idle. Readjust/replace relief valve. Clean/rebuild/replace vibratory motor. Clean/rebuild/replace vibratory pump. Replace bearings. The vibration solenoid valves are not completely closed. Problem: The hydraulic oil in the circuit overheats. Replace solenoid valves. Probable Cause The hydraulic cooler and/or radiator is restricted. An incorrect type of oil is being used in the hydraulic system. Solution Clean hydraulic cooler and radiator. Change the hydraulic oil. The pressure for the main relief valve is set too low. Adjust/replace the main relief valve. Problem: The machine will only vibrate in dual (both) drum mode. Probable Cause The vibration solenoid is not functioning properly. There is a failure in the vibration manifold. Solution Replace the vibration solenoid. Replace the vibration manifold. There is a failure in the vibration control switch. Replace the vibration control switch. Problem: The machine will only vibrate in dual (both) drum mode. Probable Cause The vibration solenoid is not functioning properly. There is a failure in the vibratory manifold. There is a failure in the vibration control switch. Problem: The vibration system does not engage. Probable Cause The vibration system fuse is open (blown). The vibration ON/OFF switch has failed. A vibration solenoid has failed. Solution Replace the vibration solenoid. Replace the vibratory manifold. Replace the vibration control switch. Solution Replace the vibration system fuse. Replace the vibration ON/OFF switch. Test/replace faulty solenoids. wc_tx000456gb.fm 146

151 RD 27 Repair 11.5 Testing Vibration Pump Flow Vibration System Hydraulics See Graphic: wc_gr Place the machine on a smooth, horizontal surface Place the control lever in the NEUTRAL position Block the drums with appropriate devices so that the machine cannot move Engage the parking brake Stop the engine Start the engine and operate it at high idle until the hydraulic oil is 43±5.6 C (110±10 F) Disconnect the hydraulic hose (a) from the P port of the vibration manifold. Place the hose in a graduated container Run the engine for 15 seconds and collect the hydraulic oil. Stop the engine. Check the amount of hydraulic oil in the graduated container. Determine the flow rate. The flow should be less than 32 l/ min (8.5 US gal/min). If the flow rate is substantially different from that listed, check the tension on the drive belt. Replace the belt or the pump Reconnect the hydraulic fittings. a wc_gr wc_tx000456gb.fm 147

152 Vibration System Hydraulics 11.6 Testing and Adjusting Vibration Valve Main Relief RD 27 Repair See Graphic: wc-gr Place the machine on a bed of tires. CAUTION: Do not conduct this test with the machine parked on a hard surface such as concrete. Damage to the machine may occur Place the control lever in the NEUTRAL position Engage the parking brake Stop the engine Connect a kpa ( psi) pressure gauge to the pressure valve (a) on top of the vibration manifold Start the engine and operate the machine at high idle until the hydraulic oil is 43±5.6 C (110±10 F) Press the vibration control button (c) on the control lever to activate the vibration system. Observe the pressure gauge. Note: The force needed to overcome the inertia of the exciter causes a momentary increase in pressure. The system pressure will reach the relief setting for a second or two. The highest pressure observed on the gauge is the main relief valve setting, 25000±1800 kpa (3630±25 psi) Stop the engine. If the pressure observed is within the specification, remove the gauge and reconnect the hydraulic line to the vibration manifold. If the pressure is not within the specification, continue Remove the cap from the main relief valve (b) Loosen the locknut and turn the adjustment screw clockwise to increase pressure, counterclockwise to decrease pressure Hold the adjustment screw in place and tighten the locknut Recheck the main relief setting. wc_tx000456gb.fm 148

153 RD 27 Repair Vibration System Hydraulics c a b wc_gr wc_tx000456gb.fm 149

154 Vibration System Hydraulics RD 27 Repair 11.7 Testing and Adjusting Vibration Valve Intercircuit Relief See Graphic: wc_gr Place the machine on a bed of tires. CAUTION: Do not conduct this test with the machine parked on a hard surface such as concrete. Damage to the machine may occur Place the control lever in the NEUTRAL position Engage the parking brake Stop the engine Disconnect the rear vibration motor line at port (a) on the rear vibration motor Install a tee fitting in the line and connect a kpa ( psi) pressure gauge to the tee Start the engine and operate the machine at high idle until the hydraulic oil is 43±5.6 C (110±10 F) Place the vibration mode selector switch to the FRONT DRUM position Press the vibration control button (c) on the control lever to activate the vibration system. Allow the system to stabilize Place the vibration mode selector switch to the BOTH DRUMS position. Observe the pressure gauge. Note: The force needed to overcome the inertia of the exciter causes a momentary increase in pressure. The system pressure will reach the relief setting for a second or two. The highest pressure observed on the gauge is the rear relief valve setting 15000±100 kpa (2180±15 psi) Stop the engine. If the pressure observed is within the specification, remove the gauge and reconnect the hydraulic line. If the pressure is not within the specification, continue Remove the cap from the rear relief valve (b) Loosen the locknut and turn the adjustment screw clockwise to increase pressure, counterclockwise to decrease pressure Hold the adjustment screw in place and tighten the locknut Recheck the main relief setting. wc_tx000456gb.fm 150

155 RD 27 Repair Vibration System Hydraulics wc_tx000456gb.fm 151

156 Vibration System Hydraulics 11.8 Testing and Adjusting Vibration Valve Anti-Lope Relief RD 27 Repair See Graphic: wc_gr Place the machine on a bed of tires. CAUTION: Do not conduct this test with the machine parked on a hard surface such as concrete. Damage to the machine may occur Place the control lever in the NEUTRAL position Engage the parking brake Stop the engine Disconnect the rear vibration motor line at port (a) on the rear vibration motor Install a tee fitting in the line and connect a kpa ( psi) pressure gauge to the tee Start the engine and operate the machine at high idle until the hydraulic oil is 43±5.6 C (110±10 F) Place the vibration mode selector switch to the BOTH DRUMS position Press the vibration control button (c) on the control lever to activate the vibration system. Observe the pressure gauge. Note: The force needed to overcome the inertia of the exciter causes a momentary increase in pressure. The system pressure will reach the relief setting for a second or two. The highest pressure observed on the gauge is the anti-lope relief valve setting 10000±50 kpa (1450±10 psi) Stop the engine. If the pressure observed is within the specification, remove the gauge and reconnect the hydraulic line. If the pressure is not within the specification, continue Loosen the locknut on anti-lope relief valve (b). Turn the adjustment screw clockwise to increase pressure, counterclockwise to decrease pressure Hold the adjustment screw in place and tighten the locknut Recheck the setting. wc_tx000456gb.fm 152

157 RD 27 Repair Vibration System Hydraulics wc_tx000456gb.fm 153

158 Vibration System Hydraulics 11.9 Testing Vibration Motor Case Drain Flow RD 27 Repair See Graphic: wc_gr Place the machine on a bed of tires. CAUTION: Do not conduct this test with the machine parked on a hard surface such as concrete. Damage to the machine may occur Place the control lever in the NEUTRAL position Engage the parking brake Start the engine and operate the machine at high idle until the hydraulic oil is 43±5.6 C (110±10 F) Stop the engine Disconnect the case drain line (a) from the vibration motor. Place the hose in a graduated container With the vibration mode selector switch set to the FRONT DRUM position and the vibration control button (b) in the ON position to activate the vibration system, run the engine for 30 seconds and collect the hydraulic oil Stop the engine. Check the amount of hydraulic oil in the graduated container. Determine the flow rate. The flow should be less than 3.8 l/ min (1 US gal/min) If the flow rate is not with the above specification, repair or replace the vibration motor. wc_tx000456gb.fm 154

