wc br0116743en 004 - Wacker Neusonproducts.wackerneuson.com/manuals/Repair/0116743en_004Rep.pdf ·...

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Roller

RD 7H

REPAIR MANUAL

0116743en 004

0707

0 1 1 6 7 4 3 E N

RD 7H Repair Foreword

Operating / Parts InformationYou must be familiar with the operation of this machine before youattempt to troubleshoot or repair it. Basic operating and maintenanceprocedures are described in the Operator’s Manual supplied with themachine. Keep a copy of the Operator’s Manual with the machine at alltimes. Use the separate Parts Book supplied with the machine to orderreplacement parts. If you are missing either of the documents, pleasecontact Wacker Corporation to order a replacement.

Damage caused by misuse or neglect of the unit should be brought tothe attention of the operator to prevent similar occurrences fromhappening in the future.

This manual provides information and procedures to safely repair andmaintain the above Wacker model(s). For your own safety andprotection from injury, carefully read, understand, and observe allinstructions described in this manual. THE INFORMATIONCONTAINED IN THIS MANUAL IS BASED ON MACHINESMANUFACTURED UP TO THE TIME OF PUBLICATION. WACKERCORPORATION RESERVES THE RIGHT TO CHANGE ANYPORTION OF THIS INFORMATION WITHOUT NOTICE.

This manual covers machines with Item Number:0008042, 0009408, 0009487, 0620079

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Foreword RD 7H Repair

CALIFORNIA Proposition 65 Warning:

Diesel engine exhaust, some of its constituents, and certain vehiclecomponents contain or emit chemicals known to the State of Californiato cause cancer and birth defects or other reproductive harm.

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

Copyright 2007 by Wacker Corporation

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

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

WARNING

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RD 7H Repair Table of Contents
1. Safety Information 8
1.1 Operating Safety .................................................................................. 91.2 Operator Safety While Using Internal Combustion Engines ............... 101.3 Service Safety .................................................................................... 111.4 Label Locations .................................................................................. 121.5 Safety and Informational Labels ......................................................... 13

2. Technical Data 18

2.1 Engine ................................................................................................ 182.2 Roller .................................................................................................. 192.3 Sound and Vibration Measurements .................................................. 19

3. Operation 20

3.1 Controls and Service Locations .......................................................... 203.2 Before Starting ................................................................................... 223.3 Engine Throttle Control ...................................................................... 223.4 Starting the Machine (RD 7H, RD 7H-S) ............................................ 233.5 Starting the Machine (RD 7H-ES) ...................................................... 243.6 Cold Weather Starting (RD 7H, RD 7H-S) ......................................... 253.7 Engine Speed ..................................................................................... 263.8 Stopping the Machine ......................................................................... 263.9 Direction and Speed Control .............................................................. 273.10 Exciter ................................................................................................ 273.11 Back-Up Stop Pad .............................................................................. 283.12 Engine Crank ...................................................................................... 283.13 Parking Brake ..................................................................................... 293.14 Watering System ................................................................................ 293.15 Operation on Slopes ........................................................................... 303.16 Rollovers ............................................................................................ 30

4. Maintenance 31

4.1 Maintenance Schedule ....................................................................... 314.2 Checking Engine Oil ........................................................................... 324.3 Changing Engine Oil and Oil Filter ..................................................... 33

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Table of Contents RD 7H Repair
4.4 Fuel System ........................................................................................344.5 Engine Air Filter ...................................................................................364.6 Checking and Adjusting Valve Clearances .........................................374.7 Engine Cooling System .......................................................................384.8 Mechanical Oil Pressure Monitoring ....................................................394.9 Scraper Bars .......................................................................................404.10 Hydraulic Oil Requirements .................................................................414.11 Hydraulic Oil Level ..............................................................................424.12 Changing Hydraulic Fluid and Filter ....................................................434.13 Direction Lever Adjustment .................................................................444.14 Lifting ...................................................................................................464.15 Transporting ........................................................................................464.16 Pressure Washing the Machine ..........................................................474.17 Storing the Machine ............................................................................474.18 Hydraulic Schematic ............................................................................484.19 Hydraulic Schematic Components ......................................................494.20 Hydraulic Diagram ...............................................................................504.21 Hydraulic Diagram Components .........................................................514.22 RD 7H-ES Electrical Schematic ..........................................................524.23 RD 7H-ES Electrical Schematic Components .....................................534.24 General Troubleshooting .....................................................................54
5. General 55

5.1 Tools ....................................................................................................555.2 Reference Numbers ( ) ........................................................................555.3 Ordering Parts .....................................................................................555.4 Repair Accessories .............................................................................55

6. Hydraulic System 56

6.1 Hydraulic System Precautions ............................................................566.2 Hydraulic System Service Basics ........................................................566.3 Analyzing Hydraulic Oil Contamination ...............................................576.4 General Description .............................................................................586.5 Vibration Circuit ...................................................................................586.6 Hydraulic Manifold Block .....................................................................596.7 Drive Circuit .........................................................................................606.8 Return Line Filter .................................................................................60


RD 7H Repair Table of Contents
6.9 Bleeding the Hydraulic System .......................................................... 616.10 Hydraulic Diagram .............................................................................. 626.11 Hydraulic Schematic ........................................................................... 636.12 Testing Hydraulic Pressures .............................................................. 646.13 Checking the Vibration Circuit ............................................................ 646.14 Checking the Drive Circuit .................................................................. 666.15 Relief Valves ...................................................................................... 68
7. Power Take-Off 70

7.1 Description ......................................................................................... 707.2 Pump Assembly ................................................................................. 717.3 Replacing the Drive Pump .................................................................. 727.4 Exciter Pump ...................................................................................... 747.5 Replacing the Engine ......................................................................... 76

