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0116743en 002
0604
Roller
RD 7H
REPAIR MANUAL
0 1 1 6 7 4 3 E N
RD 7H Repair Table of Contents
1. Foreword 5
2. Safety Information 6
3. Technical Data 16
4. Operation 18
wc_br0116743enTOC.fm 1
Table of Contents RD 7H Repair
5. Maintenance 29
6. General 49
7. Hydraulic System 50
wc_br0116743enTOC.fm 2
RD 7H Repair Table of Contents
7.8 Hydraulic Schematic ........................................................................... 55
7.9 Test Hydraulic Pressures ................................................................... 56
7.10 Check Vibration Circuit ....................................................................... 56
7.11 Checking Drive Circuit ........................................................................ 58
7.12 Relief Valves ...................................................................................... 60
7.13 Troubleshooting Vibration System ..................................................... 61
7.14 Troubleshooting Drive System ........................................................... 62
8. Power Take-Off 64
9. Roller 73
10. Troubleshooting 88
wc_br0116743enTOC.fm 3
Table of Contents RD 7H Repair
wc_br0116743enTOC.fm 4
RD 7H Repair Foreword
1. Foreword
You must be familiar with the operation of this machine before you
attempt to troubleshoot or make any repairs to it. Basic operating and
maintenance procedures are described in the operator’s / parts
manual supplied with the machine. The operator’s / parts manual
should be kept with the machine. Use it to order replacement parts
when needed. If this manual becomes lost, please contact Wacker
Corporation to order a replacement.
wc_tx000349gb.fm 5
Safety Information RD 7 /...
2. Safety Information
This manual contains DANGER, WARNING, CAUTION, and NOTE
callouts which must be followed to reduce the possibility of personal
injury, damage to the equipment, or improper service.
wc_si000115gb.fm 6
RD 7 /... Safety Information
2.2 Operating Safety
Familiarity and proper training are required for the safe operation of
equipment! Equipment operated improperly or by untrained personnel
can be dangerous! Read the operating instructions contained in both
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 equipment before
being allowed to operate the machine.
2.2.1 ALWAYS operate machine with all safety devices and guards in place
and in working order.
2.2.2 ALWAYS check that all controls are functioning properly immediately
after start-up! DO NOT operate machine unless all controls operate
correctly.
2.2.3 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.
2.2.5 ALWAYS use caution when operating near the edges of pits, trenches
or platforms. Check to be sure that ground surface is stable enough to
support the weight of the machine and that there is no danger of the
roller sliding, falling or tipping.
2.2.7 ALWAYS operate the machine with both feet on the ground! DO NOT
stand, sit, or ride on machine while in operation.
2.2.8 ALWAYS remain aware of moving parts and keep hands, feet, and
loose clothing away from moving parts of equipment.
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Safety Information RD 7 /...
2.3 Operator Safety while using Internal Combustion Engines
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RD 7 /... Safety Information
2.4 Service Safety
2.4.1 DO NOT modify the equipment without express written approval of the
manufacturer.
2.4.3 ALWAYS check and tighten all external fasteners at regular intervals.
2.4.4 ALWAYS keep area around muffler free of debris such as leaves,
paper, cartons, etc. A hot muffler could ignite them, starting a fire.
2.4.5 ALWAYS keep machine clean and labels legible. Replace all missing
and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
2.4.6 ALWAYS replace safety devices and guards after repairs and
maintenance.
2.4.8 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 position of other people around you when lifting the
machine.
2.4.9 ALWAYS turn engine off before servicing machine. If the engine has
electric start, disconnect negative terminal on battery
wc_si000115gb.fm 9
Safety Information RD 7 /...
2.5 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 I C E D 'E M P L O I D O I T
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
2.6 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
machine. Shut off engine before refueling.
WARNING!
Hot surface!
WARNING!
Read and understand the supplied operator’s
manual before operating this 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 this machine.
wc_si000115gb.fm 11
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 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 machine. Replacement Operator’s Manual can
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 be ordered through your local Wacker distribu-
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
E T R E
N O 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 .
tor.
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 /...