159 RD 27 Repair Testing Vibration Frequency Vibration System Hydraulics Place the machine on a bed of tires. CAUTION: Do not conduct this test with the machine parked on a hard surface such as concrete. Damage to the machine may occur Place the control lever in the NEUTRAL position Engage the parking brake Start the engine and operate the machine at high idle until the hydraulic oil is 43±5.6 C (110±10 F) Place a vibration tachometer such as a Sirometer on the drum Place the vibration mode selector switch in the BOTH DRUMS position and the vibration control button (b) in the ON position to activate the vibration system Observe the vibration tachometer. At high idle, the vibration frequency should be 3960 vibrations per minute (vpm); at low idle, 3300 vpm Carry out the test for each drum. When completed, shut down the engine If necessary, adjust the idle speed to obtain proper vibrations per minute. wc_tx000456gb.fm 155

160 Steering System Hydraulics 12. Steering System Hydraulics RD 27 Repair 12.1 Steering System Overview See Graphic: wc_gr The steering system consists of a gear-type pump, the steering control unit (servo), and the steering cylinder (e). The steering pump also provides charge oil to the drive system (b). When the engine is running, the steering pump (d) draws oil from the hydraulic tank (f) through a strainer (c). Supply oil from the steering pump flows to the steering control unit (a). Inside the steering control unit, pump supply oil acts against the relief valve (g) and the anticavitation check valve (h). The oil then flows to the steering control spool (i). When the steering wheel is not being rotated, the center envelope of the steering control spool is active. Supply oil flows through the open center of the steering control spool, out of the steering control unit, and to the drive system charge filter. When the operator turns the steering wheel to the right, the right envelope of the steering control spool is active. Oil entering the steering control unit flows across the steering control spool to the metering section. The metering pump rotates when the steering wheel is turned. The metering pump directs flow through the steering control spool and to the rod end of the steering cylinder. Oil that flows into the steering cylinder causes the machine to turn right. As the operator turns the steering wheel faster, the metering pump increases the flow to the steering cylinder. This allows the machine to turn faster. The steering control spool directs return oil from the head end of the steering cylinder to the charge filter for the drive system. wc_tx000456gb.fm 156

161 RD 27 Repair 12.2 Steering System Hydraulic Diagram Steering System Hydraulics a Steering control unit f Hydraulic tank b Flow to drive charge filter g Relief valve c Strainer h Anticavitation check valve d Steering pump i Steering control spool e Steering cylinder wc_tx000456gb.fm 157

162 Steering System Hydraulics 12.3 Steering System Troubleshooting RD 27 Repair Problem: The steering pump is noisy and the steering cylinder rod does not move easily. Probable Cause Air in the steering hydraulic circuit. The steering pump is worn. There is a loose connection in the oil line feeding the steering pump. The hydraulic oil level is low. Solution Vent the system. Check the steering pump flow rate. Replace the steering pump if necessary. Tighten all connections. Replace hydraulic lines if necessary. Check the hydraulic oil level and top off with correct weight and type of hydraulic oil. Viscosity of the hydraulic oil is incorrect. Change the hydraulic oil. Problem: Excessive force is required to turn the steering wheel. Probable Cause The steering unit relief valve is open. The hydraulic oil level is low. The oil pressure in the steering pump is too low. The steering unit is damaged. The hydraulic oil is cold. Solution Replace the steering unit relief valve. Check the hydraulic oil level and top off with correct weight and type of hydraulic oil. Check the steering pump flow rate. Replace the steering pump if necessary. Replace the steering unit. Start engine and run machine until hydraulic oil is warm. Alignment of steering column is not correct. Check steering column alignment and make necessary changes. Problem: The machine does not turn when the steering wheel turns. Probable Cause The hydraulic oil level is low. Air in the steering hydraulic circuit. There is dirt in the hydraulic system. The articulated steering joint is locked. Solution Check the hydraulic oil level and top off with correct weight and type of hydraulic oil. Vent the system. Change the hydraulic oil. Remove the locking pin. The steering cylinder has worn piston rings. Problem: The machine turns slowly in both directions. Repair or replace the steering cylinder. Probable Cause Solution wc_tx000456gb.fm 158

163 RD 27 Repair There is not enough oil flowing from the steering pump. The suction line to the steering pump is restricted. Steering unit operation is not correct. There is a seal leakage in the steering cylinder. Steering System Hydraulics Check steering pump flow rate. Replace the steering pump if necessary. Check hydraulic lines and repair or replace hydraulic lines as necessary. Repair or replace the steering unit. Repair or replace the steering cylinder. The pressure in the steering circuit is too low. Problem: The machine turns slowly in one direction. Check the steering pump flow rate. Replace the steering pump if necessary. Probable Cause Solution There is a restriction in the steering unit. Repair or replace the steering unit. Problem: The steering unit metering pump does not return to center position correctly. Probable Cause Alignment of the steering column is not correct. The steering unit is not functioning correctly. Problem: Hydraulic oil is overheating Probable Cause Viscosity of the hydraulic oil is not correct. Air is mixed with the hydraulic oil. The relief valve in the steering system has a defect. There is a restriction in the steering system or lines. Solution Check steering column and adjust if necessary. Repair or replace the steering unit. Solution Replace the hydraulic oil with correct weight and type of hydraulic oil. Replace the hydraulic oil with correct weight and type of hydraulic oil. Replace the steering unit relief valve. Inspect the steering circuit. Repair or replace damaged components. The oil cooler is plugged. Repair or replace the hydraulic oil cooler as necessary. Problem: The steering wheel turns without manually turning the wheel. Probable Cause Foreign material is causing the spool valve in the metering pump to jam. Centering springs are broken or damaged in the metering pump. The temperature of the hydraulic oil is too hot. Solution Repair or replace the steering unit. Repair or replace the steering unit. Top off the hydraulic oil supply. Clean the hydraulic oil cooler. Change the hydraulic oil to that of correct weight and type. wc_tx000456gb.fm 159

164 Steering System Hydraulics 12.4 Testing Steering Pump Flow RD 27 Repair See Graphic: wc_gr Place the machine on a smooth, horizontal surface Place the control lever in the NEUTRAL position Block the drums with appropriate devices so that the machine cannot move Engage the parking brake Stop the engine Place the articulated steering joint locking pin in the locked position Start the engine and operate it at high idle until the hydraulic oil is 43±5.6 C (110±10 F) Remove the steering tower cover (a) Disconnect the hydraulic hose (b) from the P port of the steering control unit. Place the hose in a graduated container Run the engine for 15 seconds and collect the hydraulic oil. Stop the engine. Check the amount of hydraulic oil in the graduated container. Determine the flow rate. The flow should be at least 19 l/min (5.0 US gal/min) Stop the engine Perform this step while in the operator s seat. Make sure all other personnel are clear of the machine. Turn the steering wheel. Run the engine for 15 seconds and collect the hydraulic oil. Stop the engine. Check the amount of hydraulic oil in the graduated container. Determine the flow rate. The flow should be at least 18 l/min (4.8 US gal/min) If the flow is not with the above specifications, the steering unit must be repaired or replaced Reconnect the hydraulic lines. Fill the hydraulic tank with the oil of the proper weight and type. wc_tx000456gb.fm 160

