Manual Taller RD25

www.wackergroup.
com
0160488en 002
0207 en
Roller
RD 25
REPAIR MANUAL
0 1 6 0 4 8 8 E N
RD 25 Repair Foreword
This manual covers machines with Item Number:

0009317
Operating / Parts Information

You must be familiar with the operation of this machine before you
attempt to troubleshoot or repair it. Basic operating and maintenance
procedures are described in the Operator’s Manual supplied with the
machine. Keep a copy of the Operator’s Manual with the machine at all
times. Use the separate Parts Book supplied with the machine to order
replacement parts. If you are missing either of the documents, 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_tx000633gb.fm 3
Foreword RD 25 Repair
CALIFORNIA
Proposition 65 Warning:
Diesel engine exhaust, some of its constituents, and certain vehicle
WARNING
components contain or emit chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
All rights, especially copying and distribution rights, are reserved.
Copyright 2007 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
violators 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_tx000633gb.fm 4
RD 25 Repair Table of Contents
1. Safety Information 10
1.1 Operating Safety ................................................................................ 11

1.2 Operator Safety while using Internal Combustion Engines ................ 13
1.3 Service Safety .................................................................................... 14
1.4 Label Locations .................................................................................. 16
1.5 Warning & Informational Labels ......................................................... 17
2. Technical Data 20
2.1 Engine ................................................................................................ 20

2.2 Roller .................................................................................................. 21
2.3 Lubrication .......................................................................................... 22
2.4 Sound and Vibration Measurements .................................................. 22
2.5 Dimensions ......................................................................................... 23
3. Maintenance 24
3.1 Hoisting the Machine .......................................................................... 24

3.2 Transporting the Machine ................................................................... 25
3.3 Towing the Machine ........................................................................... 26
3.4 Running-in Period ............................................................................... 28
3.5 Maintenance Schedule ....................................................................... 29
3.6 Recommended Products and Amounts .............................................. 30
3.7 Oil/Temperature Table ....................................................................... 31
3.8 Engine Oil ........................................................................................... 32
3.9 Hydraulic Oil ....................................................................................... 34
3.10 Fuel System ....................................................................................... 36
3.11 Sprinkler Efficiency ............................................................................. 38
3.12 Scraper Bar Wear ............................................................................... 38
3.13 Cleaning ............................................................................................. 39
3.14 Central Steering Joint ......................................................................... 40
3.15 Battery Fluid Level .............................................................................. 41
3.16 Exciter Lubrication .............................................................................. 42
3.17 Shockmounts ...................................................................................... 44
3.18 Engine Air Filter .................................................................................. 45
3.19 Engine Cooling System ...................................................................... 47
3.20 Exhaust System and Engine Air Intake System ................................. 48
3.21 Cleaning the Fuel Tank ...................................................................... 49
wc_br0160488en_002TOC.fm 5
Table of Contents RD 25 Repair
3.22 Cleaning the Water Tank .....................................................................50
3.23 Fill and Drain of Hydraulic Oil, and Cleaning the Hydraulic Oil Tank ..51
3.24 Storage ................................................................................................52
3.25 Electrical Schematic Diagrams ............................................................53
3.26 Hydraulic Schematic ............................................................................64
3.27 Hydraulic Schematic Components ...................................................65
4. General Systems Failure 66
4.1 General Systems Failure Troubleshooting ..........................................66

4.2 Checking the 40A Maxifuse .................................................................67
4.3 Checking the Warning Lights Fuse .....................................................68
4.4 Checking the Indicator Lights Fuse .....................................................68
4.5 Checking the Ignition Key Switch ........................................................69
4.6 Checking the Electric Equipment Enable Relay ..................................70
5. Engine Starting System 72
5.1 Engine Does Not Start Troubleshooting—Flowchart E1 .....................72

5.2 Checking the Drive Pump Neutral Switch ...........................................73
5.3 Checking the Engine Start Enable Relay ............................................74
5.4 Checking the Engine Start Relay ........................................................76
5.5 Checking the Starter Motor .................................................................78
6. Hydraulic System Service 79
6.1 Hydraulic System Precautions ............................................................79

6.2 Hydraulic System Service Basics ........................................................79
6.3 Analyzing Hydraulic Oil Contamination ...............................................80
6.4 Hydraulic Pressures and Test Ports ....................................................81
6.5 Hydraulic Component Locations .........................................................82
6.6 Hydraulic Schematic ............................................................................84
6.7 Hydraulic Schematic Components ......................................................85
7. Drive System 86
7.1 Drive System Overview ...................................................................... 86

7.2 Drive System Hydraulic Flow Diagrams ............................................. 87
7.3 Drive System Pictoral Diagram .......................................................... 88
7.4 Pictorial Diagram Components ........................................................... 89
7.5 Valves and Ports of the Drive Pump .................................................. 90
7.6 Troubleshooting Flowcharts ............................................................... 91
7.7 Machine Does Not Drive Troubleshooting—Flowchart A1 ................. 92
7.8 Checking the Seat Switch .................................................................. 94
7.9 Checking the Parking Brake Pushutton .............................................. 95
7.10 Checking the Parking Brake Relay ..................................................... 96
7.11 Checking the Parking Brake Solenoid ................................................ 98
7.12 Checking Pressure in the Brake Circuit .............................................. 99
7.13 Checking the Drive Pump Servo Lever ............................................ 100
7.14 Checking the Drive Pump Pressure ................................................. 101
7.15 Checking the Drive Motors ............................................................... 102
7.16 Machine Performs Poorly Troubleshooting—Flowchart F1 .............. 103
7.17 Drive Pump Adjustments .................................................................. 104
8. Vibration System 106
8.1 Vibration System Overview .............................................................. 106

8.2 Vibration System Hydraulic Diagram ................................................ 108
8.3 Troubleshooting the Vibration System—Flowchart B1 ..................... 110
8.4 Checking the Vibration Solenoids .................................................... 112
8.5 Checking the Vibration System Fuse ............................................... 113
8.6 Checking the Vibration Relay ........................................................... 114
8.7 Checking the Vibration Enable Switch ............................................. 116
8.8 Checking the Vibration Mode Switch ................................................ 117
8.9 Checking the Vibration/Steering Pump ............................................ 118
8.10 Checking the Exciter Motors ............................................................ 120
8.11 Checking the Exciter Bearings ......................................................... 122
9. Steering System 124
9.1 Steering System Overview ............................................................... 124

9.2 Steering System Troubleshooting—Flowchart C1 ........................... 126
9.3 Checking the Vibration/Steering Pump ............................................ 128
Table of Contents RD 25 Repair
9.4 Checking Steering Servo Pressure ...................................................130
9.5 Replacing and Inspecting the Steering Cylinder ...............................132
9.6 Steering Cylinder Inspection and Fitting ............................................134
10. Spray System 136
10.1 Spray System Overview ....................................................................136

10.2 Spray System Troubleshooting—Flowchart D1 ................................137
10.3 Checking the Spray System Fuse .....................................................138
10.4 Checking the Spray Switch ...............................................................139
10.5 Checking the Water Pump ................................................................140
10.6 Checking the Automatic Water Pump Relay .....................................142
10.7 Checking the Water Pump Timer Relay ............................................144
10.8 Checking the Water Pump Timer ......................................................146
11. Disassembly/Assembly Procedures 147
11.1 Tools ..................................................................................................147

11.2 Ordering Parts ...................................................................................147
11.3 Reference Numbers ( ) ......................................................................147
11.4 Weight Block .....................................................................................147
11.5 Removing the Engine ........................................................................148
11.6 Installing the Engine ..........................................................................150
11.7 Replacing the Drive Pump .................................................................152
11.8 Replacing the Vibration/Steering Pump ............................................154
11.9 Removing the Drums .........................................................................155
11.10 Installing the Drums ...........................................................................157
11.11 Replacing the Reduction Gear ..........................................................158
11.12 Reduction Gear Disassembly ............................................................160
11.13 Reduction Gear Assembly .................................................................162
11.14 Rebuilding Vibration Hub ...................................................................164
11.15 Disassembling Articulated Joint ........................................................166
11.16 Assembling Articulated Joint .............................................................167
11.17 Cleaning the Hydraulic Tank .............................................................168
11.18 Replacing the Hydraulic Oil Cooler ...................................................170
Safety Information RD 25
1. Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE and
NOTE callouts which must be followed to reduce the possibility of
personal injury, damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates a hazardous situation which, if not avoided, will

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

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

result in minor or moderate injury.
CAUTION
NOTICE: Used without the safety alert symbol, NOTICE indicates a

hazardous situation which, if not avoided, could result in property
damage.
Note: Contains additional information important to a procedure.
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RD 25 Safety Information
1.1 Operating Safety
Familiarity and proper training are required for the safe operation of
machine. Machines operated improperly or by untrained personnel
can be dangerous. Read the operating instructions contained in both
WARNING 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 machine before
being allowed to operate it.
1.1.1 ALWAYS wear protective clothing appropriate to the job site when
operating equipment.
1.1.2 ALWAYS remain aware of moving parts and keep hands, feet, and
loose clothing away from the moving parts of the machine.
1.1.3 ALWAYS read, understand, and follow procedures in the Operator’s
Manual before attempting to operate the equipment.
1.1.4 ALWAYS store the equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the reach of
children.
1.1.5 ALWAYS check that all controls are functioning properly immediately
after start-up! DO NOT operate machine unless all controls operate
correctly.
1.1.6 ALWAYS operate the machine with all safety devices and guards in
place and in working order.
1.1.7 ALWAYS remain aware of changing positions and movement of other
equipment and personnel on the job site.
1.1.8 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.
1.1.9 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 operator and there is no danger
of the machine sliding, falling or tipping.
1.1.10 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.
1.1.11 ALWAYS disengage and stow the locking bar for the articulated
steering joint before operating the machine. The machine cannot be
steered when the locking bar is engaged.
1.1.12 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 forward/
reverse control in the neutral position.
wc_si000103gb.fm 11
1.1.13 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.
1.1.14 NEVER carry passengers. Danger of crushing — keep clear of the
articulated steering joint between the front and rear frames.
1.1.15 NEVER use or attempt to repair damaged safety belts or ROPS.
Replace only with Wacker spare parts.
1.1.16 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.
1.1.17 NEVER use accessories or attachments that are not recommended by
Wacker. Damage to equipment and injury to the user may result.
1.1.18 NEVER leave machine running unattended.
1.1.19 NEVER start a defective unit in need of service or repair.
wc_si000103gb.fm 12
1.2 Operator Safety while using Internal Combustion Engines
Internal combustion engines present special hazards during operation

and fueling. Read and follow the warning instructions in the engine
owner’s manual and the safety guidelines below. Failure to follow the
DANGER warnings and safety guidelines could result in severe injury or death.
1.2.1 DO NOT run the 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.
1.2.2 DO NOT smoke while operating the machine.
1.2.3 DO NOT smoke when refueling the engine.
1.2.4 DO NOT refuel a hot or running engine.
1.2.5 DO NOT refuel the engine near an open flame.
1.2.6 DO NOT spill fuel when refueling the engine.
1.2.7 DO NOT run the engine near open flames.
1.2.8 ALWAYS refill the fuel tank in a well-ventilated area.
1.2.9 ALWAYS replace the fuel tank cap after refueling.
1.2.10 ALWAYS check the fuel lines and the fuel tank for leaks and cracks
before starting the engine. Do not run the machine if fuel leaks are
present or the fuel lines are loose.
1.2.11 ALWAYS keep the area around a hot exhaust pipe free of debris to
reduce the chance of an accidental fire.
1.2.12 DO NOT remove radiator cap when the engine is running or hot. The
radiator fluid is hot and under pressure and may cause severe burns!
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1.3 Service Safety
Poorly maintained machines can become a safety hazard! In order for

the machine to operate safely and properly over a long period of time,
periodic maintenance and occasional repairs are necessary.
WARNING
1.3.1 DO NOT stand under the machine while it is being hoisted or moved.
1.3.2 DO NOT get onto the machine while it is being hoisted or moved.
1.3.3 DO NOT use the machine as a ladder. Use safe ladders and platforms
designed for this purpose.
1.3.4 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.
1.3.5 DO NOT open hydraulic lines or loosen hydraulic connections while
the 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
the hydraulic lines.
1.3.6 DO NOT attempt to open the radiator cap while the unit is running or
before the engine has cooled down. Severe burns may result!
1.3.7 DO NOT modify the machine without the express written approval of
the manufacturer.
1.3.8 DO NOT attempt to clean or service the machine while it is running.
Rotating parts can cause severe injury.
1.3.9 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.
1.3.10 DO NOT test for spark on gasoline-powered engines if the engine is
flooded or the smell of gasoline is present. A stray spark could ignite
the fumes.
1.3.11 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.
1.3.12 ALWAYS keep the area around the muffler free of debris such as
leaves, paper, cartons, etc. A hot muffler could ignite the debris and
start a fire.
1.3.13 ALWAYS replace worn or damaged components with spare parts
designed and recommended by Wacker Corporation.
1.3.14 ALWAYS keep the machine clean and labels legible. Replace all
missing and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
1.3.15 ALWAYS check all external fasteners at regular intervals.
wc_si000103gb.fm 14
1.3.16 ALWAYS switch off the power supply at the battery disconnect before
adjusting or maintaining the electrical equipment.
1.3.17 ALWAYS turn engine off before performing maintenance or making
repairs.
1.3.18 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.
1.3.19 ALWAYS keep hands, feet and loose clothing away from moving parts.
1.3.20 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 location of other people around when lifting the machine.
1.3.21 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!
1.3.22 Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
tightened.
1.3.23 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 and allow fluids to cool before loosening hydraulic
fittings or attaching test gauges.
1.3.24 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.
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1.4 Label Locations
A B C
D E F G D
H I J K
wc_gr001223
BB98539
D L M N D
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1.5 Warning & Informational Labels
Ref. Label Meaning

A Operator's Manual must be stored on
O P E R A T O R 'S M A N U A L M U S T B E E L M A N U A L D E O P E R A C IO N D E B E
S T O
R E P
R E D
L A C
O N M
E M E N
A C
T O
H IN E .
P E R A T O R 'S
S E
C O
R R E T
N T A C
E N ID
T E A
O E
S U
N L A
D IS T
M A Q
R IB U
U IN A .
ID O R
machine. Replacement Operator's Manual
M A N U A L C A N B E O R D E R E D W A C K E R M A S C E R C A N O P A R A
T H R O U G H Y O U R L O C A L W A C K E R P E D IR U N E J E M P L A R can be ordered through your local Wacker
D IS T R IB U T O R . A D IC IO N A L .
D IE B E T R IE B S V O R S C H R IF T M U S S L A N O T IC E D 'E M P L O I D O IT distributor.
A N D E R M A S C H IN E A U F B E W A H R T E T R E M U N IE S U R L A M A C H IN E .
W E R D E N . Z U R B E S T E L L U N G V O N C O N T A C T E R L E D IS T R IB U T E U R
1 1 5 0 9 6
E R S A T Z B Ü C H E R N W E N D E N S IE W A C K E R L E P L U S P R O C H E
S IC H B IT T E A N IH R E N P O U R C O M M A N D E R U N
Ö R T L IC H E N W A C K E R H Ä N D L E R . E X E M P L A IR E S U P P L E M E N T A IR E .
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
D’EMPLOI
EMPLOI 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.
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Ref. Label Meaning
E A nameplate listing the model number, item
Wacker Corporation
Menomonee Falls, WI 53051 USA
number, revision number, and serial number is
Model attached to each unit. Please record the
Item Number Rev. Serial Number
information found on this plate so it will be
available should the nameplate become lost or
kg lbs kW hp dB(A)
damaged. When ordering parts or requesting
112232
MADE IN
max.kg max.lbs Manuf. Yr.
service information, you will always be asked
ITALY
to specify the model number, 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.
wc_si000103gb.fm 18
Ref. Label Meaning
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).
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Technical Data RD 25
2. Technical Data
2.1 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/quality 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)
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RD 25 Technical Data
2.2 Roller
Item No. RD 25
0009317
Roller
Overall Dimensions mm 2600 x 1190 x 2880
(in.) (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 0 – 8.0 (0 – 5.0)
(mph)
Gradeability % *
Vibration Frequency Hz (vpm) 53.3 (3200)
*See Operator’s manual, Driving on slopes and uneven terrain.
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Technical Data RD 25
2.3 Lubrication
Item No. RD 25
0009317
Lubrication
Engine Crankcase type Oil, Diesel Gamma
(summer or winter grade) l (gal.) 5.5 (1.5)
Hydraulic System type Oil, Arnica 46
l (gal.) 48 (12,7)
Exciter type Rotra MP 80W/90
l (gal.) 6.5 (1.7)
Articulated Joint type GR MU / EP 2
quantity 4–5 shots with a hand-held grease gun
Drive Bearings - type Sealed
front and rear drums
2.4 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 (LWA) = 109 dB(A).
-the sound pressure level at operator’s location (LpA) = 85 dB(A).
This sound value was determined according to ISO 3744 for the sound
power level (LWA).
The weighted effective acceleration value, determined according to
ISO 8662 Part 1, is approximately:
Hands = 3.9 m/s2, Seat = < 0.5 m/s2.
The vibration measurements were obtained with the machine moving
on hard asphalt at maximum RPM.
wc_td000070gb.fm 22
RD 25 Technical Data
2.5 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)
wc_td000070gb.fm 23
Maintenance RD 25
3. Maintenance
3.1 Hoisting the Machine