3. Technical Data
3.1 Engine
Engine
Engine Type One cylinder, 4-stroke, air cooled, diesel engine
Engine Make Hatz
Engine Model 1D41S 1D41S VAR I
Rated Power kW (Hp) 4.8 (6.5) @
5.5 (7.5) @ 2800 rpm
2600 rpm
Operating Speed rpm 2630±30
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
3.2 Roller
Roller
Overall Dimensions - Handle mm 1168 x 692 x 2159
up (l x w x h) (in.) (46 x 27.25 x 85)
Overall Dimensions - Handle mm 2654 x 692 x 1270
down (l x w x h) (in.) (104.5 x 27.25 x 50)
Operating Weight kg (lbs.) 650 (1430)
Area Capacity m2 (ft.2)/hr. 2613 (28115)
Forward Speed (max) m (ft.) / min. 66 (220)
Reverse Speed (max) m (ft.) / min. 33 (110)
Vibration Frequency Hz (vpm) 55 (3300)
Hydraulic System Lubrication type SAE 10W30 hydraulic fluid*
Hydraulic System Capacity l (gal.) 30 (8)
Gradeability with vibration % 40
Gradeability without vibration % 25
*See “Hydraulic Oil Requirements”
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Operation RD 7 /...
4. Operation
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RD 7 /... Operation
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Operation RD 7 /...
4.2 Before Starting
c1
a
c
d
wc_gr001338
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RD 7 /... Operation
4.4 Starting the Machine (RD 7H, RD 7H-S)
See Graphic: wc_gr001338, wc_gr01339, wc_gr001340
4.4.1 Check that the exciter (a) is in the OFF position.
4.4.2 Pull the throttle control (c) up to open engine throttle.
4.4.3 Turn the decompression lever (f) until stop (f1) is reached. In this
position, the automatic decompression system is heard to engage.
4.4.4 Insert the crank (d) into the guide sleeve (b).
4.4.5 Turn the crank 5 turns to build up pressure for the engine to fire.
4.4.6 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
4.4.7 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.
4.4.8 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.
4.4.9 If the engine begins to run backwards after backfiring (smoke emerges
from air cleaner), release the crank handle immediately and stop the
engine.
4.4.10 To restart the engine, wait until it has come to a standstill, then repeat
the starting prepartions.
4.4.11 Allow engine to warm up for a few minutes before operating machine.
e
f1
f
f0
wc_gr001339 wc_gr001340
wc_tx000294gb.fm 21
Operation RD 7 /...
4.5 Starting the Machine (RD 7H-ES)
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
4.5.4 Allow engine to warm up for a few minutes before operating machine.
wc_tx000294gb.fm 22
RD 7 /... Operation
4.6 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 23
Operation RD 7 /...
4.7 Engine Speed
During operation, run the engine at full throttle (2800 rpm). This
ensures maximum exciter speed and will produce the best
compaction.
Should the engine ever speed out of control and for some reason will
WARNING
not kill, pulling up on the decompression lever (f), which could be hot
to the touch, will kill the engine.
4.8.1 Turn the exciter off, and close the water control valve.
4.8.2 Push the throttle control to the minimum position to stop the engine.
4.8.4 Clean the scraper bars before putting the roller away.
4.9.1 Turn the exciter off, and close the water control valve.
4.9.2 Push the throttle control to the minimum position to stop the engine.
4.9.5 Clean the scraper bars before putting the roller away.
wc_tx000294gb.fm 24
RD 7 /... Operation
4.10 Direction and Speed Control
b1
wc_gr001341
4.11 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.
CAUTION: DO NOT run machine with the vibration on over hard
surfaces like concrete or compacted asphalt. The drum bearings can
be damaged.
wc_tx000294gb.fm 25
Operation RD 7 /...
4.12 Back-Up Stop Pad
STOP
wc_gr001342
a b c
wc_gr001345
wc_tx000294gb.fm 26
RD 7 /... Operation
4.14 Parking Brake
a wc_gr001343
wc_gr001344
wc_tx000294gb.fm 27
Operation RD 7 /...
4.16 Operation on Slopes
22˚
40%
wc_gr001346 wc_gr001347
4.17 Rollovers
wc_tx000294gb.fm 28
RD 7 /... Maintenance
5. Maintenance
wc_tx000295gb.fm 29
Maintenance RD 7 /...