165 RD 27 Repair Steering System Hydraulics wc_tx000456gb.fm 161

166 Steering System Hydraulics 12.5 Testing Steering Unit Relief Valve RD 27 Repair See Graphic:wc_gr Place the machine on a smooth, horizontal surface Place the control lever in the NEUTRAL position Block the drums with appropriate devices so that the machine cannot move Engage the parking brake Stop the engine Place the articulated steering joint locking pin in the locked position Start the engine and operate it at high idle until the hydraulic oil is 43±5.6 C (110±10 F) Stop the engine Disconnect the hose from the head end of the steering cylinder (a) and attach a kpa ( psi) pressure gauge to the cylinder. The cylinder can be accessed from underneath the machine Attach a second kpa ( psi) pressure gauge to the charge pressure tap (b) Start the engine. Turn the wheel to the left, and read the pressure difference between the two pressure gauges. The pressure difference should be 13250±2500 kpa (1920±360 psi) Stop the engine If the pressure is outside of the above specification, check the system for damage and/or replace the metering pump (c) of the steering unit. If the pressure is within the specification, release the pressure from the hydraulic system and remove the tooling. Reconnect the hose to the head end of the steering cylinder and disengage the steering lock pin. wc_tx000456gb.fm 162

167 RD 27 Repair Steering System Hydraulics a c b wc_gr wc_tx000456gb.fm 163

168 Steering System Hydraulics 12.6 Checking Steering Time RD 27 Repair Place the machine on a smooth, horizontal surface Place the control lever in the NEUTRAL position Start the engine and operate it at high idle until the hydraulic oil is 43±5.6 C (110±10 F) Make sure the machine is in the straight travel position Record the amount of time that is required to perform a full right turn (cycle time). Also record the number of turns of the steering wheel that is necessary to perform a full right turn. The number of turns of the steering wheel to complete a full right turn should be two and one-half turns. The cycle time for a full right turn should be less than 2 seconds Rotate the steering wheel back to the straight travel position Conduct the same test for a full left turn as you did for a full right turn. Again, the amount of turns to complete a full left turn is two and onehalf turns. The cycle time is less than 2 seconds Stop the engine. If the values for cycle times and/or steering wheel rotation are not within the specifications, there could be a leaking seal and/or a fault of the metering pump. Repair or replace the metering pump wc_tx000456gb.fm 164

169 RD 27 Repair Disassembly/Reassembly Procedures 13. Disassembly/Reassembly Procedures 13.1 Tools 13.2 Ordering Parts Since all possible problems encountered while repairing the equipment cannot be anticipated, it is up to the mechanic to use common sense and good judgment in tool selection. The use of any special tools is recommended only for those operations where the use of conventional tools proves inadequate. Before substituting another tool or procedure, you should be satisfied that neither personal injury nor damage to the component will result. The repair procedures contained in this manual do not include part numbers. For parts replacement information, refer to the Parts Book originally supplied with the unit. If the original Parts Book has been lost, a replacement may be ordered from Wacker Corporation. When ordering a replacement Parts Book, please list the model number, item number, revision level, and serial number of the machine. Parts Books are also available on the Wacker Corporation Web site. See Enter site as visitor Reference Numbers ( ) 13.4 Weight Block Repair procedures contain reference numbers enclosed in parentheses ( ). These numbers refer to the item numbers shown on the assembly drawings and other detailed drawings. They are included to aid the mechanic in identifying parts and assembling components. See Graphic: wc_gr The weight block symbol gives an approximate weight measurement to aid the mechanic when lifting/hoisting larger components. 250 kg (550 lbs.) wc_gr wc_tx000457gb.fm 165

170 Disassembly/Reassembly Procedures 13.5 Removing and Installing Steering Servo Valve RD 27 Repair See Graphic: wc_gr Disassembly: Disconnect the battery Open the hood and place the safety bar in position Remove the vandal cover Remove the screws securing the control console cover (a) and remove the control console cover Disconnect the key switch (b) from the harness Label the four hydraulic hoses (c). Remove the hydraulic hoses, one at a time, from the servo valve (f). Plug the hydraulic hoses and the fittings of the servo valve immediately to prevent contamination of the hydraulic system. There will be some leaking from the servo valve. Collect all hydraulic oil that has leaked from the servo valve. Dispose of collected hydraulic oil according to local environmental regulations Remove the three longer screws (d) securing the servo valve. Remove the shorter screw (e) and remove the servo valve from the control console. Reassembly: Install the shorter screw (e) to the secure servo valve (f) to the tower. Install the three longer screws (d) to secure the servo valve. Torque all screws to 22.5±2.5Nm (17±2 ft.lbs.) Connect the hydraulic hoses (c) to the servo valve 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.) Reconnect the key switch (b) to the harness Inspect the seal around the control console and replace the seal if necessary Reattach the control console cover (a) Reattach the vandal guard. wc_tx000457gb.fm 166

171 RD 27 Repair Disassembly/Reassembly Procedures d e a b e d c f wc_gr wc_tx000457gb.fm 167

172 Disassembly/Reassembly Procedures 13.6 Removing and Installing Drive Motors RD 27 Repair See Graphic: wc_gr Removal: Position the machine by moving it forward or reverse as needed so that the shock mount screws (a) are accessible Remove the hose cover protective plate (b) Have a container ready to collect any draining hydraulic oil. Label the hydraulic hoses (c) to aid in re-installation. Remove the hoses one at a time and plug them as soon as they are free of the motor. Dispose of collected hydraulic oil according to local environmental regulations 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 Remove the top three shock mount screws (a 1, a 2, a 3 ). Jack up the machine slightly more to relieve pressure and remove the last two shock mount screws (a 4, a 5 ) Connect an appropriate hoist or lift to the lifting point of the drum support Remove the lower two screws (e) securing the drum support to the frame. In their place, insert pins (M16x200 screws with head cut off and grooved for screwdriver). Remove the other two screws and slide and lift the drum support (f) from the machine. Remove the large spacer (g) and any shims. Note: If shock mounts are to be replaced, the size and number of shims may change Remove the five screws (h) securing the shock mount support plate (i) and remove the support plate Remove the seven screws (l) securing the motor (k) to the drum support (m) and remove the motor Remove the fittings (j) from the motor (k). Reuse the fittings on the replacement motor. wc_tx000457gb.fm 168

173 RD 27 Repair Disassembly/Reassembly Procedures a 1 a 2 g b a 3 a 5 a 4 c d e h j f h i k m l wc_gr wc_tx000457gb.fm 169

174 Disassembly/Reassembly Procedures See Graphic: wc_gr RD 27 Repair Installation: Install the hydraulic fittings (a) to the drive motor (b) Using Loctite 243 or equivalent on seven screws (c), secure the drive motor to the drum support (d). Torque the screws to 200 Nm (148 ft.lbs.) Using Loctite 243 or equivalent on five screws (e), secure the shockmount support plate (f) to the drive motor. Torque the screws to 200 Nm (148 ft.lbs.) Insert the pins (g) into the machine frame to aid in installation. Slide the shims (h) and spacers (i) over the pins Slide the drum support assembly over the pins and secure it to the machine frame with two screws. Remove the pins and install the other two screws Using the five screws (j), secure the shockmount support plate to the drum. Torque the screws to 200 Nm (148 ft.lbs.) Reconnect the hydraulic hoses (k) to the drive motor Remount the hose guard (l). wc_tx000457gb.fm 170

