Wacker Neuson RD25 User manual

www.wackergroup.com

Roller

RD 25

OPERATOR’S MANUAL

0156218en 001

0205

0156218EN

RD 25 Table of Contents

wc_bo0156218001enTOC.fm 1

1. Foreword 3

2. Safety Information 4

2.1 Operating Safety .................................................................................. 5

2.2 Operator Safety while using Internal Combustion Engines .................. 6

2.3 Service Safety ...................................................................................... 7

2.4 Label Locations .................................................................................... 9

2.5 Warning & Informational Labels ......................................................... 10

3. Technical Data 13

3.1 Engine ................................................................................................ 13

3.2 Roller .................................................................................................. 14

3.3 Lubrication .......................................................................................... 15

3.4 Sound and Vibration Measurements .................................................. 15

3.5 Dimensions ......................................................................................... 16

4. Operation 17

4.1 Operation and Service Locations ....................................................... 17

4.2 Main Features .................................................................................... 19

4.3 Application .......................................................................................... 19

4.4 Hydraulic Equipment .......................................................................... 19

4.5 Engine ................................................................................................ 19

4.6 Chassis ............................................................................................... 20

4.7 Steering .............................................................................................. 20

4.8 Driving Position .................................................................................. 20

4.9 Operator Presence System ................................................................ 20

4.10 Electrical Equipment ........................................................................... 20

4.11 Transmission ...................................................................................... 21

4.12 Exciter System ................................................................................... 23

4.13 Braking System .................................................................................. 24

4.14 Throttle Lever ..................................................................................... 25

4.15 Water Sprinkling Equipment ............................................................... 26

4.16 Panel Controls and Indications ........................................................... 26

4.17 Lighting Equipment ............................................................................. 30

4.18 Isolating the Power Supply ................................................................. 31

Table of Contents RD 25

wc_bo0156218001enTOC.fm 2

4.19 Roll Over Protection Structure (ROPS) ...............................................31

4.20 Rotating Beacon ..................................................................................33

4.21 Driving on Slopes and Uneven Terrain ...............................................34

4.22 Anti-theft Protection .............................................................................35

4.23 Tanks: Filling, Levels and Draining .....................................................36

4.24 Seat adjustment ..................................................................................37

4.25 Jump Starting ......................................................................................38

4.26 Fuse Box .............................................................................................38

4.27 Preliminary Checks .............................................................................39

4.28 Starting the Engine ..............................................................................40

4.29 Stopping the Engine ............................................................................42

5. Maintenance 43

5.1 Hoisting the Machine ...........................................................................43

5.2 Transporting the Machine ....................................................................44

5.3 Towing the Machine ............................................................................45

5.4 Running-in Period ................................................................................46

5.5 Maintenance Schedule ........................................................................47

5.6 Recommended Products and Amounts ...............................................48

5.7 Oil/Temperature Table ........................................................................49

5.8 Engine Oil ............................................................................................50

5.9 Hydraulic Oil ........................................................................................52

5.10 Fuel System ........................................................................................54

5.11 Sprinkler Efficiency ..............................................................................56

5.12 Scraper Bar Wear ................................................................................56

5.13 Cleaning ..............................................................................................57

5.14 Central Steering Joint ..........................................................................58

5.15 Battery Fluid Level ...............................................................................59

5.16 Exciter Lubrication ...............................................................................60

5.17 Shockmounts .......................................................................................61

5.18 Engine Air Filter ...................................................................................62

5.19 Engine Cooling System .......................................................................64

5.20 Exhaust System and Engine Air Intake System ..................................65

5.21 Cleaning the Fuel Tank .......................................................................66

5.22 Cleaning the Water Tank .....................................................................67

5.23 Fill and Drain of Hydraulic Oil, and Cleaning the Hydraulic Oil Tank ..68

5.24 Storage ................................................................................................69

5.25 Electrical Schematic Diagrams ............................................................70

5.26 Hydraulic Schematic Diagrams ...........................................................81

Foreword

wc_tx000001gb diesel.fm 3

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.

1. Foreword

This manual provides information and procedures to safely operate

and maintain this Wacker model. For your own safety and protection

from injury, carefully read, understand and observe the safety

instructions described in this manual.

Keep this manual or a copy of it with the machine. If you lose this

manual or need an additional copy, please contact Wacker

Corporation. This machine is built with user safety in mind; however,

it can present hazards if improperly operated and serviced. Follow

operating instructions carefully! If you have questions about operating

or servicing this equipment, please contact Wacker Corporation.

The information contained in this manual was based on machines in

production at the time of publication. Wacker Corporation reserves the

right to change any portion of this information without notice.

