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0116743en 004
0707
Roller
RD 7H
REPAIR MANUAL
0 1 1 6 7 4 3 E N
RD 7H Repair Foreword
wc_tx000349gb.fm 3
Foreword RD 7H Repair
CALIFORNIA
Proposition 65 Warning:
Diesel engine exhaust, some of its constituents, and certain vehicle
WARNING
components contain or emit chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
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RD 7H Repair Table of Contents
1. Safety Information 8
2. Technical Data 18
3. Operation 20
4. Maintenance 31
wc_br0116743en_004TOC.fm 5
Table of Contents RD 7H Repair
4.4 Fuel System ........................................................................................34
4.5 Engine Air Filter ...................................................................................36
4.6 Checking and Adjusting Valve Clearances .........................................37
4.7 Engine Cooling System .......................................................................38
4.8 Mechanical Oil Pressure Monitoring ....................................................39
4.9 Scraper Bars .......................................................................................40
4.10 Hydraulic Oil Requirements .................................................................41
4.11 Hydraulic Oil Level ..............................................................................42
4.12 Changing Hydraulic Fluid and Filter ....................................................43
4.13 Direction Lever Adjustment .................................................................44
4.14 Lifting ...................................................................................................46
4.15 Transporting ........................................................................................46
4.16 Pressure Washing the Machine ..........................................................47
4.17 Storing the Machine ............................................................................47
4.18 Hydraulic Schematic ............................................................................48
4.19 Hydraulic Schematic Components ......................................................49
4.20 Hydraulic Diagram ...............................................................................50
4.21 Hydraulic Diagram Components .........................................................51
4.22 RD 7H-ES Electrical Schematic ..........................................................52
4.23 RD 7H-ES Electrical Schematic Components .....................................53
4.24 General Troubleshooting .....................................................................54
5. General 55
6. Hydraulic System 56
wc_br0116743en_004TOC.fm 6
RD 7H Repair Table of Contents
6.9 Bleeding the Hydraulic System .......................................................... 61
6.10 Hydraulic Diagram .............................................................................. 62
6.11 Hydraulic Schematic ........................................................................... 63
6.12 Testing Hydraulic Pressures .............................................................. 64
6.13 Checking the Vibration Circuit ............................................................ 64
6.14 Checking the Drive Circuit .................................................................. 66
6.15 Relief Valves ...................................................................................... 68
7. Power Take-Off 70
8. Roller 79
9. Troubleshooting 100
wc_br0116743en_004TOC.fm 7
Safety Information RD 7 /...
1. Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE and
NOTE callouts which must be followed to reduce the possibility of
personal injury, damage to the equipment, or improper service.
wc_si000115gb.fm 8
RD 7 /... Safety Information
1.1 Operating Safety
Familiarity and proper training are required for the safe operation of the
machine. Machines operated improperly or by untrained personnel
can be dangerous. Read the operating instructions contained in both
WARNING this manual and the engine manual and familiarize yourself with the
location and proper use of all controls. Inexperienced operators should
receive instruction from someone familiar with the machine before
being allowed to operate it.
1.1.1 ALWAYS operate the machine with all safety devices and guards in
place and in working order.
1.1.2 ALWAYS check that all controls are functioning properly immediately
after start-up! DO NOT operate the machine unless all controls operate
correctly.
1.1.3 ALWAYS remain aware of changing surface conditions and use extra
care when operating over uneven ground, on hills, or over soft or
coarse material. The machine could shift or slide unexpectedly.
1.1.4 ALWAYS remain aware of changing positions and the movement of
other equipment and personnel on the job site.
1.1.5 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.
1.1.6 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.
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, and
loose clothing away from the moving parts of the machine.
1.1.9 NEVER operate the machine with the fuel cap loose or missing.
wc_si000115gb.fm 9
Safety Information RD 7 /...
1.2 Operator Safety While Using Internal Combustion Engines
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RD 7 /... Safety Information
1.3 Service Safety
1.3.1 DO NOT modify the machine without the express written approval of
the manufacturer.
1.3.2 DO NOT open hydraulic lines or loosen hydraulic connections while
the engine is running! Hydraulic fluid under pressure can penetrate the
skin, cause burns, blind, or create other potentially dangerous
hazards. Set all controls in neutral and turn engine off before loosening
the hydraulic lines.
1.3.3 ALWAYS check all external fasteners at regular intervals.
1.3.4 ALWAYS keep the area around the muffler free of debris such as
leaves, paper, cartons, etc. A hot muffler could ignite the debris and
start a fire.
1.3.5 ALWAYS keep the machine clean and labels legible. Replace all
missing and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
1.3.6 ALWAYS replace the safety devices and guards after repairs and
maintenance.
1.3.7 ALWAYS turn engine off before performing maintenance or making
repairs.
1.3.8 ALWAYS make sure slings, chains, hooks, ramps, jacks and other
types of lifting devices are attached securely and have enough weight-
bearing capacity to lift or hold the machine safely. Always remain
aware of the location of other people around when lifting the machine.
1.3.9 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.
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Safety Information RD 7 /...
