operator’s manual roller rd 7 - wacker...

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Operator’s Manual

Roller

RD 7

Copyright notice

© Copyright 2010 by Wacker Neuson Corporation.All rights, including copying and distribution rights, are reserved.This publication may be photocopied by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permission from Wacker Neuson Corporation.Any type of reproduction or distribution not authorized by Wacker Neuson Corporation represents an infringement of valid copyrights. Violators will be prosecuted.

Trademarks All trademarks referenced in this manual are the property of their respective owners.

Manufacturer Wacker Neuson CorporationN92W15000 Anthony AvenueMenomonee Falls, WI 53051 U.S.A.Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957www.wackerneuson.com

Translated instructions

This Operator’s Manual presents a translation of the original instructions. The original language of this Operator’s Manual is American English.

RD 7 /... Table of Contents

wc_bo0154645en_014TOC.fm 3

Foreword 5

1. Safety Information 7

1.1 Operating Safety .................................................................................. 81.2 Operator Safety While Using Internal Combustion Engines ................. 91.3 Service Safety .................................................................................... 101.4 Label Locations .................................................................................. 111.5 Safety and Informational Labels ......................................................... 12

2. Operation 18

2.1 Controls and Service Locations .......................................................... 182.2 Before Starting ................................................................................... 202.3 Engine Throttle Control ...................................................................... 202.4 Starting the Machine (RD 7H, RD 7H-S) ............................................ 212.5 Starting the Machine (RD 7H-ES) ...................................................... 222.6 Cold Weather Starting (RD 7H, RD 7H-S) ......................................... 232.7 Engine Speed ..................................................................................... 242.8 Stopping the Machine ......................................................................... 242.9 Direction and Speed Control .............................................................. 252.10 Exciter ................................................................................................ 252.11 Back-Up Stop Pad .............................................................................. 262.12 Engine Crank ...................................................................................... 262.13 Parking Brake ..................................................................................... 272.14 Watering System ................................................................................ 272.15 Operation on Slopes ........................................................................... 282.16 Rollovers ............................................................................................ 28

Table of Contents RD 7 /...

wc_bo0154645en_014TOC.fm 4

3. Maintenance 29

3.1 Maintenance Schedule ........................................................................293.2 Checking Engine Oil ............................................................................303.3 Changing Engine Oil and Oil Filter ......................................................313.4 Fuel System ........................................................................................323.5 Engine Air Filter ...................................................................................343.6 Checking and Adjusting Valve Clearances .........................................353.7 Engine Cooling System .......................................................................363.8 Mechanical Oil Pressure Monitoring ....................................................373.9 Scraper Bars .......................................................................................383.10 Hydraulic Oil Requirements .................................................................393.11 Hydraulic Oil Level ..............................................................................403.12 Changing Hydraulic Fluid and Filter ....................................................413.13 Direction Lever Adjustment .................................................................423.14 Lifting ...................................................................................................443.15 Transporting ........................................................................................443.16 Pressure Washing the Machine ..........................................................453.17 Storing the Machine ............................................................................453.18 Hydraulic Schematic ............................................................................463.19 Hydraulic Schematic Components ......................................................473.20 Hydraulic Diagram ...............................................................................483.21 Hydraulic Diagram Components .........................................................493.22 RD 7H-ES Electrical Schematic ..........................................................503.23 RD 7H-ES Electrical Schematic Components .....................................513.24 General Troubleshooting .....................................................................52

4. Technical Data 53

4.1 Engine .................................................................................................534.2 Roller ....................................................................................................544.3 Sound and Vibration Measurements ...................................................54

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CALIFORNIAProposition 65 Warning:

Engine exhaust, some of its constituents, and certain vehiclecomponents, contain or emit chemicals known to the State ofCalifornia to cause cancer and birth defects or other reproductiveharm.

Foreword

This manual provides information and procedures to safely operateand maintain this Wacker Neuson model. For your own safety andprotection from injury, carefully read, understand and observe thesafety instructions described in this manual.

Keep this manual or a copy of it with the machine. If you lose thismanual or need an additional copy, please contact Wacker NeusonCorporation. This machine is built with user safety in mind; however,it can present hazards if improperly operated and serviced. Followoperating instructions carefully! If you have questions about operatingor servicing this equipment, please contact Wacker NeusonCorporation.

The information contained in this manual was based on machines inproduction at the time of publication. Wacker Neuson Corporationreserves the right to change any portion of this information withoutnotice.

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

Copyright 2009 by Wacker Neuson Corporation.

No part of this publication may be reproduced in any form or by anymeans, electronic or mechanical, including photocopying, withoutexpress written permission from Wacker Neuson Corporation.

Any type of reproduction or distribution not authorized by WackerNeuson Corporation represents an infringement of valid copyrightsand will be prosecuted. We expressly reserve the right to maketechnical modifications, even without due notice, which aim atimproving our machines or their safety standards.

WARNING

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RD 7 /... Safety Information

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1. Safety Information

This manual contains DANGER, WARNING, CAUTION, NOTICE, andNOTE callouts which must be followed to reduce the possibility ofpersonal injury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potentialpersonal injury hazards. Obey all safety messages that follow thissymbol to avoid possible injury or death.

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

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

CAUTION indicates a hazardous situation which, if not avoided, couldresult in minor or moderate injury.

NOTICE: Used without the safety alert symbol, NOTICE indicates asituation which, if not avoided, could result in property damage.

Note: Contains additional information important to a procedure.

DANGER

WARNING

CAUTION

Safety Information RD 7 /...