8. Roller 79

8.1 Drum - Description ............................................................................. 798.2 Replacing the Drum ............................................................................ 808.3 Drum Disassembly and Assembly ...................................................... 848.4 Replacing the Exciter ......................................................................... 888.5 Exciter Assembly ................................................................................ 928.6 Throttle Cable ..................................................................................... 948.7 Direction Cable ................................................................................... 968.8 Direction Control Lever ....................................................................... 98

9. Troubleshooting 100

9.1 General ............................................................................................. 1009.2 Vibration System .............................................................................. 1019.3 Troubleshooting the Vibration System ............................................. 1029.4 Drive System .................................................................................... 1039.5 Troubleshooting the Drive System ................................................... 1049.6 Starting System ................................................................................ 107


Safety Information RD 7 /...
1. Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE andNOTE callouts which must be followed to reduce the possibility ofpersonal injury, damage to the equipment, or improper service.

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

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

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

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

NOTICE: Used without the safety alert symbol, NOTICE indicates ahazardous situation which, if not avoided, could result in propertydamage.Note: Contains additional information important to a procedure.

DANGER

WARNING

CAUTION

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RD 7 /... Safety Information
1.1 Operating Safety
Familiarity and proper training are required for the safe operation of themachine. Machines operated improperly or by untrained personnelcan be dangerous. Read the operating instructions contained in boththis manual and the engine manual and familiarize yourself with thelocation and proper use of all controls. Inexperienced operators shouldreceive instruction from someone familiar with the machine beforebeing allowed to operate it.

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

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

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

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

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

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

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

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

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

WARNING

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

1.2.1 DO NOT run the machine indoors or in an enclosed area such as adeep trench unless adequate ventilation, through such items asexhaust fans or hoses, is provided. Exhaust gas from the enginecontains poisonous carbon monoxide gas; exposure to carbonmonoxide can cause loss of consciousness and may lead to death.

1.2.2 DO NOT smoke while operating the machine.

1.2.3 DO NOT smoke when refueling the engine.

1.2.4 DO NOT refuel a hot or running engine.

1.2.5 DO NOT refuel the engine near an open flame.

1.2.6 DO NOT spill fuel when refueling the engine.

1.2.7 DO NOT run the engine near open flames.

1.2.8 ALWAYS refill the fuel tank in a well-ventilated area.

1.2.9 ALWAYS replace the fuel tank cap after refueling.

1.2.10 DO NOT touch or lean against hot exhaust pipes.

1.2.11 DO NOT mix diesel fuel with any other fluids.

DANGER

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1.3 Service Safety
Poorly maintained machines can become a safety hazard! In order forthe machine to operate safely and properly over a long period of time,periodic maintenance and occasional repairs are necessary.

1.3.1 DO NOT modify the machine without the express written approval ofthe manufacturer.

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

1.3.3 ALWAYS check all external fasteners at regular intervals.

1.3.4 ALWAYS keep the area around the muffler free of debris such asleaves, paper, cartons, etc. A hot muffler could ignite the debris andstart a fire.

1.3.5 ALWAYS keep the machine clean and labels legible. Replace allmissing and hard-to-read labels. Labels provide important operatinginstructions and warn of dangers and hazards.

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

1.3.7 ALWAYS turn engine off before performing maintenance or makingrepairs.

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

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

WARNING

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1.4 Label Locations
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1.5 Safety and Informational Labels
Wacker machines use international pictorial labels where needed.These labels are described below:

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.

Guaranteed sound power level in dB(A).

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CAUTION! Use only clean, filtered diesel fuel.

Operator’s Manual must be stored on machine. A replacement Operator’s Manual can be ordered through your local Wacker dis-tributor.

Water control valve.

Vibration control ON/OFF.

No lift point.(one of two)

CAUTION! Lifting point.

Tie-down point.

Label Meaning

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Engine oil drain.

Hydraulic oil reservoir fill tube.

Hydraulic oil drain.

Key switch, engine start:OffOnStart

This machine may be covered by one or more patents.

A nameplate listing the model number, item number, revision number, and serial number is attached to each unit. Please record the infor-mation found on this plate so it will be avail-able 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.

Label Meaning

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Check engine oil level. Use SAE10W30.

Check the fuel level.

Engage parking brake.

Turn vibration off.

Pull engine throttle out.

Pull decompression lever up.

Insert crank handle.

Label Meaning

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Rotate crank handle counterclockwise 5X.

Remove crank handle.

Disengage parking brake.

Label Meaning

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Technical Data RD 7 /...
2. Technical Data
2.1 Engine

Item No.RD 7H

0008042RD 7H-ES0009408

RD 7H-S0009487

RD 7-RAW 0620079

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: exhaust:

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

Battery V — 12 VDC —

Air cleaner type Dry pleated-paper element

Engine lubrication oil grade SAE15W40

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

Fuel type No. 2 diesel

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

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

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RD 7 /... Technical Data
2.2 Roller
2.3 Sound and Vibration MeasurementsThe required sound specification, Paragraph 1.7.4.f of 89/392/EECMachinery Directive, is:the sound pressure level at operator’s location (LpA) = 95 dB(A)the guaranteed sound power level (LWA) = 108 dB(A).These sound values were determined according to ISO 3744 for thesound power level (LWA) and ISO 6081 for the sound pressure level(LpA) at the operator’s location.The weighted effective acceleration value, determined according toISO 8662 Part 1, is approximately:Hands = 9.66 m/s2.The sound and vibration measurements were obtained with themachine operating on hard asphalt at maximum RPM and top speed.

Item No.RD 7H

0008042RD 7H-ES0009408

RD 7H-S0009487

RD 7-RAW0620079

Roller

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

mm(in.)

