Operator s Manual. Roller RD en

Transcription

1 Operator s Manual Roller RD en E N

2 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 Corporation N92W15000 Anthony Avenue Menomonee Falls, WI U.S.A. Tel: (262) Fax: (262) Tel: (800) Translated instructions This Operator s Manual presents a translation of the original instructions. The original language of this Operator s Manual is American English.

3 RD 7 /... Table of Contents Foreword 5 1. Safety Information Operating Safety Operator Safety While Using Internal Combustion Engines Service Safety Label Locations Safety and Informational Labels Operation Controls and Service Locations Before Starting Engine Throttle Control Starting the Machine (RD 7H, RD 7H-S) Starting the Machine (RD 7H-ES) Cold Weather Starting (RD 7H, RD 7H-S) Engine Speed Stopping the Machine Direction and Speed Control Exciter Back-Up Stop Pad Engine Crank Parking Brake Watering System Operation on Slopes Rollovers wc_bo en_014toc.fm 3

4 Table of Contents RD 7 / Maintenance Maintenance Schedule Checking Engine Oil Changing Engine Oil and Oil Filter Fuel System Engine Air Filter Checking and Adjusting Valve Clearances Engine Cooling System Mechanical Oil Pressure Monitoring Scraper Bars Hydraulic Oil Requirements Hydraulic Oil Level Changing Hydraulic Fluid and Filter Direction Lever Adjustment Lifting Transporting Pressure Washing the Machine Storing the Machine Hydraulic Schematic Hydraulic Schematic Components Hydraulic Diagram Hydraulic Diagram Components RD 7H-ES Electrical Schematic RD 7H-ES Electrical Schematic Components General Troubleshooting Technical Data Engine Roller Sound and Vibration Measurements...54 wc_bo en_014toc.fm 4

5 Foreword WARNING CALIFORNIA Proposition 65 Warning: Engine exhaust, some of its constituents, and certain vehicle components, contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. This manual provides information and procedures to safely operate and maintain this Wacker Neuson model. For your own safety and protection from injury, carefully read, understand and observe the safety instructions described in this manual. Keep this manual or a copy of it with the machine. If you lose this manual or need an additional copy, please contact Wacker Neuson Corporation. This machine is built with user safety in mind; however, it can present hazards if improperly operated and serviced. Follow operating instructions carefully! If you have questions about operating or servicing this equipment, please contact Wacker Neuson Corporation. The information contained in this manual was based on machines in production at the time of publication. Wacker Neuson Corporation reserves the right to change any portion of this information without notice. 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 any means, electronic or mechanical, including photocopying, 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 and will be prosecuted. We expressly reserve the right to make technical modifications, even without due notice, which aim at improving our machines or their safety standards. wc_tx000001gb.fm 5

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7 RD 7 / Safety Information 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 situation which, if not avoided, could result in property damage. Note: Contains additional information important to a procedure. wc_si000115gb.fm 7

8 Safety Information RD 7 / Operating Safety WARNING Familiarity and proper training are required for the safe operation of the machine. Machines operated improperly or by untrained personnel can be hazardous. Read the operating instructions contained in 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 Always operate the machine with all safety devices and guards in place and in working order ALWAYS check that all controls are functioning properly immediately after start-up! DO NOT operate the machine unless all controls operate correctly ALWAYS remain aware of changing surface conditions and use extra care when operating over uneven ground, on hills, or over soft or coarse material. The machine could shift or slide unexpectedly ALWAYS remain aware of changing positions and the movement of other equipment and personnel on the job site ALWAYS use caution when operating near the edges of pits, trenches or platforms. Check to be sure that the ground surface is stable enough to support the weight of the machine with the operator and that there is no danger of the roller sliding, falling, or tipping ALWAYS position yourself safely when operating machine in reverse or on hills. Leave enough space between yourself and the machine so you will not be placed in a hazardous position should the machine slide or tip ALWAYS operate the machine with both of your feet on the ground! DO NOT stand, sit, or ride on machine while in operation ALWAYS remain aware of moving parts and keep hands, feet, and loose clothing away from the moving parts of the machine NEVER operate the machine with the fuel cap loose or missing. wc_si000115gb.fm 8