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1.1 Operating Safety

Familiarity and proper training are required for the safe operation of themachine. Machines operated improperly or by untrained personnelcan be hazardous. Read the operating instructions contained in thismanual and the engine manual, and familiarize yourself with thelocation and proper use of all controls. Inexperienced operators shouldreceive instruction from someone familiar with the machine beforebeing allowed to operate it.

1.1.1 Always operate the machine with all safety devices and guards inplace and in working order.

1.1.2 ALWAYS check that all controls are functioning properly immediatelyafter start-up! DO NOT operate the machine unless all controls operatecorrectly.

1.1.3 ALWAYS remain aware of changing surface conditions and use extracare when operating over uneven ground, on hills, or over soft orcoarse material. The machine could shift or slide unexpectedly.

1.1.4 ALWAYS remain aware of changing positions and the movement ofother equipment and personnel on the job site.

1.1.5 ALWAYS use caution when operating near the edges of pits, trenchesor platforms. Check to be sure that the ground surface is stable enoughto support the weight of the machine with the operator and that thereis no danger of the roller sliding, falling, or tipping.

1.1.6 ALWAYS position yourself safely when operating machine in reverseor on hills. Leave enough space between yourself and the machine soyou will not be placed in a hazardous position should the machine slideor tip.

1.1.7 ALWAYS operate the machine with both of your feet on the ground!DO NOT stand, sit, or ride on machine while in operation.

1.1.8 ALWAYS remain aware of moving parts and keep hands, feet, andloose clothing away from the moving parts of the machine.

1.1.9 NEVER operate the machine with the fuel cap loose or missing.

WARNING


wc_si000115gb.fm 9

1.2 Operator Safety While Using Internal Combustion Engines

Internal combustion engines present special hazards during operationand fueling. Read and follow the warning instructions in the engineowner’s manual and the safety guidelines below. Failure to follow thewarnings and safety standards could result in severe injury or death.

1.2.1 Do not run the machine indoors or in an enclosed area such as a deeptrench unless adequate ventilation, through such items as exhaustfans or hoses, is provided. Engine exhaust contains carbon monoxide.This is a poison you cannot see or smell. Exposure to carbonmonoxide can cause loss of consciousness and CAN KILL YOU INMINUTES.

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 Refill the fuel tank in a well-ventilated area.1.2.9 Replace the fuel tank cap after refueling.1.2.10 Do not touch or lean against hot exhaust pipes.

1.2.11 DO NOT mix diesel fuel with any other fluids.

WARNING


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1.3 Service Safety

A poorly maintained machine can become a safety hazard! In orderfor the machine to operate safely and properly over a long period oftime, periodic maintenance and occasional repairs are necessary.

1.3.1 Do not modify the machine without the express written approval of themanufacturer.

1.3.2 DO NOT open hydraulic lines or loosen hydraulic connections whilethe engine is running! Hydraulic fluid under pressure can penetrate theskin, cause burns, blind, or create other potentially dangeroushazards. Set all controls in neutral and turn engine off before looseningthe hydraulic lines.

1.3.3 ALWAYS check all external fasteners at regular intervals.

1.3.4 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.

1.3.5 Keep the machine clean and labels legible. Replace all missing andhard-to-read labels. Labels provide important operating instructionsand warn of dangers and hazards.

1.3.6 ALWAYS replace the safety devices and guards after repairs andmaintenance.

1.3.7 ALWAYS turn the engine off before performing maintenance or makingrepairs.

1.3.8 ALWAYS make sure slings, chains, hooks, ramps, jacks, and othertypes of lifting devices are attached securely and have enough weight-bearing capacity to lift or hold the machine safely. Always remainaware of the location of other people in the area when lifting themachine.

1.3.9 ALWAYS turn the engine off before servicing the machine. If theengine has electric start, disconnect the negative terminal on thebattery before servicing the machine.

WARNING


wc_si000115gb.fm 11

1.4 Label Locations

SRE

P

O L

M

H

G

M

B, F, U

AS

C

T

JK

D

L

Q

N


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1.5 Safety and Informational Labels

Wacker Neuson machines use international pictorial labels whereneeded. These labels are described below:

Label Meaning

A DANGER!Engines emit carbon monoxide; operate only in well-ventilated area. Read the Operator’s Manual.No sparks, flames, or burning objects near the machine. Shut off the engine before refueling.

B WARNING! Hot surface!

C WARNING!Read and understand the supplied Operator’s Manual before operating the machine. Failure to do so increases the risk of injury to yourself or others.

D WARNING!To prevent hearing loss, wear hearing protection when operating the machine.

E Guaranteed sound power level in dB(A).

F CAUTION! Use only clean, filtered diesel fuel.


wc_si000115gb.fm 13

G Operator’s Manual must be stored on machine. A replacement Operator’s Manual can be ordered through your local Wacker Neuson distributor.

H Water control valve.

J Vibration control ON/OFF.

K No lift point.(one of two)

L CAUTION Lifting point.

M Tie-down point.

Label Meaning

��

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� � � � � # � $ � � � � � � � � � � � � � � �

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% � � � � � � � � � � � � � � � & � � � � �


wc_si000115gb.fm 14

N Engine oil drain.

O Hydraulic oil reservoir fill tube.

P Hydraulic oil drain.

Q Key switch, engine start:OffOnStart

R This machine may be covered by one or more patents.

S A nameplate listing the model number, item number, revision number, and serial number is attached to each unit. Please record the information found on this plate so it will be available should the nameplate become lost or dam-aged. When ordering parts or request-ing service information, you will always be asked to specify the model number, item number, revision number, and serial number of the unit.

Label Meaning


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T

Check engine oil level. Use SAE10W30.