1.4 Label Locations
O P E R A T O R 'S M A N U A L M U S T B E E L M A N U A L D E O P E R A C IO N D E B E
S T O R E D O N M A C H IN E . S E R R E T E N ID O E N L A M A Q U IN A .
R E P L A C E M E N T O P E R A T O R 'S C O N T A C T E A S U D IS T R IB U ID O R
M A N U A L C A N B E O R D E R E D W A C K E R M A S C E R C A N O P A R A
T H R O U G H Y O U R L O C A L W A C K E R P E D IR U N E J E M P L A R
D IS T R IB U T O R . A D IC IO N A L .
D IE B E T R IE B S V O R S C H R IF T M U S S L A N O T IC E D 'E M P L O I D O IT
A N D E R M A S C H IN E A U F B E W A H R T E T R E M U N IE S U R L A M A C H IN E .
W E R D E N . Z U R B E S T E L L U N G V O N C O N T A C T E R L E D IS T R IB U T E U R
1 1 5 0 9 6
E R S A T Z B Ü C H E R N W E N D E N S IE W A C K E R L E P L U S P R O C H E
S IC H B IT T E A N IH R E N P O U R C O M M A N D E R U N
Ö R T L IC H E N W A C K E R H Ä N D L E R . E X E M P L A IR E S U P P L E M E N T A IR E .
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RD 7 /... Safety Information
1.5 Safety and Informational Labels
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!
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.
WARNING!
To prevent hearing loss, wear hearing protec-
tion when operating the machine.
wc_si000115gb.fm 13
Safety Information RD 7 /...
Label Meaning
CAUTION!
Use only clean, filtered diesel fuel.
O P E R A T O R 'S M A N U A L M U S T B E E L M A N U A L D E O P E R A C IO N D E B E
Operator’s Manual must be stored on
S T O
R E P
R E D
L A C
O N M
E M E N
A C
T O
H IN E .
P E R A T O R 'S
S E
C O
R R E T
N T A C
E N ID
T E A
O E
S U
N L A
D IS T
M A Q
R IB U
U IN A .
ID O R machine. A replacement Operator’s Manual
M A N U A L C A N B E O R D E R E D W A C K E R M A S C E R C A N O P A R A
T H R
D IS T
O U G
R IB
H Y O
U T O R .
U R L O C A L W A C K E R P E
A D
D IR U
IC IO N
N E J E
A L .
M P L A R can be ordered through your local Wacker dis-
D IE
A N
B E T R IE B S
D E R M A S C
V O R
H IN E
S C H R IF
A U F B E
T M
W A
U S S
H R T
L A N O
E T R E
T IC E D
M U N IE
'E M P
S U R
L O I D O
L A M A
IT
C H IN E .
tributor.
W E R D E N . Z U R B E S T E L L U N G V O N C O N T A C T E R L E D IS T R IB U T E U R
1 1 5 0 9 6
E R S A T Z B Ü C H E R N W E N D E N S IE W A C K E R L E P L U S P R O C H E
S IC H B IT T E A N IH R E N P O U R C O M M A N D E R U N
Ö R T L IC H E N W A C K E R H Ä N D L E R . E X E M P L A IR E S U P P L E M E N T A IR E .
No lift point.
(one of two)
CAUTION!
Lifting point.
Tie-down point.
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RD 7 /... Safety Information
Label Meaning
Engine oil drain.
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Safety Information RD 7 /...
Label Meaning
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RD 7 /... Safety Information
Label Meaning
Rotate crank handle counterclockwise 5X.
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Technical Data RD 7 /...
2. Technical Data
2.1 Engine
Engine
Engine type One cylinder, 4-stroke, air cooled, diesel engine
Engine make Hatz
Engine model 1D41S 1D41S VAR I
Operating power kW (Hp) 5.1 (6.9) @ 2600 rpm
Operating speed rpm 2600
Valve clearance (cold)
intake: mm (in.) 0.10 (0.004)
exhaust: 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.)/
1.67 (0.44)
hr.
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RD 7 /... Technical Data
2.2 Roller
Roller
Overall dimensions - mm 1225 x 700 x 2215
handle up (l x w x h) (in.) (48.3 x 27.5 x 87.2)
Overall Dimensions - mm 2630 x 700 x 1165
handle down (l x w x h) (in.) (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”
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Operation RD 7 /...
3. Operation
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RD 7 /... Operation
wc_tx000294gb.fm 21
Operation RD 7 /...
3.2 Before Starting
c1
a
c
d
wc_gr001338
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RD 7 /... Operation
3.4 Starting the Machine (RD 7H, RD 7H-S)
See Graphic: wc_gr001338, wc_gr001339, wc_gr001340
3.4.1 Check that the exciter (a) is in the OFF position.
3.4.2 Pull the throttle control (c) up to open engine throttle.
3.4.3 Turn the decompression lever (f) until stop (f1) is reached. In this
position, the automatic decompression system is heard to engage.
3.4.4 Insert the crank (d) into the guide sleeve (b).
3.4.5 Turn the crank 5 turns to build up pressure for the engine to fire.
3.4.6 Stand alongside the engine, facing the back of the machine (e) and
grasp the tubular grip with both hands.
Do not stand in any other position! Injury may result if the engine
should backfire!
WARNING
3.4.7 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.