All rights, especially copying and distribution rights, are reserved.

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.

WARNING

Safety Information RD 25

wc_si000103gb.fm 4

2. Safety Information

This manual contains DANGER, WARNING, CAUTION, and NOTE

callouts which must be followed to reduce the possibility of personal

injury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this

symbol to avoid possible injury or death.

DANGER indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.

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.

DANGER

WARNING

CAUTION

RD 25 Safety Information

wc_si000103gb.fm 5

2.1 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.

2.1.1 ALWAYS wear protective clothing appropriate to the job site when

operating equipment.

2.1.2 ALWAYS remain aware of moving parts and keep hands, feet, and

loose clothing away from moving parts of equipment.

2.1.3 ALWAYS read, understand, and follow procedures in Operator's

Manual before attempting to operate equipment.

2.1.4 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.

2.1.5 ALWAYS check that all controls are functioning properly immediately

after start-up! DO NOT operate machine unless all controls operate

correctly.

2.1.6 ALWAYS operate machine with all safety devices and guards in place

and in working order.

2.1.7 ALWAYS remain aware of changing positions and movement of other

equipment and personnel on the jobsite.

2.1.8 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.

2.1.9 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 buggy

sliding, falling or tipping.

2.1.10 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.

2.1.11 ALWAYS disengage and stow locking bar for the articulated joint

before operating machine. The machine cannot be steered when the

locking bar is engaged.

2.1.12 DO NOT attempt to start the machine when standing alongside. Only

start the engine when seated in the driver's seat and with the forward-

reverse lever in the neutral position.

WARNING

Safety Information RD 25

wc_si000103gb.fm 6

2.1.13 NEVER allow improperly trained people to operate this equipment.

People operating this equipment must be familiar with the potential

risks and hazards associated with it.

2.1.14 NEVER carry passengers. Danger of crushing — keep clear of the

central steering joint between the front and rear frames.

2.1.15 NEVER use or attempt to repair damaged safety belts or ROPS.

Replace only with Wacker spare parts.

2.1.16 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.

2.1.17 NEVER use accessories or attachments that are not recommended by

Wacker. Damage to equipment and injury to the user may result.

2.1.18 NEVER leave machine running unattended.

2.1.19 NEVER start a defective unit in need of service or repair.

2.2 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

safety guidelines could result in severe injury or death.

2.2.1 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.

2.2.2 DO NOT smoke while operating machine.

2.2.3 DO NOT smoke when refueling engine.

2.2.4 DO NOT refuel hot or running engine.

2.2.5 DO NOT refuel engine near open flame.

2.2.6 DO NOT spill fuel when refueling engine.

2.2.7 DO NOT run engine near open flames.

2.2.8 ALWAYS refill fuel tank in well-ventilated area.

2.2.9 ALWAYS replace fuel tank cap after refueling.

2.2.10 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.

2.2.11 ALWAYS keep area around hot exhaust pipes free of debris to reduce

the chance of an accidental fire.

2.2.12 DO NOT remove engine coolant cap when engine is hot. Contents are

hot and under pressure.

DANGER

RD 25 Safety Information

wc_si000103gb.fm 7

2.3 Service Safety

Poorly maintained equipment can become a safety hazard! In order

for the equipment to operate safely and properly over a long period of

time, periodic maintenance and occasional repairs are necessary.

2.3.1 DO NOT stand under the machine while it is being hoisted or moved.

2.3.2 DO NOT get onto the machine while it is being hoisted or moved.

2.3.3 DO NOT use the machine as a ladder. Use safe ladders and platforms

designed for this purpose.

2.3.4 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.

2.3.5 DO NOT open hydraulic lines or loosen hydraulic connections while

engine is running! 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 lines.

2.3.6 DO NOT attempt to open the radiator cap while the unit is running or

before the engine has cooled down. Severe burns may result!

2.3.7 DO NOT modify the equipment without express written approval of the

manufacturer.

2.3.8 DO NOT attempt to clean or service machine while it is running.

Rotating parts can cause severe injury.

2.3.9 DO NOT crank a flooded engine with the spark plug removed on

gasoline-powered engines. Fuel trapped in the cylinder will squirt out

the spark plug opening.

2.3.10 DO NOT test for spark on gasoline-powered engines, if engine is

flooded or the smell of gasoline is present. A stray spark could ignite

fumes.

2.3.11 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.

2.3.12 ALWAYS keep area around muffler free of debris such as leaves,

paper, cartons, etc. A hot muffler could ignite them, starting a fire.

2.3.13 ALWAYS replace worn or damaged components with spare parts

designed and recommended by Wacker.

2.3.14 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.