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

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

mm(in.)

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

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

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

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

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

Vibration frequency Hz (vpm) 55 (3300)

Hydraulic system lubrication type SAE 10W30 hydraulic oil*

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

Gradeability with vibration % 25

Gradeability without vibration % 40

*See “Hydraulic Oil Requirements”

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Operation RD 7 /...
3. Operation
3.1 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

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RD 7 /... Operation

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Operation RD 7 /...
3.2 Before Starting
Before starting the machine, check the following:

• Engine oil level

• Air cleaner maintenance indicator

• Fuel level

• Hydraulic fluid level

• Water tank level

3.3 Engine Throttle Control

See Graphic: wc_gr001338

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

c

c1a

b

dwc_gr001338

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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 thisposition, 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) andgrasp the tubular grip with both hands.

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

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

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

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

You must hold the tubular grip firmly to maintain contact all the timebetween the starting handle and the engine. Maintain turning forceduring the entire hand starting operation.Note: If backfiring occurs when starting the engine because the crankhandle was not turned firmly enough, the brief reverse rotation at thehandle tube separates the link between the crank lug and the drivingdog.

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

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

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

WARNING

WARNING

wc_gr001339

e

f0

f1

g

f

wc_gr001340

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Operation RD 7 /...
3.5 Starting the Machine (RD 7H-ES)

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 isa reminder to turn the key to the OFF position when the machine is notin use. Failure to do this will result in a dead battery.Note: The alarm will stop when proper oil pressure is reached.

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

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

CAUTION

WARNING

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RD 7 /... Operation
3.6 Cold Weather Starting (RD 7H, RD 7H-S)
See Graphic: wc_gr001338, wc_gr001339, wc_gr001340

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

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

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

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

3.6.4 Insert the crank (d) into the guide sleeve (b).3.6.5 Turn the crank 10 turns (rotations) to build up pressure for the engine

to fire.

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

• remove the cover

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

• press the cover on firmly.

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

c

c1a

b

dwc_gr001338

wc_gr001339

e

f0

f1

g

f

wc_gr001340

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Operation RD 7 /...
3.7 Engine Speed
During operation, run the engine at full throttle (2800 rpm). Thisensures maximum exciter speed and will produce the bestcompaction.

3.8 Stopping the Machine


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

3.8.2 Close the water control valve.

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

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

3.8.5 Apply the parking brake.

3.8.6 Clean the scraper bars before storing the machine.

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

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RD 7 /... Operation
3.9 Direction and Speed Control

Travel direction and speed are controlled by the movable lever (a)inside the handle. From the neutral position, the handle is pushedaway from the operator to travel forward, and towards the operator totravel in reverse. Keep both hands on the handle while operating the machine. Thehandle may pivot rapidly while in operation and cause injury.

Speed is varied by the movement of the lever; the farther the lever ispushed in either direction, the faster the roller will travel in thatdirection. If the linkage separates from the directional lever while the machine isrunning, the roller could “run away” and cause injury. In the event ofthis occurring, the throttle (b1) must be pushed in to stop the engine.

3.10 Exciter

The exciter provides the vibration and can be used in most applicationsinvolving cohesive-type soils with heavy clay content, as well as loosesoils and gravel.NOTICE: DO NOT run the machine over hard surfaces like concreteor compacted asphalt with the vibration on. Damage to the drumbearings may result.

WARNING

WARNING

b1

a

wc_gr001341

wc_tx000294gb.fm 27

Operation RD 7 /...
3.11 Back-Up Stop Pad

A back-up stop pad (a) is mounted to the rear section of the machinebehind the control panel. The back-up stop pad operates in reverseonly.If the machine backs into an obstruction or if the operator becomestrapped behind it, the pad will be pressed forward and stop themachine. The machine can move only in the forward direction whenthe handle is brought back through the neutral position.

3.12 Engine Crank


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

STOP

wc_gr001342

a

wc_gr001345

a b c

wc_tx000294gb.fm 28

RD 7 /... Operation
3.13 Parking Brake

The parking brake is used to ensure that the machine will not roll whennot in use. It engages the weld stops on the drum, therefore a smallamount of movement is possible before the brake will catch and stopthe machine.To disengage the parking brake:Rotate the handle (a) 90° clockwise and bring it to rest in a shallowdetent.To engage the parking brake: Rotate the handle (a) 90° counterclockwise and allow it to rest in thedeep detent.NOTICE: The parking brake is designed to hold the machine on anincline with the engine off. Do not drive against the parking brake in theengaged position. The brake may bend and damage the machine.

3.14 Watering System


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

wc_gr001343a

a

wc_gr001344

wc_tx000294gb.fm 29

Operation RD 7 /...
3.15 Operation on Slopes
See Graphic: wc_gr001346 and wc_gr001347

When operating on slopes or hills, special care must be taken toreduce the risk of personal injury or damage to the machine. Alwaysoperate the machine up and down hills rather than from side to side.For safe operation and for protection of the engine, continuous dutyuse should be restricted to slopes of 22° (40% grade) or less.NEVER operate the machine sideways on slopes. The machine mayroll over, even on stable ground.

3.16 Rollovers

Proper operation of the machine on slopes will prevent rollovers. Readand follow Safety instructions in “Operating Safety” and “Operation onSlopes”. If a machine rollover does occur, care must be taken toprevent damage to the engine. In this position, oil from the enginecrankcase can flow into the combustion chamber, which can severelydamage the engine next time it is started. If the machine has rolled onits side, immediate steps should be taken to right the machine. NOTICE: To prevent damage to the engine after a rollover, themachine must NOT be started, AND it must be serviced to remove anyoil that may have been trapped in the combustion chambers. Contactyour local Wacker dealer for instructions or servicing.