3.4.8 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
WARNING 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.
3.4.9 If the engine begins to run backwards after backfiring (smoke emerges
from air cleaner), release the crank handle immediately and stop the
engine.
3.4.10 To restart the engine, wait until it has come to a standstill, then repeat
the starting procedures.
3.4.11 Allow engine to warm up for a few minutes before operating machine.
e
f1
f
f0
wc_gr001339 wc_gr001340
wc_tx000294gb.fm 23
Operation RD 7 /...
3.5 Starting the Machine (RD 7H-ES)
See Graphic: wc_gr001529
3.5.1 Check that the exciter (a) is in the OFF position.
3.5.2 Pull the throttle control (b) up to open the engine throttle.
3.5.3 Turn the ignition switch (c) to start the engine.
.
When the key is in the ON position, an alarm will sound. The alarm is
a reminder to turn the key to the OFF position when the machine is not
CAUTION in 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.
WARNING
3.5.4 Allow the engine to warm up for a few minutes before operating the
machine.
wc_tx000294gb.fm 24
RD 7 /... Operation
3.6 Cold Weather Starting (RD 7H, RD 7H-S)
c1
a
c
d
wc_gr001338
e
f1
f
f0
wc_gr001339 wc_gr001340
wc_tx000294gb.fm 25
Operation RD 7 /...
3.7 Engine Speed
During operation, run the engine at full throttle (2800 rpm). This
ensures maximum exciter speed and will produce the best
compaction.
wc_tx000294gb.fm 26
RD 7 /... Operation
3.9 Direction and Speed Control
b1
wc_gr001341
3.10 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 27
Operation RD 7 /...
3.11 Back-Up Stop Pad
STOP
wc_gr001342
a b c
wc_gr001345
wc_tx000294gb.fm 28
RD 7 /... Operation
3.13 Parking Brake
a wc_gr001343
wc_gr001344
wc_tx000294gb.fm 29
Operation RD 7 /...
3.15 Operation on Slopes
22˚
40%
wc_gr001346 wc_gr001347
3.16 Rollovers
wc_tx000294gb.fm 30
RD 7 /... Maintenance
4. Maintenance
wc_tx000295gb.fm 31
Maintenance RD 7 /...
4.2 Checking Engine Oil
wc_gr001348
wc_tx000295gb.fm 32
RD 7 /... Maintenance
4.3 Changing Engine Oil and Oil Filter
See Graphic: wc_gr001349
Before changing the oil:
4.3.1 Run the machine to warm the oil.
4.3.2 Park the machine on a flat level surface.
4.3.3 Turn off the engine and apply the parking brake.
Burn hazard! Avoid contact with the engine oil when draining the
engine. Hot oil can burn!
CAUTION
wc_gr001349
wc_tx000295gb.fm 33
Maintenance RD 7 /...
4.4 Fuel System
See Graphic: wc_gr001351
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.
4.4.1 Remove the cover from the roller to allow access to the fuel tank water
trap.
4.4.2 Loosen the hex screw (a) until only 2 threads are holding it in place.
4.4.3 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.
4.4.4 When only diesel fuel emerges, retighten the hex screw.
NOTICE: Diesel fuel destroys shock mounts. Clean up fuel spillage
immediately.
4.4.5 Remove the cover from the roller to allow access to the fuel filter.
4.4.6 Place a suitable container under the fuel filter to trap escaping fuel.
4.4.7 Close the fuel supply line.
4.4.8 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.
4.4.9 Make sure the fuel filter is oriented with the arrow in the direction of fuel
flow.
4.4.10 Open the fuel supply line until fuel begins to flow.
4.4.11 Run the engine briefly to check the fuel filter and lines for leaks.
wc_tx000295gb.fm 34
RD 7 /... Maintenance
a
c
wc_gr001351
wc_tx000295gb.fm 35
Maintenance RD 7 /...
4.5 Engine Air Filter
4.5.3 Loosen the wing nut (b) and remove it. Also remove the air cleaner
cover (c).
Note: The decompression lever will also come off.
4.5.4 Pull out the filter cartridge (e).
4.5.5 Check that the valve plate (f) for the air blockage indicator is clean and
in good condition.
Cleaning dry dirt from the filter cartridge
4.5.6 Blow through the filter cartridge from the inside using a compressed air
gun.
4.5.7 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
4.5.8 Change the filter cartridge.
NOTICE: Always trace and correct the cause of wet or oily
contamination of a filter element.
Checking the filter cartridge
4.5.9 Hold the element up to a light or pass a lamp through the middle to
check the condition of the element folds (g).
4.5.10 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 36
RD 7 /... Maintenance
4.6 Checking and Adjusting Valve Clearances
See Graphic: wc_gr001353
Stop the machine, apply the parking brake and switch off the engine.
4.6.1 Make sure that the compression lever is in position “0”. See section
Starting the Machine.
4.6.2 Remove the cylinder head cover and the gasket.
4.6.3 Turn the engine over in the normal direction of rotation until
compression is felt.
4.6.4 Check the inlet valve clearance between the rocker and the valve stem
using a feeler gauge (a).
4.6.5 If the valve clearance is incorrect, loosen the hex nut (c).
Note: See section Technical Data for valve clearances.