Locking the steering joint
Before hoisting the machine, clamp the central steering joint in the
locked position by fitting the clamping bracket as follows:
3.1.1 Remove the split pin A and take the pin B out of the hole.
3.1.2 Turn the lock bar C from position 1 to position 2.
3.1.3 Put the pin B back into the hole in the front half frame.
3.1.4 Fit the split pin A so as to stop the pin B.
Note: The clamping bracket may be used as an anti-theft device by
replacing the pins with two padlocks.
Hoisting
Use four ropes or chains with a minimum load bearing capacity of 1500
kg (3308 lbs.). The ropes or chains must be at least 2000 mm (6.5 ft.)
WARNING
long each. Do not use improvised ropes or chains.
Do not stand under, or get onto, the machine while it is being hoisted
or moved.
3.1.5 Attach the hoisting ropes or chains to the holes E on the machine using
hooks or shackles. Use one rope or chain to each hole.
3.1.6 Attach the other end of the ropes or chains to the hook of the hoisting
equipment. The hook must have a lifting capacity which will support the
weight of the machine (1500 kg (3308 lbs)).
3.1.7 Lift the machine.
C B E
E
C
A 2
wc_gr001090
wc_tx000194gb.fm 24
RD 25 Maintenance
3.2 Transporting the Machine

When you have loaded the machine onto a trailer, attach it to the trailer
platform by attaching shackles to the holes E and using steel ropes or
chains. Attach the machine to the front and rear of the trailer.
Note: The transmission is always braked when the diesel engine is off,
or when the hydraulic system is not functioning.
E
E
wc_gr001091
wc_tx000194gb.fm 25
Maintenance RD 25
3.3 Towing the Machine

Check that all pressure has been released from the hydraulic system
before releasing the brakes and by-passing the drive pump.
WARNING
3.3.1 Block the drums with wedges.
3.3.2 Allow the engine to cool down.
3.3.3 Disconnect the electric power using the battery isolator switch.
Drive pump by-pass
3.3.4 Open the engine hood.
3.3.5 Turn the bypass screw B, located on the drive pump, counterclockwise
2-1/2 – 3 turns.
Releasing the brakes
To release the brakes:
3.3.6 Remove the hydraulic brake hose A leading to the drive motors from
the drive pump.
3.3.7 Attach a manual pump to the hydraulic brake hose A and pump the
system up to a pressure of 18–23 bar (260–335 psi). The brakes will
release.
Towing
NOTICE: Do not tow the machine on slopes. The machine must be
towed on flat terrain only. Do not exceed a towing speed of 1 kph (0.6
mph).
The machine should only be towed for short distances.
3.3.8 Attach a rigid tow bar from the machine to a towing vehicle with
sufficient towing capacity.
3.3.9 Remove the wedges blocking the rollers in position and check that
both drums are free to rotate.
3.3.10 Tow the machine as necessary.
After Towing
3.3.11 Before removing the rigid tow bar, return the brakes to normal
operation by removing the manual pump and reconnecting the
hydraulic brake hose A to the drive pump.
3.3.12 Tighten the bypass screw B.
wc_tx000194gb.fm 26
RD 25 Maintenance
wc_gr001092
wc_tx000194gb.fm 27
Maintenance RD 25
3.4 Running-in Period
The minimum running-in period for the road roller is 100 engine hours.
During this period, the following rules should be followed closely:
• After a cold start, allow the engine to idle for a few minutes.
• Before starting work, ensure that the hydraulic oil has reached
required working temperature.
• Do not run the engine under maximum loading for long periods.
• Check all the fluid levels frequently.
• Check the tightness of the hydraulic connections and bolts at
frequent intervals.
After the first 50 hours:
• Change the engine oil.
• Change the diesel fuel filter cartridge.
• Change the engine oil filter cartridge.
• Change the hydraulic oil filter cartridge.
• Change the exciter oil.
• Check the tightness of the central steering joint.
These operations must be repeated after 100 hours, and then
according to the maintenance schedule.
wc_tx000194gb.fm 28
RD 25 Maintenance
3.5 Maintenance Schedule
Every Every Every Every Every

10 50 250 500 1000
hours hours hours hours hours

Check level of engine oil (1)
Change engine oil
Replace engine oil filter
Check level of hydraulic fluid
Clean hydraulic oil cooler
Change hydraulic fluid

Replace hydraulic fluid filter (2)
Check and clean sprinkler system
Check and clean scraper bars
Perform general cleaning
Grease central steering joint
Check central steering joint tightness
Check battery fluid level
Check exciter oil level
Change exciter oil
Service air cleaner cartridge
Inspect shockmounts
Clean cooling system
Check exhaust system
Check fuel level
Check in-line fuel filter
Replace in-line fuel filter
Replace main fuel filter
Clean all tanks
(1)
Oil consumption in the first 200 hours is higher than normal. During this period it is therefore advisable to
check the oil level at least twice daily and top off when necessary.
(2)Duringthe running-in period the filter must be changed as follows: 1st change at 100 hours, 2nd change
at 200 hours, 3rd change at 500 hours
wc_tx000194gb.fm 29
Maintenance RD 25
3.6 Recommended Products and Amounts
The amounts shown in litres 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) 5.5 1.5
Exciters ROTRA MP 80W/90 6.5 1.7
Hydraulic oil tank OIL, Arnica 46 48 12.7
Fuel tank Diesel fuel, clean and filtered 48 12.7
Water tank WATER 160 42.3
Lubricant specifications
For oils of other brands consult the comparative table of oils.
Part Agip code/name Code/name
Diesel Engine Diesel Gamma API CC - 4/SG MIL - L - 2104 E
ACEA E3-96 MIL - L - 46152 E
Exciter and transmission equipment
ROTRA MP 80W/90 API-GL-5- MIL-L-2105 D
Hydraulic system Arnica 46 DIN 51524 - Pt. 3 - Cat. HV
Grease nipples GR MU/EP 2
Lithium grease - consistency NLGI 2
wc_tx000194gb.fm 30
RD 25 Maintenance
3.7 Oil/Temperature Table
Diesel engine oil

-35 -22 -13 -4 +5 +14 +23 +32 +41 +50 +59 +68 +77 +86 +95 +104 ¡F
SAE 5 W/30
SAE 10 W
SAE 10 W/40
SAE 15 W/40
SAE 20 W/20
SAE 30
SAE 40
-35 -30 -25 -20 -15 -10 -5 0 +5 +10 +15 +20 +25 +30 +35 +40 ¡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 1400 15W/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_tx000194gb.fm 31
Maintenance RD 25
3.8 Engine Oil
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.
3.8.1 Clean around the dipstick.
3.8.2 Extract the dipstick A and check the oil level. The oil level should be
between the two notches on the dipstick. Top-up if necessary so that
the oil reaches the maximum level mark.
3.8.3 Check the condition of the O-ring on the dipstick; replace if worn.
NOTICE: 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 change
The machine must be perfectly level.
3.8.4 Open the engine hood and fix it in the raised position with the rod.
3.8.5 Unscrew the retaining nut B and detach the drain hose from the frame.
3.8.6 Drain off the old oil into an old container of at least 6–6.5 liters (1.5–
2 gallon) capacity.
3.8.7 Refit the drain hose to the frame and tighten retaining nut B.
Note: Collect, store and dispose of all old oil in accordance with
current environmental protection regulations.
Change the oil when the engine is still warm. Warm oil drains more
easily.
Danger of burns! Care must be taken when draining hot engine oil. Hot
oil can burn!
WARNING
3.8.8 Remove the dipstick A and pour in the required amount of oil [approx.
5.5 liters (1.5 gallons)]
3.8.9 Check the oil level.
NOTICE: Always use the correct oil type. Do not use oil brands or
grades which are not recommended.
wc_tx000194gb.fm 32
RD 25 Maintenance
Engine oil filter cartridge change
Stop the machine and apply the parking brake.
3.8.10 Run the engine for a few minutes and then stop the engine.
3.8.11 Wait until the oil has settled.
3.8.12 Drain the engine oil following the oil change instructions
Danger of burns! Care must be taken when draining hot engine oil. Hot
WARNING
oil can burn!
3.8.14 Unscrew the bolts and remove the engine cover from the front frame.
3.8.15 Using a large screwdriver or a filter chain wrench, unscrew the filter
cartridge C and remove it from its container
3.8.16 Clean the oil recovery plate.
3.8.17 Lightly lubricate the seal of the new filter.
3.8.18 Install the new filter and tighten it by hand.
3.8.19 Fill the engine with oil following the oil change instructions
3.8.20 Start and run the engine for a few minutes and then check the oil
pressure and the filter seal.
3.8.21 Check the oil level and top up if necessary.
3.8.22 Check the new filter for leaks.
Note: Dispose of used filters in accordance with environmental
protection legislation.
C
B
wc_gr001109
wc_tx000194gb.fm 33
Maintenance RD 25
3.9 Hydraulic Oil

Hydraulic oil level
Check the level on the transparent level plug A on the left side of the
tank. The level should be at the halfway mark on the level plug. If the
level is low, top up through the filler B.
NOTICE: Only use oil which meets the standards specified in the table
of recommended lubricants.
Hydraulic oil cooler
Clean the hydraulic oil cooler.
3.9.2 Clean the oil cooler fins using a vacuum cleaner. Do not knock the fins.
Knocking will bend the fins.
Hydraulic oil filter cartridge change
3.9.4 Unscrew the old filter cartridge C keeping a plastic bag over the
cartridge to contain any oil loss.
3.9.5 Oil the seal of the new cartridge.
3.9.6 Fill the new filter with hydraulic oil.
3.9.7 Install the new filter. Screw the new filter on by hand, ensuring that it is
not cross-threaded.
3.9.8 Tighten using both hands.
3.9.9 Start and run the engine at idling speed for a few minutes
3.9.10 Check that the seal washer is not leaking.
3.9.11 Check the hydraulic oil tank level.
NOTICE: During the running-in period the filter must be changed as
follows:
1st change at 100 hours
2nd change at 200 hours
3rd change at 500 hours
NOTICE: Only use original, recommended filter cartridges.
wc_tx000194gb.fm 34
RD 25 Maintenance
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
A
wc_gr001110
wc_tx000194gb.fm 35
Maintenance RD 25
3.10 Fuel System

Fuel level
Check the fuel level on the transparent plug D and top up if necessary.
Main fuel filter cartridge change
Danger of explosion. Diesel fuel is flammable and must be treated with
the necessary caution. Do not smoke. Avoid sparks and open flames.
WARNING
3.10.2 Remove the engine cover.
3.10.3 Place an absorbent cloth under the filter B to contain any fuel spillage.
3.10.4 Stop the fuel supply to the filter by pinching the inlet hose with a clamp.
NOTICE: Use care not to damage the hose.
3.10.5 Using a filter wrench C, unscrew the filter cartridge clockwise.
3.10.6 Remove the old cartridge.
3.10.7 Lightly lubricate the seal of the new filter.
3.10.8 Install the new filter and screw it down by hand. Do not use tools.
3.10.9 Reconnect the fuel supply.
3.10.10 Run the engine for a few moments and check the seal of the filter and
hoses.
3.10.11 Reinstall the engine cover and close the hood.
NOTICE: Only use original spare parts.
In-line fuel filter cartridge inspection
The maintenance interval for these operations depends on the purity
of the diesel fuel used and should be adjusted accordingly. If your fuel
is dirty, perform this operation at 250 hours. If your fuel is clean, you
may extend the maintenance interval and perform the operation at
1000 hours.
wc_tx000194gb.fm 36
RD 25 Maintenance
3.10.13 Check the fuel filter E. It should not be clogged. The filter body is
transparent and takes the color of the fuel passing through it. If the
color is very dark this indicates that the filter is clogged and should be
changed.
In-line fuel filter cartridge change
WARNING
3.10.15 Place an absorbent cloth under the filter E to prevent any fuel spillage
from spreading.
3.10.16 Detach the fuel hoses F from both sides of the fuel filter E.
3.10.17 Install the new filter observing the direction of flow indicated by the
arrow on the cartridge.
3.10.18 Run the engine for a few moments and check the seal of the filter and
hoses.
NOTICE: Only use original spare parts.
C
‹
F
F
wc_gr001111
wc_tx000194gb.fm 37
Maintenance RD 25
3.11 Sprinkler Efficiency

Stop the machine, apply the parking brake but keep the engine
switched on.
Check that the water sprinkling equipment is functioning efficiently as
follows:
3.11.1 Check that the nozzles on the sprinkler bars H are not clogged.
3.11.2 Open the water tap and make sure that water comes out of all the
nozzles.
3.11.3 Switch off the engine.
NOTICE: Use clean water only.
J
H
wc_gr001112
J
3.12 Scraper Bar Wear

Check the wear of the drum scraper bars J. Drum scraper bars made
of synthetic materials wear very quickly when used with abrasive
materials and should only be used where absolutely necessary. Take
this into account when adjusting the distance between the drum
scraper bar and the drum.
wc_tx000194gb.fm 38
RD 25 Maintenance
3.13 Cleaning
Protect the following parts with covers and adhesive tape:
• Engine cooling louvers
• Exhaust pipe
• Dashboard
• Forward/reverse lever
Clean the roller thoroughly with a high-pressure water jet and a strong
brush. Remove all dirt, mud and tar from the drum and bodywork.
Cleaning the vehicle thoroughly will reveal 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_tx000194gb.fm 39
Maintenance RD 25
3.14 Central Steering Joint

Greasing the central steering joint
Grease the grease nipples O (4 to 5 strokes of the grease gun).
Checking the tightness of the central steering joint
The machine should be perfectly level and on a vehicle lift with a
suitable load bearing capacity.
Check the tightness of the nuts on the vertical and horizontal pins of
the central steering joint as follows:
3.14.1 Loosen the retaining nut J on the horizontal pin.
3.14.2 Tighten the nut J to a torque wrench setting of 20 Kg/m.
3.14.3 Loosen the 2 bolts K and remove the pin retaining plate L holding the
central pin M in place.
3.14.4 Loosen the retaining bolts N of the oil seal retainer flange P.
3.14.5 Remove the flange P.
3.14.6 Loosen the ring nuts Q and then re-tighten to a torque wrench setting
of 20 Kg/m.
3.14.7 To re-assemble the central steering joint, reverse the dismantling
procedure.
P
N
M J
L
K
O
wc_gr000873
wc_tx000194gb.fm 40
RD 25 Maintenance
3.15 Battery Fluid Level

Battery fluid is poisonous and corrosive. In the event of ingestion or
contact with skin or eyes, seek medical attention immediately.
WARNING
Check the battery fluid level with the machine standing on a level
surface.
Maintenance-free batteries
Check the battery charge status at regular intervals. Where necessary,
tighten the cables and grease the cable clamps with petroleum jelly.
Batteries requiring maintenance

3.15.2 Remove the battery cover I and check the fluid level inside the battery.
The fluid should cover the tops of the elements. If necessary, top off so
that the elements are completely covered with fluid.
3.15.3 Reinstall the battery cover.
wc_gr001113
wc_tx000194gb.fm 41
Maintenance RD 25
3.16 Exciter Lubrication

Checking exciter oil level
3.16.1 Position the machine so that the drums are as shown. Move the
machine backwards and forwards until the plugs J are parallel to the
ground surface.
3.16.2 Remove the plugs J.
3.16.3 Check the hydraulic oil level. The oil should just reach the lower edge
of the plug holes.
3.16.4 Top off the oil level if necessary.
3.16.5 Check the plug seals and change if necessary.
3.16.6 Reinstall and tighten the plugs J.
Changing the exciter oil

The machine should be standing on a level surface.
3.16.7 Position the machine so that the plug hole is positioned at the lowest
point H1 as shown.
3.16.8 Remove the plug and allow the old oil to drain off completely.
3.16.9 Position the machine so that the drums are positioned as shown. The
plug hole must be at its highest point H2 and must be accessible for
filling.
3.16.10 Pour in the required amount of oil.
3.16.11 Reinstall the plug.
3.16.12 Check the oil level as described above in exciter oil level.
wc_tx000194gb.fm 42
RD 25 Maintenance
H2
J J
H1
J J
wc_gr000875
wc_tx000194gb.fm 43
Maintenance RD 25
3.17 Shockmounts