9 RD 7 /... Safety Information 1.2 Operator Safety While Using Internal Combustion Engines WARNING Internal combustion engines present special hazards during operation and fueling. Read and follow the warning instructions in the engine owner s manual and the safety guidelines below. Failure to follow the warnings and safety standards could result in severe injury or death 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. Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. Exposure to carbon monoxide can cause loss of consciousness and CAN KILL YOU IN MINUTES Do not smoke while operating the machine Do not smoke when refueling the engine Do not refuel a hot or running engine Do not refuel the engine near an open flame Do not spill fuel when refueling the engine Do not run the engine near open flames Refill the fuel tank in a well-ventilated area Replace the fuel tank cap after refueling Do not touch or lean against hot exhaust pipes DO NOT mix diesel fuel with any other fluids. wc_si000115gb.fm 9

10 Safety Information RD 7 / Service Safety WARNING A poorly maintained machine 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 Do not modify the machine without the express written approval of the manufacturer 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 ALWAYS check all external fasteners at regular intervals 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 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 ALWAYS replace the safety devices and guards after repairs and maintenance ALWAYS turn the engine off before performing maintenance or making repairs ALWAYS make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices are attached securely and have enough weightbearing capacity to lift or hold the machine safely. Always remain aware of the location of other people in the area when lifting the machine ALWAYS turn the engine off before servicing the machine. If the engine has electric start, disconnect the negative terminal on the battery before servicing the machine. wc_si000115gb.fm 10

11 RD 7 / Label Locations Safety Information K J T D S C A L B, F, U Q N M O L G P H E R S M wc_si000115gb.fm 11

12 Safety Information RD 7 / Safety and Informational Labels Wacker Neuson machines use international pictorial labels where needed. These labels are described below: A B Label Meaning 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. 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 12

13 RD 7 /... Safety Information Label Meaning G 2-4 ) ) 7 ) * , ) ) ) ) 7 ) + ) * - 4, - 4 -, / 0 ; ) 9 ) + - 4, * 7 6 4, 1- * * ), - 4 ) ) 7. * - 9 ) , * / ) 6 * , * ) ) , ) 7 ), ) + 1, - * , - ) ) ) + 6 ) ) 5 7, * 7 1, 4 9 ) ) ) 2 ) 4 ) 2 -, ) 4 ), 1+ 1 ) ) , - 2 1, ) ) ) , * ) ), : - 2 ) ) 14 - # ' $ Operator s Manual must be stored on machine. 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. wc_si000115gb.fm 13

14 Safety Information RD 7 /... N Label Meaning Engine oil drain. O Hydraulic oil reservoir fill tube. P Hydraulic oil drain. Q Key switch, engine start: Off On Start 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 damaged. When ordering parts or requesting service information, you will always be asked to specify the model number, item number, revision number, and serial number of the unit. wc_si000115gb.fm 14

15 RD 7 /... Safety Information T Label Meaning 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. wc_si000115gb.fm 15

16 Safety Information RD 7 /... Label Meaning Rotate crank handle counterclockwise 5X. Remove crank handle. Disengage parking brake. U Low sulfur fuel or ultra low sulfur fuel only. wc_si000115gb.fm 16

17 RD 7 /... Notes: Safety Information wc_si000115gb.fm 17

18 Operation RD 7 / 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 wc_tx000294gb.fm 18

19 RD 7 /... Operation wc_tx000294gb.fm 19

20 Operation RD 7 / 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_gr The engine throttle control (c) is pulled out to start the engine. Press in on the rubber button (c1) with your thumb while pulling the control out. The control will stay at any position, and can be fine-tuned by twisting the control in or out. To stop the engine, push the throttle control all the way in by pressing on the rubber button with the heel of your hand. a c c1 b d wc_gr wc_tx000294gb.fm 20