4.6.6 Turn the adjusting screw (b) with a screwdriver until the feeler gauge
(a) can just be pulled through between the rocker and the valve stem
with slight resistance to its movement after the nut (c) has been
retightened.
4.6.7 Repeat this adjustment with the outlet valve.
4.6.8 Place a new gasket under the cylinder head cover, reinstall the
cylinder head cover, and tighten down the screws uniformly.
4.6.9 Run the engine briefly and make sure that the cylinder head cover is
not leaking.
a b
c
wc_gr001353
d
e
a b c
g f
wc_gr001352
wc_tx000295gb.fm 37
Maintenance RD 7 /...
4.7 Engine Cooling System
wc_gr001354
wc_tx000295gb.fm 38
RD 7 /... Maintenance
4.8 Mechanical Oil Pressure Monitoring
Even with the mechanical oil pressure control monitoring the oil level,
it must be checked every 8–15 operating hours.
CAUTION
wc_tx000295gb.fm 39
Maintenance RD 7 /...
4.9 Scraper Bars
a a
a
wc_gr001355
wc_tx000295gb.fm 40
RD 7 /... Maintenance
4.10 Hydraulic Oil Requirements
wc_tx000295gb.fm 41
Maintenance RD 7 /...
4.11 Hydraulic Oil Level
wc_gr001356
wc_tx000295gb.fm 42
RD 7 /... Maintenance
4.12 Changing Hydraulic Fluid and Filter
See Graphic: wc_gr001357
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.
4.12.1 Remove the top cover of the roller.
4.12.2 Remove the drain plug (b) from the end of the drain hose that is
attached to the hydraulic tank.
4.12.3 Allow the hydraulic oil to drain into a suitable container.
4.12.4 When all the oil has drained out, reinstall the drain plug back into the
hose and secure it in place.
4.12.5 Place a plastic bag around the filter (a) to contain any oil spillage.
4.12.6 Unscrew the old hydraulic filter.
4.12.7 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.
4.12.8 Tighten the hydraulic filter using both hands.
4.12.9 Fill the hydraulic tank with hydraulic oil until the level is visible halfway
up the sightglass.
4.12.10 Run the engine briefly, then stop the engine and check for leaks.
4.12.11 Check the oil level in the sightglass, and top up if necessary.
a
b
wc_gr001357
wc_tx000295gb.fm 43
Maintenance RD 7 /...
4.13 Direction Lever Adjustment
wc_tx000295gb.fm 44
RD 7 /... Maintenance
2
1 F
8 N
R
7
5
4
3
6
10
2
wc_gr003672
wc_tx000295gb.fm 45
Maintenance RD 7 /...
4.14 Lifting
See Graphic: wc_gr001359
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
WARNING 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.
WARNING
a a
wc_gr001360
wc_gr001359
4.15 Transporting
See Graphic: wc_gr001360
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 46
RD 7 /... Maintenance
4.16 Pressure Washing the Machine
wc_tx000295gb.fm 47
Maintenance RD 7 /...
4.18 Hydraulic Schematic
2
P
3
1
206 bar
3000 psi
15
14
12 13
100 bar 200 bar
1450 psi 2900 psi
11
10 5 4
10 micron
7
16 6
wc_gr003636
wc_tx000295gb.fm 48
RD 7 /... Maintenance
4.19 Hydraulic Schematic Components
wc_tx000295gb.fm 49
Maintenance RD 7 /...
4.20 Hydraulic Diagram
16
15
1
7
8
2
11
(9)
(12)
10
13
3
14
wc_gr003637
wc_tx000295gb.fm 50
RD 7 /... Maintenance
4.21 Hydraulic Diagram Components
wc_tx000295gb.fm 51
Maintenance RD 7 /...
4.22 RD 7H-ES Electrical Schematic
Br R
P
8
B
1 2 3 4 5 6
6 5 4 3 2 1
0 4
1
3
wc_gr003663
wc_tx000295gb.fm 52
RD 7 /... Maintenance
4.23 RD 7H-ES Electrical Schematic Components
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 53
Maintenance RD 7 /...
4.24 General Troubleshooting
wc_tx000295gb.fm 54
RD 7 /... Repair General
5. General
5.1 Tools
Because all possible problems encountered while repairing the
machine cannot be anticipated, it is up to the mechanic to use common
sense and good judgement in tool selection.
The use of any special tools is recommended only for those operations
where the use of conventional tools proves inadequate.
Before substituting another tool or procedure, you should be satisfied
that neither personal injury nor damage to the component will result.
5.2 Reference Numbers ( )
Repair procedures contain reference numbers enclosed in
parentheses ( ). These numbers refer to the item numbers shown on
the assembly drawings and other detailed drawings. They are included
to aid the mechanic in identifying parts and assembling components.
wc_tx000350gb.fm 55
Hydraulic System RD 7 /... Repair
6. Hydraulic System
wc_tx000351gb.fm 56
RD 7 /... Repair Hydraulic System
6.3 Analyzing Hydraulic Oil Contamination
wc_tx000351gb.fm 57
Hydraulic System RD 7 /... Repair
6.4 General Description
wc_tx000351gb.fm 58
RD 7 /... Repair Hydraulic System
6.6 Hydraulic Manifold Block
1 2
7
5
6
wc_gr001503
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Hydraulic System RD 7 /... Repair
6.7 Drive Circuit
The oil returning from the vibration function is directed out of the
manifold to a return line filter. A back pressure valve located at the
return line filter is used to protect the system. When pressure from the
exciter circuit exceeds 14.5 psi (1 bar), the valve opens and the oil
flows directly to the tank.