2.3.15 ALWAYS check and tighten all external fasteners at regular intervals.

WARNING

Safety Information RD 25

wc_si000103gb.fm 8

2.3.16 ALWAYS switch off the power supply at the battery disconnect before

adjusting or maintaining the electrical equipment.

2.3.17 ALWAYS turn engine off before performing maintenance or making

repairs.

2.3.18 ALWAYS secure the articulated joint using the locking bar before

lifting, jacking, and servicing the machine. Machine halves could swing

together unexpectedly and cause a serious injury.

2.3.19 ALWAYS keep hands, feet and loose clothing away from moving parts.

2.3.20 ALWAYS make sure slings, chains, hooks, ramps, jacks and other

types of lifting devices are attached securely and have enough weight-

bearing capacity to lift or hold the machine safely. Always remain

aware of the position of other people around you when lifting the

machine.

2.3.21 ALWAYS secure the lockarm at the articulated joint before attempting

any service or repair, to prevent machine halves from swinging

together. This is especially important before lifting or jacking the

machine up. Failure to do so could result in a serious injury!

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

from the machine and that replacement parts and adjusters are firmly

tightened.

2.3.23 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.

2.3.24 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.

RD 25 Safety Information

wc_si000103gb.fm 9

2.4 Label Locations

wc_gr001223

BB98539

A

B

C

D

E

F

G

D

HI

J

K

D

L

M

N

D

Safety Information RD 25

wc_si000103gb.fm 10

2.5 Warning & Informational Labels

Ref. Label Meaning

A Operator's Manual must be storred on

machine. Replacement operator's manual can

be ordered through your local Wacker

distributor.

B CAUTION!

Read and understand the supplied operator's

manuals before operating this machine.

Failure to do so increases the risk of injury to

yourself or others.

DANGER!

Engines emit carbon monoxide; operate only

in well ventilated area.

WARNING!

To prevent hearing loss, wear hearing

protection when operating this machine.

WARNING!

Always wear seat belt when operating roller.

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

E L M A N U A L D E O P E R A C I O N D E B E

S E R R E T E N I D O E N L A M A Q U I N A .

C O N T A C T E A S U D I S T R I B U I D O R

W A C K E R M A S C E R C A N O P A R A

P E D I R U N E J E M P L A R

A D I C I O N A L .

L A N O T I C E D ' E M P L O I D O I T

E T R E M U N I E S U R L A M A C H I N E .

C O N T A C T E R L E D I S T R I B U T E U R

W A C K E R L E P L U S P R O C H E

P O U R C O M M A N D E R U N

E X E M P L A I R E S U P P L E M E N T A I R E .

1 1 5 0 9 6

O P E R A T O R ' S M A N U A L M U S T B E

S T O R E D O N M A C H I N E .

R E P L A C E M E N T O P E R A T O R ' S

M A N U A L C A N B E O R D E R E D

T H R O U G H Y O U R L O C A L W A C K E R

D I S T R I B U T O R .

D I E B E T R I E B S V O R S C H R I F T M U S S

A N D E R M A S C H I N E A U F B E W A H R T

W E R D E N . Z U R B E S T E L L U N G V O N

E R S A T Z B Ü C H E R N W E N D E N S I E

S I C H B I T T E A N I H R E N

Ö R T L I C H E N W A C K E R H Ä N D L E R .

RD 25 Safety Information

wc_si000103gb.fm 11

E 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!

Pinch point.

G Throttle control lever:

Idle or Slow

Full or Fast

H Hydraulic oil reservoir drain

I Hydraulic oil reservoir level

J Hydraulic oil reservoir fill

Ref. Label Meaning

Menomonee Falls, WI 53051 USA

Wacker Corporation

112232

hp

kW

Rev.

Model

kg

Item Number

lbs

max.lbs

MADE IN

ITALY

max.kg

Manuf. Yr.

Serial Number

dB(A)

Safety Information RD 25

wc_si000103gb.fm 12

K Water tank fill

L WARNING!

Hot surface.

M Water control valve is fully open

N Water control valve is fully closed.

Guaranteed sound power level in dB(A).

Ref. Label Meaning

RD 25 Technical Data

wc_td000070gb.fm 13

3. Technical Data

3.1 Engine

Item No.

RD 25

0009317

Engine

Engine Make Hatz

Engine Model 2M41L

Rated Power

kW (Hp)

25 (34)

Displacement

cm³ (in³)

1716 (104.7)

Starter

type/V/kW

Electric / 12 / 2.7

Alternator

Volts/Amp

14V / 50A

Operating Speed

rpm

2600

Valve Clearance (cold)

intake / exhaust:

mm (in.)