21 RD 7 / Starting the Machine (RD 7H, RD 7H-S) Operation See Graphic: wc_gr001338, wc_gr001339, wc_gr Check that the exciter (a) is in the OFF position Pull the throttle control (c) up to open engine throttle Turn the decompression lever (f) until stop (f1) is reached. In this position, the automatic decompression system is heard to engage Insert the crank (d) into the guide sleeve (b) Turn the crank 5 turns to build up pressure for the engine to fire Stand alongside the engine, facing the back of the machine (e) and grasp the tubular grip with both hands. WARNING Do not stand in any other position! Injury may result if the engine should backfire! Turn the handle slowly until the pawl engages the rachet, then increase the turning force to build up speed. Note: The highest speed must be reached when the decompression lever (f) returns to the (f0) position As soon as the engine has started, pull the starting handle out of the guide sleeve. You must hold the tubular grip firmly to maintain contact all the time between the starting handle and the engine. Maintain turning force during the entire hand starting operation. Note: If backfiring occurs when starting the engine because the crank handle was not turned firmly enough, the brief reverse rotation at the handle tube separates the link between the crank lug and the driving dog If the engine begins to run backwards after backfiring (smoke emerges from air cleaner), release the crank handle immediately and stop the engine To restart the engine, wait until it has come to a standstill, then repeat the starting procedures Allow engine to warm up for a few minutes before operating machine. WARNING e f1 g f0 f wc_gr wc_gr wc_tx000294gb.fm 21

22 Operation RD 7 / Starting the Machine (RD 7H-ES) See Graphic: wc_gr Check that the exciter (a) is in the OFF position Pull the throttle control (b) up to open the engine throttle Turn the ignition switch (c) to start the engine. CAUTION. When the key is in the ON position, an alarm will sound. The alarm is a reminder to turn the key to the OFF position when the machine is not in use. Failure to do this will result in a dead battery. Note: The alarm will stop when proper oil pressure is reached. WARNING Do not crank the engine starter for more than 15 seconds at one time. Longer cranking cycles could lead to starter damage Allow the engine to warm up for a few minutes before operating the machine. wc_tx000294gb.fm 22

23 RD 7 / Cold Weather Starting (RD 7H, RD 7H-S) Operation See Graphic: wc_gr001338, wc_gr001339, wc_gr At temperatures below approximately -5 C (30 F), always turn the engine over to ensure that it rotates freely Check that the exciter switch (a) is in the OFF position Pull the throttle control (c) up to open the engine throttle Move the decompression lever (f) to a position that is approximately halfway between f0 and f Insert the crank (d) into the guide sleeve (b) Turn the crank 10 turns (rotations) to build up pressure for the engine to fire 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 Start the engine as normal. See section Starting the Machine. a c c1 b d wc_gr e f1 g f0 f wc_gr wc_gr wc_tx000294gb.fm 23

24 Operation RD 7 / Engine Speed During operation, run the engine at full throttle. This ensures maximum exciter speed and will produce the best compaction. 2.8 Stopping the Machine See Graphic: wc_gr Place the exciter switch (a) in the OFF position Close the water control valve Push the throttle control (b) to the minimum position to stop the engine On electric start machines, turn the engine switch (c) to the OFF position Apply the parking brake Clean the scraper bars before storing the machine. NOTICE: Should the engine ever speed out of control and not stop by using the throttle control, pulling up on the decompression lever, which could be hot to the touch, will stop the engine. wc_tx000294gb.fm 24