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RD 7 /... Repair Hydraulic System
6.9 Bleeding the Hydraulic System
wc_gr001504
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Hydraulic System RD 7 /... Repair
6.10 Hydraulic Diagram
P 1
3
1
21 mPa
3000 PSI 2
2
12 13
10 mPa 20 mPa
1450 PSI 2900 PSI
5 4
11
9
10
10 micron
7
16
6 wc_gr001361
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RD 7 /... Repair Hydraulic System
6.11 Hydraulic Schematic
16
15
1
7
8
2
11
(9)
(12)
10
13
3
14
wc_gr003637
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Hydraulic System RD 7 /... Repair
6.12 Testing Hydraulic Pressures
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RD 7 /... Repair Hydraulic System
a 1
d
f
b
e
c
2
3
wc_gr001505
c Hose 0078002 -
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Hydraulic System RD 7 /... Repair
6.14 Checking the Drive Circuit
Relief Pressure
6.14.5 Block in front of and behind both drums to prevent the machine from
moving, or dead head the machine against a solid concrete abutment.
Make sure the blocks are large enough so that the machine will not
climb over them during testing.
WARNING
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RD 7 /... Repair Hydraulic System
1
2
3
4
wc_gr001506
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Hydraulic System RD 7 /... Repair
6.15 Relief Valves
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RD 7 /... Repair Hydraulic System
7
11
10
9
8
4 2
1
3
12
13
wc_gr003668
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Power Take-Off RD 7 /... Repair
7. Power Take-Off
7.1 Description
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RD 7 /... Repair Power Take-Off
7.2 Pump Assembly
4
2
3
5
1
wc_gr001509
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Power Take-Off RD 7 /... Repair
7.3 Replacing the Drive Pump
7.3.2 Tag and disconnect the hose lines (1) from the pump. Cap or plug all
open connections. For recommended caps or plugs, see Repair
Accessories.
7.3.3 Remove the support bracket (2) from the exciter pump (3). Save the
locknuts (4) and washers (5) for installation.
7.3.4 Remove the two locknuts (6) that secure the exciter pump to the drive
pump (7) and remove the drive pump.
7.3.5 Remove two mounting screws (8) holding the drive pump to the
engine/pump adapter.
7.3.6 Remove the control lever (9), hydraulic fittings (10), O-ring (11) and
coupling (12) and transfer them to the new pump.
Installation
7.3.7 Install the new pump and fasten it to the engine/pump adapter. Secure
the mounting screws (8) using Loctite 271 or an equivalent high-
strength threadlocker.
7.3.8 Install the exciter pump (3) to the new drive pump using the locknuts
(6).
7.3.9 Install the support bracket (2) to the exciter pump using the locknuts
(4) and the washers (5).
7.3.10 Reconnect the hose lines (1) to the fittings (10).
7.3.11 Bleed the drive circuit.
NOTICE: It is recommended that the drive circuit be flushed after a
pump failure to remove any contaminants which may be trapped in the
lines.
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RD 7 /... Repair Power Take-Off
Before you start the machine, ensure that all tools have been removed
from the machine and that the replacement parts and adjusters are
firmly tightened.
WARNING
10
8
1
7
12
9
10
5 11
4
3 1
2 wc_gr001510
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Power Take-Off RD 7 /... Repair
7.4 Exciter Pump
7.4.2 Tag and disconnect hose lines (1) from exciter pump (3). Cap or plug
all open connections. For recommended caps or plugs, see section
Repair Accessories.
7.4.3 Remove the support bracket (2) from the exciter pump (3). Save the
locknuts (4) and the washers (5) for installation.
7.4.4 Remove the two locknuts (6) that secure the exciter pump to the drive
pump (7) and remove the exciter pump.
7.4.5 Remove the O-ring (8), coupling (9) and fitting (10) and transfer them
to the new pump.
Installation
7.4.6 Install the new exciter pump (3) to the drive pump (7) using the
locknuts (6).
7.4.7 Install the support bracket (2) to the exciter pump using the locknuts
(4) and washers (5).
7.4.8 Reconnect the hose lines (1) to the fitting (10).
7.4.9 Bleed the hydraulic system before starting. See section Bleeding the
Hydraulic System.
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING tightened.
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RD 7 /... Repair Power Take-Off
1
7
5 8 1
4
3
6
10
2 wc_gr001511
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Power Take-Off RD 7 /... Repair
7.5 Replacing the Engine
7.5.1 Tag and disconnect all the hoses that are attached to the engine. Also
disconnect the throttle cable.
7.5.2 Remove the pump support bracket (2) at the front of the hydraulic
pumps (3).
7.5.3 Remove the exhaust pipe (4).
7.5.4 Attach steel lifting ropes or chains from a suitable crane to the engine's
lifting eye.