175 RD 27 Repair Disassembly/Reassembly Procedures e a b d c e f h i g j l k wc_gr wc_tx000457gb.fm 171

176 Disassembly/Reassembly Procedures 13.7 Removing and Installing Exciter Motor RD 27 Repair See Graphic: wc_gr Turn the engine off and disconnect the battery. Removal: Remove the screws securing the hose protective cover (a) and remove the hose protective cover Remove the hose clamps (b) securing the exciter motor to the drum support Have a container ready to collect any draining hydraulic oil. Remove the case drain hose (c) from the motor. Plug the case drain line to prevent hydraulic system contamination. Label the two remaining hoses (d and e). Remove the hoses one at a time. Plug the hoses to prevent hydraulic system contamination. Dispose of any hydraulic oil according to local environmental regulations Remove the fittings (f and g) from the motor to access the screws (h) securing the motor. Reuse the fittings Remove the two screws (h) and remove the motor (i). Installation: 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 mesh with the green adapter. Apply Loctite 243 or equivalent to the two screws (h) and mount the exciter motor (i) with the two screws hand tighten the screws only If the hydraulic fittings (f and g) are already attached to the exciter motor (i), remove them. Then, torque the screws (h) securing the exciter motor to 40 Nm (29 ft.lbs.). Reattach the hydraulic fittings; however, at this time hand tighten the hydraulic fittings only Connect the two hydraulic hoses (d and e) removed in step Connect the case drain hose (c) Tighten all the hydraulic fittings Install the hose clamps (b) Install the hose protective cover (a). wc_tx000457gb.fm 172

177 RD 27 Repair Disassembly/Reassembly Procedures a b f g c e d h i j wc_gr wc_tx000457gb.fm 173

178 Disassembly/Reassembly Procedures 13.8 Removing Drum RD 27 Repair See Graphic: wc_gr Removal: Support the machine with jacks from underneath and/or a crane at the towing point (a) Remove the drive-side drum support. See section Removing and Installing Drive Motor Remove the hydraulic hoses from the exciter motor. See section Removing and Installing Exciter Motor To aid in reinstallation, mark the floor (b) where the drum rests. Mark the center point of contact and the outside edges Remove the bottom two screws (c) securing the drum support. In their place, insert two pins. Remove the top two screws (d). Remove the pins and rotate the drum support to the floor Remove the large spacer and the shims Lift the machine slightly if necessary to roll the drum (e) from underneath the machine. wc_tx000457gb.fm 174

179 RD 27 Repair Disassembly/Reassembly Procedures 250 kg (550 lbs.) wc_gr wc_tx000457gb.fm 175

180 Disassembly/Reassembly Procedures 13.9 Disassembling Drum RD 27 Repair See Graphic: wc_gr Disassembly: Remove the drum from the machine. See section Removing Drum Using an appropriate lift or hoist, lift the drum into the vertical position resting on the side where the drive motor was mounted Remove the four screws (a) securing the exciter-motor-side drum support (b) and remove the drum support Mark (c) the bearing cover (d) for ease of re-installation Remove the four screws securing the bearing cover. Pry the bearing cover loose with a screwdriver. If the prying doesn t work, mount a piece of steel to the bearing cover using the screws for the drive motor. Then, using a lift or hoist, pull the bearing cover from the drum Remove the snap ring (e) Temporarily re-attach the drum support (f) to the drum. Then, using an appropriate lift or hoist, pull the drum support and the shockmount plate (g) (with shockmounts still attached) off the drum Remove the seal (h) 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 Remove the gear (j). Then, remove the inner four screws (k) and remove the exciter shaft coupling (l) Remove the six screws securing the bearing flange/drum cover (m) and remove the bearing flange/drum cover. If necessary, remove the plug screws (n) and insert the pusher screws (o) to push the bearing flange/drum cover loose Attach a lifting eye to the exciter shaft (p) and lift the exciter shaft from the drum Inspect the interior of the drum and clean it if necessary Inspect the exciter shaft for wear and discoloration Replace the exciter shaft bearings. See section Exciter Shaft Bearings. wc_tx000457gb.fm 176

181 RD 27 Repair Disassembly/Reassembly Procedures a b c d e g f k j i h l n p o m wc_gr wc_tx000457gb.fm 177

182 Disassembly/Reassembly Procedures Exciter Shaft Bearings RD 27 Repair See Graphic: wc_gr Removal: Remove the drum from the machine. See section Removing Drum Disassemble the drum. See section Disassembling Drum Remove the retaining ring (a), grease retainer (b), outer bearing race (c), and the grease seal (d) from the exciter-side bearing flange. Note: The outer bearing race is press fit into the flange, and will be destroyed during removal Remove the drive-side bearing flange (e) from the drum. Then, remove the retaining ring, grease retainer, and the outer bearing race (f) from the drive-side bearing flange. Note: The outer bearing race is press fit into the flange, and will be destroyed during removal Heat the inner bearing races (g and h) to remove them from the exciter shaft Remove the bearing (i) and the grease ring (j) from the support plate. Installation: Coat the grease ring (j) with a thin film of grease and install it into the support plate 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. Tap the bearing cover if necessary with a rubber mallet. Remove the bearing cover when the bearing is in place Press the inner bearing races (g and h) on to the exciter shaft 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) Press the outer bearing race (f) into the drive-side bearing flange. Pack the bearing with 60 grams (2 oz.) of grease. Add the grease retainer and the retaining ring. wc_tx000457gb.fm 178

183 RD 27 Repair Disassembly/Reassembly Procedures b a d c e f g h j i wc_gr wc_tx000457gb.fm 179

184 Disassembly/Reassembly Procedures Drum Shock Mounts RD 27 Repair See Graphic: wc_gr 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 To replace the drive-side shockmounts, carry out the procedures in section Removing and Installing Drive Motors to access the shockmounts (a) Using the special tool (c), remove the shockmounts from the drum To replace the exciter-side shockmounts (b), carry out the procedures in section Disassembling Drum through the step in which the support plate is removed Secure the support plate to a workbench. Using the special tool, remove the shockmounts Using the special tool and Loctite 243 or equivalent, install the shockmounts to the drum and/or the support plate See sections Removing and Installing Drive Motors and Reassembling Drum. wc_tx000457gb.fm 180

185 RD 27 Repair Disassembly/Reassembly Procedures wc_tx000457gb.fm 181

186 Disassembly/Reassembly Procedures Reassembling Drum RD 27 Repair See Graphic: wc_gr Replace and repack the exciter shaft bearings. See section Exciter Shaft Bearings Using Loctite 243 or equivalent on six M10 screws, secure the driveside bearing flange/drum cover (a) (with outer bearing race installed) to the drum. Torque the screws to 50 Nm (37 ft.lbs.) Using an appropriate crane or hoist, flip the drum end for end to gain access to the exciter side Insert the exciter shaft (b) (with inner bearing races installed) into the drum and seat it in the bearing on the drive side Place the exciter-side bearing flange (c) on the drum. Align the marks (d) made during disassembly. Using Loctite 243 or equivalent on six M10 screws, secure the exciter-side bearing flange to the drum. Torque the screws to 50 Nm (37 ft.lbs.) Install the outer seal (e), lip-side up, to the exciter-side bearing flange Using Loctite 243 or equivalent on the four M8 screws (g), secure the coupling (f) to the exciter shaft. Torque the screws to 30 Nm (22 ft.lbs.). Install the coupling gear (h) Attach a lifting eye to the exciter shaft. Using an appropriate crane or hoist, raise and lower the exciter shaft to check the end play of the exciter shaft. There should be approximately 3 5 mm (1/8 3/16 in.) of play Install the shockmounts. See section Drum Shockmounts Install the shockmount plate (i) (with bearing and shockmounts installed to it) onto the exciter-side bearing flange Attach the retaining clip (j) Align the marks (k) made on the bearing cover (l) during disassembly. Using Loctite 243 or equivalent on the four M16 screws, secure the bearing cover to the support plate. Torque the screws to 50 Nm (37 ft.lbs.). wc_tx000457gb.fm 182