25 RD 7 / Direction and Speed Control Operation See Graphic: wc_gr WARNING WARNING Travel direction and speed are controlled by the movable lever (a) inside the handle. From the neutral position, the handle is pushed away from the operator to travel forward, and towards the operator to travel in reverse. Keep both hands on the handle while operating the machine. The handle may pivot rapidly while in operation and cause injury. Speed is varied by the movement of the lever; the farther the lever is pushed in either direction, the faster the roller will travel in that direction. If the linkage separates from the directional lever while the machine is running, the roller could run away and cause injury. In the event of this occurring, the throttle (b1) must be pushed in to stop the engine. b1 a wc_gr Exciter The exciter provides the vibration and can be used in most applications involving cohesive-type soils with heavy clay content, as well as loose soils and gravel. NOTICE: DO NOT run the machine over hard surfaces like concrete or compacted asphalt with the vibration on. Damage to the drum bearings may result. wc_tx000294gb.fm 25

26 Operation RD 7 / Back-Up Stop Pad See Graphic: wc_gr A back-up stop pad (a) is mounted to the rear section of the machine behind the control panel. The back-up stop pad operates in reverse only. If the machine backs into an obstruction or if the operator becomes trapped behind it, the pad will be pressed forward and stop the machine. The machine can move only in the forward direction when the handle is brought back through the neutral position. a STOP wc_gr Engine Crank See Graphic: wc_gr The engine crank is equipped with kick-back damping to protect the operator from injury should the engine backfire. The brief reverse rotation at the handle tube (a) separates the link between the crank lug (b) and the driving dog (c). a b c wc_gr wc_tx000294gb.fm 26

27 RD 7 / Parking Brake Operation See Graphic: wc_gr The parking brake is used to ensure that the machine will not roll when not in use. It engages the weld stops on the drum, therefore a small amount of movement is possible before the brake will catch and stop the machine. To disengage the parking brake: Rotate the handle (a) 90 clockwise and bring it to rest in a shallow detent. To engage the parking brake: Rotate the handle (a) 90 counterclockwise and allow it to rest in the deep detent. NOTICE: The parking brake is designed to hold the machine on an incline with the engine off. Do not drive against the parking brake in the engaged position. The brake may bend and damage the machine. a wc_gr Watering System See Graphic: wc_gr The RD 7 is equipped with a water control valve which allows the roller to be used wet or dry, and a sprinkler system to distribute the water evenly across the drums. The water is gravity fed to the sprinklers when the control valve is in the OPEN (horizontal) position (a). a wc_gr wc_tx000294gb.fm 27

28 Operation RD 7 / Operation on Slopes See Graphic: wc_gr and wc_gr WARNING When operating on slopes or hills, special care must be taken to reduce the risk of personal injury or damage to the machine. Always operate the machine up and down hills rather than from side to side. For safe operation and for protection of the engine, continuous duty use should be restricted to slopes of 22 (40% grade) or less. NEVER operate the machine sideways on slopes. The machine may roll over, even on stable ground % wc_gr wc_gr Rollovers Proper operation of the machine on slopes will prevent rollovers. Read and follow Safety instructions in Operating Safety and Operation on Slopes. If a machine rollover does occur, care must be taken to prevent damage to the engine. In this position, oil from the engine crankcase can flow into the combustion chamber, which can severely damage the engine next time it is started. If the machine has rolled on its side, immediate steps should be taken to right the machine. NOTICE: To prevent damage to the engine after a rollover, the machine must NOT be started, AND it must be serviced to remove any oil that may have been trapped in the combustion chambers. Contact your local Wacker Neuson dealer for instructions or servicing. wc_tx000294gb.fm 28

29 RD 7 / Maintenance Maintenance 3.1 Maintenance Schedule Daily before starting After first 25 hrs.* Every 250 hrs. Every 500 hrs. Every 1200 hrs. 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. wc_tx000295gb.fm 29

30 Maintenance RD 7 / Checking Engine Oil See Graphic: wc_gr 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 Clean around the dipstick Check the oil level on the extended dipstick (a). If necessary, top up to the max mark. The engine may be hot enough to cause burns! Allow the engine to cool prior to servicing. WARNING a wc_gr wc_tx000295gb.fm 30