Note: The engine lifting eye (104439) was originally packaged with the
HATZ Engine Manual. To install lifting eye, remove the throttle bracket
(5) and the mount lifting eye in its place.
7.5.5 Remove the screws (6), washers (7), and nuts (8) that mount the
engine to the frame.
7.5.6 Leaving the pumps mounted to the engine, lift the engine slightly to
check that it is correctly balanced.
7.5.7 Lift and remove the engine from the machine.
Do not stand under or get near the engine while it is being lifted or
moved.
WARNING
7.5.8 Remove the hydraulic pumps (3) and the pump adapter (9). On older
versions (10a), loosen the screw (15) and remove the coupler (14)
from the shaft. A pry bar between the coupler and the shaft may be
needed. Remove the six screws (11) that secure the flywheel coupling
to the engine and remove the flywheel coupling.
7.5.9 On newer versions (10b), the pump mounts directly into the clutch.
Remove the two screws (16) and washers (17) that secure the clutch
to the engine and remove the clutch.
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RD 7 /... Repair Power Take-Off
10b
11 16
4 14
6 15 17
9 1
7
13
10a
3
12
2
8
wc_gr001512
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Power Take-Off RD 7 /... Repair
Installation
7.5.10 Apply Loctite 243 or an equivalent to the six screws (11) and secure
the flywheel coupling (10) to the engine. Torque the screws to 18 ft.lbs.
(25 Nm).
7.5.11 Apply Loctite 243 or an equivalent to the screw (15) and secure the
coupler (14) to the pump shaft. Torque the screw to 45 ft.lbs. (60 Nm).
7.5.12 Apply Loctite 243 or an equivalent to the ten screws (12) and secure
the pump adapter (9) to the engine. Torque the screws to 51 ft.lbs. (69
Nm).
7.5.13 Apply Loctite 243 or an equivalent to the two screws (13) and secure
the hydraulic pump (3) to the engine. Torque the screws to 36 ft.lbs.
(49 Nm).
7.5.14 Attach steel lifting ropes or chains from a suitable crane to the engine's
lifting eye. Lift the engine and place it into the machine.
7.5.15 Install the pump support bracket (2) onto the hydraulic pump.
7.5.16 Mount the engine to the frame reusing the screws (6), washers (7), and
nuts (8).
7.5.17 Attach the pump support bracket to the frame.
7.5.18 Attach the exhaust pipe (4) to the engine.
7.5.19 Attach all hose lines to the pumps.
7.5.20 Attach all electrical wiring and throttle cable to the engine.
7.5.21 Attach the control lever bracket (1) to the drive pump. The drive control
cable may need to be adjusted. See section Direction Lever
Adjustment.
7.5.22 The engine valve clearance may need to be adjusted. See section
Checking and Adjusting Valve Clearances.
Note: See sealant and torque reference charts in the back of this
manual for the appropriate threadlocking adhesives and torque values.
Before starting the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING tightened.
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RD 7 /... Repair Roller
8. Roller
The front and rear drums operate as static rollers to aid in smoothing
and finishing.
The front and rear drums are driven by hydraulic motors. Each motor
is mounted to a drive hub which is mounted directly to the left side of
each drum. The drive motor is designed to provide low speeds and
high torques without the need for any type of speed reduction gears,
belts, or pulleys.
A mechanical parking brake is attached to the rear drum on the right
side and is used to ensure that the machine will not roll when not in
use. The brake is mounted directly to the drum support and is engaged
and disengaged by the operator.
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.
Note: Wacker Corporation does not recommend the disassembly or
attempted repair of hydraulic components (pumps, motors) by anyone
other than a trained hydraulic repair technician. Repair and rebuilding
of hydraulic components may be available from component
manufacturers. Hydraulic component parts are not available from
Wacker Corporation.
wc_tx000353gb.fm 79
Roller RD 7 /... Repair
8.2 Replacing the Drum
8.2.1 Tag and disconnect the hydraulic lines to the drive motor. Cap or plug
all open connections. For recommended caps or plugs, see section
Repair Accessories.
8.2.2 Remove the four screws (1) that secure the porting block (2) to the
lower frame. Pull the porting block out to access the three upper
hydraulic lines. Tag, disconnect, and cap the three upper hydraulic
lines (3) from the porting block.
8.2.3 Attach steel lifting ropes or chains from a suitable crane to the
machine's lifting eye (4).
Only use slings or chains for hoisting. The ropes, chains, and crane
must have the suitable specified lifting capacity—830 Kg.(1829 lbs.).
WARNING Do not use improvised slings or chains.
NOTICE: Never use any other part of the roller to lift the machine, as
severe damage may occur.
Do not stand under the machine while it is being lifted or moved.
WARNING
Lift the machine so that it is 6 mm (0.25 in.) off the ground.
8.2.4 On the nondrive-motor side of the machine, remove the four screws (5)
that secure the drum support (6) to the hub assembly (7).
8.2.5 On the drive-motor side of the machine, remove the three screws (8)
that secure the drum support (9) to the frame.