187 RD 27 Repair Disassembly/Reassembly Procedures c a d b g h d c e f 3 5 mm 1/8 3/16 inch k l i j wc_gr wc_tx000457gb.fm 183

188 Disassembly/Reassembly Procedures Remounting Drum RD 27 Repair See Graphic: wc_gr 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.) Mount the drive motor to the drive-side drum support. Mount the shockmount support plate to the drive motor. Then, mount the drum support to the drum. See section Removing and Installing Drive Motors Position the drum so that the drum supports rest on the ground Manually release the brake on the drive motor. See section Manually Releasing Parking Brake Roll the drum into position under the machine. Align it with the marks (b) previously placed on the floor during disassembly If the shockmounts were changed, a new shim (d) arrangement may be necessary. Temporarily attach the large spacers (e) to the machine with the previous shim arrangement. Rotate both drum supports (f) up from the floor to the machine. Measure both sides and determine the shims required. Add or subtract shims as needed After the shim arrangement has been determined, route the hydraulic hoses (h and i) through the drum supports 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.) Reattach the hydraulic hoses to either the drive motor or the exciter motor Reset the brake from the manually released position to the springactivated position. See section Manually Releasing Parking Brake Mount the hose protector plates (g) on each drum support Fill the hydraulic tank. Start the engine and run the unit for a few minutes. Stop the engine and allow the machine to rest for 10 minutes. Recheck/top off the hydraulic oil supply. wc_tx000457gb.fm 184

189 RD 27 Repair Disassembly/Reassembly Procedures a b d e f g c c g h i wc_gr kg (550 lbs.) wc_gr wc_tx000457gb.fm 185

190 Disassembly/Reassembly Procedures Removing and Installing Fuel Tank RD 27 Repair See Graphic: wc_gr Removal: Disconnect the battery Remove the supply and return hoses (a) from the fuel tank (d) Remove the two locknuts (b) and remove the metal retaining band (c) Pull the fuel tank from the frame. Installation: Set the fuel tank (d) into the machine frame. Secure it to the machine using retaining band (c) and locknuts (b) Reinstall the supply and return hoses (a). wc_tx000457gb.fm 186

191 RD 27 Repair Disassembly/Reassembly Procedures b c b d a c b wc_gr wc_tx000457gb.fm 187

192 Disassembly/Reassembly Procedures Removing and Installing Radiator RD 27 Repair See Graphic: wc_gr Removal: Burn hazard. Hot engine coolant can cause severe burns. Allow the engine and coolant to cool before working on the radiator. WARNING Disconnect the battery Place a large pan (a) underneath the machine to collect the coolant Remove the lower radiator hose (b). This will drain the radiator. Dispose of the coolant in accordance with local environmental regulations Remove the upper hose (c) from the radiator Loosen the hardware (d) securing the radiator to the support plate (e) Remove the hardware (f) securing the support plate to the engine and remove the support plate Remove the screws securing the fan guard (g) to the radiator and remove the fan guard Loosen the two nuts (h) on the underside of the radiator securing it to the frame. Then, pull the radiator (i) from the machine. Installation: Place the radiator (i) through the two holes in the machine frame. Secure the radiator to the frame with two nuts (h) Mount the fan guard (g) to the radiator Mount the support plate (e) to the engine Secure the support plate to the radiator Using new hose clamps (j), attach the upper hose (c) and the lower hose (b) to the radiator Fill the radiator with the proper type and amount of coolant. See Technical Data. wc_tx000457gb.fm 188

193 RD 27 Repair Disassembly/Reassembly Procedures d e f j i g c h j b c a i b wc_gr wc_tx000457gb.fm 189

194 Disassembly/Reassembly Procedures Removing and Installing Vibration Pump Belts RD 27 Repair See Graphic: wc_gr Removal: Run the machine and turn the steering wheel as if making a full left turn. This will articulate the machine open resulting in improved access to the vibration pump Turn off the engine and disconnect the battery. Note: For clarity, the graphics show the machine with the radiator removed Loosen the three screws (a) securing the face plate; once loose, loosen the adjusting screw (b) Slide the pulley assembly (c) up enough to remove the vibration pump belts (d) To remove the vibration pump (e), remove the pulley (f), disconnect the hydraulic hoses, and remove the screws (g) securing the vibration pump to the bracket. Installation: Using four screws (g), mount the vibration pump (e) to the bracket Connect the hydraulic hoses and the pulley (f) to the vibration pump Position the vibration pump belts (d) around the pulley (f) and around the engine pulley Slide the pulley assembly (c) down to take up the slack in the vibration pump belts. Tighten three screws (a) but do not torque down Using the adjusting screw (b), adjust the pulley assembly so that belt deflection is 3 mm (1/8 in.) at approximately 430±20 N (97±5 pounds) of force. Loosen the three screws (a) to allow the plate to settle. Then, torque the screws to 50 Nm (37 ft.lbs.). wc_tx000457gb.fm 190

195 RD 27 Repair Disassembly/Reassembly Procedures b a d e c f g a b f d wc_gr wc_tx000457gb.fm 191

196 Disassembly/Reassembly Procedures Removing and Installing Steering Cylinder RD 27 Repair See Graphic: wc_gr Removal: Run the machine and turn the steering wheel as if making a full left turn. This will articulate the machine open resulting in improved access to the steering cylinder Turn off the engine and disconnect the battery Disconnect the hoses from the cylinder (a). There may be some hydraulic oil leakage. Collect and dispose of hydraulic oil according to local environmental regulations. To prevent contamination of the hydraulic system, plug the hoses immediately after disconnecting them Remove the screw (b) securing the pin (c) at the articulated joint and remove the pin Remove the screw (d) securing the pin (e) on the frame. There is a hole in the frame to access the pin to drive it up and out Remove the piston-side plugged fitting to allow oil to drain and push the piston into the cylinder Maneuver the cylinder so that it can be removed from the machine and remove it. There are two rings (f) that go on either side of the piston heads where they connect to the machine. Be sure to retrieve these two rings from the machine when the cylinder is removed. Installation: Place the cylinder (a) into position on the machine frame Mount the cylinder to the machine frame using the pin (e) and the screw (d) Mount the cylinder to the articulating steering joint with the pin (c) and the screw (b) Connect the hydraulic hoses to the cylinder. wc_tx000457gb.fm 192

197 RD 27 Repair Disassembly/Reassembly Procedures b c e d f a wc_gr wc_tx000457gb.fm 193

198 Disassembly/Reassembly Procedures Removing and Installing Articulated Steering Joint RD 27 Repair See Graphic: wc_gr Removal: Note: The steering cylinder must be disconnected from the articulated steering joint before the articulated steering joint may be removed. See section Removing and Installing Steering Cylinder. Start the following procedures with the drums straight in-line Remove the ground strap (a) Support both halves of the machine with jacks mounted underneath the machine near the articulated steering joint There is a hose clamp secured to the end of one of the screws that secures the articulated joint to the frame. The hardware securing this hose clamp must be removed before removing the articulated joint. Locate the clamp on the inside of the frame. Remove the hardware (b) securing the hose clamp (c) and remove the hose clamp from the end of the screw Remove the screws, except for the lower right rear screw (d), securing the articulated steering joint to the frame. Before removing the last screw, secure the articulated steering joint with a suitable sling, hoist, or jack. Once secured, pry the two machine halves apart using a piece of lumber or similar object until the articulated steering joint (e) may be pulled from the machine. Installation: Assemble the articulated steering joint (e) to the frame using four screws on either half, but do not fully tighten the screws. Before tightening the screws, place the locking pin in place and check that it moves freely. Once the locking pin moves freely, torque the screws to 240 Nm (177 ft.lbs.). wc_tx000457gb.fm 194