5.2 Engine Oil System
wc_gr001348
wc_tx000295gb.fm 30
RD 7 /... Maintenance
5.3 Changing Engine Oil and Oil Filter
5.3.1 Unscrew the oil drain plug and allow all the oil to drain into a container
that will hold about 1–1.5 liters (1–1.5 quarts).
5.3.2 Clean the oil drain plug and attach a new seal. Insert and tighten the
plug.
5.3.3 Replace the oil filter element with a new one, inserting it with the “TOP”
mark up.
5.3.4 Check the condition of the O-ring (b) and replace it if necessary.
5.3.5 Wet the O-ring and threads of the screw plug on the oil filter housing
using high temperature grease available from your Hatz dealer.
5.3.6 Add engine oil up to the “MAX” mark on the dipstick, approximately
1.1–1.2 liters (1–1¼ quarts).
5.3.7 Run the engine for a short period, then check the oil level again and
top up if necessary.
5.3.8 Make sure that there is no leakage past the screw plug on the oil filter
housing.
wc_gr001349
wc_tx000295gb.fm 31
Maintenance RD 7 /...
5.4 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.
5.4.1 Remove the cover from the roller to allow access to the fuel tank water
trap.
5.4.2 Loosen the hex screw (a) until only 2 threads are holding it in place.
5.4.3 Trap the drops 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.
5.4.4 When only diesel fuel emerges, tighten the hex screw.
CAUTION: Diesel fuel destroys shockmounts. Clean fuel spillage
immediately.
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.
Danger of explosion! Diesel fuel is flammable and must be treated with
the necessary caution. Do not smoke. Avoid sparks and open flames.
WARNING
5.4.5 Remove the cover from the roller to allow access to the fuel filter.
5.4.6 Place a suitable container under the filter to trap escaping fuel.
5.4.7 Close the fuel supply line.
5.4.8 Pull the fuel supply line (a) off the fuel filter trap (b) at both sides, and
insert the new filter.
CAUTION: Keep the area clean to prevent dirt from entering the fuel
lines.
5.4.9 Make sure the filter is oriented with the arrow in the direction of flow.
5.4.10 Open the fuel supply line until fuel begins to flow.
5.4.11 Run the engine briefly to check the fuel filter and lines for leaks.
wc_tx000295gb.fm 32
RD 7 /... Maintenance
a
c
wc_gr001351
d
e
a b c
g f
wc_gr001352
wc_tx000295gb.fm 33
Maintenance RD 7 /...
5.5 Engine Air Filter
5.5.3 Loosen the wing nut (a) and remove it and the air cleaner cover (b).
Note: The decompression lever will also come off.
5.5.4 Pull out the filter cartridge (a).
5.5.5 Check that the valve plate (b) for the air blockage indicator is clean and
in good condition.
Cleaning dry dirt from the filter cartridge
5.5.6 Blow through the filter cartridge from the inside using a compressed air
gun.
5.5.7 Continue until all dust has been removed.
CAUTION: 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 inches) from the element.
Cleaning wet or oily dirt from the filter
5.5.8 Change the filter cartridge.
CAUTION: Always trace and correct the cause of wet or oily
contamination of a filter element.
Checking the filter cartridge
5.5.9 Hold the element up to a light or pass a lamp through the middle to
check the condition of the element folds (c).
5.5.10 Check that the sealing surface (d) is in good condition.
CAUTION: If there is even slight damage to the paper filter element or
the sealing surface, replace the filter cartridge.
wc_tx000295gb.fm 34
RD 7 /... Maintenance
5.6 Checking and Adjusting Valve Clearances
a b
c
wc_gr001353
wc_tx000295gb.fm 35
Maintenance RD 7 /...
5.7 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
5.7.1 Clean all air guide elements and the complete cooling air zones (a) on
the cylinder head, cylinder and flywheel blades without making them
wet. Blow them dry with compressed air.
5.7.2 Clean the complete area with a solvent or cold cleaner according to its
manufacturer’s instructions, then spray down with a high pressure
water jet. Dry with compressed air.
5.7.3 Trace the source of oil leaks causing greasy dirt. Repair the leaks,
seeking advice of your Hatz engine dealer if necessary.
5.7.4 After cleaning, run the engine to dry it out and to prevent the formation
of rust.
wc_gr001354
wc_tx000295gb.fm 36
RD 7 /... Maintenance
5.8 Scraper Bars
a a
a
wc_gr001355
wc_tx000295gb.fm 37
Maintenance RD 7 /...