8.2.6 Slide the drum (10) from the frame.
wc_tx000353gb.fm 80
RD 7 /... Repair Roller
2
1
10
8
9
11
5
10
7
wc_gr003666
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Roller RD 7 /... Repair
Installation
8.2.7 If the non-drive-motor-side drum support (6) was removed, reinstall it.
Be sure to include the shims (11) during re-installation.
8.2.8 Position the drum (10) under the machine frame. Align the holes in the
hub assembly with the holes in the nondrive-motor side drum support
(6).
8.2.9 Apply Loctite 243 or an equivalent to the four screws (5) and secure
the drum support (6) to the drum hub assembly (7).
8.2.10 Apply Loctite 243 or an equivalent to the three screws (8) and secure
the drum support (9) to the frame. Torque the screws to 120 Nm (88
ft.lbs.).
8.2.11 Reconnect all hydraulic hoses to the drive motors.
8.2.12 Reconnect all hydraulic hoses (3) to the porting block (2).
8.2.13 Apply Loctite 243 or an equivalent to the four screws (1) and secure
the porting block to the lower frame. Torque the screws to 49 Nm (36
ft.lbs.).
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING tightened.
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RD 7 /... Repair Roller
2
1
10
8
9
11
5
10
7
wc_gr003666
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Roller RD 7 /... Repair
8.3 Drum Disassembly and Assembly
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RD 7 /... Repair Roller
8.3.16 Apply Loctite 243 or an equivalent to the four screws (2). Align the
drum support (3), O-ring (14), and drive motor (1) (at the correct angle)
with the outer drive hub (4a) and secure them with the four screws (2).
Torque the screws to 86 Nm (63 ft.lbs.).
NOTICE: When installing the drive motor, care must be taken to
ensure splined shaft does not separate from inside of motor.
4b
9b
5
8
7
12
13 9a
17
10
11
6b
13
12 6a
11 17
10
4a 14
8
7
5
3 1
wc_gr003664
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Roller RD 7 /... Repair
wc_tx000353gb.fm 86
RD 7 /... Repair Roller
4b
9b
5
8
7
12
13 9a
17
10
11
6b
13
12 6a
11 17
10
4a 14
8
7
5
3 1
wc_gr003664
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Roller RD 7 /... Repair
8.4 Replacing the Exciter
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RD 7 /... Repair Roller
8.4.11 Remove the four screws (24) and washers (25) that mount the exciter
assembly (26) to the lower frame (19).
5
4
3
20
8
7
6
15
13
15
13
14
1
2
26 C B
27 18 A D
a
b
c 17
b 16
c
19
25
24
10
21 11
12
23 9
22
wc_gr003667
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Roller RD 7 /... Repair
Installation
8.4.12 Place the exciter assembly (25) on the frame. Rock the housing on the
frame to determine if a corner needs to be shimmed. Place shims (27)
as needed between the frame and the housing.
8.4.13 Lay a bead of Loctite 515 or equivalent on the milled surface (b) of the
frame between the threaded holes.
8.4.14 Apply Loctite 243 or an equivalent to the screws (24). Mount the exciter
assembly to frame using the four screws (24) and the washers (25).
Torque the screws in the pattern A, B, C, D. (a) following this
sequence:
• Step 1 - tighten by hand
• Step 2 - 54 Nm (40 ft.lbs.)
• Step 3 - 120 Nm (88 ft.lbs.)
• Step 4 - recheck 120 Nm (88 ft.lbs.)
8.4.15 Fill in the space between the exciter and the frame, along the entire
length of the exciter (c), with Silicone.
8.4.16 Install the scraper bar (21) with two screws (22) and washers (23).
8.4.17 Position the upper mass of the machine over the lower mass by using
the central lifting eye (20).
8.4.18 Apply Loctite 243 or an equivalent to the screws (16) and secure the
shock mounts (18) with the washers (17) and the screws. Torque the
screws to 86Nm. (63 ft.lbs).
8.4.19 Re-install both the front and the rear plates (13) and the screws (15) to
upper frame (14).
8.4.20 Reconnect the three hydraulic hoses (9) to the exciter motor (10) and
the three hoses (11) to the porting block (12).
8.4.21 Fill the hydraulic tank with hydraulic oil (SAE 10W 30) until the oil level
is visible halfway up the sightglass. Run the engine briefly, then stop
the engine and check for leaks. Check the level in the sightglass, and
top off if necessary.
8.4.22 Install the water tank (5) with the three screws (6 & 7) and washer (8).
8.4.23 Install the top cover (1) with the six screws (2).
8.4.24 Reconnect the water hose (3) to the fitting (4).
Note: See sealant and torque reference charts in the back of this
manual for appropriate threadlocking adhesives and torque values.
Before starting the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING tightened.
wc_tx000353gb.fm 90
RD 7 /... Repair Roller
5
4
3
20
8
7
6
15
13
15
13
14
1
2
26 C B
27 18 A D
a
b
c 17
b 16
c
19
25
24
10
21 11
12
23 9
22
wc_gr003667
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Roller RD 7 /... Repair
8.5 Exciter Assembly
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RD 7 /... Repair Roller
6b
8 6a
5
4
1
7 2
wc_gr001516
wc_tx000353gb.fm 93
Roller RD 7 /... Repair
8.6 Throttle Cable
wc_tx000353gb.fm 94
RD 7 /... Repair Roller
8 5
6 4
3
7
10
1
2
wc_gr001517
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Roller RD 7 /... Repair
8.7 Direction Cable
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RD 7 /... Repair Roller
2
1
11
5
4
3 10
6
9
8
10
1
11
3
12 wc_gr003670
wc_tx000353gb.fm 97
Roller RD 7 /... Repair
8.8 Direction Control Lever
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RD 7 /... Repair Roller
Note: Make sure the bearings are flush with both sides of the guide
handle.