Engine shock mounts
• Open the engine hood and fix it in the raised position with the rod.
• Check the wear of the diesel engine shock mounts J. The rubber
should not be broken, nor should it show any signs of having lost
its resilience. The blocks 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 shock mounts
• Check the wear of the exciter drum shock mounts K. The rubber
should not be broken, nor should it show any signs of having lost
its resilience. The shocks prevent excessive vibration from
reaching the frame and thus also protect the other components
from damage and faulty operation.
NOTICE: Fuel and hydraulic oils corrode the rubber of the shock
mounts. The engine compartment should therefore be thoroughly
cleaned at regular intervals.
Should it be necessary to replace one or more of the shock mounts, it
is advisable to change all of the other shock mounts at the same time.
K wc_gr001114
wc_tx000194gb.fm 44
RD 25 Maintenance
3.18 Engine Air Filter

3.18.2 Release the clips C and remove the filter cover D.
3.18.3 Clean the area around the filter element E.
3.18.4 Remove the bolts F and extract the filter container and the cover G.
3.18.5 Carefully remove the filter element E.
3.18.6 Cover the inlet manifold with a clean rag to keep dirt out.
3.18.7 Clean the filter container and cover.
3.18.8 Clean the filter element or replace it if the old filter is very dirty or
clogged.
Cleaning dry dirt from the filter
a) Quick method
Tap the cartridge against the palm of your hand to dislodge the dust
and dirt .
NOTICE: Do not knock the filter element against hard objects.
b) Thorough method
3.18.9 Clean the filter element with a compressed air gun fitted with a straight
or bent nozzle.
3.18.10 Blow through the filter from the inside to the outside along the folds of
the filter.
3.18.11 Continue until all dust has been removed
NOTICE: Only use filtered, dry compressed air. Do not exceed an air
pressure of 70 psi (5 bar). Keep the nozzle at a distance of 150 mm (6
inches) from the element.
Cleaning wet or oily dirt from the filter
Soak the filter element for 10 minutes in a warm (40°C) detergent
solution.
NOTICE: Only use diluted detergent solution. Do not use concentrated
liquids, petrol, hot liquids or high-pressure steam.
3.18.12 Rinse the element in clean water and shake dry
3.18.13 Allow the element to dry in warm, dust-free surroundings.
NOTICE: Do not dry the element in an oven. Do not dry at
temperatures above 60°C.
Before you reinstall a filter element, be sure that it is dry.
NOTICE: Always trace and correct the cause of wet or oily
contamination of a filter element.
wc_tx000194gb.fm 45
Maintenance RD 25
Checking the filter element
Air filter elements should not be cleaned more than twice; after this
they must be replaced.
• Check that the sealed surface I is in good condition.
• Hold the element up to the light or pass a lamp through the mid-
dle to check the condition of the element folds.
NOTICE: Do not re-use damaged filters. Replace damaged filters even
though the damage may be very slight.
F
G
D
E
I
I wc_gr001115
wc_tx000194gb.fm 46
RD 25 Maintenance
3.19 Engine Cooling System

3.19.2 Remove the cover L.
3.19.3 Clean the cooling system as follows:
Dry dirt:
Use a jet of compressed air to clean the dust and dry dirt from the air
intakes, engine fins, the cylinder head, engine block and all other
surfaces with a cooling function.
Grease and oil:
Soak all parts to be cleaned with a detergent solution. Allow the
detergent time to start dissolving the greasy dirt and then wash down
with a cold, high-pressure water jet and a brush.
Use a sponge on delicate components.
Danger of burns. Only clean the engine cooling system when the
engine is cold.
WARNING
NOTICE: Do not clean electrical equipment and connections with the
water jet. If these parts become wet, dry them immediately with a jet of
compressed air.
• Trace the source of oil leaks causing greasy dirt. Repair the leak,
seeking the advice of your Hatz engine dealer if necessary.
• After cleaning, run the engine to dry it out and to prevent the for-
mation of rust.
NOTICE: Do not run the engine with the air intakes removed.
L
wc_gr001116
wc_tx000194gb.fm 47
Maintenance RD 25
3.20 Exhaust System and Engine Air Intake System
Danger of burns. Only clean the engine cooling system when the
engine is cold.
WARNING
3.20.2 Check the exhaust pipe and muffler for leaks and holes.
3.20.3 Check the seal of the exhaust system gaskets for leaks.
3.20.4 Check the tightness of all retaining bolts.
3.20.5 Check that the air intake manifold does not leak.
wc_tx000194gb.fm 48
RD 25 Maintenance
3.21 Cleaning the Fuel Tank

WARNING
The machine should be perfectly level.
• Unscrew the drain plug A from the fuel tank and drain the diesel
fuel off completely.
• Remove the inspection cover B and wash the tank out using
clean diesel fuel.
• Clean the filler cap and drain plug and change the seals where
necessary.
NOTICE: Always use a reputable brand of diesel fuel with a sulphur
content of less than 0.5%. Only use clean and filtered fuel. Always use
the correct type of fuel for the time of year: either normal diesel or
winter diesel.
Clean the mesh filter at regular intervals or at every filling.
NOTICE: The tank must be cleaned more frequently if the vehicle is
being used in very humid or dusty conditions
wc_gr001117
wc_tx000194gb.fm 49
Maintenance RD 25
3.22 Cleaning the Water Tank

The machine should be standing on a level surface.
3.22.1 Unscrew the drain plug B and drain off the water tanks.
3.22.2 Remove the inspection cover C under the driver’s seat. Disconnect the
water supply pipes to the roller sprinkling equipment. Clean the inside
of the tank thoroughly by flushing with generous quantities of clean
water.
3.22.3 Check that the filler cap D seal is in good condition.
3.22.4 Clean the filler cap filter E. Reinstall the filler cap, the drain plug and
the inspection cover. Ensure that all seals are in good condition.
D
C
E
wc_gr001118
wc_tx000194gb.fm 50
RD 25 Maintenance
3.23 Fill and Drain of Hydraulic Oil, and Cleaning the Hydraulic Oil Tank

The machine should be perfectly level.
• Unscrew and remove the magnetic drain plug F and allow the
hydraulic oil to drain off completely.
• Remove the inspection cover G and clean any deposits from
inside the tank.
• Clean any pieces of metal from the magnetic drain plug F.
• Change the inspection cover gasket G.
• Reinstall the inspection cover G.
• Clean the filler/vent cap H and fill the tank.
• Change the hydraulic oil filter cartridge.
• Change the filler/vent cap H if it is clogged.
• Check the oil level on the transparent level plug I.
NOTICE: Do not mix oil types or grades. Do not use liquids to clean
the tank. Do not use petrol or other solvents.
F wc_gr001119
wc_tx000194gb.fm 51
Maintenance RD 25
3.24 Storage
When you first receive the machine, check for any damage which may
have occurred during delivery. Report any damage to your local
dealer.
During transport certain parts of the machine are protected against
corrosion by the application of a special resin. We recommend that you
remove this resin using a suitable, environment-friendly product. Place
plastic sheeting under the machine to collect fluids and residues and
then dispose of any waste material following current environmental
If the vehicle is to remain idle for a period and will be parked outside
during this time, cover it with a tarpaulin.
Prolonged period of idleness
If the vehicle is to remain idle for an extended period the following
operations should be carried out:
• General cleaning of the vehicle.
• Lubricate all grease nipples.
• Fill the fuel tank completely.
• Check all fluid levels.
• Charge the battery.
• Put the vehicle under cover; if this is not possible remove the battery
and protect it from freezing conditions.
• 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 protec-
tion of transmission parts.
• Follow the instructions in the sections “Prolonged period of idleness”
and “Precautions against freezing conditions” in the Instruction and
Maintenance Manual for the diesel engine.
• Completely drain the water tank, water filter, and the roller sprinkling
equipment.
NOTICE: After a prolonged period of idleness, all filters must be
changed before the machine is returned to service.
wc_tx000194gb.fm 52
RD 25 Maintenance
3.25 Electrical Schematic Diagrams
See Graphic: wc_gr001125, wc_gr0001126, wc_gr001127, wc_gr001128,

wc_gr001129, wc_gr001130, wc_gr001229, wc_gr001089
Components
Ref. Description Ref. Description

C1 Battery isolator C18 Engine oil pressure low sensor
C2 Battery C19 Engine high temperature sensor
C3 Starter motor C20 Air filter clogged sensor
C4 Generator C21 Warning light test button
C6 Ignition key switch C23 Switch, water spraying manual/
automatic
C7 Parking brake button C24 Water pump
C8 Water pump time switch C26 Switch, vibrator enable
C9 Seat microswitch C27 Vibrator selector switch
C10 Transmission pump neutral C28 Switch, lights and horn
microswitch
C11 Emergency button C29 Horn
C12 Engine stop solenoid C30 Reverse warning horn (optional)
C13 Hazard warning light button, illu- C31 Reverse warning horn microswitch
minated
C14 Flashing warning lights, direction C32 Hydraulic fluid fan sensor
indicators
C15 Direction indicator switch C33 Hydraulic fluid fan
C16 Hour counter C34 Hydraulic oil filter clogged sensor
C17 Parking brake sensor
wc_tx000194gb.fm 53
Maintenance RD 25
Fuses

F1 Fuse, engine warning lights, F6 Fuse, warning horn, dimmed head-
engine stop, negative brake, stop lights, rear work light
lights, water pump enable
F2 Fuse, reverse warning horn and F7 Fuse, rear work light and dimmed
emergency button headlight relay
F3 Fuse, water pump F8 Fuse, side lights and dashboard
light
F4 Fuse, hydraulic fluid fan F9 Fuse, direction indicators
F5 Fuse, vibrator F10 Maxifuse (40A)
Lights

L1 Rear left stop light L8 Rear work light
L2 Rear right stop light L9 Left dimmed headlight
L3 Rear left direction indicator light L10 Right dimmed headlight
L4 Front left direction indicator light L11 Front left side light
L5 Rear right direction indicator light L12 Front right side light
L6 Front right direction indicator light L13 Rear left side light
L7 Rotary beacon L14 Rear right side light
Warning lights

S1 Direction indicator warning light S7 Air filter clogged warning light
S3 Alternator warning light S8 Water pump warning light
S4 Parking brake warning light S9 Vibrator on warning light
S5 Engine oil pressure low warning S10 Dashboard light warning light
light
S6 Engine high temperature warning S11 Hydraulic oil filter clogged warning
light light
wc_tx000194gb.fm 54
RD 25 Maintenance
Connectors

I Connector, 40-pin, dashboard - R Connector, 8-pin, engine
main electrical system
M Connector, 8-pin, warning light T Connector, 2-pin, seat microswitch
test
H1 Negative junction (dashboard wir- N Connector, 2-pin, transmission
ing) pump neutral microswitch
H2 Negative junction (dashboard wir- U Connector, 2-pin, front left direction
ing) indicator
H3 Negative junction (dashboard wir- Z Connector, 2-pin, vibrator enable
ing) switch
H4 Negative junction (main electrical W Connector, 2-pin, front right direc-
system) tion indicator
H5 Negative junction (main electrical X Connector, 2-pin, hydraulic fluid fan
system)
H6 Negative junction (main electrical Y Connector, 2-pin, water pump
system)
H7 Negative junction (main electrical G Connector, 2-pin, engine start relay
system) power supply
H8 Negative junction (main electrical CM Connector, 2-pin, reverse warning
system) horn microswitch
H9 Negative junction (main electrical CR Connector, 2-pin, reverse warning
system) horn
HH Frame earth (negative) CL Connector, 2-pin, rotary beacon
P1 Connector, 1-pin, electrical circuit D1 Non-return diode for maintained
enable relay brake relay
P2 Connector, 1-pin, Maxifuse power D2 Non-return diode for parking brake
supply
Q1 Connector, 1-pin, engine start D3 Non-return diode for rear work light
relay
Q2 Connector, 1-pin, engine starter
motor
wc_tx000194gb.fm 55
Maintenance RD 25
Relays

E1 Relay, electrical equipment E6 Relay, engine start enable
enable
E2 Relay, parking brake E7 Relay, Engine start
E3 Relay, water pump in automatic E8 Relay, water pump in automatic
mode mode
E4 Relay, dipped headlights E9 Relay, vibrator on
E5 Relay, hydraulic fluid radiator fan
Solenoid

A1 Parking brake solenoid valve A3 Front/rear roller vibrator solenoid
valve
A2 Front vibrator solenoid valve
wc_tx000194gb.fm 56
RD 25 Maintenance
112-PU
A-A
201-BK
5 1
112-PU
E1 H3
3 2
B-B
109-RD
C-C
109-RD
D-D
105-RD
E-E
CONTROL 200-BK
RELE
H1 308-YL F1
BAT
D1 D2
STARTER 307-OR 419-YL 110-GN 123-WH
F-F
C6
109-RD
307-OR
330-YL
110-GN
1 3
1 3
E6 E2
C11
F765-BR
777-PU
NC
2 5 4
2 5 4
110-GN
308-YL
306-GN
201-BK
C906-PU
307-OR
777-PU
H3 G1 I7 I1
306-GN
308-YL
110-GN
I6 C7 I20
P1 NC
3 1
HH R2 N2
109-RD
C906-PU
E7
C12
C10
5 2 NC
F10
I22
0 1
304-WH
C1
201-BK
R1 N1
C906-PU
307-OR
777-PU
Q1 G2 HH
307-OR
304-WH
307-OR
-
304-WH
C2
109-RD
+ G-G
307-OR
307-OR
201-BK
P2 Q2 T1
1
H3 C9 A1 L2 L1
304-WH
NO
2
T2
30 50
206-BK
204-BK
206-BK
C3
206-BK
MOT.AVVIAM.
H5 H4 H5 H5
wc_gr001125
112602003-2/A
Wire Colors
OR Orange YL Yellow WH White
BU Blue BR Brown GN Green
PU Violet BK Black RD Red
wc_tx000194gb.fm 57
Maintenance RD 25
112-PU
A-A H-H
777-PU
B-B I-I
109-RD-12a
C-C L-L
C922 BR
D-D M-M
105-RD
E-E N-N
C21
123-WH
123-WH
123-WH
123-WH
F-F
M1 M3 M5 M7
S3
200-BK
450-BU
S4 S5 S6 S7 S11
H1
406-PU
403-GN
406-PU
430-BU
405-YL
419-YL
427-GN
I9 I12 I10 I11 I13 I29
427-GN
403-GN
406-PU
430-BU
405-YL
419-YL
403-GN
403-GN
R4 R5 R6
R3
NO
NO
0000
HH C16 P C18 C20
G-G
403-GN
NO
NO
NC
B+ B- D+
P C17 T C19 C34
GENERATORE
C4
204-BK
H4 HH HH HH HH HH
wc_gr001126
112062003-2/B
Wire Colors
wc_tx000194gb.fm 58
RD 25 Maintenance
H-H O-O
112-PU
I-I P-P
L-L
M-M Q-Q
N-N
F2 F9
106-WH
+
A541-PU
C14 P
108-BU
121-YL
S1
537-GN
15 30 49
200-BK
49a 537-GN
121-YL
606-GN
C13 L
H1
R
31
I2 C15
605-YL
121-YL
201-BK
121-YL
605-YL
606-GY
CM2
H3 I14 I15
606-GY
605-GY
605-YL
606-YL
CM1 CL1
U1 W1
321-BR
L7
202-BK
201-BK
CR1 CL2
L4 L6
201-BK
202-BK
C30 L3 L5
CR2 U2 W2
206-BK
206-BK
205-BK
202-BK
201-BK
205-BK
H7 H7 H5 H8 H5 H9
wc_gr001127
112062003-2/C
Wire Colors
wc_tx000194gb.fm 59
Maintenance RD 25
O-O R-R
112-PU
112-PU
P-P S-S
Q-Q
F3 F4
118-GY 122-BU
122-BU
118-GY
1 3
1 3
S1 E8
E5
2 5 4 C23
2 5 4
C935-PU
202-BK
C935-PU
201-BK
H2 1 3
C935-PU
- T + E3
C8
H3
G736-PK
6797-BU
2 5 4
C922-BR
202-BK
C922-BR
C937-WH
H2 I3 I21 I19
C922-BR
H1 H3
122-BU
I23
S8
200-BK
201-BK
NO
G736-PK
6797-BU
200-BK
T
C922-BR
C32
I4 I5
H1
Y1 X1
+ +
H8 H5 H4 H6 H9
C33
C24 - -
Y2 X2
200-BK
201-BK
201-BK
204-BK
203-BK
202-BK
206-BK
204-BK
205-BK
HH HH HH H6 HH HH HH HH H4
wc_gr001128
112062003-2/D
Wire Colors
wc_tx000194gb.fm 60
RD 25 Maintenance
R-R
112-PU
S-S
F5 F6
102-RD
T-T
0
102-RD
125-OR
1
125-OR 2
3
57/58 614-PU
30 U-U
86 30
56b 619A-GN
E9 V-V
85 87 87a
56a 608A-GN
Z-Z
C28 0
01
C903-BU
49a
202-BK
C903-BU
H2
I27 C27
C903-BU
322-GY
C903-BU
A990-BU
A990-BU
I26 I8
Z1
S9 H2
A990-BU
C926-BU
200-BK
C903-BU
202-BK
H1
C26
I25 I24 I28
A990-BU
C926-BU
C903-BU
C903-BU
322-GY
1 1
Z2
A3 C29
2 2
A2
203-BK
203-BK
203-BK
207-BK
H6 H6 HH H6
wc_gr001129
112062003-2/E
Wire Colors
wc_tx000194gb.fm 61
Maintenance RD 25
T-T
614-PU
U-U
619A-GN
V-V
608A-GN
Z-Z
D3
1 3
608A-GN
F7 E4 F8
2 5 4
614-PU
614-PU
608A-GN
619-GN
I17
S10
I16 I18
200-BK
H1
619-GN
608-GN
614-PU
614-PU
614-PU
614-PU
619-GN
619-GN
614-PU
U3
L8
L9 L10 L11 L12 L13 L14
U4
202-BK
202-BK
201-BK
202-BK
201-BK
206-BK
206-BK
206-BK
H5 H2 H9 H5 H9 H8 H5 H5
wc_gr001130
112062003-2/F
Wire Colors
wc_tx000194gb.fm 62
RD 25 Maintenance
E8
C8
E7
E1 E6 E2 E3
E5 E4 E9 C14
wc_gr001229
112062003-1/G
F1 (15A) F5 (15A) F9 (15A)
F2 (15A) F6 (25A) D1
F3 (15A) F7 (15A) D2
F4 (15A) F8 (15A) D3
wc_gr001089
112062003-2/H
wc_tx000194gb.fm 63
Maintenance RD 25
3.26 Hydraulic Schematic
Revised: APRIL 2004

wc_gr001120
112068005
7
5
8
11 6
13
12
3
9
10
4
2
14
1
wc_tx000194gb.fm 64
RD 25 Maintenance
3.27 Hydraulic Schematic Components