31 RD 7 / Changing Engine Oil and Oil Filter Maintenance See Graphic: wc_gr Before changing the oil: Run the machine to warm the oil Park the machine on a flat level surface Turn off the engine and apply the parking brake. CAUTION Burn hazard! Avoid contact with the engine oil when draining the engine. Hot oil can burn! Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid that drains off. Dispose of this liquid in accordance with environmental protection legislation Unscrew the oil drain plug and allow the oil to drain into a liter (1 1.5 quarts) container Clean the oil drain plug and attach a new seal to it Reinstall the drain plug Unscrew the filler cap of the oil filter housing. Check the condition of the O-ring (a) on the filler cap and replace it if it is damaged Remove the used filter element. Install a new filter element with the TOP mark facing up Add engine oil up to the MAX mark on the dipstick; approximately liters (1 1¼ quarts) Wet the O-ring and threads of the filler plug with high-temperature grease available from your Hatz Dealer. Then, reinstall the filler plug Run the engine for two minutes. Turn off the engine and check the engine oil level again. Add engine oil as necessary Make sure that there is no oil leakage past the filler cap. a wc_gr wc_tx000295gb.fm 31

32 Maintenance RD 7 / Fuel System See Graphic: wc_gr Fuel tank water trap The interval at which you should check the water trap depends upon the amount of water in the fuel. The normal interval is one week. Stop the machine, switch off the engine, and apply the parking brake Remove the cover from the roller to allow access to the fuel tank water trap Loosen the hex screw (a) until only 2 threads are holding it in place Trap the drops of water that emerge in a transparent container. Note: Since water has a higher specific gravity than diesel fuel, the water emerges first. The two substances separate at a clearly visible line When only diesel fuel emerges, retighten the hex screw. NOTICE: Diesel fuel destroys shock mounts. Clean up fuel spillage immediately. WARNING Changing the fuel filter cartridge Fuel filter maintenance intervals depend on the purity of the diesel fuel used. 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 with the necessary caution. Do not smoke near the machine. Avoid sparks and open flames Remove the cover from the roller to allow access to the fuel filter Place a suitable container under the fuel filter to trap escaping fuel Close the fuel supply line Pull the fuel supply line (b) off of the fuel filter trap (c) at both sides, and insert the new filter. NOTICE: Keep the area clean to prevent dirt from entering the fuel lines Make sure the fuel filter is oriented with the arrow in the direction of fuel flow Open the fuel supply line until fuel begins to flow Run the engine briefly to check the fuel filter and lines for leaks. wc_tx000295gb.fm 32

33 RD 7 /... Maintenance b a c wc_gr wc_tx000295gb.fm 33

34 Maintenance RD 7 / Engine Air Filter See Graphic: wc_gr Checking the air cleaner blockage indicator Briefly run the engine at full speed. If the rubber bellows is pulled in and obscures the green zone (a), clean or replace the air filter In dusty operating conditions, check the rubber bellows several times per day. Cleaning or replacing the engine air filter The engine may be hot enough to cause burns! Allow the engine to cool prior to servicing. WARNING Loosen the wing nut (b) and remove it. Also remove the air cleaner cover (c). Note: The decompression lever will also come off Pull out the filter cartridge (e) Check that the valve plate (f) for the air blockage indicator is clean and in good condition. Cleaning dry dirt from the filter cartridge Blow through the filter cartridge from the inside using a compressed air gun Continue until all dust has been removed. NOTICE: Only use filtered, dry compressed air. Do not exceed an air pressure of more than 5 bar (70 psi). Keep the nozzle at a distance of 150 mm (6 in.) from the element. Cleaning wet or oily dirt from the filter Change the filter cartridge. NOTICE: Always trace and correct the cause of wet or oily contamination of a filter element. Checking the filter cartridge Hold the element up to a light or pass a lamp through the middle to check the condition of the element folds (g) Check that the sealing surface (d) is in good condition. NOTICE: If there is even slight damage to the paper filter element or the sealing surface, replace the filter cartridge. wc_tx000295gb.fm 34