8.8.20 Insert the shaft (17) through the guide handle. Slide the spring (18)
over the shaft.
8.8.21 Apply Loctite 243 or an equivalent to the threads of the shaft and screw
the plunger (16) onto the end of the shaft.
Before starting the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING
tightened.
14
12
5
2 15 4
3 13
19
10
11
9
8
7
6
18 16
2
17 20
1
wc_gr001519
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Troubleshooting RD 7 /... Repair
9. Troubleshooting
9.1 General
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RD 7 /... Repair Troubleshooting
9.2 Vibration System
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Troubleshooting RD 7 /... Repair
9.3 Troubleshooting the Vibration System
The exciter pump is designed to put out a constant flow of oil at a set
engine speed. This ensures that the vibration frequency remains
steady. When troubleshooting the exciter circuit, the vibration speed
should be measured along with the operating and relief pressures to
help determine the cause of any problems.
To measure vibration speed:
9.3.1 Start the machine and run it for several minutes to bring hydraulic oil
up to normal operating temperatures.
9.3.2 Check the engine rpm using a tachometer. The engine must be
running at the correct rpm to accurately measure vibration.
9.3.3 Position the roller on a rubber mat and start vibration. Hold the
vibrotach (P/N 53397) against the outer rim on the drum and measure
the vibration speed.
9.3.4 The vibration speed along with the operating and relief valve pressures
can be used to determine the condition of the exciter system as shown
in the chart below.
If the exciter is binding (causing high operating pressures), it will be
necessary to disconnect and remove the exciter motor from the
housing to determine if the binding is occurring in the exciter bearings
or in the motor. Turn the motor shaft and exciter shaft by hand and
check that they turn freely.
N N N System OK.
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RD 7 /... Repair Troubleshooting
9.4 Drive System
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Troubleshooting RD 7 /... Repair
9.5 Troubleshooting the Drive System
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RD 7 /... Repair Troubleshooting
1
2
wc_gr003669
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Troubleshooting RD 7 /... Repair
Checking Drive Motors
Failure of the drive circuit to reach operating pressures is normally
caused by a worn or damaged drive pump, although the problem could
also be the result of a badly worn motor.
To check drive motor operation:
9.5.7 Stop the machine, apply the parking brake, and switch off the machine.
The lifting devices must have the capacity of at least 650 kg (1430
lbs.).
WARNING
NOTICE: Use only the lifting eye of the roller to lift the machine. Using
any other part of the machine may severely damage the machine.
9.5.8 Lift the machine so that the drums are 12 mm (0.5 in.) off the ground.
Support the machine as necessary so that it is secure in this position.
9.5.9 Place a reference mark on each drum with tape or chalk.
9.5.10 Start the engine.
9.5.11 Place the direction lever in the full FORWARD position. Count the
revolutions of each drum as they spin. Look for a significant difference
in the speed of one drum over the other. Conduct the same test in with
the direction lever in the full REVERSE position. If one drum spins
faster than the other in both directions, the motor spinning the slow
drum may have failed.
By checking the flow from the drive motor case drain hoses, one can
tell if the drive motor seals are functioning. When new, the drive motors
will let pass a very slow drip.
9.5.12 Position the machine so that the front drum is up against an abutment,
such as a brick wall or concrete barricade.
9.5.13 Turn off the engine and disconnect the drain line from the front drive
motor.
9.5.14 Position the hose from the front drive motor into a graduated container.
9.5.15 Start the engine. With the throttle at full and the direction control lever
in the full FORWARD position, collect all the oil that drains from the
drive motor over a one-minute time period.
• If the drive motor drains approximately 40 ml (1.3 oz.) of hydraulic
oil per minute or less, it is operating properly.
• If the drive motor drains 80 ml (2.6 oz.) or more of hydraulic oil
per minute, it has failed; rebuild or replace the drive motor.
9.5.16 Test the rear drive motor in a similar fashion: Position the machine so
that the rear drum is up against an abutment such as a brick wall or
concrete barricade.
9.5.17 With the throttle at full and the forward/reverse control lever in the full
REVERSE position, collect all oil that drains from the drive motor over
a one-minute time period.
wc_tx000354gb.fm 106
RD 7 /... Repair Troubleshooting
• If the drive motor drains approximately 40 ml (1.3 oz.) of hydraulic
oil per minute or less, it is operating properly.
• If the drive motor drains 80 ml (2.6 oz.) or more of hydraulic oil
per minute, it has failed; rebuild or replace the drive motor.
wc_tx000354gb.fm 107
Troubleshooting RD 7 /... Repair
Notes
wc_tx000354gb.fm 108
Threadlockers and Sealants
Threadlockers and Sealants