5.9 Hydraulic Oil Requirements
wc_gr001356
wc_tx000295gb.fm 38
RD 7 /... Maintenance
5.11 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.
5.11.1 Remove the top cover of the roller.
5.11.2 Remove the drain plug (b) from the end of the drain hose that is
attached to the hydraulic tank.
5.11.3 Allow the hydraulic oil to drain into a suitable container.
5.11.4 When all the oil has drained out, reinstall the drain plug back into the
hose and secure in place.
5.11.5 Place a plastic bag around the filter (a) to contain any oil spillage.
5.11.6 Unscrew the old filter.
5.11.7 Install the new filter. Screw the new filter on by hand, making sure that
it is not cross threaded.
CAUTION: Use only original spare parts.
5.11.8 Tighten using both hands.
5.11.9 Fill the hydraulic tank with hydraulic oil until the level is visible halfway
up the sightglass.
5.11.10 Run the engine briefly, then stop the engine and check for leaks.
5.11.11 Check the level in the sightglass, and top up if necessary.
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.
wc_tx000295gb.fm 39
Maintenance RD 7 /...
5.12 Direction Lever Adjustment
b g
a
c d e
f wc_gr001358
wc_tx000295gb.fm 40
RD 7 /... Maintenance
5.13 Pressure Washing the Machine
wc_tx000295gb.fm 41
Maintenance RD 7 /...
5.15 Hoisting
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 1430 lbs
(650 Kg).
Only use steel ropes or chains for hoisting. The rope or chain must
WARNING have the suitable specified lifting capacity of 1430 lbs (650 Kg). Do not
use improvised ropes or chains.
CAUTION: 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
WARNING or moved.
wc_gr001359
wc_tx000295gb.fm 42
RD 7 /... Maintenance
5.16 Transporting
wc_gr001360
wc_tx000295gb.fm 43
Maintenance RD 7 /...
5.17 Hydraulic Schematic
See Graphic: wc_gr001361, wc_gr0001362
P 1
3
1
21 mPa
3000 PSI 2
2
12 13
10 mPa 20 mPa
1450 PSI 2900 PSI
5 4
11
10
10 micron
7
6 wc_gr001361
wc_tx000295gb.fm 44
RD 7 /... Maintenance
5.18 Hydraulic Diagram
15
2
8
14
wc_gr001362
wc_tx000295gb.fm 45
Maintenance RD 7 /...
5.19 Electrical Schematic (RD 7H-ES)
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 46
RD 7 /... Maintenance
wc_tx000295gb.fm 47
Maintenance RD 7 /...
5.20 Troubleshooting
wc_tx000295gb.fm 48
RD 7 /... Repair General
6. General
6.1 Tools
Since all possible problems encountered while repairing the
equipment cannot be anticipated, it is up to the mechanic to use
common sense and good judgment 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.
wc_tx000350gb.fm 49
Hydraulic System RD 7 /... Repair
7. Hydraulic System
7.2 Vibration
wc_tx000351gb.fm 50
RD 7 /... Repair Hydraulic System
7.3 Hydraulic Manifold Block
1 2
7
5
6
wc_gr001503
wc_tx000351gb.fm 51
Hydraulic System RD 7 /... Repair
7.4 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 after the
filter is used to maintain 14.5 psi (0.1 mPa) to the inlet side of the
charge pump to supply the drive circuit. When pressure to the inlet of
the charge pump exceeds 14.5 psi the valve opens and returns the
excess flow back to the tank.
wc_tx000351gb.fm 52
RD 7 /... Repair Hydraulic System
7.6 Bleeding the Hydraulic System
wc_gr001504
wc_tx000351gb.fm 53
Hydraulic System RD 7 /... Repair
7.7 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
10
10 micron
7
6 wc_gr001361
wc_tx000351gb.fm 54
RD 7 /... Repair Hydraulic System
7.8 Hydraulic Schematic
15
2
8
14
wc_gr001362
wc_tx000351gb.fm 55
Hydraulic System RD 7 /... Repair
7.9 Test Hydraulic Pressures
7.9.4 Run machine for 5-10 minutes before testing to allow time for hydraulic
system to warm up.