WARNING

22˚40%

wc_gr001346 wc_gr001347

wc_tx000294gb.fm 30

RD 7 /... Maintenance
4. Maintenance
4.1 Maintenance Schedule

Dailybefore

starting

Afterfirst

25 hrs.*

Every250hrs.

Every500hrs.

Every1200hrs.

Check engine oil level.

Check air cleaner maintenance indicator.

Check the water trap.

Check hydraulic oil level.

Clean the scraper bars.

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

Check tappet clearance.

Examine screw connections.

Replace engine oil and filter.

Check and adjust valve clearances.

Clean cooling system.

Replace fuel filter.

Clean or replace air filter.

Change hydraulic system return line filter.

Check and adjust scraper bars.

**Check linkage components.

Clean battery terminals (RD 7H-ES).

Change hydraulic oil and filter.

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

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

wc_tx000295gb.fm 31

Maintenance RD 7 /...
4.2 Checking Engine Oil

Engine oil levelStop the machine, switch off the engine and apply the parking brake.Check the oil with the machine standing on a level surface.

4.2.1 Clean around the dipstick.

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

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

WARNING

a

wc_gr001348

wc_tx000295gb.fm 32

4.3 Changing Engine Oil and Oil Filter

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 theengine. Hot oil can burn!

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

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

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

4.3.6 Reinstall the drain plug.

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

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

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

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

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

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

CAUTION

wc_gr001349

a

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4.4 Fuel System

Fuel tank water trapThe interval at which you should check the water trap depends uponthe amount of water in the fuel. The normal interval is one week.Stop the machine, switch off the engine, and apply the parking brake.

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

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, thewater emerges first. The two substances separate at a clearly visibleline.

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

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

Changing the fuel filter cartridgeFuel filter maintenance intervals depend on the purity of the diesel fuelused. If your fuel is dirty, perform this operation at 250 hours.Stop the machine, switch off the engine, and apply the parking brake. Danger of explosion! Diesel fuel is flammable and must be treated withthe necessary caution. Do not smoke near the machine. Avoid sparksand open flames.

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, andinsert the new filter.

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

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

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.

WARNING

wc_tx000295gb.fm 34


a

b

c

wc_gr001351

wc_tx000295gb.fm 35

4.5 Engine Air Filter

Checking the air cleaner blockage indicator4.5.1 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.

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

Cleaning or replacing the engine air filterThe engine may be hot enough to cause burns! Allow the engine tocool prior to servicing.

4.5.3 Loosen the wing nut (b) and remove it. Also remove the air cleanercover (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 cartridge4.5.6 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 airpressure of more than 5 bar (70 psi). Keep the nozzle at a distance of150 mm (6 in.) from the element.Cleaning wet or oily dirt from the filter

4.5.8 Change the filter cartridge.

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

4.5.9 Hold the element up to a light or pass a lamp through the middle tocheck 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 orthe sealing surface, replace the filter cartridge.

WARNING

wc_tx000295gb.fm 36

4.6 Checking and Adjusting Valve Clearances

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 sectionStarting 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 untilcompression is felt.

4.6.4 Check the inlet valve clearance between the rocker and the valve stemusing 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 stemwith slight resistance to its movement after the nut (c) has beenretightened.

4.6.7 Repeat this adjustment with the outlet valve.

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

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

a b

c

wc_gr001353

a b c

de

fg

wc_gr001352

wc_tx000295gb.fm 37

4.7 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

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

Moist or oily contamination4.7.2 Clean the entire area with a solvent or cold cleaner according to its

manufacturer's instructions, then spray down with a high pressurewater jet. Blow them dry with compressed air.

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

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

a

a

a

wc_gr001354

wc_tx000295gb.fm 38

4.8 Mechanical Oil Pressure Monitoring

The mechanical oil pressure monitor should be activated:

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

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

• after freeing it by turning it at low temperatures.

4.8.1 Add fuel.

4.8.2 Check the engine oil level.

4.8.3 To activate the oil pressure monitor, press the lever (a).4.8.4 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 arementioned on the label (b) placed on the engine.

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

CAUTION

wc_tx000295gb.fm 39

4.9 Scraper Bars

Check the four scraper bars (a) for wear. Replace the scraper bars asneeded.Cleaning the scraper barsThe scraper bars should be cleaned daily after use or as often asneeded to remove built-up dirt, mud, and tar.Use a high-pressure water jet and a strong brush if needed.

wc_gr001355

a

a a

wc_tx000295gb.fm 40

4.10 Hydraulic Oil Requirements
Wacker recommends the use of a premium grade, petroleum-basedhydraulic oil with anti-wear and anti-foam characteristics. Good anti-wear oils contain additives to reduce oxidation, prevent foaming, andprovide for good water separation. These oils offer superior motor andpump life.When selecting hydraulic oil for your machine, be sure to specify anti-wear properties. Wacker offers a premium grade hydraulic oil for usein this machine.

• Wacker Hydraulic Oil - P/N 85094

Avoid mixing different brands and grades of hydraulic oils.Oil ViscosityMost hydraulic oils are available in different viscosities. The SAEnumber for an oil is used strictly to identify viscosity. It does not indicatethe type of oil (engine, hydraulic, gear, etc.). The higher the SAEnumber, the thicker the oil.For normal applications use a good non-detergent, anti-wear,hydraulic oil with a viscosity rating of SAE 10W30.

wc_tx000295gb.fm 41

4.11 Hydraulic Oil Level

A hydraulic oil level sightglass (a) is located on the hydraulic tank andis visible through the slots on the top cover.Check the oil level with the machine standing on a level surface. Theoil level should be at the halfway mark on the sightglass. If the level islow, remove the top cover and top up with hydraulic oil as necessary. If hydraulic oil continually needs to be added, inspect the hoses andconnections for possible leaks. Repair hydraulic leaks immediately toprevent damage to the hydraulic components.

a

wc_gr001356

wc_tx000295gb.fm 42

4.12 Changing Hydraulic Fluid and Filter

Stop the machine, switch off the engine, and apply the parking brakewith the machine standing on a level surface.Note: In the interests of environmental protection, place plasticsheeting and a container under the machine to collect the liquid whichdrains off. Dispose of this liquid properly.