Check the fuel level.

Engage parking brake.

Turn vibration off.

Pull engine throttle out.

Pull decompression lever up.

Insert crank handle.

Label Meaning


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Rotate crank handle counterclockwise 5X.

Remove crank handle.

Disengage parking brake.

U Low sulfur fuel or ultra low sulfur fuel only.

Label Meaning


wc_si000115gb.fm 17

Notes:

Operation RD 7 /...

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2. Operation

2.1 Controls and Service Locations

Ref. Description Ref. Description

1 Handle locking pin 15 Crank guide sleeve

2 Tie-down location 16 Fuel tank fill cap

3 Scraper bar (4 total) 17 Top cover

4 Water control valve 18 Hydraulic tank (under front cover)

5 Shock mount (4 total) 19 Hydraulic tank fill port (under top cover)

6 Parking brake 20 Hydraulic tank sightglass (through slots)

7 Back-up stop pad 21 Fuel tank

8 Forward/reverse control lever 22 Front cover

9 Exciter control lever 23 Lifting eye

10 Water tank fill cap 24 Operator’s Manual holder

11 Crank storage location 25 Water tank

12 Throttle control 26 Battery

13 Air cleaner indicator 27 Ignition switch

14 Oil dipstick 28 Alarm

RD 7 /... Operation

wc_tx000294gb.fm 19

Operation RD 7 /...

wc_tx000294gb.fm 20

2.2 Before Starting

Before starting the machine, check the following:

• Engine oil level

• Air cleaner maintenance indicator

• Fuel level

• Hydraulic fluid level

• Water tank level

2.3 Engine Throttle Control

See Graphic: wc_gr001338

The engine throttle control (c) is pulled out to start the engine. Pressin on the rubber button (c1) with your thumb while pulling the controlout. The control will stay at any position, and can be fine-tuned bytwisting the control in or out.

To stop the engine, push the throttle control all the way in by pressingon the rubber button with the heel of your hand.

c

c1a

b

dwc_gr001338

RD 7 /... Operation

wc_tx000294gb.fm 21

2.4 Starting the Machine (RD 7H, RD 7H-S)

See Graphic: wc_gr001338, wc_gr001339, wc_gr001340

2.4.1 Check that the exciter (a) is in the OFF position.

2.4.2 Pull the throttle control (c) up to open engine throttle.

2.4.3 Turn the decompression lever (f) until stop (f1) is reached. In thisposition, the automatic decompression system is heard to engage.

2.4.4 Insert the crank (d) into the guide sleeve (b).

2.4.5 Turn the crank 5 turns to build up pressure for the engine to fire.

2.4.6 Stand alongside the engine, facing the back of the machine (e) andgrasp the tubular grip with both hands.

Do not stand in any other position! Injury may result if the engineshould backfire!

2.4.7 Turn the handle slowly until the pawl engages the rachet, thenincrease the turning force to build up speed.

Note: The highest speed must be reached when the decompressionlever (f) returns to the (f0) position.

2.4.8 As soon as the engine has started, pull the starting handle out of theguide sleeve.

You must hold the tubular grip firmly to maintain contact all the timebetween the starting handle and the engine. Maintain turning forceduring the entire hand starting operation.

Note: If backfiring occurs when starting the engine because the crankhandle was not turned firmly enough, the brief reverse rotation at thehandle tube separates the link between the crank lug and the drivingdog.

2.4.9 If the engine begins to run backwards after backfiring (smoke emergesfrom air cleaner), release the crank handle immediately and stop theengine.

2.4.10 To restart the engine, wait until it has come to a standstill, then repeatthe starting procedures.

2.4.11 Allow engine to warm up for a few minutes before operating machine.

WARNING

WARNING

wc_gr001339

e

f0

f1

g

f

wc_gr001340

Operation RD 7 /...

wc_tx000294gb.fm 22

2.5 Starting the Machine (RD 7H-ES)


2.5.1 Check that the exciter (a) is in the OFF position.

2.5.2 Pull the throttle control (b) up to open the engine throttle.

2.5.3 Turn the ignition switch (c) to start the engine.

.

When the key is in the ON position, an alarm will sound. The alarm isa reminder to turn the key to the OFF position when the machine is notin use. Failure to do this will result in a dead battery.

Note: The alarm will stop when proper oil pressure is reached.

Do not crank the engine starter for more than 15 seconds at one time.Longer cranking cycles could lead to starter damage.

2.5.4 Allow the engine to warm up for a few minutes before operating themachine.

CAUTION

WARNING

RD 7 /... Operation

wc_tx000294gb.fm 23

2.6 Cold Weather Starting (RD 7H, RD 7H-S)

See Graphic: wc_gr001338, wc_gr001339, wc_gr001340

At temperatures below approximately -5°C (30°F), always turn theengine over to ensure that it rotates freely.

2.6.1 Check that the exciter switch (a) is in the OFF position.

2.6.2 Pull the throttle control (c) up to open the engine throttle.

2.6.3 Move the decompression lever (f) to a position that is approximatelyhalfway between f0 and f1.

2.6.4 Insert the crank (d) into the guide sleeve (b).

2.6.5 Turn the crank 10 turns (rotations) to build up pressure for the engineto fire.

2.6.6 Clean around the cover of the metering device (g), then:

• remove the cover

• fill with lubricating oil until the level reaches the upper rim

• press the cover on firmly.

2.6.7 Start the engine as normal. See section Starting the Machine.

c

c1a

b

dwc_gr001338

wc_gr001339

e

f0

f1

g

f

wc_gr001340

Operation RD 7 /...

wc_tx000294gb.fm 24

2.7 Engine Speed

During operation, run the engine at full throttle. This ensures maximumexciter speed and will produce the best compaction.