1 Power steering 8 Rear vibrator motor
2 Steering cylinder 9 Vibrator block
3 Internal combustion engine 10 Vibrator / steering pump
4 Filter 11 Transmission pump
5 Front drive motor 12 Brake block
6 Rear drive motor 13 Pressure switch
7 Front vibrator motor 14 Single-acting valve
wc_tx000194gb.fm 65
General Systems Failure RD 25 Repair
4. General Systems Failure
4.1 General Systems Failure Troubleshooting
Check battery shutoff switch.
Is
the battery shutoff Yes Check battery voltage.
switch positioned
correctly?
Is
Charge or replace No the battery
No the battery. voltage OK?
Yes
Reposition the
switch.
Check the 40A maxifuse.
See Checking 40A Maxifuse.
Replace the Is
No the 40A maxifuse
40A maxifuse. OK?
Yes
Check the indicator lights fuse (F9). Check the warning lights fuse (F1).
See Checking the Indicator Lights Fuse (F9). See Checking the Warning Lights Fuse (F1).
Is the indicator Is the warning

lights fuse (F9) No Yes lights fuse (F1)
OK? OK?
Yes No
Replace the
indicator lights
fuse (F9).
Replace the
warning lights
fuse (F1).
Check the ignition switch.
See Checking the Ignition Switch.

Check electric equipment enable relay.
Is the ignition Yes See Checking Electric Equipment Enable Relay.
switch OK?
No Is the electric
equipment enable No
relay OK?
Replace the Yes Replace the

ignition switch. electric equipment
enable relay.
Call Wacker Corporation Service.
wc_gr003587
wc_tx000645gb.fm 66
RD 25 Repair General Systems Failure
4.2 Checking the 40A Maxifuse

The 40A maxifuse is inline between the battery positive terminal, via
the starter motor, and the electric-equipment enable relay. The 40A
maxifuse is mounted to the frame near the battery.
4.2.1 Open the hood and locate the 40A maxifuse (a).
4.2.2 Remove the 40A maxifuse from the enclosure and inspect it.
4.2.3 Replace the 40A maxifuse if it is blown.
Note: Always use replacement fuses of the same type and rating.
RD 15 a
RD 25
wc_gr003588
wc_tx000645gb.fm 67
4.3 Checking the Warning Lights Fuse

The warning lights fuse, F1 on the electrical schematic, protects the
components and warning lights of the control panel from short circuits
and over-current conditions. To check the warning lights fuse:
4.3.1 Remove the cover from the fuse box.
4.3.2 Remove the warning lights fuse (F1) and inspect it.
4.3.3 Replace the warning lights fuse if it is blown.
F1 (15A) F5 (15A) F9 (15A)
F2 (15A) F6 (25A) D1
F3 (15A) F7 (15A) D2
F4 (15A) F8 (15A) D3
wc_gr003589
4.4 Checking the Indicator Lights Fuse

The indicator lights fuse, F9 on the electrical schematic, protects the
indicator lights and the ignition switch from short circuits and over-
current conditions. To check the indicator lights fuse:
4.4.2 Remove the indicator lights fuse (F9) and inspect it.
4.4.3 Replace the warning lights fuse if it is blown.
wc_tx000645gb.fm 68
4.5 Checking the Ignition Key Switch
Before checking the ignition key switch, the battery must be charged
and connected, and the battery cut-off switch must be in the ON
position.
To check the ignition key switch:
4.5.1 Remove the screws that secure the control panel (a) to the console
and tilt the control panel to provide access to the components.
4.5.2 Locate the ignition key switch (b).
4.5.3 Disconnect the wiring connector (c) from the ignition key switch.
4.5.4 Using a multimeter, check for battery voltage (approximately 12V)
between pin 1 and pins 2, 3, and 4 of the ignition key switch wiring
connector. There should be 12V measured in each case.
• If 12V is measured, the ignition key switch has failed; replace it.
To do so, remove the retainer (d) and slide the ignition key switch
from the control panel.
• If 12V is not measured, check the wiring to the ignition key switch
wiring connector. Repair the wiring as needed.
a
c
1
2 F 1000
200 V
20
2
200m
3 4
V- COM
wc_gr003718
wc_tx000645gb.fm 69
4.6 Checking the Electric Equipment Enable Relay

When energized, the electric equipment enable relay provides battery
voltage to the components of the control panel. The check the
operation of the electric equipment enable relay, carry out the following
procedure:
4.6.2 Locate the electric equipment enable relay (E1) (b) and unplug the
connector running to it.
between terminal 3 of the connector and ground.
• If 12V is not measured, check the wiring between the electric
equipment enable relay and the 40A maxifuse. Repair the wiring
as needed.
• If 12V is measured, continue.
4.6.4 Place the ignition key switch in the ON position.
4.6.5 Check for battery voltage (approximately 12V) between terminal 2 of
the connector and ground.
• If 12V is not measured, check the wiring between the electric
equipment enable relay and the ignition switch. Repair the wiring
as needed.
4.6.6 Check for continuity between terminal 1 of the connector and ground.
• If there is no continuity, check the wiring between the connector
and ground. Repair the wiring as needed.
• If there is continuity, continue.
4.6.7 Plug the connector back into the electric equipment enable relay.
4.6.8 Place the keyswitch in the ON position. Using a multimeter with an
appropriate extension, back probe the wiring between terminal 5 (wire
112-PU) (c) and ground. Battery voltage should be measured.
• If 12V is measured, the electric equipment enable relay is func-
tioning properly.
• If 12V is not measured, the electric equipment relay has failed;
replace it.
wc_tx000645gb.fm 70
a
b
1000 1000
F 200
20
V F 200
20
V
2 2
200m 200m
A 5 A
V- COM
c V- COM
1
2
wc_gr003719
wc_tx000645gb.fm 71
Engine Starting System RD 25 Repair
5. Engine Starting System
5.1 Engine Does Not Start Troubleshooting—Flowchart E1
Before conducting in-depth troubleshooting, be sure that:

· The battery cutoff switch (isolator) is in the ON position (closed).
· The battery is charged.
· The fuel tank is full of fresh fuel.
· All functions found in General Systems Failure Troubleshooting are OK.
Check the drive pump lever neutral switch.
See Checking Drive Pump Neutral Switch.
Is the Replace the

neutral switch No neutral switch.
OK?
Yes
Check the engine start enable relay.
See Checking the Engine Start Enable Relay.
Is the Replace the

engine start enable relay No engine start enable
OK? relay.
Yes
Check the engine start relay.
See Checking the Engine Start Relay.
Is the Replace the

engine start relay No engine start relay.
OK?
Yes
Check the starter motor.
See Checking the Starter Motor.
Is the Replace the

starter motor receiving Yes starter motor.
power?
No
Repair wiring to
the starter motor.
wc_gr003688
wc_tx000634gb.fm 72
RD 25 Repair Engine Starting System
5.2 Checking the Drive Pump Neutral Switch

The drive pump neutral switch is a normally closed switch. When in the
closed position (neutral), it allows the engine to be started. When in the
open position, it also allows power to the automatic water pump relay.
To check the drive pump, carry out the following procedure:
5.2.1 Remove the battery.
5.2.2 Remove the battery bracket (a)
5.2.3 Locate the drive pump neutral switch connector (b) and disconnect it.
5.2.4 Place the forward/reverse control in the NEUTRAL(N) position.
5.2.5 Using a multimeter, check for continuity across the pins of the drive
pump switch connector. The drive pump neutral switch should have
continuity when the forward/reverse control lever is in the NEUTRAL
position and no continuity in either the FORWARD or REVERSE
positions. If the drive pump neutral switch does not perform
accordingly, replace it.
b
a
wc_gr003726
wc_tx000634gb.fm 73
5.3 Checking the Engine Start Enable Relay

When energized, the engine start enable relay provides battery voltage
to the engine start relay. To check the operation of the engine start
enable relay, carry out the following procedure:
5.3.2 Locate the engine start enable relay (E6) (b) and unplug the connector
running to it.
5.3.3 Place the ignition key switch into the ON position.
5.3.4 Move the forward/reverse control lever into the neutral position.
• If 12V is not measured, check the wiring between the engine start
enable relay and the forward/reverse lever neutral switch. Repair
the wiring as needed.
5.3.6 Have an assistant place the ignition key switch in the START position.
Check for battery voltage (approximately 12V) between terminal 1 of
• If 12V is not measured, check the wiring between the ignition key
switch and the engine start enable relay. Repair the wiring as
needed.
5.3.7 Plug the connector back into the engine start enable relay.
5.3.8 Check continuity between terminal 2 (wire C201-BK) and ground. To
do so, back probe terminal 2 with an appropriate extension.
• If continuity does not exist, repair wire C201-BK.
• If continuity does exist, continue.
Check the voltage between terminal 5 (wire 306-GN) (c) and ground.
To do so, back probe terminal 5 with an appropriate extension or probe
connector. Battery voltage (approximately 12V) should be measured.
• If 12V is measured, the engine start enable relay is functioning
properly.
• If 12V is not measured, the engine start enable relay has failed,
replace it.
wc_tx000634gb.fm 74
a
b
1000 1000
F 200
20
V F 200
20
V
2 2
200m 200m
A 5 A
V- COM V- COM
c
1
2
wc_gr003716
wc_tx000634gb.fm 75
5.4 Checking the Engine Start Relay

When energized, the engine start relay provides battery voltage to the
starter motor. To check the operation of the engine start relay, carry
out the following procedure:
5.4.2 Locate the engine start relay (E7) (b).
5.4.3 Move the forward/reverse control lever into the neutral position.
between terminal 3 (red wire) of the engine start relay and ground.
relay and the electric equipment enable relay (E1). Repair the
wiring as needed.
Check for battery voltage (approximately 12V) between terminal 1 of
the engine start relay and ground. Do so by probing green wire of
connector.
relay and the engine start enable relay. Repair the wiring as
needed.
5.4.6 Check continuity between terminal 2 (wire C201-BK) and ground. Do
so by probing black wire of connector.
• If continuity does not exist, repair wire C201-BK.
• If continuity does exist, continue.
Check the voltage between terminal 5 (wire 304-WH) and ground.
Battery voltage (approximately 12V) should be measured.
• If 12V is not measured, the engine start relay has failed, replace
it.
• If 12V is measured, the engine start relay is OK.
wc_tx000634gb.fm 76
wc_gr003717
wc_tx000634gb.fm 77
5.5 Checking the Starter Motor

When energized, the engine start relay provides battery voltage to the
starter motor. To check the operation of the starter motor, carry out the
following procedure:
5.5.1 Open the engine compartment hood (a).
5.5.2 Locate the engine starter motor (b).
Check the voltage between terminal 50 (wire 304-WH) and ground.
Battery voltage (approximately 12V) should be measured.
• If 12V is measured, the engine starter motor has failed; replace it.
relay and the starter motor. Repair the wiring as needed.
a
RD 15 RD 25
a
wc_gr003613
wc_tx000634gb.fm 78
RD 25 Repair Hydraulic System Service
6. Hydraulic System Service
6.1 Hydraulic System Precautions

Escaping hydraulic oil under pressure, even a pinhole size leak, can
penetrate body tissue, causing serious injury, and possible death. If oil
WARNING is injected into your skin, you must be treated immediately by a doctor
familiar with this kind of injury.
• Always use a board or cardboard when checking for hydraulic oil

leaks.
• Relieve the hydraulic pressure before working on the machine.
• 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.
6.2 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 the hydraulic fittings. Check the hoses for
holes and/or leaks. Air within the hydraulic system can greatly
affect machine performance.
• Check/change the 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(s) before operating the
machine.
• Carry out hydraulic tests with the 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 37.4–48.6°C (100–120°F).
wc_tx000636gb.fm 79
Hydraulic System Service RD 25 Repair
6.3 Analyzing Hydraulic Oil Contamination
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 the damaged components and replace them
with new ones.
wc_tx000636gb.fm 80
6.4 Hydraulic Pressures and Test Ports
M2 M3
M5
M1
M4
M6
wc_gr003572
Drive circuit Test Port

Charge pressure at max rpm bar (psi) 22±2 (319±29) M3
Max pressure, reverse bar (psi) 270±10 (3916±145) M2
Max pressure, forward bar (psi) 270±10 (3916±145) M1
Steering circuit
Max pressure at 1400 rpm bar (psi) 140±10 (2031±145) M6
Working pressure bar (psi) 50 (725) M6
Shock prevention valve bar (psi) 220 (2466) M6
Vibrating circuit
Max pressure bar (psi) 185±10 (2683±145) M4
Working pressure with only front vibrating bar (psi) 100±10 (1450±145) M4
Working pressure with both drums vibrating bar (psi) 150±10 (2176±145) M4
Parking brake
Brake unlocking pressure bar (psi) 20 (290) M5
wc_tx000636gb.fm 81
6.5 Hydraulic Component Locations
7 6 5 1 8
11
10
3 12 2 13 9 4
wc_gr003711
wc_tx000636gb.fm 82
1 Diesel engine 8 Rear exciter motor

2 Drive pump 9 Steering servo valve
3 Front drive motor 10 Front parking brake
4 Rear drive motor 11 Rear parking brake
5 Vibration/steering (charge) pump 12 Oil radiator
6 Vibration solenoid valve 13 Brake manifold
7 Front exciter motor - ---
wc_tx000636gb.fm 83
6.6 Hydraulic Schematic
19
7
wc_gr003710
5
20
8
6
11
21
18
13
12
17
3
16
9
4
10
1
22
15
220 bar
2
14
wc_tx000636gb.fm 84
6.7 Hydraulic Schematic Components

1 Steering pump (servo) 12 Brake manifold block
2 Steering cylinder 13 Pressure switch
3 Engine (prime mover) 14 Single-acting valve
4 Filter 15 Oil cooler
5 Front drive motor 16 Vibration solenoid valve
6 Rear drive motor 17 Filter
7 Front vibration motor 18 Brake solenoid valve
8 Rear vibration motor 19 Front parking brake
9 Vibration manifold block 20 Rear parking brake
10 Vibration/steering pump 21 Tow valve (gate valve)
11 Drive pump 22 Tank
wc_tx000636gb.fm 85
Drive System RD 25 Repair
7. Drive System
7.1 Drive System Overview