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 isattached 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 thehose 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 byhand, 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 halfwayup 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.

ab

wc_gr001357

wc_tx000295gb.fm 43

4.13 Direction Lever Adjustment

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

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

4.13.2 Stop the engine.

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

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

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

4.13.4 Disconnect the clevis (1) from the pivot (2).4.13.5 Rotate the pivot so that the drive pump control arm rotates as far as

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

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

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

• If the machine creeps forwards or backwards, continue.

4.13.7 Turn off the engine.

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

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

wc_tx000295gb.fm 44


wc_gr003672

1 2F N

R7

63

45

8

9

10

2

wc_tx000295gb.fm 45

4.14 Lifting

Attach a sling or chain to the lifting eye (a) using a suitable hook orshackle. Each lifting device must have capacity of at least 650 Kg(1430 lbs). Only use steel ropes or chains for hoisting. The rope or chain musthave the suitable specified lifting capacity of 650 Kg (1430 lbs). Do notuse improvised ropes or chains.NOTICE: Never use any other part of the roller to lift the machine, assevere damage may occur. Do not stand under, or get onto, the machine while it is being hoistedor moved.

4.15 Transporting


Before transporting the machine:

• place blocks in front of and behind each drum.

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

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

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

WARNING

WARNING

a

wc_gr001359wc_gr001360

a

b

wc_tx000295gb.fm 46

4.16 Pressure Washing the Machine
When pressure washing the machine, avoid using harsh chemicalsand only use moderate water pressure (35–70 MPa [500–1000 psi]) . Avoid direct pressure to the following components:

• Engine

• Hydraulic

• Water tank/Plastic parts

• Hoses

• Labels

4.17 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 47

4.18 Hydraulic Schematic
7

16 6

8

10

11

13200 bar2900 psi

12100 bar1450 psi

5 4

1206 bar3000 psi

2

15

14

3P

10 micron

wc_gr003636

wc_tx000295gb.fm 48

4.19 Hydraulic Schematic Components


1 Exciter relief valve 9 Charge pump

2 Exciter control valve 10 Exciter pump

3 Exciter motor 11 Drive pump

4 Rear drive motor 12 Charge pressure relief valve

5 Front drive motor 13 Internal drive pump relief valves

6 Return filter 14 Porting block

7 Suction filter 15 Manifold

8 Pump assembly 16 Tank

wc_tx000295gb.fm 49

4.20 Hydraulic Diagram
wc_gr003637

15

28

11(9)(12)

1

10

6

7

16

3

14

4

5

13

wc_tx000295gb.fm 50

4.21 Hydraulic Diagram Components










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4.22 RD 7H-ES Electrical Schematic
wc_gr003663

1 2 3 4 5 62 13456

41

3

Br

P

B

R

0

8

wc_tx000295gb.fm 52

4.23 RD 7H-ES Electrical Schematic Components


1 Key switch 5 Starter

2 15 Amp fuse 6 Regulator

3 Alternator 7 Alarm

4 Battery 8 Oil pressure switch

Wire Colors

B Black R Red Y Yellow Or Orange

G Green T Tan Br Brown Pr Purple

L Blue V Violet Cl Clear Sh Shield

P Pink W White Gr Gray LL Light blue

wc_tx000295gb.fm 53

4.24 General Troubleshooting
Problem / Symptom Reason / Remedy

Engine does not start • Fuel tank empty.

• Wrong type of fuel.

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

• Fuel system not primed.

• Fuel filter restricted or plugged. Replace filter.

• Check/adjust valve clearance.

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

• Air cleaner element plugged.

• Check/adjust decompression device.

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

• Starter motor defective (RD 7H-ES).

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

• Key switch defective (RD 7H-ES).

Engine stops by itself • Fuel tank empty.

• Fuel filter plugged.

• Fuel lines broken or loose.

No vibration • Valve damaged.

• Exciter assembly damaged.

• Exciter motor coupling damaged or broken.

• Exciter motor damaged.

• Pump damaged.

No travelorTravel only in one direction

• Control cable loose or broken.

• Drive motor damaged.

• Drive pump damaged.

• Defective relief valve or valves.

wc_tx000295gb.fm 54

RD 7 /... Repair General

wc_tx000350gb.fm 55

5. General

5.1 Tools

Because all possible problems encountered while repairing themachine cannot be anticipated, it is up to the mechanic to use commonsense and good judgement in tool selection. The use of any special tools is recommended only for those operationswhere the use of conventional tools proves inadequate.Before substituting another tool or procedure, you should be satisfiedthat neither personal injury nor damage to the component will result.

5.2 Reference Numbers ( )

Repair procedures contain reference numbers enclosed inparentheses ( ). These numbers refer to the item numbers shown onthe assembly drawings and other detailed drawings. They are includedto aid the mechanic in identifying parts and assembling components.

5.3 Ordering Parts

The repair procedures contained in this manual do not include partnumbers. For parts replacement information, refer to the Parts Bookoriginally supplied with the machine. If the original Parts Book has been lost, a replacement may be orderedfrom Wacker Corporation. When ordering a replacement Parts Book,please list the model number, item number, revision level, and serialnumber of the machine. Parts Books are also available on the WackerCorporation Web site. See www.wackergroup.com. Enter the site as avisitor.