35 RD 7 / Checking and Adjusting Valve Clearances See Graphic: wc_gr Maintenance Stop the machine, apply the parking brake and switch off the engine Make sure that the compression lever is in position 0. See section Starting the Machine Remove the cylinder head cover and the gasket Turn the engine over in the normal direction of rotation until compression is felt Check the inlet valve clearance between the rocker and the valve stem using a feeler gauge (a) If the valve clearance is incorrect, loosen the hex nut (c). Note: See section Technical Data for valve clearances Turn the adjusting screw (b) with a screwdriver until the feeler gauge (a) can just be pulled through between the rocker and the valve stem with slight resistance to its movement after the nut (c) has been retightened Repeat this adjustment with the outlet valve Place a new gasket under the cylinder head cover, reinstall the cylinder head cover, and tighten down the screws uniformly Run the engine briefly and make sure that the cylinder head cover is not leaking. a b c wc_gr d e a b c g f wc_gr wc_tx000295gb.fm 35

36 Maintenance RD 7 / Engine Cooling System See Graphic: wc_gr Stop the machine, apply the parking brake and switch off the engine. The engine must be allowed to cool down before cleaning. Dry contamination Clean all air guide elements and the complete cooling air zones (a) on the cylinder head and the cylinder and flywheel blades without making them wet. Blow them dry with compressed air. Moist or oily contamination Clean the entire area with a solvent or cold cleaner according to its manufacturer's instructions, then spray down with a high pressure water jet. Blow them dry with compressed air Trace the source of oil leaks causing greasy dirt. Repair the leaks, seeking advice of your Hatz dealer if necessary After cleaning, run the engine to dry it out and to prevent the formation of rust. a a a wc_gr wc_tx000295gb.fm 36

37 RD 7 / Mechanical Oil Pressure Monitoring Maintenance See Graphic: wc_gr 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 Add fuel Check the engine oil level To activate the oil pressure monitor, press the lever (a) Re-assemble all the parts repositioned or removed. Check that the capsule elements make a good seal. Note: Instructions to activate the mechanical oil pressure control are mentioned on the label (b) placed on the engine. CAUTION Even with the mechanical oil pressure control monitoring the oil level, it must be checked every 8 15 operating hours. wc_tx000295gb.fm 37

38 Maintenance RD 7 / Scraper Bars See Graphic: wc_gr Check the four scraper bars (a) for wear. Replace the scraper bars as needed. Cleaning the scraper bars The scraper bars should be cleaned daily after use or as often as needed to remove built-up dirt, mud, and tar. Use a high-pressure water jet and a strong brush if needed. a a a wc_gr wc_tx000295gb.fm 38

39 RD 7 / Hydraulic Oil Requirements Maintenance Wacker Neuson recommends the use of a premium grade, petroleumbased hydraulic oil with anti-wear and anti-foam characteristics. Good anti-wear oils contain additives to reduce oxidation, prevent foaming, and provide for good water separation. These oils offer superior motor and pump life. When selecting hydraulic oil for your machine, be sure to specify antiwear properties. Wacker Neuson offers a premium grade hydraulic oil for use in this machine. Wacker Neuson Hydraulic Oil - P/N Avoid mixing different brands and grades of hydraulic oils. Oil Viscosity Most hydraulic oils are available in different viscosities. The SAE number for an oil is used strictly to identify viscosity. It does not indicate the type of oil (engine, hydraulic, gear, etc.). The higher the SAE number, the thicker the oil. For normal applications use a good non-detergent, anti-wear, hydraulic oil with a viscosity rating of SAE 10W30. wc_tx000295gb.fm 39

40 Maintenance RD 7 / Hydraulic Oil Level See Graphic: wc_gr A hydraulic oil level sightglass (a) is located on the hydraulic tank and is visible through the slots on the top cover. Check the oil level with the machine standing on a level surface. The oil level should be at the halfway mark on the sightglass. If the level is low, remove the top cover and top up with hydraulic oil as necessary. If hydraulic oil continually needs to be added, inspect the hoses and connections for possible leaks. Repair hydraulic leaks immediately to prevent damage to the hydraulic components. a wc_gr wc_tx000295gb.fm 40