The Wacker Corporation RD 25 Roller utilizes a hydrostatic drive
system. The drive system consists of the drive pump (11) which is a
variable-displacement piston-type, and two drive motors (5 & 6)—one
for each drum—which are gear-type motors. The drive motors are
plumbed in series. Each is mounted to a reduction gear assembly
which includes a Spring-Activated and Hydraulically Released (SAHR-
type) parking brake (19 & 20).
The vibration/steering pump (10) acts as a charge pump for the
hydrostatic drive system. The charge pump provides oil to the control
valve, the brake circuit, and any makeup oil the drive system may need
due to leakage.
The drive pump also includes a tow valve (21). When opened, the tow
valve allows oil flow through the system which enables the machine to
be towed in an emergency. Note: In order to tow the machine, the
brakes must be released.
The parking brake solenoid valve (18) controls flow to the brake
manifold (12). When the parking brake solenoid valve is de-
energized—which happens when the parking brake pushbutton is ON,
the operator is off the driver’s seat, or the engine is OFF—oil is diverted
from the brake circuit back to the tank. In this state, the parking brakes
engage, and flow from the drive pump ceases because oil flow to the
servo spool of the control valve also diverts back to the tank. With little
oil pressure available, the springs of the servo spool center it. When
the servo spool is centered, there is no angle to the drive pump’s
swashplate. With no angle to the swashplate, there is no oil flow from
the drive pump and thus no movement of the drive motors.
wc_tx000637gb.fm 86
RD 25 Repair Drive System
7.2 Drive System Hydraulic Flow Diagrams
18
16
10 11
20 19
21
3 6 5
17
4
12
14 15
22 13
Brakes on and flow through motors not allowed
18
16
10 11
20 19
21
3 6 5
17
4
12
14 15
22 13
Brakes off and flow through motors allowed

wc_gr003712
wc_tx000637gb.fm 87
7.3 Drive System Pictoral Diagram
1 2
5 4
Brake circuit
3
2
1 4
5
Drive and charge circuits

wc_gr003713
wc_tx000637gb.fm 88
7.4 Pictorial Diagram Components

1 Front drive motor 5 Rear drive motor
2 Front parking brake 6 Vibration manifold/solenoid valve
3 Drive pump 7 Vibration/steering pump (charge
pump)
4 Rear parking brake 8 Brake manifold block
wc_tx000637gb.fm 89
7.5 Valves and Ports of the Drive Pump
h
d b M1
e
g
f
a
c M2
M3 wc_gr003556

a Load pressure limiting valve g Tow valve (by-pass gate valve)
b High pressure limiting valve h Brake solenoid valve
(reverse)
c High pressure limiting valve M1 High pressure test port (reverse)
(forward)
d Mechanical zeroing valve M2 High pressure test port (forward)
e Volume maximum adjustment M3 Charge pressure test port
(forward)
f Volume maximum adjustment - ---
(reverse)
wc_tx000637gb.fm 90
7.6 Troubleshooting Flowcharts
The troubleshooting flowcharts are designed to take you through the

process of determining the source of a problem with engine starting or
machine operation. Many of the tests involve live voltages and
therefore should only be attempted by qualified personnel. Detailed
procedures for carrying out the tests are included in this manual. All
highlighted text within the flowcharts have matching sections in this
manual.
wc_tx000637gb.fm 91
7.7 Machine Does Not Drive Troubleshooting—Flowchart A1

· When attempting to drive the parking brake pushbutton is in the OFF position.
· Neither drum is obstructed.
· If you left the driver's seat, you reset the control lever by returning it to the neutral position.
· When attempting to drive the throttle lever is in the MAX position.
· When attempting to drive the tow valve is closed.
Is
the parking brake No See Flowchart A2
light on?
Yes
Check function of the operator present switch.
See Checking the Operator Present Switch.
Is Replace
the operator No
present switch the operator present
OK? switch.
Yes
Check function of the parking brake pushbutton. Check function of the parking brake relay.
See Checking the Parking Brake Pushbutton. See Checking the Parking Brake Relay.
Is Is
parking brake pushbutton Yes parking brake relay No
OK? OK?
No Yes
Replace the
parking brake
pushbutton.
Replace the
parking brake
pushbutton.
Check brake circuit pressure. Check function of the parking brake solenoid.
See Checking Brake Circuit Pressure. See Checking the Parking Brake Solenoid.
Is Is
No the brake circuit pressure Yes parking brake solenoid
OK? OK?
Yes No
Replace the
vibration/steering
(charge) pump.
Replace the
parking brake
solenoid.

wc_gr003557
wc_tx000637gb.fm 92
Machine Does Not Drive Troubleshooting—Flowchart A2

· The hydraulic oil is up to temperature.
· The hydraulic reservoir is filled with oil to the full line.
· There are no leaks and all fittings are tight.
· The intake filter is not clogged.
Check function of the drive pump servo lever.
See Checking Drive Pump Servo Lever.
Is
the servo No Repair servo
lever OK? lever.
Yes
Check drive pump pressure.
See Checking Drive Pump Pressure.
Is Replace the
the drive pump pressure No
OK? drive pump.
Yes
Check fluid flow at drive motors.
See Checking Drive Motors.
Are the
drive motors No Replace the
OK? drive motors.
Yes
Call Wacker Corporation Service. wc_gr003563
wc_tx000637gb.fm 93
7.8 Checking the Seat Switch

The seat switch is a normally open switch located under the driver’s
seat. The seat switch provides a path to ground for the parking brake
relay when the parking brake pushbutton is in the ON position and the
operator is seated in the driver’s seat. To check the operation of the
seat switch, carry out the following procedure:
7.8.1 Remove the screws that secure the guard panel and tilt the guard
panel toward the steering column to provide access.
7.8.2 Locate the seat switch and disconnect it from the harness.
7.8.3 Have an assistant sit in the driver’s seat. Using a multimeter, check for
continuity across the pins of the seat switch connector (a). The seat
switch should have continuity when an operator is seated in the
driver’s seat and no continuity when the operator is not seated in the
driver’s seat. If the seat switch does not perform accordingly, replace it.
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wc_tx000637gb.fm 94
7.9 Checking the Parking Brake Pushutton

The parking brake pushbutton switch is a normally closed switch
located on the control panel. The parking brake pushbutton switch
provides a path to ground for the parking brake relay when the
operator is seated in the driver’s seat. To check the operation of the
parking brake pushbutton switch, carry out the following procedure:
7.9.2 Locate the parking brake pushbutton switch (b).
7.9.3 Check the continuity of the parking brake pushbutton switch across
terminals “C” and “+”. The parking brake pushbutton switch should
have continuity when in the OFF position and no continuity when in the
ON position. If the parking brake pushbutton switch does not perform
accordingly, replace it.
wc_gr003740
wc_tx000637gb.fm 95
7.10 Checking the Parking Brake Relay

When energized, the parking brake relay provides battery voltage to
the parking brake solenoid. The parking brake relay is located in the
steering column. To check the operation of the parking brake relay,
carry out the following procedure:
7.10.2 Locate the parking brake relay (E2) (b) and unplug the connector
running to it.
7.10.3 Place the ignition key switch in the ON position.
7.10.4 Using a multimeter, check for battery (approximately 12V) voltage
• If 12V is not measured, check the wiring between the parking
brake relay and the power regulator. Repair the wiring as needed.
7.10.5 Check for battery voltage (approximately 12V) between terminal 1 and
ground.
brake relay and the power regulator via the drive pump idle
switch. Repair the wiring as needed.
7.10.6 Place the ignition key switch in the ON position. Have an assistant sit
in the driver’s seat and place the parking brake pushbutton in the OFF
position.
7.10.7 Using a multimeter with an appropriate extension, back probe the
wiring between terminal 2 and ground (wire C906-PU). Battery voltage
(approximately 12V) should be measured.
brake relay and the parking brake pushbutton. Repair the wiring
as needed.
• If 12V is measured, continue
7.10.8 Using a multimeter with an appropriate extension, back probe the
wiring between terminal 5 (wire 777-PU) (c) and ground. Battery
voltage (approximately 12V) should be measured.
• If 12V is measured, the parking brake relay is functioning
properly.
• If 12V is not measured, the parking brake relay has failed; replace
it.
wc_tx000637gb.fm 96
a b
1000 1000
F 200
20
V F 200
20
V
2 2
200m 200m
A 5 A
V- COM
c V- COM
1
2
wc_gr003742
wc_tx000637gb.fm 97
7.11 Checking the Parking Brake Solenoid

When the parking brake solenoid is energized, it shifts the parking
brake valve into a position that sends hydraulic pressure to the parking
brake manifold and onto the parking brakes. This pressure releases
the parking brakes and the machine is free to travel. The parking brake
solenoid is mounted directly on the drive pump. To check the operation
of the parking brake solenoid, carry out the following procedure:
7.11.1 Have an assistant sit in the driver’s seat, start the engine, and place
the parking brake pushbutton in the ON position.
7.11.2 Disconnect the connector (a) from the parking brake solenoid.
between the wires of the solenoid.
• If 12V is measured, the solenoid is receiving power. Continue
troubleshooting by checking the pressure of the brake circuit.
brake relay and the parking brake solenoid. Repair the wiring as
needed.
1000
F 200
20
V
2
200m
V- COM
wc_gr003737
wc_tx000637gb.fm 98
7.12 Checking Pressure in the Brake Circuit

The parking brake is a Spring-Activated and Hydraulically Released
(SAHR-type) brake. It takes approximately 20 bar (290 psi) of hydraulic
pressure to release the parking brake. The hydraulic pressure to
release the brake is provided by the parking brake solenoid valve.
When it is in the closed (energized) position, oil flow from the vibration/
steering (charge) pump, via the vibration manifold, builds pressure
within the brake circuit. This pressure can be measured at the parking
brake manifold. To check the pressure in the brake circuit:
7.12.1 Remove the side panel (a) from the engine compartment to gain
access to the drive pump and the parking brake manifold.
7.12.2 Attach a 0–60 bar (0–1000 psi) gauge to the test port (b) of the parking
brake manifold.
7.12.3 Have an assistant sit in the driver’s seat, start the engine, place the
throttle in the fast position, and place the parking brake pushbutton in
the ON position.
7.12.4 Check the pressure on the gauge. The pressure in the parking brake
circuit should be equal to the charge pressure provided by the
vibration/steering pump—25±2 bar (363±29 psi).
• If the hydraulic pressure measures 25±2 bar (363±29 psi), the
brake circuit is receiving the appropriate pressure.
• If the hydraulic pressure does not measure 25±2 bar (363±29
psi), the brake circuit is not receiving the appropriate pressure.
Adjust the pressure relief valve.
25 bar
(363 psi)
b
a
wc_gr003779
wc_tx000637gb.fm 99
7.13 Checking the Drive Pump Servo Lever

The forward/reverse control lever is connected to the drive pump servo
valve through a cable and a second lever (a). The second lever must
be connected securely to the servo shaft for the system to function
properly. When checking the servo lever, check that it is located in the
correct position and that it is secure. If necessary, re-zero the
connection. To re-zero the connection:
7.13.1 Place the forward/reverse control lever in the N (neutral) position.
7.13.2 If the servo lever is loose, tighten the screw that secures it to the pump.
7.13.3 If the machine moves when the forward/reverse lever is in the neutral
position, re-zero the connection. To re-zero:
7.13.4 Lightly loosen the bolts that fix the servo control to the casing of the
pump.
7.13.5 Place the control lever in the neutral position and start the engine.
7.13.6 Rotate the body of the servo control in a clockwise or counter-
clockwise direction until the machine completely stops.
7.13.7 Tighten the servo control on the pump casing.
wc_gr003738
wc_tx000637gb.fm 100
7.14 Checking the Drive Pump Pressure

This procedure requires a 340 bar (5000 psi) pressure gauge.
A properly operating drive pump will produce approximately 270 bar
(3916 psi) of pressure in both the forward drive and the reverse drive
circuits. To check the drive pressure, carry out the following procedure:
7.14.1 Disconnect and plug the delivery hoses to each of the drive motors or
block the travel of the machine by positioning the machine behind (for
forward test), in front of (for rearward test) a concrete wall or abutment.
7.14.2 Connect a 340 bar (5000 psi) pressure gauge to the M1 test port.
7.14.3 Start the engine and allow the machine to warm up for a few minutes.
7.14.4 With the throttle set at full, position the forward/reverse control lever
first, in the full FORWARD position then, in the full REVERSE position.
Check the reading on the pressure gauge in both positions. The gauge
should read 270±10 bar (3916±145 psi) in each position.
• If the gauge reads 270±10 bar (3916±145 psi) the drive pump is
operating properly. Reconnect the drive motors.
• If the gauge does not read 270±10 bar (3916±145 psi), continue.
7.14.5 The pressure valves are adjusted at the factory and under normal
operation do not require any adjustment. To adjust, the pressure
valves, loosen the lock nut (a) and turn the adjustment screw clockwise
to increase the pressure; counterclockwise to decrease the pressure.
270 bar
(3916 psi)
a
M1
M2
wc_gr003806
7.15 Checking the Drive Motors
By checking the flow from the drive motor case drain hoses one can
tell if the drive motor seals are functioning. When new, the drive motors
will let pass approximately 150 ml (5 oz.) of hydraulic fluid per minute.
To check the drive motors, carry out the following procedure:
7.15.1 Position the machine so that the front drum is up against an abutment
such as a brick wall or concrete barricade.
7.15.2 Turn off the engine and disconnect the drain line (a) from the front drive
motor.
7.15.3 Position the hose from the front drive motor into a graduated container
(b).
7.15.4 Start the engine. With the throttle at full and the forward/reverse control
lever in the full FORWARD position, collect all the oil that drains from
the drive motor over a one-minute time period.
• If the drive motor drains approximately 150 ml (5 oz.) of hydraulic
oil per minute or less, it is operating properly.
• If the drive motor drains 300 ml (10 oz.) or more of hydraulic oil
per minute, it has failed; rebuild or replace the drive motor.
7.15.5 Test the rear drive motor in a similar fashion: Position the machine so
that the rear drum is up against an abutment such as a brick wall or
concrete barricade.
7.15.6 With the throttle at full and the forward/reverse control lever in the full
REVERSE position, collect all oil that drains from the drive motor over
a one-minute time period.
• If the drive motor drains approximately 150 ml (5 oz.) of hydraulic
oil per minute or less, it is operating properly.
• If the drive motor drains 300 ml (10 oz.) or more of hydraulic oil
per minute, it has failed; rebuild or replace the drive motor.
wc_gr003798
7.16 Machine Performs Poorly Troubleshooting—Flowchart F1

· When attempting to drive, the parking brake pushbutton is in the OFF position.
· Neither drum is obstructed.
· When attempting to drive, the throttle lever is in the MAX position.
· When attempting to drive, the tow valve is closed.
Check function of the drive pump servo lever.
See Checking Drive Pump Servo Lever.
Is
the servo No Repair servo
lever OK? lever.
Yes
Check drive pump pressure.
See Checking Drive Pump Pressure.
Is Replace the
the drive pump pressure No
OK? drive pump.
Yes
Check fluid flow at drive motors.
See Checking Drive Motors.
Are the
drive motors No Replace the
OK? drive motors.
Yes

wc_gr003609
7.17 Drive Pump Adjustments

Drive/Adjustment Pump Load Pressure
Components:
A Load pressure limiting valve
B High pressure limiting valve BACK
C High pressure limiting valve FORWARD
D Mechanical zeroing
E Swept volume maximum adjustment FORWARD
F Swept volume maximum adjustment BACK
G By-pass
H Electromagnetic valve brake/zeroing swept volume
M1 High pressure test point BACK
M2 High pressure test point FORWARD
M3 Load pressure test point
Load Pressure Adjustment
7.17.1 Connect a meter of 60 bar (900 psi) to the test point Ref. M3
Ensure that the pressure test flexible hose is not damaged
Do not touch the pump or the hot hydraulic oil

CAUTION
7.17.2 Rev the engine at 1500 rpm until the oil temperature reaches 50°C
(122°F).
7.17.3 Do not activate the drive control, so that pump is calibrated at zero
capacity.
7.17.4 The value of the pressure shown must be 20±2 bar (290±29 psi). At an
engine rotation of 3000 rpm the pressure must rise to 22±2 bar
(319±29 psi).
7.17.5 If the value is different, proceed as follows:
7.17.6 Loosen the lock nut and turn the adjustment screw A clockwise to
increase the pressure; turn it counter-clockwise to decrease the
pressure.
7.17.7 Tighten the lock-nut.
Zeroing solenoid valve
The zeroing solenoid valve is a safety device that releases the load
pressure when the solenoid is not activated. The pump can therefore
be operated only when the electromagnetic valve is activated.
Valves and Ports of the Drive Pump
h
d b M1
e
g
f
a
c M2
M3 wc_gr003556

a Load pressure limiting valve g Tow valve (by-pass gate valve)
b High pressure limiting valve h Brake solenoid valve
(reverse)
c High pressure limiting valve M1 High pressure test port (reverse)
(forward)
d Mechanical zeroing valve M2 High pressure test port (forward)
e Volume maximum adjustment M3 Charge pressure test port
(forward)
f Volume maximum adjustment - ---
(reverse)
Vibration System RD 25 Repair
8. Vibration System
8.1 Vibration System Overview