2.8 Stopping the Machine


2.8.1 Place the exciter switch (a) in the OFF position.

2.8.2 Close the water control valve.

2.8.3 Push the throttle control (b) to the minimum position to stop the engine.

2.8.4 On electric start machines, turn the engine switch (c) to the OFFposition.

2.8.5 Apply the parking brake.

2.8.6 Clean the scraper bars before storing the machine.

NOTICE: Should the engine ever speed out of control and not stop byusing the throttle control, pulling up on the decompression lever, whichcould be hot to the touch, will stop the engine.

RD 7 /... Operation

wc_tx000294gb.fm 25

2.9 Direction and Speed Control


Travel direction and speed are controlled by the movable lever (a)inside the handle. From the neutral position, the handle is pushedaway from the operator to travel forward, and towards the operator totravel in reverse.

Keep both hands on the handle while operating the machine. Thehandle may pivot rapidly while in operation and cause injury.

Speed is varied by the movement of the lever; the farther the lever ispushed in either direction, the faster the roller will travel in thatdirection.

If the linkage separates from the directional lever while the machine isrunning, the roller could “run away” and cause injury. In the event ofthis occurring, the throttle (b1) must be pushed in to stop the engine.

2.10 Exciter

The exciter provides the vibration and can be used in most applicationsinvolving cohesive-type soils with heavy clay content, as well as loosesoils and gravel.

NOTICE: DO NOT run the machine over hard surfaces like concreteor compacted asphalt with the vibration on. Damage to the drumbearings may result.

WARNING

WARNING

b1

a

wc_gr001341

Operation RD 7 /...

wc_tx000294gb.fm 26

2.11 Back-Up Stop Pad


A back-up stop pad (a) is mounted to the rear section of the machinebehind the control panel. The back-up stop pad operates in reverseonly.

If the machine backs into an obstruction or if the operator becomestrapped behind it, the pad will be pressed forward and stop themachine. The machine can move only in the forward direction whenthe handle is brought back through the neutral position.

2.12 Engine Crank


The engine crank is equipped with kick-back damping to protect theoperator from injury should the engine backfire. The brief reverserotation at the handle tube (a) separates the link between the crank lug(b) and the driving dog (c).

STOP

wc_gr001342

a

wc_gr001345

a b c

RD 7 /... Operation

wc_tx000294gb.fm 27

2.13 Parking Brake


The parking brake is used to ensure that the machine will not roll whennot in use. It engages the weld stops on the drum, therefore a smallamount of movement is possible before the brake will catch and stopthe machine.

To disengage the parking brake:

Rotate the handle (a) 90° clockwise and bring it to rest in a shallowdetent.

To engage the parking brake:

Rotate the handle (a) 90° counterclockwise and allow it to rest in thedeep detent.

NOTICE: The parking brake is designed to hold the machine on anincline with the engine off. Do not drive against the parking brake in theengaged position. The brake may bend and damage the machine.

2.14 Watering System


The RD 7 is equipped with a water control valve which allows the rollerto be used wet or dry, and a sprinkler system to distribute the waterevenly across the drums. The water is gravity fed to the sprinklerswhen the control valve is in the OPEN (horizontal) position (a).

wc_gr001343a

a

wc_gr001344

Operation RD 7 /...

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2.15 Operation on Slopes

See Graphic: wc_gr001346 and wc_gr001347

When operating on slopes or hills, special care must be taken toreduce the risk of personal injury or damage to the machine. Alwaysoperate the machine up and down hills rather than from side to side.For safe operation and for protection of the engine, continuous dutyuse should be restricted to slopes of 22° (40% grade) or less.

NEVER operate the machine sideways on slopes. The machine mayroll over, even on stable ground.

2.16 Rollovers

Proper operation of the machine on slopes will prevent rollovers. Readand follow Safety instructions in “Operating Safety” and “Operation onSlopes”. If a machine rollover does occur, care must be taken toprevent damage to the engine. In this position, oil from the enginecrankcase can flow into the combustion chamber, which can severelydamage the engine next time it is started. If the machine has rolled onits side, immediate steps should be taken to right the machine.

NOTICE: To prevent damage to the engine after a rollover, themachine must NOT be started, AND it must be serviced to remove anyoil that may have been trapped in the combustion chambers. Contactyour local Wacker Neuson dealer for instructions or servicing.

WARNING

22˚40%

wc_gr001346 wc_gr001347

RD 7 /... Maintenance

wc_tx000295gb.fm 29

3. Maintenance

3.1 Maintenance Schedule

Dailybefore

starting

Afterfirst

25 hrs.*

Every250hrs.

Every500hrs.

Every1200hrs.

Check engine oil level.

Check air cleaner maintenance indicator.

Check the water trap.

Check hydraulic oil level.

Clean the scraper bars.

Check function of back-up stop pad and direction control lever.

Check tappet clearance.

Examine screw connections.

Replace engine oil and filter.

Check and adjust valve clearances.

Clean cooling system.

Replace fuel filter.

Clean or replace air filter.

Change hydraulic system return line filter.

Check and adjust scraper bars.

**Check linkage components.

Clean battery terminals (RD 7H-ES).

Change hydraulic oil and filter.

*For new or reconditioned engines.CAUTION: DO NOT tighten cylinder head fastenings.** Maintain linkages more frequently in dusty environments. Lubricating linkages is not

recommended. However, if necessary, use a dry lubricant that does not attract dust.