5.4 Repair Accessories

In order to avoid contamination of the hydraulic system while repairwork involving hydraulic hoses is performed, the following plastic capsand plugs for fitting ends are available:

PartNumber

Description(Male)

PartNumber

Description(Female)

0111709 Plug-fitting, #4 0111714 Cap-fitting, #4




0111713 Plug-fitting, #4, flare end 0111718 Cap-fitting, #4, flare end

Hydraulic System RD 7 /... Repair
6. Hydraulic System
6.1 Hydraulic System PrecautionsEscaping hydraulic oil under pressure, even a pinhole size leak, canpenetrate body tissue, causing serious injury, and possible death. If oilis injected into your skin, you must be treated immediately by a doctorfamiliar with this kind of injury.

• Always use a board or cardboard when checking for hydraulic oil leaks.

• Relieve the hydraulic pressure before working on the machine.

• Personal injury can result from contact with hot hydraulic oil.

• Use extreme care and wear appropriate clothing, such as gloves and safety glasses, when working with hot hydraulic oil.

6.2 Hydraulic System Service Basics

Many hydraulic system problems may be rectified by basic service andmaintenance tasks. Before attempting in-depth service procedures,carry out the basic hydraulic service procedures listed below.

• Top off the hydraulic oil supply with the correct type and grade of oil.

• Clean and tighten all the hydraulic fittings. Check the hoses for holes and/or leaks. Air within the hydraulic system can greatly affect machine performance.

• Check/change the hydraulic filter. Particles and debris in the filter are signs of failing component(s). Change the hydraulic oil and clean all components if there is debris found in the filter. Locate and replace the failing component(s) before operating the machine.

• Carry out hydraulic tests with the machine/hydraulic oil warm. Start and operate the machine at high idle for several minutes before conducting troubleshooting procedures. The hydraulic oil should be between 37.4–48.6°C (100–120°F).

WARNING

wc_tx000351gb.fm 56

RD 7 /... Repair Hydraulic System
6.3 Analyzing Hydraulic Oil Contamination
If the hydraulic oil becomes contaminated, premature componentfailure could occur. Contaminated oil can also contribute tooverheating. When inspecting the hydraulic oil filter for contamination,the type of contamination can help determine the probable cause ofproblems.

• Bronze colored particles suggest a pump or motor port plate failure.

• Shiny steel particles suggest pump or motor piston failure.

• Rubber particles indicate a seal failure or a hose failure.

• Aluminum particles suggest a steering and/or charge pump failure.

If any particles are found in the hydraulic filter element, all componentsof the hydraulic oil system must be cleaned. Do not use any damagedcomponents. Remove the damaged components and replace themwith new ones.

wc_tx000351gb.fm 57

6.4 General Description

The hydraulic system is powered by two pumps mounted in tandemand driven directly by the engine crankshaft through a flex coupling.Internal relief valves within the drive pump protect the drive motors andcomponents of the drive system.A relief valve (1) is located on the vibration manifold block. The hydraulic system is protected by a return line filter which removesparticles down to 10 microns and includes a by-pass relief valve to aidin cold weather start-up and to protect the system, should the filter beclogged.The hydraulic tank is equipped with a strainer at the fill port to trap largeobjects or particles which may accidentally fall into the tank whenadding hydraulic fluid. Additional system protection is provided by asuction filter mounted in-line with the exciter pump inlet.

6.5 Vibration Circuit


The vibration system is an open-loop series circuit driven by a fixeddisplacement, gear-type pump. Components of the vibration circuitinclude: the gear-type pump, a manifold block, a 3000-psi relief valve,a control valve, and the exciter motor. The vibration circuit is controlled by the exciter control valve. This valveis operated by an ON/OFF lever located on the handle. Supply oil fromthe pump enters the manifold where it is directed to the exciter controlvalve. When the lever is in the OFF position, the exciter control valveis open, allowing oil to pass through the system without driving theexciter motor. When switched to the ON position, the exciter controlvalve closes and oil from the pump is directed to the exciter motorwhich drives the eccentric weight between the drums. The relief valve(1), connected to the manifold, limits system pressure to 3000 psi (206bar).

wc_tx000351gb.fm 58

6.6 Hydraulic Manifold Block

1 Relief valve (3000 psi [206 bar]) 5 Exciter motor return line

2 Exciter control pressure lines 6 Porting block return line

3 Exciter pump pressure line 7 Filter bypass return line

4 Exciter motor pressure line - ---

wc_gr001503

1 2

3

4

5

6

7

wc_tx000351gb.fm 59

6.7 Drive Circuit
The drive system is a closed-loop circuit consisting of: a drive pump, amanifold, two relief valves, and front and rear drive motors arranged inseries. Both drive motors rotate at the same speed.The drive pump is a variable displacement, piston-type pump with anintegral charge pump. Charge pressure is maintained at 100 psi (7 bar)through an internal relief valve.The drive pump is manually actuated by the control lever mounted tothe end of the handle. When the control lever is shifted forward, oil isdirected from the high-pressure side of the drive pump to the manifoldblock, and downstream to both the front and rear drive motors. Returnflow from the drive motors is directed back through the manifold andreturns to the low-pressure side of the drive pump. When operating in reverse, the high- and low-pressure sides of thedrive pump are reversed.System pressure is limited to 2900 psi (200 bar) by two relief valves inthe drive pump.