The vibration system consists of a fixed-displacement, gear-type pump
(2); a manifold (3); two fixed-displacement, gear-type motors (4 & 5)—
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 the solenoid
valve (6), which exciters will be rotating—front drum only or both front
and rear drum exciters.
RD 25 Repair Vibration System
2
7
A
B 8 T
FT1
A1 8
P M1
3
wc_gr003714

1 Intake filter 6 Front vibration (exciter) motor
2 Vibration/steering (charge ) 7 Test port
pump
3 Pressure relief valve 8 Check valve
4 Solenoid valve 9 Vibration manifold
5 Rear vibration (exciter) motor - ---
8.2 Vibration System Hydraulic Diagram
B
3
T
185 bar
1
P 7
M1
e2 5 4
9
B T
A P
to
6 transmission
pump
e1
R C
i=1.12
90 micron 1
Front drum only vibration
A1A
1A B FT1
3 8 8
T
185 bar
P 7
M1 e2
9 5 4
B T
A P
6 to
transmission
e1
pump
R C
i=1.12
90 micron 1
wc_gr003745
Front and rear drum vibration
Notes
8.3 Troubleshooting the Vibration System—Flowchart B1

Is the Check power to vibration solenoids.

vibration lamp on Yes
control panel
lit? See Checking Vibration Solenoids.
No
Are the
See Flowchart B2 Yes vibration solenoids
receiving power?
No
Check condition of vibration fuse (F5).
See Checking Vibration System Fuse. Repair the wiring

to the vibration
solenoids.
Is
the fuse No Replace fuse.
OK?
Yes
Check condition of vibration relay.
See Checking Vibration Relay.
Is Replace the
the vibration relay No vibration relay.
OK?
Yes
Check function of vibration enable switch.
See Checking Vibration Enable Switch.
Is Check function of vibration mode switch.

the vibration enable Yes
switch OK? See Checking Vibration Mode Switch.
No Replace the Is
vibration mode No the vibration mode
switch. switch OK?
Replace the
vibration enable Yes
switch.
wc_gr003575
Vibration System Troubleshooting—Flowchart B2
Continued from Flowchart B1
Check vibration/steering pump pressure.
See Checking Vibration/Steering Pump.
Is Adjust vibration/steering pump relief valve pressure.

the pressure No
OK? See Checking Vibration/Steering Pump.
Yes Is
Replace the
vibration/steering No the pressure
pump. OK?
Yes
Check flow from exciter motor case drain.
See Checking Exciter Motors.
Replace the Is
vibration solenoid No the flow
valve. OK?
Yes
Check the exciter bearings.
See Checking the Exciter Bearings.
Are
the exciter bearings No Replace the
OK? exciter bearings.
Yes
Check VPM of exciter motor(s).
See Checking Exciter Motors.
Is
the exciter motor(s) No Replace the
OK? exciter motor(s).
Yes
wc_gr003576
8.4 Checking the Vibration Solenoids

The vibration valve is located in the engine bay. By checking the
electrical power (battery voltage approximately 12V) to the solenoids
of the vibration valve one can tell if the solenoids—and the valve—are
functioning.
To check the solenoids, carry out the following procedure:
8.4.1 Locate the vibration valve (a).
8.4.2 Disconnect the wiring (b) to the left-side solenoid. This is the solenoid
that controls vibration to both front and rear exciter motors.
8.4.3 Turn the ignition key switch to the ON position. Place the vibration
mode switch to the front and rear drum position.
8.4.4 Turn the vibration enable switch to the ON position and using a
multimeter, check for battery voltage (approximately 12V) across the
wiring connector.
• If 12V is measured, the solenoid is receiving electrical power and
should be functioning. If the vibration valve is not shifting when
power is applied to the solenoid, the vibration valve is not
functioning; replace it.
• If 12V is not measured, check the wiring to the solenoid. Repair
8.4.5 Check the right-side solenoid (c) in the same manner. This is the
solenoid that controls vibration to the front exciter motor.
b
c
1000
F 200
20
V
2
a 200m
V- COM
wc_gr003739
8.5 Checking the Vibration System Fuse

The vibration fuse, F5 on the electrical schematic, protects the
vibration circuit from short circuits and over-current conditions. To
check the vibration fuse:
8.5.2 Remove the vibration fuse (F5) and inspect it.
8.5.3 Replace the vibration fuse if it is blown.
F1 (15A) F5 (15A) F9 (15A)
F2 (15A) F6 (25A) D1
F3 (15A) F7 (15A) D2
F4 (15A) F8 (15A) D3
wc_gr003589
8.6 Checking the Vibration Relay

When energized, the vibration relay provides battery voltage to the
vibration enable switch and on to the vibration mode switch and
vibration solenoid valve. The vibration relay is located in the steering
column. To check the operation of the vibration relay, carry out the
8.6.2 Locate the vibration relay (E9) (b).
8.6.3 Turn the ignition key switch to the ON position. Have an assistant sit in
the driver’s seat.
between terminal 86 of the relay and ground.
• If 12V is not measured, check the wiring between the vibration
relay and the 15A vibration fuse. Repair the wiring as needed.
the relay and ground.
• If 12V is not measured, check the wiring between terminal 86 and
terminal 30. Repair the wiring as needed.
8.6.6 Check for continuity between terminal 85 of the relay and ground.
• If there is no continuity, check the wiring between the relay and
ground. Repair the wiring as needed.
the relay and ground. Battery voltage should be measured.
• If battery voltage (approximately 12V) is measured, the vibration
relay is functioning properly.
• If battery voltage (approximately 12V) is not measured, the vibra-
tion relay has failed; replace it.
1000
F 200
20
V
2
200m
V- COM
wc_gr003748
8.7 Checking the Vibration Enable Switch

The vibration enable switch sends electrical power to the vibration
mode switch. The vibration enable switch is located on the forward/
reverse control lever. To check the vibration enable switch, carry out
the following procedure:
8.7.1 Remove the screws that secure the floor plate and remove the floor
plate.
8.7.2 Locate the vibration enable switch connector (a) and disconnect it.
8.7.3 Using a multimeter, check for continuity across the pins of the
connector. There should be continuity when the vibration enable
switch is in one position and no continuity when the vibration enable
switch is in the opposite position. If the vibration enable switch does
not perform accordingly, replace it.
wc_gr003743
8.8 Checking the Vibration Mode Switch

The vibration mode switch determines which solenoid of the vibration
valve receives electrical power. The vibration mode switch is located
on the control panel. To check the vibration mode switch, carry out the
8.8.2 Locate the vibration mode switch (b). Label then disconnect the wires
from terminals 2a, 2b, and 2c.
8.8.3 Using a multimeter, check for continuity between the input side of the
switch (terminal 2a) and the output side of the switch (terminals 2b and
2c). When in the front drum position, the switch should only have
continuity between terminal 2a and terminal 2b. When in the front and
rear drum position, the switch should only have continuity between
terminal 2a and terminal 2c. If the vibration mode switch does not
perform accordingly; replace it.
Note: Terminal 1a will have continuity between terminal 1b and 1c in
both the front drum position and the front and rear drum position.
b
1c 2c
1a 2a
1b 2b
wc_gr003744
8.9 Checking the Vibration/Steering Pump

The vibration/steering pump provides hydraulic pressure for the
vibration and steering circuits. The performance of the pump can be
determined by measuring the pressure at the vibration valve. To check
the vibration/steering pump, carry out the following procedure:
8.9.1 Drive the machine onto a compactible surface such as gravel or a bed
of old tires.
8.9.2 Open the engine compartment and locate the vibration valve (a).
8.9.3 Attach a 250 bar (3500 psi) pressure gauge to test port M4 (b) of the
vibration valve.
8.9.4 Disconnect the fittings from bores A and B. Plug these bores high
pressure plugs.
8.9.5 Run the engine at full throttle and turn on the vibration. The gauge
should read 185±10 bar (2683±145 psi).
• If the gauge does not read 185±10 bar (2683±145 psi), adjust the
relief valve adjusting screw (b) until it does. Tighten the lock nut
and stop the vibration. If 185±10 bar (2683±145 psi) cannot be
obtained, the vibration/steering pump has failed; replace it.
• If the gauge reads 185±10 bar (2683±145 psi), continue.
8.9.6 Run the engine at full throttle (2600 rpm) and turn on the vibration. The
gauge should read 100±10 bar (1450±145 psi) with front drum only
vibration and 150±10 bar (2176±145 psi) with both drums vibrating.
• If the gauge reads 100±10 bar (1450±145 psi), the system is
functioning properly.
• If the gauge does not read 100±10 bar (1450±145 psi), check
engine rpm, hydraulic oil temperature, exciter motors, and exciter
bearings.
a
b
B
A
wc_gr003746
8.10 Checking the Exciter Motors

The exciters will run at a vpm (vibrations per minute) proportional to the
engine rpm. One can determine the vpm using a vibrotach (Sirometer)
(a). By measuring the vpm one can determine if a problem is
associated with the vibration/steering pump or the exciter motor. To
check the vpm, carry out the following procedure:
of old tires.
8.10.2 Start the engine and place the throttle in the full position. Measure the
engine rpm. It should be 2600±100.
8.10.3 With the engine running, turn on the vibration and measure the vpm of
either drum with the vibrotach. It should be 3200±100.
• If the vpm equals 3200±100, the system is functioning properly.
• If the vpm is less than 3200±100, it signifies a problem with the
exciter bearings or the exciter motor.
The exciter motors are plumbed in parallel. Each has an inlet, an
outlet, and a drain to tank. By measuring the amount of hydraulic oil
being drained to the tank, one can determine how well the exciter
motors are performing. To check the exciter motor, carry out the
of old tires.
8.10.5 Remove the drain hose at the fitting (b) and cap the fitting.
8.10.6 Start the engine and turn on the vibration.
8.10.7 Collect the draining hydraulic oil in a graduated container (c). A
properly functioning exciter motor will drain very little oil—
approximately 30 ml (1.0 oz.) per minute. If the exciter motor drains
more than 120 ml (4 oz.) per minute, the exciter motor is not
functioning properly; replace it.
wc_gr003799
8.11 Checking the Exciter Bearings

Removal
8.11.1 Remove the drum from the machine. See Removing the Drum.
8.11.2 Clean the vibrating side and rotate the drum so that a drain plug 6 is in
the lowest position. Position a suitable container under the drain hole
to avoid oil leakage and environmental pollution. Drain the oil through
the plug 6.
8.11.3 Lift the drum into an erect position.
8.11.4 Remove the screws 1 that secure the vibration hub 5 to the drum.
8.11.5 Insert two M10 lifting eyes into the vibration hub/motor assembly 2.
With an appropriate crane or hoist, lift the vibration hub/motor
assembly from the drum.
8.11.6 Remove the exciter shaft 3 from the drum.
8.11.7 Remove the oil seal 13 and inspect the surface of the shaft on which it
is installed.
8.11.8 Check the bearing 4 and, if necessary, replace it.
8.11.9 Replace the oil seal 13.
8.11.10 Check the bearing 9 on the other end of the exciter shaft and, if
necessary, replace it.
8.11.11 Lay the drum back on the floor.
8.11.12 Remove the screws 7 that secure the cover 8 to the drum and remove
the cover. Inspect the cover and, if necessary, replace it.
Installation
8.11.13 Using the screws 7 install the cover 8 to the drum. Torque the screws
to 50 Nm (37 ft.lbs.).
8.11.14 Using an appropriate crane or hoist, lift the drum into an erect position.
8.11.15 Install the exciter shaft 3 into the drum.
8.11.16 Fill the drum with oil.
8.11.17 Using screws 1, install the vibration hub 5 to the drum. Torque the
screws to 24 Nm (18 ft.lbs.).
8.11.18 Using an appropriate crane or hoist, lay the drum back on the floor.
8.11.19 Re-install the drum to the machine.
40 kg
13 4
1
5 9 8
wc_gr003749
Steering System RD 25 Repair
9. Steering System
9.1 Steering System Overview

The steering system consists of a gear-type pump (steering/vibration
pump)(3), the steering control unit (servo)(2), and the steering cylinder
(1). The steering/vibration pump also provides charge oil to the drive
system.
When the engine is running, the steering/vibration pump draws oil from
the hydraulic tank through a strainer (4). Supply oil from the steering/
vibration pump flows to the steering control unit. Inside the steering
control unit, supply oil acts against the relief valve (6) and the anti-
cavitation valves (5). The oil then flows to the steering control spool.
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 flows 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.
When the operator turns the steering wheel to the left, the left envelope
of the steering control spool is active; oil flows through the steering
control spool and to the piston end of the steering cylinder. Oil that
flows into the steering cylinder causes the machine to turn left. Return
oil is directed back to the hydraulic tank.
RD 25 Repair Steering System
6
4
BB52356
3 7
130 bar
8
6
5 8 1
R C 3
2
1 90 micron
4
wc_gr003750

1 Intake filter 5 hydraulic oil cooler
2 Vibration/steering (charge) pump 6 Relief valve
3 Steering servo 7 Anti-shock/anti-cavitation valves
4 Steering cylinder 8 Unidirectional valve (by-pass)
9.2 Steering System Troubleshooting—Flowchart C1

Check vibration/steering pump pressure.
See Checking Vibration/Steering Pump.
Is Check pump-to-engine connection.

the pressure No
OK? See Pump-to-Engine Connection.
Yes Is
Repair connection. No pump-to-engine
connection
OK?
Yes
Replace the
vibration/steering
pump.
Check steering servo pressure setting.
See Checking Steering Servo Pressure.
Is Remove locking
pressure setting Yes arm or clear any jams.
OK? Call Wacker Corporation
Service.
No
Replace or rebuild
steering servo.
Replace or rebuild
steering cylinder.
wc_gr003578
Notes
9.3 Checking the Vibration/Steering Pump

The vibration/steering pump provides hydraulic pressure for the
vibration and steering circuits. The performance of the pump can be
determined by measuring the pressure at the vibration valve. To check
the vibration/steering pump, carry out the following procedure:
of old tires.
9.3.2 Open the engine compartment and locate the vibration valve (a).
9.3.3 Attach a 250 bar (3500 psi) pressure gauge to test port M4 (b) of the
vibration valve.
9.3.4 Disconnect the fittings from bores A and B. Plug these bores high
pressure plugs.
9.3.5 Run the engine at full throttle and turn on the vibration. The gauge
should read 185±10 bar (2683±145 psi).
• If the gauge does not read 185±10 bar (2683±145 psi), adjust the
relief valve adjusting screw (b) until it does. Tighten the lock nut
and stop the vibration. If 185±10 bar (2683±145 psi) cannot be
obtained, the vibration/steering pump has failed; replace it.
• If the gauge reads 185±10 bar (2683±145 psi), continue.
9.3.6 Run the engine at full throttle (2600 rpm) and turn on the vibration. The
gauge should read 100±10 bar (1450±145 psi) with front drum only
vibration and 150±10 bar (2176±145 psi) with both drums vibrating.
• If the gauge reads 100±10 bar (1450±145 psi), the system is
• If the gauge does not read 100±10 bar (1450±145 psi), check
engine rpm, hydraulic oil temperature, exciter motors, and exciter
bearings.
a
b
B
A
wc_gr003746
9.4 Checking Steering Servo Pressure

This procedure requires a 250 bar (3500 psi) pressure gauge and a
test fitting for the pressure gauge.
9.4.1 Turn off the engine.