Note: There are no designated test ports on the hydraulic block. Use
pressure fittings and adapters designed for use with Wacker hydraulic
test equipment.
Before opening hydraulic connections, shut engine off and make sure
all controls are in neutral.
WARNING
7.10.1 Remove vibration pressure line (1) from hydraulic manifold (2).
7.10.2 Install a #6 T-fitting and test fitting into manifold. Install 5000 psi gauge
in test fitting.
7.10.3 Start engine and run machine at full throttle, forward/reverse control in
neutral.
7.10.4 Switch vibration on. Gauge will read relief pressure momentarily as
exciter starts and then fall to normal operating pressure as exciter
reaches full speed.
wc_tx000351gb.fm 56
RD 7 /... Repair Hydraulic System
a 1
d
f
b
e
c
2
3
wc_gr001505
c. Hose 0078002 -
wc_tx000351gb.fm 57
Hydraulic System RD 7 /... Repair
7.11 Checking Drive Circuit
Operating Pressure
7.11.1 Remove drive pressure line (3) from hydraulic pump (1).
7.11.2 Install a #6 T-fitting (2) and test fitting (4) into pump. Install 5000 PSI
gauge in test fitting.
7.11.4 Shift control lever into either forward or reverse and read operating
pressure.
Relief Pressure
7.11.5 Block in front of and behind both drums to prevent machine from
moving or dead head machine against a solid concrete abutment.
Make sure blocks are large enough so machine will not climb over
them during testing.
WARNING
7.11.7 Start engine and run machine at full throttle. Shift control slowly into
forward or reverse until pressure on gauge tops out. This is the forward
or reverse relief valve pressure.
wc_tx000351gb.fm 58
RD 7 /... Repair Hydraulic System
1
2
3
4
wc_gr001506
wc_tx000351gb.fm 59
Hydraulic System RD 7 /... Repair
7.12 Relief Valves
4
2
3
1
wc_gr001507
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RD 7 /... Repair Hydraulic System
7.13 Troubleshooting 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:
7.13.1 Start machine and run it for several minutes to bring hydraulic fluid up
to normal operating temperatures.
7.13.2 Check engine RPM using a tachometer. The engine must be running
at the correct RPM to accurately measure vibration.
7.13.3 Position roller on a rubber mat and start vibration. Hold vibrotach (P/N
53397) against outer rim on drum and measure vibration speed.
Minimum
Engine RPM
Vibration Speed
2700–2900 3300
7.13.4 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 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 the motor. Turn motor shaft and exciter shaft by hand and check that
they turn freely.
N N N System OK
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Hydraulic System RD 7 /... Repair
7.14 Troubleshooting Drive System
7.14.1 Tag and disconnect hydraulic lines to drive motor. Cap or plug all open
connections. For recommended caps or plugs, see Repair
Accessories.
7.14.2 Remove four screws (1) mounting porting block (2) to lower frame.
Tag, disconnect, and cap three upper hydraulic lines (3) from porting
block.
7.14.3 Support the machine before separating drum from frame by attaching
a sling or chain to the lifting eye (4) using a suitable hook or shackle.
Each lifting device must have capacity of at least 1430 lbs (650 Kg).
Only use slings or chains for hoisting. The sling or chain must have the
suitable specified lifting capacity. Do not use improvised slings or
WARNING chains.
CAUTION: Never use any other part of the roller to lift the machine, as
severe damage may occur.
7.14.4 Remove six screws (5) mounting drum support to frame. Remove
drum out from frame.
WARNING
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RD 7 /... Repair Hydraulic System
3
2
1
5
wc_gr001508
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Power Take-Off RD 7 /... Repair
8. Power Take-Off
8.1 Description
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RD 7 /... Repair Power Take-Off
8.2 Pump Assembly
4
2
3
5
1
wc_gr001509
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Power Take-Off RD 7 /... Repair
8.3 Drive Pump
8.3.2 Tag and disconnect hose lines (1) from pump. Cap or plug all open
connections. For recommended caps or plugs, see Repair
Accessories.
Before dismantling hydraulic connectors or hoses, ensure that all
pressure has been relieved from the circuit. Open hose fittings slowly.
WARNING
8.3.3 Remove the support bracket (2) from the exciter pump (3). Save
locknuts (4) and washers (5) for remounting.