199 RD 27 Repair Disassembly/Reassembly Procedures a c b d e wc_gr wc_tx000457gb.fm 195

200 Disassembly/Reassembly Procedures Articulated Steering Joint Exploded View RD 27 Repair wc_tx000457gb.fm 196

201 RD 27 Repair Disassembly/Reassembly Procedures Articulated Steering Joint Components Ref. Pos. Part No. Artikel Nr. Qty. St. Description Beschreibung Descripción Description Measurem./Abm. Torque/Drehm. Norm Sealant Schmierstoff Fitting-grease Schmiernippel Grasera Graisseur Axle Achse Eje Essieu Seal ring Dichtungsring Anillo sellador Rondelle à étancher Bearing Lager Rodamiento Roulement Washer-spring Tellerfeder Arandela de resorte Ressort Belleville Seal-oil Öldichtung Empaque de aceite Joint d'huile Bearing Lager Rodamiento Roulement Washer Scheibe Arandela Rondelle Plug cap Schraubverschluß Tapón roscado Bouchon Hitch Anhänger-Öse Enganche Attelage Bearing bracket assembly Halterungsflansch kpl. Conjunto caballete de soporte para rodamiento Ensemble support pour roulement Washer Scheibe Arandela Rondelle Bolt Bolzen Perno Boulon M16 x Nut Mutter Tuerca Écrou M16 x Bolt Bolzen Perno Boulon M16 x Bolt Bolzen Perno Boulon M16 x Washer Scheibe Arandela Rondelle wc_gr wc_tx000457gb.fm 197

202 Disassembly/Reassembly Procedures Rebuilding Articulated Steering Joint RD 27 Repair See Graphic: wc_gr Disassembly: Remove the screw (a) from the threaded hole of the axle Remove the spacer (b) and the conical washer (c) Insert a sacrificial screw (d) into the threaded hole of the axle. Suspend the joint between two pieces of pipe or similar objects. Pound the sacrificial screw until the axle portion (e) of the joint separates from the hitch casting. The larger bearing will separate; the outer race will remain on the axle and the inner race will remain in the hitch casting Remove the grease from inside the hitch casting and from around the axle Remove the pillow blocks/bearings (f and g) from the hitch casting. Note: Pillow blocks/bearings come as a set. If either the pillow block or bearing is faulty, the pillow block/bearing must be replaced. If one set of pillow blocks/bearings is faulty, replace both sets of pillow blocks/ bearings Invert the hitch and place it on a thick board. Using a punch (i), knock out the smaller bearing (h) and the inner seal 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. wc_tx000457gb.fm 198

203 RD 27 Repair Disassembly/Reassembly Procedures a b c f d g e h i e k j wc_gr wc_tx000457gb.fm 199

204 Disassembly/Reassembly Procedures Rebuilding Articulated Steering Joint continued RD 27 Repair See graphic: wc_gr Reassembly: Lubricate the seal (a) with multipurpose grease and install it onto the axle (b) Heat the inner bearing race (c) of the larger bearing and install it onto the axle. Make sure the inner bearing race seats against the shoulder of the axle. Install the inner bearing race of the smaller bearing to the axle in the same manner 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) Place the hitch casting over the axle. Fill the hitch casting with multipurpose grease Install the oil seal (f) as shown 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) 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. wc_tx000457gb.fm 200

205 RD 27 Repair Disassembly/Reassembly Procedures b a c d e f g i h j k wc_gr wc_tx000457gb.fm 201

206 Disassembly/Reassembly Procedures Removing and Installing Spray System Water Pump RD 27 Repair See Graphic: wc_gr Removal: Unplug the electrical connector (a) from the harness Remove the two screws (b) securing the pump to the frame Disconnect the hoses straight-fitting side (c) first, then the 90 -fitting side (d) and pull the pump (e) out. Installation: Note: New pumps include the four rubber mounts (f) Connect the hoses to the fittings 90 -fitting side (d) first, then the straight-fitting side (c) Using the two screws (b), secure the pump to the frame Connect the electrical connector (a). wc_tx000457gb.fm 202

207 RD 27 Repair Disassembly/Reassembly Procedures e b f a c d wc_gr wc_tx000457gb.fm 203

208 Disassembly/Reassembly Procedures Removing and Installing Water Tank RD 27 Repair See Graphic: wc_gr Removal: Stop the engine and disconnect the battery Drain the water tank. See section Sprinkler Efficiency Remove the rotating beacon. Disconnect the wiring from the beacon. Remove the wiring from the ROPS. See section Rotating Beacon Make sure all four locking pins (a) of the ROPS are in good shape and securely held in place by the retaining pins (b) Secure the ROPS (c) with a suitable crane or hoist Remove the six bolts (d) securing the ROPS and remove the ROPS Remove the five screws (e) securing the operator platform. Adjust the seat on the platform as far back as possible. Then, push on the seat to rotate the whole platform towards the front of the machine. Secure the platform (f) in this position Disconnect the water line between the tank and the filter at the filter (g) With the drain cap removed, carefully pull the tank (h) (with hose attached) up and out of the machine. Installation: Position the tank (h) into the machine frame Reconnect the water line between the tank and the filter at the filter (g) Rotate the operator platform (f) back so that it covers the water tank. Secure the operator platform to the machine using five screws (e). Do not use the machine without the ROPS in place. The ROPS is designed to protect the operator in a rollover accident. WARNING Do not weld or drill into the ROPS. Drilling or welding on the ROPS will nullify the ROPS certification Apply a thin coat of oil to the six original bolts (d) used to mount the ROPS (c). Using these same bolts and nuts, secure the ROPS to the machine frame. Torque the hardware to 240Nm (177 ft.lbs.) Connect the rotating beacon. See section Rotating Beacon. wc_tx000457gb.fm 204

209 RD 27 Repair Disassembly/Reassembly Procedures d c b a f e h g wc_gr wc_tx000457gb.fm 205

210 Disassembly/Reassembly Procedures Removing and Installing Hydraulic Oil Cooler RD 27 Repair See Graphic: wc_gr Removal: Stop the machine and disconnect the battery Disconnect the connectors (a and b) running between the hydraulic oil cooler (c) and the electrical harness. Cut the wire ties if necessary Remove the hardware (d) securing the hose clamp (e) and remove the hose clamp and hoses from the hydraulic oil cooler Remove the input hose (f) Remove the output hose (g) from underneath the hydraulic oil cooler. Drain the oil from the hydraulic oil cooler into a suitable container. Reuse or dispose of hydraulic oil according to local environmental regulations. Plug the output hose Remove the two hose clamps (h) from the support plate. Move the fuel hoses (i) held by the hose clamps off to the side. Remove the four screws (j) and hardware securing the hydraulic oil cooler to the bulkhead and pull the hydraulic oil cooler straight up and out of the machine. Installation: Position the hydraulic oil cooler (c) into the frame and secure it to the bulkhead with four screws (j) and hardware Connect the input (f) and output (g) hoses Secure the hoses and hose clamp (e) with hardware (d) Reconnect the electrical connectors (a and b) to the electrical harness. wc_tx000457gb.fm 206