Maintenance RD 7 /...

wc_tx000295gb.fm 30

3.2 Checking Engine Oil


Engine oil level

Stop the machine, switch off the engine and apply the parking brake.

Check the oil with the machine standing on a level surface.

3.2.1 Clean around the dipstick.

3.2.2 Check the oil level on the extended dipstick (a). If necessary, top up tothe “max” mark.

The engine may be hot enough to cause burns! Allow the engine tocool prior to servicing.

WARNING

a

wc_gr001348


wc_tx000295gb.fm 31

3.3 Changing Engine Oil and Oil Filter


Before changing the oil:

3.3.1 Run the machine to warm the oil.

3.3.2 Park the machine on a flat level surface.

3.3.3 Turn off the engine and apply the parking brake.

Burn hazard! Avoid contact with the engine oil when draining theengine. Hot oil can burn!

Note: In the interests of environmental protection, place a plastic sheetand a container under the machine to collect any liquid that drains off.Dispose of this liquid in accordance with environmental protectionlegislation.

3.3.4 Unscrew the oil drain plug and allow the oil to drain into a 1–1.5 liter(1–1.5 quarts) container.

3.3.5 Clean the oil drain plug and attach a new seal to it.

3.3.6 Reinstall the drain plug.

3.3.7 Unscrew the filler cap of the oil filter housing. Check the condition ofthe O-ring (a) on the filler cap and replace it if it is damaged.

3.3.8 Remove the used filter element. Install a new filter element with the“TOP” mark facing up.

3.3.9 Add engine oil up to the “MAX” mark on the dipstick; approximately1.1–1.2 liters (1–1¼ quarts).

3.3.10 Wet the O-ring and threads of the filler plug with high-temperaturegrease available from your Hatz Dealer. Then, reinstall the filler plug.

3.3.11 Run the engine for two minutes. Turn off the engine and check theengine oil level again. Add engine oil as necessary.

3.3.12 Make sure that there is no oil leakage past the filler cap.

CAUTION

wc_gr001349

a


wc_tx000295gb.fm 32

3.4 Fuel System


Fuel tank water trap

The interval at which you should check the water trap depends uponthe amount of water in the fuel. The normal interval is one week.

Stop the machine, switch off the engine, and apply the parking brake.

3.4.1 Remove the cover from the roller to allow access to the fuel tank watertrap.

3.4.2 Loosen the hex screw (a) until only 2 threads are holding it in place.

3.4.3 Trap the drops of water that emerge in a transparent container.

Note: Since water has a higher specific gravity than diesel fuel, thewater emerges first. The two substances separate at a clearly visibleline.

3.4.4 When only diesel fuel emerges, retighten the hex screw.

NOTICE: Diesel fuel destroys shock mounts. Clean up fuel spillageimmediately.

Changing the fuel filter cartridge

Fuel filter maintenance intervals depend on the purity of the diesel fuelused. If your fuel is dirty, perform this operation at 250 hours.

Stop the machine, switch off the engine, and apply the parking brake.

Explosion hazard! Diesel fuel is flammable and must be treated withthe necessary caution. Do not smoke near the machine. Avoid sparksand open flames.

3.4.5 Remove the cover from the roller to allow access to the fuel filter.

3.4.6 Place a suitable container under the fuel filter to trap escaping fuel.

3.4.7 Close the fuel supply line.

3.4.8 Pull the fuel supply line (b) off of the fuel filter trap (c) at both sides, andinsert the new filter.

NOTICE: Keep the area clean to prevent dirt from entering the fuellines.

3.4.9 Make sure the fuel filter is oriented with the arrow in the direction of fuelflow.

3.4.10 Open the fuel supply line until fuel begins to flow.

3.4.11 Run the engine briefly to check the fuel filter and lines for leaks.

WARNING


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a

b

c

wc_gr001351


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3.5 Engine Air Filter


Checking the air cleaner blockage indicator

3.5.1 Briefly run the engine at full speed. If the rubber bellows is pulled in andobscures the green zone (a), clean or replace the air filter.

3.5.2 In dusty operating conditions, check the rubber bellows several timesper day.

Cleaning or replacing the engine air filter

The engine may be hot enough to cause burns! Allow the engine tocool prior to servicing.

3.5.3 Loosen the wing nut (b) and remove it. Also remove the air cleanercover (c).

Note: The decompression lever will also come off.

3.5.4 Pull out the filter cartridge (e).

3.5.5 Check that the valve plate (f) for the air blockage indicator is clean andin good condition.

Cleaning dry dirt from the filter cartridge

3.5.6 Blow through the filter cartridge from the inside using a compressed airgun.

3.5.7 Continue until all dust has been removed.

NOTICE: Only use filtered, dry compressed air. Do not exceed an airpressure of more than 5 bar (70 psi). Keep the nozzle at a distance of150 mm (6 in.) from the element.

Cleaning wet or oily dirt from the filter

3.5.8 Change the filter cartridge.

NOTICE: Always trace and correct the cause of wet or oilycontamination of a filter element.

Checking the filter cartridge

3.5.9 Hold the element up to a light or pass a lamp through the middle tocheck the condition of the element folds (g).

3.5.10 Check that the sealing surface (d) is in good condition.

NOTICE: If there is even slight damage to the paper filter element orthe sealing surface, replace the filter cartridge.

WARNING


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3.6 Checking and Adjusting Valve ClearancesSee Graphic: wc_gr001353

Stop the machine, apply the parking brake and switch off the engine.