8.3.4 Remove two locknuts (6) holding exciter pump to drive pump (7).
8.3.5 Remove 2 mounting screws (8) holding drive pump to engine / pump
adapter.
8.3.6 Remove control lever (9), hydraulic fittings (10), O-ring (11) and
coupling (12) and transfer to new pump.
Installation
8.3.7 Install new pump and fasten it to engine / pump adapter. Secure
mounting screws (8) using Loctite 271 or an equivalent high strength
threadlocker.
8.3.8 Install exciter pump (3) to new drive pump using locknuts (6).
8.3.9 Install support bracket (2) to exciter pump using locknuts (4) and
washers (5).
8.3.10 Reconnect hose lines (1) to fittings (10).
8.3.11 Bleed drive circuit.
CAUTION: It is recommended that the drive circuit be flushed after a
pump failure to remove any contaminants which may be trapped in the
lines.
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
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
8.4 Exciter Pump
Removal
8.4.2 Tag and disconnect hose lines (1) from exciter pump (3). Cap or plug
all open connections. For recommended caps or plugs, see Repair
Accessories.
8.4.3 Remove the support bracket (2) from the exciter pump (3). Save
locknuts (4) and washers (5) for remounting.
8.4.4 Remove two locknuts (6) holding exciter pump to drive pump (7).
8.4.5 Remove O-ring (8), coupling (9) and fitting (10) and transfer to new
pump.
Installation
8.4.6 Install new exciter pump (3) to drive pump (7) using locknuts (6).
8.4.7 Install support bracket (2) to exciter pump using locknuts (4) and
washers (5).
8.4.9 Bleed hydraulic system before starting. See 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
8.5 Engine
8.5.3 Remove the pump support bracket (2) at the front of the hydraulic
pump (3).
8.5.4 Remove exhaust pipe (4).
8.5.5 Attach lifting ropes or chains to engine’s lifting eye.
Note: The engine lifting eye (104439) was originally packaged with the
HATZ engine manual. To install lifting eye, remove throttle bracket (5)
and mount lifting eye in its place.
Only use slings or chains for hoisting. Slings or chains must have the
suitable lifting capacity. Do not use improvised slings or chains.
WARNING
8.5.6 Remove screws (6), washers (7), and nuts (8) that mount the engine
to the frame.
8.5.7 Leaving the pump mounted to the engine, lift the engine slightly to
check that it is correctly balanced.
8.5.8 Lift and remove engine from machine.
Do not stand under or get near the engine, while it is being hoisted or
moved.
WARNING
8.5.9 Remove hydraulic pump (3) and Pump adapter (9). On older versions
(10a), loosen screw (15) and remove coupler (14) from shaft. A pry bar
between coupler and shaft may be needed. Remove six screws (11)
mounting flywheel coupling to engine.
8.5.10 On newer versions (10b), the pump mounts directly into the clutch.
Remove two screws (16) and washers (17) mounting clutch to engine.
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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
Only use steel ropes or chains for hoisting. Ropes or chains must have
the suitable lifting capacity. Do not use improvised ropes or chains.
WARNING
8.5.6 Lift engine and place in machine.
8.5.8 Mount engine to frame reusing screws (6), washers (7) and nuts (8).
8.5.13 Attach control lever bracket (1) to drive pump. The drive control cable
may need to be adjusted. See Direction Lever Adjustment.
8.5.14 The engine valve clearance may need to be adjusted. See Checking
and adjusting valve clearances.
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
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
9. 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 (1) each motor
is mounted to a drive hub (17), 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.
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Roller RD 7 /... Repair
9.2 Drum
9.2.2 Remove four screws (1) mounting porting block (2) to lower frame.
Tag, disconnect, and cap three upper hydraulic lines (3) from porting
block.
9.2.3 Support the machine before separating drum from frame by attaching
a sling or chain to the lifting eye (4) using a suitable hook or shackle.
Each lifting device must have capacity of at least 1600 lbs. (725 Kg.).
Only use slings or chains for hoisting. The sling or chain must have the
suitable specified lifting capacity. Do not use improvised slings or
WARNING chains.
CAUTION: 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 hoisted or moved.
WARNING
9.2.4 Remove six screws (5) mounting drum support to frame. Remove
drum out from frame.