41 RD 7 / Changing Hydraulic Fluid and Filter Maintenance See Graphic: wc_gr Stop the machine, switch off the engine, and apply the parking brake with the machine standing on a level surface. Note: In the interests of environmental protection, place plastic sheeting and a container under the machine to collect the liquid which drains off. Dispose of this liquid properly Remove the top cover of the roller Remove the drain plug (b) from the end of the drain hose that is attached to the hydraulic tank Allow the hydraulic oil to drain into a suitable container When all the oil has drained out, reinstall the drain plug back into the hose and secure it in place Place a plastic bag around the filter (a) to contain any oil spillage Unscrew the old hydraulic filter Install the new hydraulic filter. Screw the new hydraulic filter on by hand, making sure that it is not cross-threaded. NOTICE: Use only original spare parts Tighten the hydraulic filter using both hands Fill the hydraulic tank with hydraulic oil until the level is visible halfway up the sightglass Run the engine briefly, then stop the engine and check for leaks Check the oil level in the sightglass, and top up if necessary. wc_tx000295gb.fm 41

42 Maintenance RD 7 / Direction Lever Adjustment See Graphic: wc_gr The forward/reverse control lever should have long forward travel and short reverse travel. If the lever appears out of adjustment, it can be readjusted as follows: Start the engine. Place the forward/reverse control lever in the NEUTRAL position (N). Confirm that the machine does not creep. If the machine does creep, turn the large adjusting nut (4) on the springloaded, cable centering device (5) so that the machine does not creep Stop the engine Place the forward/reverse control lever in the full FORWARD position (F). Check the rotation of the drive pump control arm (9). In the full FORWARD position, the drive pump control arm should rotate, in the direction 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 Disconnect the clevis (1) from the pivot (2) Rotate the pivot so that the drive pump control arm rotates as far as possible. With the forward/reverse control lever in the full FORWARD position, adjust the clevis and lock nut (8) so that it can hold the drive pump control arm in the fully rotated position. Reattach the clevis to the pivot. Note: If the adjustment cannot be made with the clevis alone, adjust the linkage (10) 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 Turn off the engine Adjust the nut (4) on the spring-loaded, cable centering device as needed so that the machine remains stationary when the control lever is in the NEUTRAL position. Start the engine and recheck for machine creeping/movement. It may take several attempts to find the correct position. Loosen the nuts (6) holding the cable (3) to the bracket (7) and reposition the cable if necessary The maximum allowable reverse travel speed is 2 km/hr. Do not adjust the direction control lever so that reverse travel speed is greater than 2 km/hr. (1.2 mph). CAUTION wc_tx000295gb.fm 42

43 RD 7 /... Maintenance wc_tx000295gb.fm 43

44 Maintenance RD 7 / Lifting See Graphic: wc_gr WARNING WARNING Attach a sling or chain to the lifting eye (a) using a suitable hook or shackle. 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 must have the suitable specified lifting capacity of 650 Kg (1430 lbs). Do not use improvised ropes or chains. NOTICE: Never use any other part of the roller to lift the machine, as severe damage may occur. Do not stand under, or get onto, the machine while it is being hoisted or moved Transporting See Graphic: wc_gr 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 use any other part of the roller to tie the machine down as severe damage to the machine may occur. wc_tx000295gb.fm 44

45 RD 7 / Pressure Washing the Machine Maintenance When pressure washing the machine, avoid using harsh chemicals and only use moderate water pressure (35 70 MPa [ 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 45

46 Maintenance RD 7 / Hydraulic Schematic 2 P bar 3000 psi bar 1450 psi bar 2900 psi micron 16 6 wc_gr wc_tx000295gb.fm 46

47 RD 7 / Hydraulic Schematic Components Maintenance See Graphic: wc_gr Ref. Description Ref. Description 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 47