3.6.1 Make sure that the compression lever is in position “0”. See sectionStarting the Machine.

3.6.2 Remove the cylinder head cover and the gasket.

3.6.3 Turn the engine over in the normal direction of rotation untilcompression is felt.

3.6.4 Check the inlet valve clearance between the rocker and the valve stemusing a feeler gauge (a).

3.6.5 If the valve clearance is incorrect, loosen the hex nut (c).

Note: See section Technical Data for valve clearances.

3.6.6 Turn the adjusting screw (b) with a screwdriver until the feeler gauge(a) can just be pulled through between the rocker and the valve stemwith slight resistance to its movement after the nut (c) has beenretightened.

3.6.7 Repeat this adjustment with the outlet valve.

3.6.8 Place a new gasket under the cylinder head cover, reinstall thecylinder head cover, and tighten down the screws uniformly.

3.6.9 Run the engine briefly and make sure that the cylinder head cover isnot leaking.

a b

c

wc_gr001353

a b c

de

fg

wc_gr001352


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3.7 Engine Cooling System


Stop the machine, apply the parking brake and switch off the engine.The engine must be allowed to cool down before cleaning.

Dry contamination

3.7.1 Clean all air guide elements and the complete cooling air zones (a) onthe cylinder head and the cylinder and flywheel blades without makingthem wet. Blow them dry with compressed air.

Moist or oily contamination

3.7.2 Clean the entire area with a solvent or cold cleaner according to itsmanufacturer's instructions, then spray down with a high pressurewater jet. Blow them dry with compressed air.

3.7.3 Trace the source of oil leaks causing greasy dirt. Repair the leaks,seeking advice of your Hatz dealer if necessary.

3.7.4 After cleaning, run the engine to dry it out and to prevent the formationof rust.

a

a

a

wc_gr001354


wc_tx000295gb.fm 37

3.8 Mechanical Oil Pressure Monitoring


The mechanical oil pressure monitor should be activated:

• when first filling, or after running the fuel tank dry.

• if the engine shut down automatically because the lubricating oil supply was inadequate.

• after freeing it by turning it at low temperatures.

3.8.1 Add fuel.

3.8.2 Check the engine oil level.

3.8.3 To activate the oil pressure monitor, press the lever (a).

3.8.4 Re-assemble all the parts repositioned or removed. Check that thecapsule elements make a good seal.

Note: Instructions to activate the mechanical oil pressure control arementioned on the label (b) placed on the engine.

Even with the mechanical oil pressure control monitoring the oil level,it must be checked every 8–15 operating hours.

CAUTION


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3.9 Scraper Bars


Check the four scraper bars (a) for wear. Replace the scraper bars asneeded.

Cleaning the scraper bars

The scraper bars should be cleaned daily after use or as often asneeded to remove built-up dirt, mud, and tar.

Use a high-pressure water jet and a strong brush if needed.

wc_gr001355

a

a a


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3.10 Hydraulic Oil Requirements

Wacker Neuson recommends the use of a premium grade, petroleum-based hydraulic oil with anti-wear and anti-foam characteristics. Goodanti-wear oils contain additives to reduce oxidation, prevent foaming,and provide for good water separation. These oils offer superior motorand pump life.

When selecting hydraulic oil for your machine, be sure to specify anti-wear properties. Wacker Neuson offers a premium grade hydraulic oilfor use in this machine.

• Wacker Neuson Hydraulic Oil - P/N 85094

Avoid mixing different brands and grades of hydraulic oils.

Oil Viscosity

Most hydraulic oils are available in different viscosities. The SAEnumber for an oil is used strictly to identify viscosity. It does not indicatethe type of oil (engine, hydraulic, gear, etc.). The higher the SAEnumber, the thicker the oil.

For normal applications use a good non-detergent, anti-wear,hydraulic oil with a viscosity rating of SAE 10W30.


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3.11 Hydraulic Oil Level


A hydraulic oil level sightglass (a) is located on the hydraulic tank andis visible through the slots on the top cover.

Check the oil level with the machine standing on a level surface. Theoil level should be at the halfway mark on the sightglass. If the level islow, remove the top cover and top up with hydraulic oil as necessary.

If hydraulic oil continually needs to be added, inspect the hoses andconnections for possible leaks. Repair hydraulic leaks immediately toprevent damage to the hydraulic components.

a

wc_gr001356


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3.12 Changing Hydraulic Fluid and Filter


Stop the machine, switch off the engine, and apply the parking brakewith the machine standing on a level surface.

Note: In the interests of environmental protection, place plasticsheeting and a container under the machine to collect the liquid whichdrains off. Dispose of this liquid properly.

3.12.1 Remove the top cover of the roller.

3.12.2 Remove the drain plug (b) from the end of the drain hose that isattached to the hydraulic tank.

3.12.3 Allow the hydraulic oil to drain into a suitable container.

3.12.4 When all the oil has drained out, reinstall the drain plug back into thehose and secure it in place.

3.12.5 Place a plastic bag around the filter (a) to contain any oil spillage.

3.12.6 Unscrew the old hydraulic filter.

3.12.7 Install the new hydraulic filter. Screw the new hydraulic filter on byhand, making sure that it is not cross-threaded.

NOTICE: Use only original spare parts.

3.12.8 Tighten the hydraulic filter using both hands.

3.12.9 Fill the hydraulic tank with hydraulic oil until the level is visible halfwayup the sightglass.

3.12.10 Run the engine briefly, then stop the engine and check for leaks.

3.12.11 Check the oil level in the sightglass, and top up if necessary.


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3.13 Direction Lever Adjustment


The forward/reverse control lever should have long forward travel andshort reverse travel. If the lever appears out of adjustment, it can be re-adjusted as follows:

3.13.1 Start the engine. Place the forward/reverse control lever in theNEUTRAL position (N). Confirm that the machine does not creep. If themachine does creep, turn the large adjusting nut (4) on the spring-loaded, cable centering device (5) so that the machine does not creep.