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RD 7 /... Repair Roller
wc_gr001514
Installation
9.2.1 Position drum under machine frame and line up holes in drum support
(6) with holes in frame.
9.2.2 Mount drum to frame using six screws (5). Apply Loctite 243 or an
equivalent medium strength threadlocker and torque to 88 ft.lbs. (120
Nm).
9.2.3 Reconnect all hydraulic hoses to drive motors.
9.2.4 Reconnect all hydraulic hoses (3) to porting block (2). Mount porting
block to lower frame using four screws (1). Apply Loctite 243 or an
equivalent medium strength threadlocker and torque to 36 ft.lbs. (49
Nm).
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
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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Roller RD 7 /... Repair
9.3 Drum Assembly
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RD 7 /... Repair Roller
CAUTION: When installing drive motor, care must be taken to ensure
splined shaft does not separate from inside of motor. Also, mount drive
motor at the correct angle.
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
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.
16
4b
15
13
6 17
12
11
10
14
4a
8
7
5
3 1
2
wc_gr001513
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Roller RD 7 /... Repair
9.4 Exciter
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RD 7 /... Repair Roller
5
4
3
C B
20
8 A D
7 a
6
15
13
15
13
14
1
2
26
27
18
17
16
19
25
24
10
21 11
12
23 9
22
wc_gr001515
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Roller RD 7 /... Repair
Installation
9.4.1 Place exciter assembly (25) on frame. Rock housing on frame to
determine which corner needs to be shimmed. Shim (27) as needed
between the frame and the housing.
9.4.2 Mount exciter assembly to frame using four screws (24) and washers
(25). Apply Loctite 243 or an equivalent medium strength threadlocker.
Torque screws in sequence A, B, C, D. (a) following these steps:
• Step 1 - snug by hand
• Step 2 - 40 ft. lbs. ( 54 Nm)
• Step 3 - 88 ft. lbs. (120 Nm)
• Step 4 - 88 ft. lbs. (120 Nm)
9.4.3 Replace scraper bar (21) with two screws (22) and washers (23).
9.4.4 Replace upper mass of machine over lower mass by using the central
lifting eye (20).
9.4.5 Reinstall the screws (16) and washers (17) for shock mounts (18)
using Loctite 243 or an equivalent medium strength threadlocker and
torque to 63 ft. lbs. (86 Nm).
9.4.6 Remount both front and rear plates (13) and screws (15) to upper
frame (14).
9.4.7 Reconnect the three hydraulic hoses (9) to exciter motor (10) and three
hoses (11) to porting block (12).
9.4.8 Fill hydraulic tank with hydraulic oil (SAE 10W 30) until the level is
visible halfway up the sight glass. Run engine briefly, then stop the
engine and check for leaks. Check the level in the sight glass, and top
off if necessary.
9.4.9 Remount water tank (5) with three screws (6 & 7) and washer (8).
9.4.10 Remount top cover (1) with six screws (2).
9.4.11 Reconnect water hose (3) to fitting (4).
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
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
9.5 Exciter Assembly
Disassembly
9.5.1 Remove the exciter assembly from the frame. See Exciter.
9.5.2 Remove four screws (1) mounting exciter motor (2) to cover plate (3).
9.5.3 Remove ten screws (4) mounting cover plates (3) and (8) to exciter
housing (5).
9.5.4 Press bearings (6a) and (6b) shaft (7) as a unit from housing. Inspect
bearings for damage and replace if necessary.
Assembly
9.5.5 Press non-motor side bearing (6b) into exciter housing (5) .
9.5.6 Turn housing on end with motor side facing up, insert shaft (7) with
splined end facing up and press into lower bearing.
9.5.7 Press motor side bearing (6a) into housing and over shaft.
9.5.8 Mount cover plates (3) and (8) to housing using ten screws (4). Apply
Loctite 243 or an equivalent medium strength threadlocker and torque
to 7 ft.lbs. (10 Nm).
9.5.9 Mount exciter motor (2) to cover plate (3) using four screws (1). Apply
Loctite 243 or an equivalent medium strength threadlocker and torque
to 7 ft.lbs. (10 Nm).