211 RD 27 Repair Disassembly/Reassembly Procedures c j i h f e a d b g wc_gr wc_tx000457gb.fm 207

212 Disassembly/Reassembly Procedures Removing and Installing Drive Pump RD 27 Repair See Graphic: wc_gr Removal: Stop the engine and disconnect the battery Drain the hydraulic oil tank. See section Hydraulic Oil Prepare the drive pump for removal: Remove all of the hoses (a) from the drive pump. Start with the most outer most then move to inner hoses. Label and cap all the hoses as you go. Use a pan below the pump to catch any excess oil. Remove the solenoid valve (b). There is a seal (c) on the end of the solenoid shaft. When removing the solenoid, be sure the seal stays in place. Remove the pressure gauge fitting (d) on the lower, left-hand side of the drive pump to allow access to the two fittings behind it. Remove the brake/neutral block (e) and move it to the side. Remove the plug (f) on the left side of the drive pump to access the hex screw in the back securing the pump Remove the two hex screws (g and h) securing the drive pump to the engine. Carefully slide the drive pump (i) from the engine and out of the frame. Note: The only serviceable part on the pump assembly is the solenoid valve. The gear on the shaft is replaceable but is not part of the pump assembly. wc_tx000457gb.fm 208

213 RD 27 Repair Disassembly/Reassembly Procedures a h a a b c g f d e i wc_gr wc_tx000457gb.fm 209

214 Disassembly/Reassembly Procedures RD 27 Repair See graphic: wc_gr Installation: Remove the plug (f) on the left side of the drive pump. This allows better access to the hex screw in the back securing the pump to the engine. After the pump is secured to the engine, re-install the plug Slide the drive pump (i) into the frame and position the drive pump onto the engine. Secure the pump to the engine using the two screws (g and h) Secure the brake/neutral block (e) Install the pressure gauge fitting (d) on the lower, left-hand side of the drive pump Check that the solenoid valve seal (c) is on the shaft. Install the solenoid valve (b) Reinstall all of the hoses (a) to the drive pump. Start with the inner most hoses then move to the outer hoses Fill the hydraulic oil tank. See section Hydraulic Oil Reconnect the battery. wc_tx000457gb.fm 210

215 RD 27 Repair Disassembly/Reassembly Procedures a h a a b c g f d e i wc_gr wc_tx000457gb.fm 211

216 Disassembly/Reassembly Procedures Removing Engine RD 27 Repair See Graphic: wc_gr002702, wc_gr002704, wc_gr002708, wc_gr Disconnect the battery Open the fuel tank cap to relieve pressure. Remove the smaller return hose (a) leading to the fuel tank to relieve any remaining pressure. Remove the supply hose (b). Remove the fuel hoses from the radiator mounting bracket (c). Plug the fuel hoses and inlets of the fuel tank Remove the air cleaner intake hose (d). Remove the screw (e) securing the air cleaner bracket (f) to the hydraulic oil tank. Bend the air cleaner bracket back and remove the air cleaner (g) from the air cleaner bracket. Place the air cleaner on top of the engine Remove the radiator. See section Removing and Installing Radiator Drain the hydraulic oil tank. See section Hydraulic Oil Disconnect the large hydraulic hose (h). Cap fittings to prevent contamination Disconnect the small hydraulic hose (i) at vibratory manifold that runs to the hydraulic oil cooler. Cap the fittings to prevent contamination Label then disconnect the four hoses (j) on top of the vibratory manifold. Cap the fittings to prevent contamination. Also, disconnect the hydraulic hose (k) on front of vibratory manifold at P port Disconnect the two hydraulic hoses (l) to the seat switch solenoid valve. Cap the fittings to prevent contamination Disconnect the hydraulic hoses running to the main drive pump. There are two on the left, three on the right (two of which are multiples), and one on the bottom right behind the solenoid. Refer to section Removing and Installing Main Drive Pump Disconnect the hydraulic hose (m) running to the right side of the filter. Also, disconnect the hose clamp (n) that retains this hose and the hose to the vibratory valve. wc_tx000457gb.fm 212

217 RD 27 Repair Disassembly/Reassembly Procedures c b a d g e f j i h k m l n wc_gr wc_tx000457gb.fm 213

218 Disassembly/Reassembly Procedures RD 27 Repair Disconnect the drain line (o) from the steering pump Remove the screw and the clamp (p) securing the two hydraulic hoses to the engine near the ground strap Remove the three screws (q) securing the vibration pump mounting bracket. Also, remove the upper adjusting screw (r) and the two belts (s). Allow the vibration pump and the vibration pump mounting plate to rest inside the machine frame Remove the electrical harness. Start with the two connections at the vibratory manifold solenoids (t). There is a wire tie (u) directly below the solenoids; cut this wire tie. This wire tie also secures the wires to the seat switch solenoid; unplug the wires to the seat switch solenoid Remove the other wire ties securing the electrical harness. There is one wire tie (v) just behind the vibratory manifold and two (w) more on top of the engine Disconnect the ground wires (x) on the filter bracket. Also disconnect the wire (y) feeding the glow plugs. wc_tx000457gb.fm 214

219 RD 27 Repair Disassembly/Reassembly Procedures o p r s q t u v x w y wc_gr wc_tx000457gb.fm 215

220 Disassembly/Reassembly Procedures RD 27 Repair Cut the wire tie (aa) securing that portion of the harness running to the neutral/brake solenoid Disconnect the wiring from the starter motor solenoid (bb), the alternator (cc), and the coolant temperature sensor (dd). There are two clamps securing the portion of the harness to the starter; remove these clamps. One of the clamps also secures the positive (red) wires to the starter motor solenoid and to the alternator; disconnect both these wires Cut the wire tie (ee) near the lifting eye Thread the harness through the engine back to the clamp (ff) near the fuel pump. Remove the screw securing the clamp. Remove the harness from the clamp Disconnect the wires to the fuel shutoff solenoid, and those to the oil pressure sensor (near dipstick) Thread the harness through the miscellaneous engine components and out and away from the engine Disconnect the ground strap (gg) Remove the throttle linkage (hh) by loosening the nut on the shaft and the small nut securing the lever. wc_tx000457gb.fm 216

221 RD 27 Repair Disassembly/Reassembly Procedures aa dd bb cc ee ff gg hh wc_gr wc_tx000457gb.fm 217

222 Disassembly/Reassembly Procedures RD 27 Repair Remove the four screws (ii) securing the exhaust pipe to the manifold Remove the hardware (jj) securing the engine at the three engine mount locations Cut the wire tie (kk) securing the engine oil drain hose to the machine frame Using an appropriate crane or hoist, lift the engine (ll) up and out of the machine. wc_tx000457gb.fm 218

223 RD 27 Repair Disassembly/Reassembly Procedures ii jj jj kk ll wc_gr wc_tx000457gb.fm 219

224 Disassembly/Reassembly Procedures Installing the Engine RD 27 Repair See graphic: wc_gr002710, wc_gr002711, wc_gr002712, wc_gr Using an appropriate crane or hoist, position the engine (ll) over the machine. Make sure all the hydraulic hoses and the sections of the wiring harness are positioned so that they are not pinched when the engine is installed Position the engine in the machine onto the engine mounts. Secure the engine with three bolts (jj) Secure the exhaust pipe to the engine with the four screws (ii) Secure the oil drain hose with a new wire tie (kk). wc_tx000457gb.fm 220