3.13.2 Stop the engine.

3.13.3 Place the forward/reverse control lever in the full FORWARD position(F). Check the rotation of the drive pump control arm (9). In the fullFORWARD position, the drive pump control arm should rotate, in thedirection shown, as far as possible.

• If the drive pump control arm rotates as far as possible, no further adjustment is required.

• If the drive pump control arm does not rotate as far as possible, continue.

3.13.4 Disconnect the clevis (1) from the pivot (2).

3.13.5 Rotate the pivot so that the drive pump control arm rotates as far aspossible. With the forward/reverse control lever in the full FORWARDposition, adjust the clevis and lock nut (8) so that it can hold the drivepump control arm in the fully rotated position. Reattach the clevis to thepivot.Note: If the adjustment cannot be made with the clevis alone, adjustthe linkage (10).

3.13.6 Start the engine and check the NEUTRAL position of the control lever.

• If the machine remains stationary, no further adjustment is required.

• If the machine creeps forwards or backwards, continue.

3.13.7 Turn off the engine.

3.13.8 Adjust the nut (4) on the spring-loaded, cable centering device asneeded so that the machine remains stationary when the control leveris in the NEUTRAL position. Start the engine and recheck for machinecreeping/movement. It may take several attempts to find the correctposition. Loosen the nuts (6) holding the cable (3) to the bracket (7)and reposition the cable if necessary.

3.13.9 The maximum allowable reverse travel speed is 2 km/hr. Do not adjustthe direction control lever so that reverse travel speed is greater than2 km/hr. (1.2 mph).CAUTION


wc_tx000295gb.fm 43


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3.14 Lifting


Attach a sling or chain to the lifting eye (a) using a suitable hook orshackle. Each lifting device must have capacity of at least 650 Kg(1430 lbs).

Only use steel ropes or chains for hoisting. The rope or chain musthave the suitable specified lifting capacity of 650 Kg (1430 lbs). Do notuse improvised ropes or chains.

NOTICE: Never use any other part of the roller to lift the machine, assevere damage may occur.

Do not stand under, or get onto, the machine while it is being hoistedor moved.

3.15 Transporting


Before transporting the machine:

• place blocks in front of and behind each drum.

• use the front and rear tie-downs (b) to secure the machine to the trailer.

• place the lift handle (a) into the upright position.

NOTICE: Only use the tie-downs to secure the machine. Do not useany other part of the roller to tie the machine down as severe damageto the machine may occur.

WARNING

WARNING


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3.16 Pressure Washing the Machine

When pressure washing the machine, avoid using harsh chemicalsand only use moderate water pressure (35–70 MPa [500–1000 psi]) .

Avoid direct pressure to the following components:

• Engine

• Hydraulic

• Water tank/Plastic parts

• Hoses

• Labels

3.17 Storing the Machine

If the machine is to be stored for more than 30 days:

• Drain the fuel tank and the water tank.

• Open the water valve and drain water from the sprinkling system.

• Change the oil.

• Clean the entire roller and engine compartment.

• Remove dirt from the engine cooling fins.

• Cover the roller and place it in a dry, protected area.

• Remove the diesel injectors and put a little oil into the engine cylinders.

• Remove the battery from the machine and charge it periodically (RD 7H-ES).


wc_tx000295gb.fm 46

3.18 Hydraulic Schematic

7

16 6

8

10

11

13200 bar2900 psi

12100 bar1450 psi

5 4

1206 bar3000 psi

2

15

14

3P

10 micron

wc_gr003636


wc_tx000295gb.fm 47

3.19 Hydraulic Schematic Components



1 Exciter relief valve 9 Charge pump

2 Exciter control valve 10 Exciter pump

3 Exciter motor 11 Drive pump

4 Rear drive motor 12 Charge pressure relief valve

5 Front drive motor 13 Internal drive pump relief valves

6 Return filter 14 Porting block

7 Suction filter 15 Manifold

8 Pump assembly 16 Tank


wc_tx000295gb.fm 48

3.20 Hydraulic Diagram

wc_gr003637

15

28

11(9)(12)

1

10

6

7

16

3

14

4

5

13


wc_tx000295gb.fm 49

3.21 Hydraulic Diagram Components



1 Exciter relief valve 9 Charge pump

2 Exciter control valve 10 Exciter pump

3 Exciter motor 11 Drive pump

4 Rear drive motor 12 Charge pressure relief valve

5 Front drive motor 13 Internal drive pump relief valves

6 Return filter 14 Porting block

7 Suction filter 15 Manifold

8 Pump assembly 16 Tank


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3.22 RD 7H-ES Electrical Schematic

wc_gr003663

1 2 3 4 5 62 13456

41

3

Br

P

B

R

0

8


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3.23 RD 7H-ES Electrical Schematic Components



1 Key switch 5 Starter

2 15 Amp fuse 6 Regulator

3 Alternator 7 Alarm

4 Battery 8 Oil pressure switch

Wire Colors

B Black R Red Y Yellow Or Orange

G Green T Tan Br Brown Pr Purple

L Blue V Violet Cl Clear Sh Shield

P Pink W White Gr Gray LL Light blue


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3.24 General Troubleshooting

Problem / Symptom Reason / Remedy

Engine does not start • Fuel tank empty.

• Wrong type of fuel.

• Old fuel. Drain tank, change fuel filter and fill with fresh fuel.

• Fuel system not primed.

• Fuel filter restricted or plugged. Replace filter.

• Check/adjust valve clearance.