6.8 Return Line Filter

The oil returning from the vibration function is directed out of themanifold to a return line filter. A back pressure valve located at thereturn line filter is used to protect the system. When pressure from theexciter circuit exceeds 14.5 psi (1 bar), the valve opens and the oilflows directly to the tank.

wc_tx000351gb.fm 60

6.9 Bleeding the Hydraulic System

6.9.1 Fill the hydraulic system with clean hydraulic oil until it is visible in thesightglass. Do not reuse used hydraulic oil.

6.9.2 Disconnect the line (1) from drive pump. Fill the pump case withhydraulic oil through the open connection. Reconnect the line.

6.9.3 Start the engine and run the machine at full throttle. Move the controlslowly back and forth from forward to reverse for a short time to bleedair trapped in the drive circuit.

6.9.4 Check the hydraulic oil level and add oil as required.

Note: If the drive pump chatters or operation is noisy, turn the machineoff and check for air leaks in the inlet line of the charge pump.

1

wc_gr001504

wc_tx000351gb.fm 61

6.10 Hydraulic Diagram









7

6

8

16

910

11

1320 mPa

2900 PSI

1210 mPa

1450 PSI

5 4

121 mPa

3000 PSI 2

3P 1

2

10 micron

wc_gr001361

wc_tx000351gb.fm 62


6.11 Hydraulic Schematic

wc_gr003637

15

28

11(9)(12)

1

10

6

7

16

3

14

4

5

13

wc_tx000351gb.fm 63

6.12 Testing Hydraulic Pressures
Before making pressure checks:

6.12.1 Inspect the machine for hydraulic leaks.

6.12.2 Check the level of hydraulic oil in the tank.

6.12.3 Check the engine operating speed at full throttle.

6.12.4 Run the machine for 5-10 minutes before testing to allow time for thehydraulic system to warm up.

Note: There are no designated test ports on the hydraulic block. Usepressure fittings and adapters designed for use with Wacker hydraulictest equipment.

Before opening the hydraulic connections, shut the engine off andmake sure all controls are in neutral.

6.13 Checking the Vibration Circuit


Test the vibration circuit with the machine on soil or gravel. If testing isdone indoors, position the machine on a heavy mat or old tires toabsorb the vibration. NOTICE: Do not run vibration on concrete.

6.13.1 Remove the vibration pressure line (1) from the hydraulic manifold (2).6.13.2 Install a #6 T-fitting (f) and a test fitting (d) into the manifold. Install a

5000 psi gauge (a) to the test fitting.

6.13.3 Start the engine and run the machine at full throttle with the forward/reverse control in neutral.

6.13.4 Switch the vibration on. The gauge will read relief pressuremomentarily as the exciter starts and then will fall to normal operatingpressure as the exciter reaches full speed.

If it is not possible to read the relief valve pressure accurately,disconnect the exciter motor inlet line (3) on the manifold. Cap off andplug open line connections both on the manifold and on the line. Startthe engine and run the test. If the pump is in working condition, thegauge will immediately come up to relief valve pressure and remainthere.

WARNING

wc_tx000351gb.fm 64


Ref. Description Part No. Part No.

a Pressure gauges 10 mPa (1000 psi) 0077999

30 mPa (5000 psi) 0078000

b Gauge adapter 0078005 -

c Hose 0078002 -

d Test fitting 0089203 -

e Hex nutORFS adapter

#6 0087227#6 0087228

#8 0116798#8 0116799

f T-Fitting #6 0083412 #8 0029099

wc_gr001505

a

32

1

c

b

d

e

f

wc_tx000351gb.fm 65

6.14 Checking the Drive Circuit

Operating PressureCheck operating pressures with the machine on a firm, level surface.

6.14.1 Remove the drive pressure line (3) from the hydraulic pump (1).6.14.2 Install a #6 T-fitting (2) and a test fitting (4) into the pump. Install a

5000-psi gauge onto the test fitting.

6.14.3 Start the engine and run it at full throttle.

6.14.4 Shift the control lever into either forward or reverse and read theoperating pressure.

Note: Operating pressures will increase significantly when running themachine uphill, off road or against an object.

Relief Pressure6.14.5 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 notclimb over them during testing.

6.14.6 Install a 5000-psi gauge in the test fitting (4).6.14.7 Start the engine and run the machine at full throttle. Shift the control

slowly into forward or reverse until the pressure on the gauge tops out.This is the forward or reverse relief valve pressure.

Note: Make sure the drums do not spin.

WARNING

wc_tx000351gb.fm 66


Normal OperatingPressure bar (psi)

Relief ValvePressure bar (psi)

Forward 69 (1000) 200 (2900)

Reverse 41 (600) 200 (2900)

Exciter 69 (1000) 206 (3000)

1

4

2

3

wc_gr001506

wc_tx000351gb.fm 67

6.15 Relief Valves

The relief valves are preset at the factory and normally do not requirefurther adjustment. Any valve adjustment is done by shims. However,adjusting relief valves is not recommended, as shims are not spareparts. Replace the complete relief valve. NOTICE: Do not increase pressures above machine specifications!Higher pressures can damage pumps and motors.

Drive Circuit ReliefsCurrent machines have relief valves (1) built into the drive pump.These relief valves are preset at 2900 psi (200 bar) and do not requirefurther adjustment unless they are operating at below therecommended setting.

Exciter Relief Pressure DO NOT remove the plug or attempt to set the valve while the engineis running or the system is under pressure!

6.15.1 Turn off the engine.

6.15.2 Remove the water tank (7) to access the vibration manifold. To do so,remove the two screws attaching the tank to the frame and remove thescrew (8) and the washer (9) from the bracket located under the watertank. Also remove the hose (10) and fitting (11).