9.4.2 Turn the steering wheel to the right slightly to discharge pressure on
the piston side of the cylinder.
9.4.3 Carefully unscrew the hose on the piston side of the cylinder. In its
place, install a test fitting (M5) and the 250 bar pressure gauge.
9.4.4 Run the engine at 1400 rpm and operate the steering so that the
steering cylinder is at full lock. The gauge must read 140±10 bar
(2030±145 psi).
• If the pressure gauge reads at least 140±10 bar (2030±145 psi),
the steering servo is holding the correct amount of pressure.
• If the pressure gauge does not read 140±10 bar (2030±145 psi),
the anti-shock valve, cylinder piston seals, or steering relief valve
are faulty; continue.
9.4.5 Check valve (1). To do so, remove the cap (a) and screw in the
adjuster (b) until you obtain the correct pressure.
• If the correct pressure was obtained, the steering servo is holding
the correct pressure.
• If the correct pressure was not obtained, continue.
9.4.6 Change the piston seals of the cylinder.
• If the correct pressure was obtained, the steering system is
• If the correct pressure was not obtained, continue.
9.4.7 Check the valves (2). To do so, remove the cap (c) and screw the
adjuster (d) until you obtain the correct pressure.
• If the correct pressure was obtained, the steering servo is holding
the correct pressure.
Note: If adjustments were required to valves (2), reset valve (1).
See step 5.
• If the correct pressure was not obtained, replace the steering
servo.
463
2
c
d
c
d
a
b
wc_gr003579
9.5 Replacing and Inspecting the Steering Cylinder
To reduce the risk of injury, before beginning any service work on the
machine: drive it onto a level surface, stop the engine, and remove the
ignition switch key, release the hydraulic pressure from the circuits,
WARNING chock the drums, allow the machine to cool off, and disconnect and
remove the battery.
Removal:
9.5.1 Turn the steering wheel towards the right so that te rod of the cylinder
is drawn in.
9.5.2 Mark and remove the hydraulic hoses from the cylinder. Cap the hoses
and the fittings to prevent contamination.
NOTICE: Position a suitable container under the connections to avoid
oil leakage and consequent environmental pollution.
9.5.3 Remove the pins that secure the cylinder to the machine and remove
the cylinder.
Disassembly:
9.5.4 Clean the outside of the cylinder.
9.5.5 Fix rod A in a vice or another support tool, taking care not to damage it.
9.5.6 Utilize a wrench to loosen and remove head B from tube A.
9.5.7 Pull the piston rod C directly out from tube A avoiding damage to the
rod.
9.5.8 Secure eye D of the piston rod.
9.5.9 Remove piston F from the piston rod.
9.5.10 Remove head B from the piston rod.
9.5.11 Remove seal 5 and O-ring 4 from piston F.
9.5.12 Remove O-ring 3 and seals 2 and 1from head B.
B 3 4 5
D 1 2 C A F
BB01117
wc_gr002270
9.6 Steering Cylinder Inspection and Fitting

Inspection:
9.6.1 Clean piston F, head B, piston rod C, and rod A using a cleaning
solvent.
9.6.2 Discard the seals and O-rings removed from piston F and head B.
9.6.3 Illuminate the inside of rod A. Inspect the inside of the rod to check for
the absence of deep grooves or other damage. If rod A is damaged,
replace it.
9.6.4 Check that piston rod C is straight. If piston rod C is not straight,
replace it.
9.6.5 Remove the small scratches on piston rod C or inside rod A with an
emery cloth of medium grain. Use the emery cloth with a rotary
movement.
9.6.6 Check if there is rust on head B. Remove any rust.
9.6.7 Check the extremity of the head of rod A to see if there are sharp
edges that could cut the O-ring 3. Remove the sharp edges.
9.6.8 Check piston F for damage and wear. Replace it if it is damaged.
Fitting:
9.6.1 Install seal 1, seal 2 and O-ring 3 in head B.
9.6.2 Remove marks and cut edges on the bevel at the end of piston rod C.
9.6.3 Lubricate the hole in the head with clean oil B.
9.6.4 Push the head B on the rod of piston C. If necessary, use a soft
hammer to guide head B onto the rod of piston C. Fit a new O-ring 4
on piston F.
9.6.5 Apply Loctite 542 on the first six threads on the rod of piston C.
9.6.6 Tighten piston F on the end of the rod of piston C. Tighten to 150 Nm
(110.6 ft. lbs.).
9.6.7 Fit a new seal 5 on the outside of piston F.
9.6.8 Fix rod A into a vice or another support tool, taking care not to damage
it.
9.6.9 Lubricate the internal part of rod A and piston F with clean oil.
9.6.10 Push piston F straight into rod A.
9.6.11 When piston F is located in the smooth part of rod A, guide head B into
rod A.
9.6.12 Lubricate O-ring 3 on gland B with clean oil .
9.6.13 Tighten head B to 250 Nm (184.4 ft. lbs.).
B 3 4 5
D 1 2 C A F
BB01117
¯ 8 mm
¯ 45 mm
BB01162
BB01163
¯ 8 mm
wc_gr002271
Spray System RD 25 Repair
10. Spray System
10.1 Spray System Overview

The spray system consists of the components shown below. Control
for the spray system is done through a toggle switch on the control
panel. The toggle switch has two modes: manual and automatic. In the
automatic mode, the pump is controlled by two relays and a timer
resulting in a periodic spray cycle. In the manual mode, the pump runs
continuously.
2
1
3 9 6
wc_gr003751
5

1 Pump 6 Rear spray bar
2 Basket filter 7 Water tank
3 Intake filter 8 Drain tap
4 Water tap 9 Choke
5 Front spray bar - ---
RD 25 Repair Spray System
10.2 Spray System Troubleshooting—Flowchart D1

· The control tap is functioning.
· The water tank is filled with water to the full line.
· There are no leaks and all fittings are tight. Check voltage to spray pump.
See Checking Spray Pump.
Check condition of spray system fuse (F3). Is

No the spray pump
See Checking Spray System Fuse. OK?
Is Yes
the fuse Yes
OK?
Replace the
No spray pump.
Replace fuse.
Check funtion of spray switch.
See Checking the Spray Switch.
Check funtion of automatic water pump relay.

Is
See Checking Automatic Water Pump Relay. Yes the spray switch
OK?
Is Replace the No
the relay No automatic water pump
OK? relay.
No
Replace the
spray switch.
Check funtion of water pump timer relay. Check funtion of water system timer.
See Checking Water Pump Timer Relay. See Checking Water System Timer.
Is Is
the relay Yes Yes the timer
OK? OK?
No Call Wacker Corporation Service. No
Replace the Replace the

water pump timer water system timer.
relay.
wc_gr003602
10.3 Checking the Spray System Fuse

The spray system fuse, F3 on the electrical schematic, protects the
spray system circuit from short circuits and over-current conditions. To
check the vibration fuse:
10.3.2 Remove the spray system fuse (F3) and inspect it.
10.3.3 Replace the spray system fuse if it is blown.
F1 (15A) F5 (15A) F9 (15A)
F2 (15A) F6 (25A) D1
F3 (15A) F7 (15A) D2
F4 (15A) F8 (15A) D3
wc_gr003589
10.4 Checking the Spray Switch

In the MANUAL mode the spray switch sends electric power directly to
the spray pump. If the spray pump does not operate when the spray
switch is in the MANUAL position, check its operation. To check the
operation of the spray switch, carry out the following procedure:
10.4.2 Locate the spray switch (C23) (b).
10.4.3 Using a multimeter, check for continuity across terminals 1 and 2 when
the switch is in the down (automatic mode). Also check for continuity
between terminals 2 and 3 in the up (manual mode) position. If the
switch does not perform accordingly, replace it.
a
b
1
2
3
wc_gr003603
10.5 Checking the Water Pump

In the MANUAL mode the spray switch sends electric power directly to
the water pump. To check voltage to the water pump, carry out the
10.5.1 Remove the screws that secure the floor plate and remove the floor
plate.
10.5.2 Locate the water pump (a) and disconnect it.
10.5.3 Place the ignition key switch in the ON position. Place the spray switch
in the MANUAL position.
across the pins of the connector (b).
• If 12V is not measured, check the wiring between the spray
switch and the water pump.
• If 12V is measured, the water pump should operate. If it does not,
replace the water pump.
1000
F 200
20
V
2
200m
V- COM wc_gr003753
10.6 Checking the Automatic Water Pump Relay

When energized, the automatic water pump relay provides battery
voltage to the water pump timer relay. To check the operation of the
automatic pump relay, carry out the following procedure:
10.6.2 Locate the automatic pump relay (E8) (b) and unplug the connector
running to it.
10.6.4 Place the spray switch into the AUTOMATIC position and move the
forward/reverse control lever to the neutral position.
• If 12V is not measured, check the wiring between the forward/
reverse control lever and the automatic water pump relay. Repair
• If 12V is not measured, check the wiring between the spray
switch and the automatic water pump relay. Repair the wiring as
needed.
10.6.7 Check for continuity between terminal 2 of the connector and ground.
• If there is no continuity, check the wiring between the connector
and ground. Repair the wiring as needed.
10.6.8 Plug the connector back into the automatic water pump relay.
10.6.9 Move the forward/reverse control lever out of the neutral position.
Using a multimeter with an appropriate extension, back probe the
wiring between terminal 4 (wire C935-PU) (c) and ground. Battery
• If 12V is measured, the automatic water pump relay is functioning
properly.
• If 12V is not measured, the automatic water pump relay has
failed: replace it.
1000
F 200 V 1000
20
2
F 200
20
V
200m 2
200m
4 c A
V- COM 1 V- COM
wc_gr003754
10.7 Checking the Water Pump Timer Relay

When energized, the water pump timer relay provides battery voltage
to the water pump timer. To check the operation of the water pump
timer relay, carry out the following procedure:
10.7.2 Locate the water pump timer relay (E3) (b) and unplug the connector
running to it.
forward/reverse control lever out of the neutral position.
• If 12V is not measured, check the wiring between the automatic
water pump relay and the water pump timer relay. Repair the wir-
ing as needed.
• If 12V is not measured, check the wiring between the automatic
water pump relay and the water pump timer relay. Repair the wir-
ing as needed.
10.7.7 Plug the connector back into the automatic water pump relay.
10.7.8 Check the voltage between terminal 2 (wire C937-WH) (c) and ground.
To do so, back probe terminal 2 with an appropriate extension. Battery
• If 12V is not measured, the water pump relay timer has failed,
replace it.
10.7.9 Check the voltage between terminal 5 (wire C922-BR) and ground. To
do so, back probe terminal 5 with an appropriate extension. Battery
• If 12V is measured, the water pump timer relay is functioning
properly.
• If 12V is not measured, the water pump timer relay has failed;
replace it.
1000 1000
F 200
20
V F 200
20
V
2 2
200m 200m
A 5 A
V- COM c V- COM
1
2
wc_gr003755
10.8 Checking the Water Pump Timer

The water pump timer provides battery voltage to the water pump in a
periodic cycle. To check the water pump timer, carry out the following
procedure:
10.8.2 Locate the water pump timer (b). Check that all wires to the water
pump timer are secure.
forward/reverse control lever out of the neutral position.
between 12V+ terminal of the timer and ground.
• If 12V is not measured, check the wiring between the water pump
timer relay and the water pump timer. Repair the wiring as
needed.
• If 12V is measured, the water pump timer should be functioning.
If it is not, replace the water pump timer.
1000
F 200
20
V
2
200m
V- COM
wc_gr003756
RD 25 Repair Disassembly/Assembly Procedures
11. Disassembly/Assembly Procedures
11.1 Tools
Because all possible problems encountered while repairing the

machine cannot be anticipated, it is up to the mechanic to use common
sense and good judgement 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.
11.2 Ordering Parts
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 machine.
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 www.wackergroup.com. Enter the site as a
visitor.
11.3 Reference Numbers ( )
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.
11.4 Weight Block

The weight block symbol gives an approximate weight measurement
to aid the mechanic when lifting/hoisting larger components.
250 kg
(550 lbs.)
wc_gr000843
Disassembly/Assembly Procedures RD 25 Repair
11.5 Removing the Engine

Before starting any maintenance on the machine, move it to a flat
surface, turn off the engine and remove the ignition key.
Release the hydraulic pressure from the circuits. Lock the drums and
CAUTION
leave the machine to cool. Disconnect the battery using the
appropriate switch.
Removal
11.5.1 Disconnect and remove the battery 1 and support 2.
11.5.2 Remove the hinged hood 3.
11.5.3 Remove the flexible air tubes 4 from the right-hand side panel.
11.5.4 Remove the rear panel 5 and the right-hand side panel 6.
11.5.5 Detach the cable from the lever of the drive pump and support bracket.
11.5.6 Mark and detach all hoses and connections from the engine.
11.5.7 Mark and detach all flexible hoses from the pumps.
11.5.8 Detach the flexible exhaust tube 7 from the terminal section welded to
the frame.
11.5.9 Loosen the bolts 8 that secure the engine support frame to the shock
mounts.
11.5.10 Connect lifting chains to an appropriate crane capable of lifting 250 kg
(560 lbs.). Carefully raise the engine slightly to check that it is correctly
balanced.
11.5.11 Lift the engine/pumps group and remove it from the machine.
Crushing hazard. Do not lift loads above people.
CAUTION
11.5.12 Lower and rest the engine on a stable support.
11
6 6
250 kg
BB52354
wc_gr003757
11.6 Installing the Engine

Installation
11.6.1 Connect lifting chains to an appropriate crane capable of lifting 250 kg
(560 lbs.). Lift the engine/pumps group and place into the machine.
Tighten the bolts 8 that secure the engine support frame to the shock
mounts.
11.6.2 Connect the flexible exhaust tube 7 to the terminal section welded to
the frame.
11.6.3 Reconnect all flexible hoses to the pumps.
11.6.4 Reconnect all hoses and connections to the engine.
11.6.5 Connect the cable to the lever of the drive pump and support bracket.
11.6.6 Reinstall the rear panel 5 and the right-hand side panel 6.
11.6.7 Reinstall the flexible air tubes 4 from the right-hand side panel.
11.6.8 Reinstall the hinged hood 3.
11.6.9 Reinstall and reconnect the battery 1 and support 2.
NOTICE: Ensure that all the pressure tubes are properly closed.
11
6 6
250 kg
BB52354
wc_gr003757
11.7 Replacing the Drive Pump

Removal:
To reduce the risk of injury, and before beginning any service work on
the machine: drive it onto a level surface, stop the engine, and remove
the ignition switch key, release the hydraulic pressure from the circuits,
remove the battery.
11.7.1 Tag and disconnect all the hoses from the drive pump.
11.7.2 Remove the screws (a), washers (b and c) and remove the drive pump
(d) from the bell housing (e).
11.7.3 Remove the bell housing from the engine.
11.7.4 Remove the retaining ring (f) and remove the hub (g).
11.7.5 Remove the screws (h) that secure the elastic hub (i) to the spacer and
remove the elastic hub.
11.7.6 Remove the screws that secure the spacer (j) to the engine and
remove the spacer,
11.7.7 Check the components for wear. Even if just one component is found
to be defective, change the entire coupling assembly.
Installation:
11.7.8 Secure the spacer (j) to the engine.
11.7.9 Secure the elastic hub (i) to the spacer with screws (h).
11.7.10 Secure the hub (g) with retaining ring (f).
11.7.11 Attach the bell housing to the engine.
11.7.12 Secure the drive pump (d) to the bell housing (e) with washers (b and
c) and screws (a). Torque the screws to 125 Nm (93 ft.lbs.).
20 Kg
5 38
44 43
h
d g f
j
i
c wc_gr003800
a b
11.8 Replacing the Vibration/Steering Pump

The pump is connected through the hub 1 directly to the crankshaft of
the engine (transmission ratio 01:01 AM).
Removal:
11.8.1 Label then disconnect all hydraulic hoses connected to the pump 4.
11.8.2 Remove the screws 3 that secure the pump to the engine and remove
the pump.
11.8.3 Remove hub 1.
11.8.4 Remove the engine cover screws 2 and 7.
Installation:
11.8.5 Tighten screw 2 applying a torque of 24.6 Nm (18.1 ft. lbs.).
11.8.6 Tighten screw 7 applying a torque of 24.6 Nm (18.1 ft. lbs.).
11.8.7 Install the hub 1.
11.8.8 Secure the pump 4 to the engine with screws 3.
wc_gr002243
3
11.9 Removing the Drums

remove the battery.
11.9.1 Connect the front and rear frames with the locking bar 1.
11.9.2 Position the jacks 2 under the two sides of the sub-assembly.
Utilize jacks with an adequate load capacity.
2500 kg
wc_gr002245
Vibration side
11.9.3 Disconnect the hydraulic hoses from the exciter motor 7. Cap the
hoses and fittings to prevent contamination.
11.9.4 Remove the screws 1 that secure the bracket 3 to the anti-vibration
support 2.
Drive side
11.9.5 Disconnect the hydraulic hoses from the drive motor, brake, and the
drain of the reduction gear. Cap the hoses and fittings to prevent
contamination.
11.9.6 Attach cables or chains of a suitable crane, and capable of supporting
the weight of the bracket, to the bracket 4.
11.9.7 Remove the screws 5 that secure the bracket to the reducer and the
screws 6 that secure the bracket 4 to the frame.
11.9.8 Remove the drum from the machine.
2
6
3 4
7 1
1
3 2 6
4 5 5
BB01705
wc_gr003801
11.10 Installing the Drums

Drive side
11.10.1 Position the drum under the machine.
11.10.2 Install the bracket 4 to the reducer with the screws 5. Torque the
screws to 143 Nm (106 ft.lbs.).
11.10.3 Install the bracket 4 to the frame with the screws 6. Torque the screws
to 50 Nm (37 ft.lbs.).
11.10.4 Reconnect the hydraulic hoses to the drive motor, brake, and the drain
of the reduction gear.
Vibration side
11.10.5 Install the bracket 3 to the anti-vibration support 2 with the screws 1.
Torque the screws to 50 Nm (37 ft.lbs.).
11.10.6 Reconnect the hydraulic hoses to the exciter motor 7.
2
6
3 4
7 1
1
3 2 6
4 5 5
BB01705
wc_gr003802
11.11 Replacing the Reduction Gear