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
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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Roller RD 7 /... Repair
6b
8 6a
5
4
1
7 2
wc_gr001516
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RD 7 /... Repair Roller
9.6 Throttle Cable
8 5
6 4
3
7
10
1
2
wc_gr001517
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Roller RD 7 /... Repair
9.7 Direction Cable
Removal
9.7.1 Remove pin (1) from pivot bracket (2). Unscrew from cable (3).
9.7.5 Remove four screws (8) mounting covers (9) to expose handle linkage.
9.7.6 Remove cable ball end (10) from pivot plate. Unscrew from cable.
Installation
9.7.8 Feed cable (3) through handle frame. Screw cable end into cable ball
end (10).
9.7.10 Feed cable into spring cylinder (5). Screw on until cable bottoms out.
9.7.15 Before mounting covers, the cable needs to be adjusted properly. See
Direction Lever Adjustment.
Before you start the machine, ensure that all tools have been removed
WARNING
from the machine and that replacement parts and adjusters are firmly
tightened.
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RD 7 /... Repair Roller
2
1
5
4
10
3
6
9
8 wc_gr001518
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Roller RD 7 /... Repair
9.8 Direction Control Lever
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RD 7 /... Repair Roller
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
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.
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
10. Troubleshooting
10.1 General
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RD 7 /... Repair Troubleshooting
10.3 Drive System
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Troubleshooting RD 7 /... Repair
10.4 Starting System
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Threadlockers and Sealants
Threadlockers and Sealants
Threadlocking adhesives and sealants are specified throughout this
manual by a notation of “S” plus a number (S#) and should be used
where indicated. Threadlocking compounds normally break down at
temperatures above 175°C (350°F). If a screw or bolt is hard to
remove, heat it using a small propane torch to break down the sealant.
When applying sealants, follow instructions on container. The sealants
listed below are recommended for use on Wacker equipment.
Loctite 222 Purple Low strength, for locking threads smaller than 6 mm 73287 - 10 ml
Hernon 420 (1/4").
Omnifit 1150 (50M) Hand tool removable.
Temp. range, -54 to 149 ° C (-65 to 300 ° F)
Hernon 423 Blue Medium strength, for locking threads larger than 29311 - .5 ml
Omnifit 1350 (100M) 6 mm (1/4"). 17380 - 50 ml
Hand tool removable.
Temp. range, -54 to 149 ° C (-65 to 300 ° F)
Loctite 271/277 Red High strength, for all threads up to 25 mm (1”). 29312 - .5 ml
Hernon 427 Heat parts before disassembly. 26685 - 10 ml
Omnifit 1550 (220M) Temp. range, -54 to 149 ° C (-65 to 300 ° F) 73285 - 50 ml
Loctite 290 Green Medium to high strength, for locking preassembled 28824 - .5 ml
Hernon 431 threads and for sealing weld porosity (wicking). 25316 - 10 ml
Omnifit 1710 (230LL) Gaps up to 0.13 mm (0.005")
Temp. range, -54 to 149 ° C (-65 to 300 ° F)
Loctite 609 Green Medium strength retaining compound for slip or press 29314 - .5 ml
Hernon 822 fit of shafts, bearings, gears, pulleys, etc.
Omnifit 1730 (230L) Gaps up to 0.13 mm (0.005")
Temp. range, -54 to 149 ° C (-65 to 300 ° F)
Loctite 592 White Pipe sealant with Teflon for moderate pressures. 26695 - 6 ml
Hernon 920 Temp. range, -54 to 149 ° C (-65 to 300 ° F) 73289 - 50 ml
Omnifit 790
Loctite 496 Clear Instant adhesive for bonding rubber, metal and plas- 52676 - 1 oz.
Hernon 110 tics; general purpose.
Omnifit Sicomet 7000 For gaps up to 0.15 mm (0.006")
Read caution instructions before using.
Temp. range, -54 to 82 ° C (-65 to 180 ° F)
Threadlockers and Sealants
TYPE PART NO. -
( ) = Europe COLOR USAGE SIZE
Loctite Primer T Aerosol Fast curing primer for threadlocking, retaining and 2006124 -
Hernon Primer 10 Spray sealing compounds. Must be used with stainless 6 oz.
Omnifit VC Activator steel hardware. Recommended for use with gasket
sealants.
Torque Values
Torque Values
M6 7 10 10 14 13 17 - 10 - 5
M8 18 25 26 35 30 41 1/2 13 - 6
M10 36 49 51 69 61 83 11/16 17 - 8