225 RD 27 Repair Disassembly/Reassembly Procedures ll jj jj ii kk wc_gr wc_tx000457gb.fm 221

226 Disassembly/Reassembly Procedures RD 27 Repair Connect the throttle linkage (hh) Connect the ground strap (gg) Thread the harness through the miscellaneous engine components to the appropriate locations Connect the wires to the fuel shutoff solenoid, and those to the oil pressure sensor (near dipstick) Secure the harness to the engine with the clamp (ff) Connect the harness to the neutral/brake solenoid and secure with a new wire tie (aa) Connect the harness to the engine with a new wire tie (ee) near the lifting eye Connect the wiring to the starter motor solenoid (bb), the alternator (cc), and the coolant temperature sensor (dd). There are two clamps securing the portion of the harness to the starter; install these clamps. One of the clamps also secures the positive (red) wires to the starter motor solenoid and to the alternator. Connect both these wires. wc_tx000457gb.fm 222

227 RD 27 Repair Disassembly/Reassembly Procedures hh gg ff ee dd bb aa cc wc_gr wc_tx000457gb.fm 223

228 Disassembly/Reassembly Procedures RD 27 Repair Connect the ground wires (x) on the filter bracket. Also, connect the wire (y) feeding the glow plugs Install new wire ties securing harness at the vibratory manifold (v) and on top of the engine (w) Connect the harness at the vibratory manifold solenoids (t). Install a new wire tie (u) directly below the solenoids. This tie also secures the wires to the seat switch solenoid; connect the wires to the seat switch solenoid Secure the vibration pump mounting bracket with the three screws (q). Install the two belts (s). See section Removing and Installing Vibration Pump Secure the hoses to the engine near the ground strap with the screw and clamp (p) Connect the drain line (o) to the steering pump. wc_tx000457gb.fm 224

229 RD 27 Repair Disassembly/Reassembly Procedures x w y v u s t q p o wc_gr wc_tx000457gb.fm 225

230 Disassembly/Reassembly Procedures RD 27 Repair Connect the hydraulic hose (m) running to the right side of the filter. Also connect the hose clamp (n) that retains this hose and the hose to the vibratory valve Connect the hydraulic hoses running to the main drive pump. There are two on the left and three on the right two of which are multiples. And one on the bottom right behind the solenoid. Refer to section Removing and Installing Main Drive Pump Connect the two hydraulic hoses (l) to the seat switch solenoid valve Connect the four hoses (j) on top of the vibratory manifold. Cap fittings to prevent contamination. Also disconnect the hydraulic hose (k) on front of vibratory manifold at P port Connect the small hose (i) at the vibratory manifold that runs to the hydraulic oil cooler Connect the large hydraulic hose (h) Fill the hydraulic reservoir. See section Hydraulic Oil Install the radiator. See section Removing and Installing Radiator Connect the air cleaner intake hose (d). Bend the bracket back and install the air cleaner (g) into the air cleaner bracket. Install the screw (e) securing the air cleaner bracket (f) to the hydraulic oil tank Connect the fuel return hose (a) and the fuel supply hose (b). Secure the hoses to the radiator mounting bracket (c) Open the fuel tank cap to relieve pressure. Remove the smaller return hose (a) leading to the fuel tank to relieve any remaining pressure. Then, remove the supply hose (b). Remove the fuel hoses from the radiator mounting bracket (c). Plug the fuel hoses and the inlets of the fuel tank Connect the battery. wc_tx000457gb.fm 226

231 RD 27 Repair Disassembly/Reassembly Procedures m l n j i k h g d e f c b a wc_gr wc_tx000457gb.fm 227

232 Disassembly/Reassembly Procedures RD 27 Repair Removing and Installing the Hydraulic Oil Tank See Graphic: wc_gr002714, wc_gr Removal: Drain the hydraulic oil tank. See section Hydraulic Oil Remove the fuel tank. See section Removing and Installing Fuel Tank Remove the four sets of hydraulic fittings (a) from the fuel tank. Plug the fittings to prevent contamination Disconnect the hydraulic oil temperature sensor (b) Cut the wire ties (c) securing the harness to the hydraulic oil tank Remove the air cleaner intake hose (d) Remove the two screws (e) securing the bottom portion of the hydraulic tank to the machine frame Remove the screw (also secures wiring harness clamp (f)) on the front side of the bulkhead near the fuel tank sender unit. Remove the other two screws (g) that secure the hydraulic tank to the bulkhead. The lower screw will require the fuel tank to be tipped out of the way. Refer to section Removing and Installing Fuel Tank With the help of an assistant, lift the hydraulic tank up and out of the machine. wc_tx000457gb.fm 228

233 RD 27 Repair Disassembly/Reassembly Procedures b a d c e f g wc_gr wc_tx000457gb.fm 229

234 Disassembly/Reassembly Procedures RD 27 Repair Installation: With the help of an assistant, position the the hydraulic tank into the machine Re-install the fuel tank. See section Replacing Fuel Tank Install the screw (also secures wiring harness clamp (f)) on the front side of the bulkhead near the fuel tank sender unit. Install the other two screws (g) that secure the hydraulic tank to the bulkhead. The lower screw will require the fuel tank to be tipped out of the way. Refer to section Replacing the Fuel Tank Install the two screws (e) securing the bottom portion of the hydraulic tank to the machine frame Install the air cleaner intake hose (d) Install the new wire ties (c) securing the harness to the hydraulic oil tank Connect the hydraulic oil temperature sensor (b) Connect the four sets of hydraulic fittings (a) to the tank Fill the hydraulic tank with oil. See section Technical Data for appropriate type and quantity of hydraulic oil. wc_tx000457gb.fm 230

235 RD 27 Repair Disassembly/Reassembly Procedures g f e b a d c wc_gr wc_tx000457gb.fm 231

236 Disassembly/Reassembly Procedures Removing and Installing Vibration Pump RD 27 Repair See Graphic: wc_gr Removal: Disconnect the battery Lock the articulated steering joint Remove the radiator. See section Removing and Installing Radiator Release the pressure in the hydraulic system by slowly loosening the hydraulic oil tank fill cap Drain the hydraulic oil tank. See section Hydraulic Oil Disconnect the hydraulic hose (a) from the vibration pump. Cap the fittings immediately to prevent contamination Remove the tension adjustment screw (b) and the three screws (c) securing the support plate Maneuver the pump until you can reach the underside hydraulic fitting (d) and remove it. If necessary, remove the hydraulic hose from the hydraulic oil tank. Installation: Position the vibration pump in the machine frame Connect the hydraulic hose at the fitting (d) Secure the support pump and the support plate with screws (b and c). Tension the belt. See section Removing and Installing Vibration Belts Connect the hydraulic hose (a) Install the radiator. See section Removing and Installing Radiator Fill the hydraulic oil tank with the correct type and amount of hydraulic oil. See section Technical Data Reconnect the battery. wc_tx000457gb.fm 232

237 RD 27 Repair Disassembly/Reassembly Procedures a b c d wc_gr wc_tx000457gb.fm 233

238 Disassembly/Reassembly Procedures Removing and Installing Steering Pump RD 27 Repair See Graphic: wc_gr Removal: Disconnect the battery Lock the articulated steering joint Release the pressure in the hydraulic system by slowly loosening the hydraulic oil tank fill cap Drain the hydraulic oil tank. See section Hydraulic Oil Disconnect the hydraulic hoses (b) from the steering pump (a). Cap the fittings immediately to prevent contamination Remove the four screws (c) and the steering pump from the engine. Installation: Position the steering pump (a) on the engine and secure it with four screws (c) Connect the hydraulic hoses (b) Fill the hydraulic oil tank with the correct type and amount of hydraulic oil. See section Technical Data Reconnect the battery. b a b c wc_gr wc_tx000457gb.fm 234