• Oil pressure lost. Check engine oil level/activate mechanical oil pressure monitor.

• Air cleaner element plugged.

• Check/adjust decompression device.

• Battery connections loose or corroded. Battery dead (RD 7H-ES).

• Starter motor defective (RD 7H-ES).

• Electrical connections loose or broken (RD 7H-ES).

• Key switch defective (RD 7H-ES).

Engine stops by itself • Fuel tank empty.

• Fuel filter plugged.

• Fuel lines broken or loose.

No vibration • Valve damaged.

• Exciter assembly damaged.

• Exciter motor coupling damaged or broken.

• Exciter motor damaged.

• Pump damaged.

No travelorTravel only in one direction

• Control cable loose or broken.

• Drive motor damaged.

• Drive pump damaged.

• Defective relief valve or valves.

RD 7 /... Technical Data

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4. Technical Data

4.1 Engine

Engine Power Rating

Net power rating per ISO 3046/1-IFN. Actual power output may varydue to conditions of specific use.

Item No. RD 7H0008042

RD 7H-ES0009408

RD 7H-S0009487

Engine

Engine type One cylinder, 4-stroke, air cooled, diesel engine

Engine make Hatz

Engine model 1D41S 1D41S VAR I

Max. rated power @ rated speed

kW (Hp)5.1 (6.9) @ 2600 rpm

Operating speed rpm 2600

Valve clearance (cold) intake: exhaust:

mm (in.) 0.10 (0.004)0.20–0.25 (0.008–0.010)

Battery V — 12 VDC —

Air cleaner type Dry pleated-paper element

Engine lubrication oil grade SAE15W40

Engine oil capacity l (qt.) 1.2 (1.25)

Fuel type No. 2 diesel

Fuel tank capacity l (gal.) 5.0 (1.3)

Fuel consumption l (gal.)/hr. 1.67 (0.44)

Item No. RD 7-RAW0620079 0620478 0620596

Battery V — 12 VDC —

Air cleaner type Dry pleated-paper element

Fuel type No. 2 diesel

Fuel tank capacity l (gal.) 5.0 (1.3)

Fuel consumption l (gal.)/hr. 1.67 (0.44)

Technical Data RD 7 /...

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4.3 Sound and Vibration Measurements

4.2 Roller

The required sound specification, Paragraph 1.7.4.f of 89/392/EECMachinery Directive, is:

the sound pressure level at operator’s location (LpA) = 95 dB(A)

the guaranteed sound power level (LWA) = 108 dB(A).

These sound values were determined according to ISO 3744 for thesound power level (LWA) and ISO 6081 for the sound pressure level(LpA) at the operator’s location.

The weighted effective acceleration value, determined according toISO 8662 Part 1, is approximately:

Hands = 9.66 m/s2.

The sound and vibration measurements were obtained with themachine operating on hard asphalt at maximum RPM and top speed.

Item No.

RD 7H0008042

RD 7H-ES0009408

RD 7H-S0009487

RD 7-RAW062007906204780620596

Roller

Overall dimensions -handle up (l x w x h)

mm(in.)

1225 x 700 x 2215(48.3 x 27.5 x 87.2)

Overall Dimensions - handle down (l x w x h)

mm(in.)

2630 x 700 x 1165(103.5 x 27.5 x 46)

Operating weight kg (lbs.) 810 (1785) 830 (1829) 810 (1785)

Area capacity m2 (ft.2)/hr. 2613 (28115)

Forward speed (max) km/h (mph) 0-4.0 (0-2.5)

Reverse speed (max) km/h (mph) 0-2.0 (0-1.2)

Vibration frequency Hz (vpm) 55 (3300)

Hydraulic system lubrication type SAE 10W30 hydraulic oil*

Hydraulic system capacity l (gal.) 30 (8)

Gradeability with vibration % 25

Gradeability without vibration % 40

*See “Hydraulic Oil Requirements”

William Lahner Paul SinaVice President of Engineering Manager, Product Engineering

WACKER NEUSON CORPORATION

2010

-CE

-RD

7H_e

n.fm

EC DECLARATION OF CONFORMITY

WACKER NEUSON CORPORATION, N92W15000 ANTHONY AVENUE, MENOMONEE FALLS, WISCONSIN USA

hereby certifies that the construction equipment specified hereunder:

has been sound tested per Directive 2000/14/EC:

AUTHORIZED REPRESENTATIVE IN THE EUROPEAN UNION Axel HäretWACKER NEUSON SEPreußenstraße 4180809 München

1. Category:Vibrating Walk-Behind Rollers

2. Machine function:This machine is intended to be used for compacting sand, gravel, soil, and asphalt on roadways, walkways, bridges, and parking lots.

3. Type / ModelRoller RD 7H-ES, RD 7H-S

4. Item number of equipment:0620794, 0620795

5. Net installed power:5,1 kW

Conformity Assessment Procedure

Name and address of notified body Measured sound power level Guaranteed sound power level

ANNEX VIII Lloyds Register Quality Assurance Limited (Notified

Body No 0088)71 Fenchurch StreetLondon EC3M 4BS

United Kingdom

107 dB(A) 108 dB(A)

6. This machinery fulfills the relevant provisions of Machinery Directive 2006/42/EC and is also produced in accordance with these standards:2000/14/EC2004/108/ECEN 500-1EN 500-4

The original language of this EC Declaration of Conformity is American English.

18.12.09Date

Wacker Neuson SE · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02-0 · Fax: +49 - (0)89-3 54 02-390Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.Tel: (852) 3605 5360, Fax: (852) 2758 0032

operator’s manual roller rd 7 - wacker...

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