48 Maintenance RD 7 / Hydraulic Diagram (9) (12) wc_gr wc_tx000295gb.fm 48

49 RD 7 / Hydraulic Diagram Components Maintenance See Graphic: wc_gr Ref. Description Ref. Description 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 49

50 Maintenance RD 7 / RD 7H-ES Electrical Schematic Br R 8 B P wc_gr wc_tx000295gb.fm 50

51 RD 7 / RD 7H-ES Electrical Schematic Components Maintenance See Graphic: wc_gr Ref. Description Ref. Description 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 wc_tx000295gb.fm 51

52 Maintenance RD 7 / 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 travel or Travel only in one direction Control cable loose or broken. Drive motor damaged. Drive pump damaged. Defective relief valve or valves. wc_tx000295gb.fm 52

53 RD 7 / Technical Data 4.1 Engine Technical Data Engine Power Rating Net power rating per ISO 3046/1-IFN. Actual power output may vary due to conditions of specific use. Item No. RD 7H RD 7H-ES RD 7H-S Engine Engine type Engine make One cylinder, 4-stroke, air cooled, diesel engine Hatz Engine model 1D41S 1D41S VAR I Max. rated rated speed kw (Hp) rpm Operating speed rpm 2600 Valve clearance (cold) intake: exhaust: mm (in.) 0.10 (0.004) ( ) 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 (0.44) Item No. RD 7-RAW 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 (0.44) wc_td000115gb.fm 53

54 Technical Data RD 7 / Roller Item No. RD 7H RD 7H-ES RD 7H-S RD 7-RAW Roller Overall dimensions - handle up (l x w x h) Overall Dimensions - handle down (l x w x h) mm (in.) mm (in.) 4.3 Sound and Vibration Measurements The required sound specification, Paragraph f of 89/392/EEC Machinery Directive, is: the sound pressure level at operator s location (L pa ) = 95 db(a) the guaranteed sound power level (L WA ) = 108 db(a). These sound values were determined according to ISO 3744 for the sound power level (L WA ) and ISO 6081 for the sound pressure level (L pa ) at the operator s location. The weighted effective acceleration value, determined according to ISO 8662 Part 1, is approximately: Hands = 9.66 m/s x 700 x 2215 (48.3 x 27.5 x 87.2) 2630 x 700 x 1165 (103.5 x 27.5 x 46) Operating weight kg (lbs.) 810 (1785) 830 (1829) 810 (1785) Area capacity m 2 (ft. 2 )/hr (28115) Forward speed (max) km/h (mph) (0-2.5) Reverse speed (max) km/h (mph) (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 The sound and vibration measurements were obtained with the machine operating on hard asphalt at maximum RPM and top speed. wc_td000115gb.fm 54

55 EC DECLARATION OF CONFORMITY WACKER NEUSON CORPORATION, N92W15000 ANTHONY AVENUE, MENOMONEE FALLS, WISCONSIN USA AUTHORIZED REPRESENTATIVE IN THE EUROPEAN UNION Axel Häret WACKER NEUSON SE Preußenstraße München hereby certifies that the construction equipment specified hereunder: 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 / Model Roller RD 7H-ES, RD 7H-S 4. Item number of equipment: , Net installed power: 5,1 kw has been sound tested per Directive 2000/14/EC: 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 Street London 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/EC 2004/108/EC EN EN Date William Lahner Vice President of Engineering Paul Sina Manager, Product Engineering 2010-CE-RD7H_en.fm WACKER NEUSON CORPORATION The original language of this EC Declaration of Conformity is American English.

56 Wacker Neuson SE Preußenstraße 41 D München Tel.: +49-(0) Fax: (0) Wacker Neuson Corporation P.O. Box 9007 Menomonee Falls, WI Tel. : (262) Fax: (262) Tel. : (800) Wacker Neuson Limited - Room & , 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong. Tel: (852) , Fax: (852)