Removal:
11.11.1 Remove the drum. See section Removing the Drum.
Place the drum in an upright position.
Note: If the vibrating bearing oil is not drained, the drum must be kept
in a vertical position only for the time strictly necessary, as oil will leak
from the breather pipe.
11.11.1 Remove the screws 3 that secure the support 2 to the rubber
insulators.
11.11.2 Attach two M10 lifting eyes on opposite sides of the reduction gear.
11.11.3 Attach cables or chains of a suitable crane, and capable of supporting
the weight of the reduction gear, to the reduction gear.
11.11.4 Lift the reduction gear assembly off the drum.
11.11.5 Remove the screws 4 that secure the reduction gear 1 to the support 2.
Installation:
11.11.6 Secure the reduction gear to the support plate 2 with screws 4. Torque
the screws to 50 Nm (37 ft.lbs.).
11.11.7 Secure the reduction gear assembly to the rubber insulators with
screws 3. Torque the screws to 50 Nm (37 ft.lbs.).
11.11.8 Remove the M10 lifting eyes.
11.11.9 Reinstall the drum to the machine. See section Installing Drum.
40 kg
2 3
BB01710
2 1 3 4
4
wc_gr002249
11.12 Reduction Gear Disassembly

This procedure requires an Arbor or similar-type press and a source of
compressed air.
11.12.1 Remove the four socket head screws that secure the drive motor to the
reduction gear assembly and remove the drive motor.
11.12.2 Remove the eight socket head screws that secure the bearing flange
(29) to the housing and remove the bearing flange. Check the seal
(23).
11.12.3 Remove the retaining ring (31)
11.12.4 Press the shaft (17) from the bearing flange (29).
11.12.5 Remove the bearing (28) from the shaft.
11.12.6 Press the bearing (28) from the bearing flange.
11.12.7 Remove the screws (1) and the cover (2). Check the seal (3).
11.12.8 Remove the planet gears (6) and ring (7).
11.12.9 Remove gears (5 & 8) from (6).
11.12.10Check the seal (3) on the housing. Replace the seal if it is damaged.
11.12.11Remove the retaining ring (9).
11.12.12Press the hub (15) from the housing (13).
11.12.13Press the bearing (10) from the housing.
11.12.14Pull bearing (10) from the hub.
11.12.15Remove the O-ring (14) from the hub (15).
11.12.16Using compressed air, lift the piston out of the hub.
11.12.17Check the O-rings (23 & 22) in the hub. Replace the O-rings if they are
damaged.
11.12.18Pull out the interior and exterior ring gears (19 & 20).
11.12.19Remove the spacer (18).
22
7
21
19
18
20 17
6
5 16
4
3 24
2 27 23
1 26
15
14
11
13
12
25
10
8
9
26
2
27
1
3
4
5 6
8
22
9
18 25
14 11
12
19
10 13
20
15
14
17 21 16 7 23 24 wc_gr003633
11.13 Reduction Gear Assembly

This procedure requires an Arbor or similar-type press and a source of
compressed air.
11.13.1 Install the spacer (18).
11.13.2 Install the interior and exterior ring gears (19 & 20).
11.13.3 Install the O-rings (23 & 22) in the hub.
11.13.4 Install the piston into the hub.
11.13.5 Install the O-ring (14) into the hub (15).
11.13.6 Install the bearing (10) into the hub.
11.13.7 Press the bearing (10) into the housing.
11.13.8 Press the hub (15) into the housing (13).
11.13.9 Install the retaining ring (9).
11.13.10Install the seal (3) onto the housing
11.13.11Install gears (5 & 8) into (6).
11.13.12Install the planet gears (6) and ring (7).
11.13.13Install the seal (3) and the screws (1) and the cover (2).
11.13.14Press the bearing (28) into the bearing flange (29).
11.13.15Press the shaft (17) into the bearing flange.
11.13.16Press the bearing (28) ont the shaft.
11.13.17Install the retaining ring (31).
11.13.18Install the seal (23).
11.13.19Install the bearing flange (29) to the housing.
11.13.20Fasten the drive motor to the reduction gear assembly.
22
7
21
19
18
20 17
6
5 16
4
3 24
2 27 23
1 26
15
14
11
13
12
25
10
8
9
26
2
27
1
3
4
5 6
8
22
9
18 25
14 11
12
19
10 13
20
15
14
17 21 16 7 23 24 wc_gr003633
11.14 Rebuilding Vibration Hub

Disassembly:
11.14.1 Remove the vibration hub/motor assembly. See section Checking
Exciter Bearings.
11.14.2 Place the group removed from the drum on a flat and stable surface.
11.14.3 Remove the screws 11 that secure the cover 10 and remove the cover.
11.14.4 Remove the retaining ring 12.
11.14.5 Separate the exciter motor support 2 from the hub 5 using an extractor.
11.14.6 Inspect the bearings 14 and 15 and their respective seats and replace
the bearings if worn.
11.14.7 Remove and inspect the coupling C and the ring B. Replace them if
they are damaged.
Assembly:
11.14.8 Press bearings 14 and 15 into the hub 5.
11.14.9 Press the hub assembly 5 onto the exciter motor support 2.
11.14.10Install the retaining ring 12.
11.14.11Install the cover 10 with screws 11. Torque the screws to 10 Nm (7.4
ft.lbs.).
D B
12 C
14 11
10 15
2
5 D
26 mm 20 mm 34 mm
A D
C
B
wc_gr003804
11.15 Disassembling Articulated Joint

remove the battery.
Removal:
11.15.1 Support each half of the machine with two jack stands of adequate
capacity.
11.15.2 Mark and remove all the electrical, hydraulic, and mechanical
connections between the front and rear frames.
11.15.3 Remove the steering piston rod 12 from its hinge, taking out the pin 13.
11.15.4 Ensure that the rear frame is a firmly supported and remove the bolts
1 of the steering coupling from the rear frame.
11.15.5 Lift the front frame, take it away from the rear one, and place it on a
solid support.
Disassembly:
11.15.6 Loosen and remove the horizontal nut 2.
11.15.7 Remove the support 3 from the horizontal king pin.
11.15.8 Loosen and remove the bolts 4 that fix base plate 5 under the vertical
king pin.
11.15.9 Loosen and remove the flange of the seal stop.
11.15.10Loosen and remove the vertical nut, lock-nut, and washer 7, 8, 9.
11.15.11Remove the king pin stop 10.
While supporting the entire articulated joint, remove the vertical king
pin 11 from above.
2
10 3
1
11
2500 Kg
12
9
8
BB98466 BB98467
13 7
6
4
BB98465
wc_gr002252
11.16 Assembling Articulated Joint

Assembly:
11.16.1 While supporting the entire articulated joint, install the vertical king pin
11 from above.
11.16.2 Install the king pin stop 10.
11.16.3 In stall the vertical nut, lock-nut, and washer 7, 8, 9.
11.16.4 Install the flange of the seal stop.
11.16.5 Install the bolts 4 that fix base plate 5 under the vertical king pin.
11.16.6 Install the support 3 to the horizontal king pin with the horizontal nut 2.
Installation:
11.16.7 Position the frames close to one another.
11.16.8 Install the bolts 1 of the steering coupling to the rear frame.
11.16.9 Install the steering piston rod 12 to its hinge with the pin 13.
11.16.10Reconnect all the electrical, hydraulic, and mechanical connections
between the front and rear frames.
11.17 Cleaning the Hydraulic Tank

11.17.1 Turn off the machine and allow it to cool.
Unscrew and remove the magnetic drain plug (1) and allow the
hydraulic fluid to drain off completely.
11.17.2 Remove the inspection cover (2) and clean the inside of the tank. Do
not use solvents or gasoline to clean the tank.
11.17.3 Replace the mesh filter located inside the tank with a new one.
11.17.4 Clean any pieces of metal from the magnetic drain plug.
11.17.5 Change the inspection cover gasket.
11.17.6 Refit the inspection cover (2).
11.17.7 Clean the filler/vent cap (3) and change it if it is clogged.
11.17.8 Change the filter on the drive pump.
11.17.9 Fill the hydraulic tank with oil so that the oil is visible in the sight gauge
(4). Do not mix oil types or grades.
3
BB52248
BB52214
4 1
wc_gr002275
11.18 Replacing the Hydraulic Oil Cooler

Removal:
To reduce the risk of injury, and before beginning any service work on
the machine: drive it onto a level surface, stop the engine, and remove
the ignition switch key, release the hydraulic pressure from the circuits,
remove the battery.
11.18.1 Remove the engine hood.
Drain the hydraulic oil from the hydraulic tank.
11.18.2 Tag and disconnect all the hydraulic hoses from the hydraulic oil
cooler.
11.18.3 Disconnect the electrical sensor connections.
11.18.4 Remove the bolts that secure the hydraulic oil cooler to the machine
and remove the hydraulic oil cooler.
Installation:
11.18.5 Secure the hydraulic oil cooler to the machine with the bolts.
11.18.6 Reconnect the electrical sensor connections.
11.18.7 Reconnect all the hydraulic hoses to the hydraulic oil cooler.
11.18.8 Fill the hydraulic oil tank with oil.
BB98443
wc_gr002276
Threadlockers and Sealants
Threadlocking adhesives and sealants are specified throughout this

manual by a notation of “S” plus a number (S#) and should be used
where indicated. Threadlocking compounds normally break down at
temperatures above 175°C (350°F). If a screw or bolt is hard to
remove, heat it using a small propane torch to break down the sealant.
When applying sealants, follow instructions on container. The sealants
listed are recommended for use on Wacker equipment.
TYPE PART NO. –

( ) = Europe COLOR USAGE SIZE
Loctite 222 Purple Low strength, for locking threads smaller 73287 - 10 ml
Hernon 420 than 6 mm (1/4”).
Omnifit 1150 (50M) Hand tool removable.
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 243 Blue Medium strength, for locking threads 29311 - .5 ml
Hernon 423 larger than 6 mm (1/4”). 17380 - 50 ml
Omnifit 1350 (100M) Hand tool removable.
Loctite 271/277 Red High strength, for all threads up to 25 mm 29312 - .5 ml
Hernon 427 (1”). 26685 - 10 ml
Omnifit 1550 (220M) Heat parts before disassembly. 73285 - 50 ml
Loctite 290 Green Medium to high strength, for locking 28824 - .5 ml
Hernon 431 preassembled threads and for sealing 25316 - 10 ml
Omnifit 1710 (230LL) weld porosity (wicking).
Gaps up to 0.13 mm (0.005”)
Loctite 609 Green Medium strength retaining compound for 29314 - .5 ml
Hernon 822 slip or press fit of shafts, bearings, gears,
Omnifit 1730 (230L) pulleys, etc.
Gaps up to 0.13 mm (0.005”)
Loctite 545 Brown Hydraulic sealant 79356 - 50 ml
Hernon 947 Temp. range: -54 to 149°C (-65 to 300°F)
Omnifit 1150 (50M)
Loctite 592 White Pipe sealant with Teflon for moderate 26695 - 6 ml
Hernon 920 pressures. 73289 - 50 ml
Omnifit 790 Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 515 Purple Form-in-place gasket for flexible joints. 70735 - 50 ml
Hernon 910 Fills gaps up to 1.3 mm (0.05”)
Omnifit 10 Temp. range: -54 to 149°C (-65 to 300°F)
Threadlockers and Sealants (continued)
Threadlocking adhesives and sealants are specified throughout this

manual by a notation of “S” plus a number (S#) and should be used
where indicated. Threadlocking compounds normally break down at
temperatures above 175°C (350°F). If a screw or bolt is hard to
remove, heat it using a small propane torch to break down the sealant.
When applying sealants, follow instructions on container. The sealants
listed are recommended for use on Wacker equipment.
TYPE PART NO. –

( ) = Europe COLOR USAGE SIZE
Loctite 496 Clear Instant adhesive for bonding rubber, metal 52676 - 1oz.
Hernon 110 and plastics; general purpose.
Omnifit Sicomet 7000 For gaps up to 0.15 mm (0.006”)
Read caution instructions before using.
Loctite Primer T Aerosol Fast curing primer for threadlocking, 2006124-6 oz.
Hernon Primer 10 Spray retaining and sealing compounds. Must
Omnifit VC Activator be used with stainless steel hardware.
Recommended for use with gasket
sealants.
Torque Values
Torque Values
Metric Fasteners (DIN)
TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE
8.8 10.9 12.9
Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch
M3 1.2 *11 1.6 *14 2.1 *19 5.5 7/32 2.5 –

M4 2.9 *26 4.1 *36 4.9 *43 7 9/32 3 –
M5 6.0 *53 8.5 6 10 7 8 5/16 4 –
M6 10 7 14 10 17 13 10 – 5 –
M8 25 18 35 26 41 30 13 1/2 6 –
M10 49 36 69 51 83 61 17 11/16 8 –
M12 86 63 120 88 145 107 19 3/4 10 –
M14 135 99 190 140 230 169 22 7/8 12 –
M16 210 155 295 217 355 262 24 15/16 14 –
M18 290 214 405 298 485 357 27 1-1/16 14 –
M20 410 302 580 427 690 508 30 1-1/4 17 –
1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm

Torque Values
Torque Values (continued)
Inch Fasteners (SAE)
Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch
No.4 0.7 *6 1.0 *14 1.4 *12 5.5 1/4 – 3/32
No.6 1.4 *12 1.9 *17 2.4 *21 8 5/16 – 7/64
No.8 2.5 *22 3.5 *31 4.7 *42 9 11/32 – 9/64
No.10 3.6 *32 5.1 *45 6.8 *60 – 3/8 – 5/32
1/4 8.1 6 12 9 16 12 – 7/16 – 3/32
5/16 18 13 26 19 33 24 13 1/2 – 1/4
3/8 31 23 45 33 58 43 – 9/16 – 5/16
7/16 50 37 71 52 94 69 16 5/8 – 3/8
1/2 77 57 109 80 142 105 19 3/4 – 3/8
9/16 111 82 156 115 214 158 – 13/16 – –
5/8 152 112 216 159 265 195 24 15/16 – 1/2
3/4 271 200 383 282 479 353 – 1-1/8 – 5/8
1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm

Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90
Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957
Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. +852 2406 60 32 · Fax: +852 2406 60 21

Manual Taller RD25

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This manual covers machines with Item Number:

Operating / Parts Information

Damage caused by misuse or neglect of the unit should be brought to

This manual provides information and procedures to safely repair and

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

Copyright 2007 by Wacker Corporation

No part of this publication may be reproduced in any form or by any

Any type of reproduction or distribution not authorized by Wacker

1.1 Operating Safety ................................................................................ 11

2.1 Engine ................................................................................................ 20

3.1 Hoisting the Machine .......................................................................... 24

4. General Systems Failure 66

4.1 General Systems Failure Troubleshooting ..........................................66

5. Engine Starting System 72

5.1 Engine Does Not Start Troubleshooting—Flowchart E1 .....................72

6. Hydraulic System Service 79

6.1 Hydraulic System Precautions ............................................................79

7.1 Drive System Overview ...................................................................... 86

8. Vibration System 106

8.1 Vibration System Overview .............................................................. 106

9. Steering System 124

9.1 Steering System Overview ............................................................... 124

10. Spray System 136

10.1 Spray System Overview ....................................................................136

11. Disassembly/Assembly Procedures 147

11.1 Tools ..................................................................................................147

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

DANGER indicates a hazardous situation which, if not avoided, will

WARNING indicates a hazardous situation which, if not avoided, could

CAUTION indicates a hazardous situation which, if not avoided, could

NOTICE: Used without the safety alert symbol, NOTICE indicates a

Note: Contains additional information important to a procedure.

Internal combustion engines present special hazards during operation

Poorly maintained machines can become a safety hazard! In order for

Ref. Label Meaning

G Throttle control lever:

H Hydraulic oil reservoir drain

I Hydraulic oil reservoir level

J Hydraulic oil reservoir fill.

M Water control valve is fully open

N Water control valve is fully closed.

Guaranteed sound power level in dB(A).

2.4 Sound and Vibration Measurements

The operating sound level, measured per the requirements of

See Graphic: wc_gr0001124

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

3.1 Hoisting the Machine

See Graphic: wc_gr001090

See Graphic: wc_gr001091

See Graphic: wc_gr001092

Every Every Every Every Every

Change engine oil 

Replace engine oil filter 

Check level of hydraulic fluid 

Clean hydraulic oil cooler 

Change hydraulic fluid 

Check and clean sprinkler system 

Check and clean scraper bars 

Perform general cleaning 

Grease central steering joint 

Check central steering joint tightness 

Check battery fluid level 

Change engine oil

Replace engine oil filter

Check level of hydraulic fluid

Clean hydraulic oil cooler

Change hydraulic fluid

Check and clean sprinkler system

Check and clean scraper bars

Perform general cleaning

Grease central steering joint

Check central steering joint tightness

Check battery fluid level

Check exciter oil level

Change exciter oil

Service air cleaner cartridge

Clean cooling system

Check exhaust system

Check fuel level

Check in-line fuel filter

Replace in-line fuel filter

Replace main fuel filter

Clean all tanks