0.15 (0.006)

Air Cleaner

type

Single element

Battery

V / size

12 / 100 Amp-hour

Engine Oil Capacity

l (gal.)

5.5 (1.5)

Fuel

type

Clean, filtered diesel

Fuel Tank Capacity

l (gal.)

48 (12.7)

Fuel Consumption

l (gal.)/hr.

6.7 (1.8)

Technical Data RD 25

wc_td000070gb.fm 14

3.2 Roller

Item No.

RD25

0009317

Roller

Overall Dimensions

mm

(in.)

2600 x 1190 x 2880

(102.5 x 47 x 113.5)

Operating Weight

kg (lb.)

2500 (5510)

Dry Weight

kg (lb.)

2320 (5113)

Drum Width

mm (in.)

1100 (43.3)

Drum Diameter

mm (in.)

750 (29.5)

Ground Clearance

mm (in.)

200 (8)

Water Tank Capacity

l (gal)

160 (42.3)

Outside Turning Radius

m (ft.)

4 (13)

Forward/Reverse Speed

km/hr

(mph)

0 – 8.0 (0 – 5.0)

Gradeability

%

*

Vibration Frequency

Hz (vpm)

53.3 (3200)

*See Operator’s manual, Driving on slopes and uneven terrain.

RD 25 Technical Data

wc_td000070gb.fm 15

3.3 Lubrication

3.4 Sound and Vibration Measurements

The operating sound level, measured per the requirements of

Appendix 1, Paragraph 1.7.4.f of the EC-Machine Regulations, is:

-the guaranteed sound power level (L

WA

) = 109 dB(A).

-the sound pressure level at operator’s location (L

pA

) = 85 dB(A).

This sound value was determined according to ISO 3744 for the sound

power level (L

WA

).

The weighted effective acceleration value, determined according to

ISO 8662 Part 1, is approximately:

Hands = 3.9 m/s

2

, Seat = < 0.5 m/s

2

.

The vibration measurements were obtained with the machine moving

on hard asphalt at maximum RPM.

Item No.

RD25

0009317

Lubrication

Engine Crankcase

(summer or winter grade)

type

l (gal.)

Oil, Diesel Gamma

5.5 (1.5)

Hydraulic System

type

l (gal.)

Oil, Arnica 46

48 (12,7)

Exciter

type

l (gal.)

Rotra MP 80W/90

6.5 (1.7)

Articulated Joint

type

quantity

GR MU / EP 2

4–5 shots with a hand-held grease gun

Drive Bearings -

front and rear drums

type

Sealed

Technical Data RD 25

wc_td000070gb.fm 16

3.5 Dimensions

See Graphic: wc_gr0001124

Ref. Dimensions mm (inches) Ref. Dimensions mm (inches)

a 2600 (102.5) f 1190 (47)

b 1100 (43.3) g 375 (14.8)

c 750 (29.5) h 408 (16.1)

d 2878 (113.2) i 1437 (56.5)

e 1850 (72.8) j 2040 (80.2)

RD 25 Operation

wc_tx000193gb.fm 17

4. Operation

4.1 Operation and Service Locations

Ref. Description Ref. Description

1 Diesel engine 7 Front exciter hydraulic motor

2 Hydraulic transmission pump 8 Rear hydraulic transmission pump

3 Front hydraulic transmission motor 9 Servo steering

4 Rear exciter hydraulic motor 10 Brake

5 Exciter / Steering hydraulic pump 11 Oil Cooler

6 Exciter solenoid valve 12 Electric water pump

A Throttle lever P Fuse box

B Ingnition key block Q Exciter selector switch

C Alternator Warning Light R Exciter ON/OFF switch (on forward/

reverse lever)

D Engine oil pressure warning light S Drum sprinkler valve

E Lamp Test Button T Water pump switch

F FORWARD/REVERSE lever U Water pump warning light

G Steering Wheel V Engine temperatur high warning light

H Parking and emergency brake button W Engine air filter clogged warning light

I Parking Brake warning light X Water drain tap

J Light switch and horn button Y Dashboard lights

L Direction indicator switch Z Parking brake control

M Direction indicator warning light AA Hour Meter

N Rear work lights switch AB Battery Isolator

O Vibrator on warning light AC Hydraulic oil filter clogged warning light

Operation RD 25

wc_tx000193gb.fm 18

6

BB01206

5128

10

BB52242

BB52223

BB52208

wc_gr000844

BB

5

22

03

3

11

6

7

1

2

9

4

C

D

V

M

W

U

IO

Y

B

L

Q

H

E

J

N

T

Z

A

AA

AB

P

S

G

R

F

X

BB52319

AC

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