6.15.3 Remove the plug (3) or the retaining ring (12) and from the end of thevalve (2) to access the adjusting screw.

6.15.4 Use a 1/4-inch Allen wrench (4) and turn the adjusting screw in or outas necessary.

6.15.5 Re-install the plug or the cap and retaining ring.

6.15.6 Start the engine and recheck the pressure.

6.15.7 If the valve needs further adjustment, turn off the engine and adjust itagain. Continue this process until the correct pressure (206 bar [3000psi]) is set.

WARNING

wc_tx000351gb.fm 68


wc_gr003668

1

2

3

4

1213

711

10

89

wc_tx000351gb.fm 69

Power Take-Off RD 7 /... Repair
7. Power Take-Off
7.1 Description


The pumps used to power the hydraulic system are driven directly bythe engine through a flywheel coupling or a clutch (1), depending onthe age of the machine. The pumps are connected along their shaftsthrough a solid mounted coupling (2).The exciter pump (3) is a fixed displacement, gear-type pump. Itprovides a constant flow of oil to the vibration circuit. A constant flowof oil equates to a constant speed. The drive pump (4) is a variable displacement, axial piston pump. Avariable flow of oil equates to a variable travel speed. The more flowthere is, the faster the travel speed. Flow through the drive pump iscontrolled by the angle of the pump’s swash plate. The pump’s swashplate is controlled through the movement of a lever attached to thepump’s control shaft (5). This provides for infinitely variable speedsbetween 0 (zero) and the top speed of 4.0 km/hr. (2.5 mph) forward,and 2.0 km/hr. (1.2 mph) reverse.Note: Wacker Corporation does not recommend the disassembly orattempted repair of hydraulic components (pumps, motors) by anyoneother than a trained hydraulic repair technician. Repair and rebuildingof hydraulic components may be available from componentmanufacturers. Hydraulic component parts are not available fromWacker Corporation.

wc_tx000352gb.fm 70

RD 7 /... Repair Power Take-Off
7.2 Pump Assembly
wc_gr001509

43 2

1

5

wc_tx000352gb.fm 71

7.3 Replacing the Drive Pump

RemovalNOTICE: The failure of a drive pump and/or motor, caused by factorsother than normal wear, can contaminate the drive circuit with metalparticles.

7.3.1 Thoroughly clean the pump and the hose connections.

Danger of burns! The pump may be hot—care must be taken whenremoving hydraulic components and oil. Hot oil can burn!

Before dismantling the hydraulic connectors or the hoses, ensure thatall pressure has been relieved from the circuit. Open the hose fittingsslowly.

7.3.2 Tag and disconnect the hose lines (1) from the pump. Cap or plug allopen connections. For recommended caps or plugs, see RepairAccessories.

7.3.3 Remove the support bracket (2) from the exciter pump (3). Save thelocknuts (4) and washers (5) for installation.

7.3.4 Remove the two locknuts (6) that secure the exciter pump to the drivepump (7) and remove the drive pump.

7.3.5 Remove two mounting screws (8) holding the drive pump to theengine/pump adapter.

7.3.6 Remove the control lever (9), hydraulic fittings (10), O-ring (11) andcoupling (12) and transfer them to the new pump.

Installation7.3.7 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 apump failure to remove any contaminants which may be trapped in thelines.

WARNING

WARNING

wc_tx000352gb.fm 72

Before you start the machine, ensure that all tools have been removedfrom the machine and that the replacement parts and adjusters arefirmly tightened.
WARNING

1

1011

9

7

8

10

1

1

12

54

2

6

3

wc_gr001510

wc_tx000352gb.fm 73

7.4 Exciter Pump

Removal7.4.1 Thoroughly clean the pump and the hose connections.

Danger of burns! The pump may be hot—care must be taken whenremoving hydraulic components and oil. Hot oil can burn!


7.4.2 Tag and disconnect hose lines (1) from exciter pump (3). Cap or plugall open connections. For recommended caps or plugs, see sectionRepair Accessories.

7.4.3 Remove the support bracket (2) from the exciter pump (3). Save thelocknuts (4) and the washers (5) for installation.

7.4.4 Remove the two locknuts (6) that secure the exciter pump to the drivepump (7) and remove the exciter pump.

7.4.5 Remove the O-ring (8), coupling (9) and fitting (10) and transfer themto the new pump.

Installation7.4.6 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 removedfrom the machine and that replacement parts and adjusters are firmlytightened.

WARNING

WARNING

WARNING

wc_tx000352gb.fm 74


1

10

8

71

9

54

2

6

3

wc_gr001511

wc_tx000352gb.fm 75

7.5 Replacing the Engine

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


7.5.1 Tag and disconnect all the hoses that are attached to the engine. Alsodisconnect the throttle cable.

7.5.2 Remove the pump support bracket (2) at the front of the hydraulicpumps (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 theHATZ 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 theengine to the frame.

7.5.6 Leaving the pumps mounted to the engine, lift the engine slightly tocheck 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 ormoved.

7.5.8 Remove the hydraulic pumps (3) and the pump adapter (9). On olderversions (10a), loosen the screw (15) and remove the coupler (14)from the shaft. A pry bar between the coupler and the shaft may beneeded. Remove the six screws (11) that secure the flywheel couplingto 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 clutchto the engine and remove the clutch.

WARNING

WARNING

wc_tx000352gb.fm 76


4

5

67

8

11

1415

10a

10b

17

16

1

2

3

13

12

9

wc_gr001512

wc_tx000352gb.fm 77

Installation
7.5.10 Apply Loctite 243 or an equivalent to the six screws (11) and securethe 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 thecoupler (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 securethe pump adapter (9) to the engine. Torque the screws to 51 ft.lbs. (69Nm).

7.5.13 Apply Loctite 243 or an equivalent to the two screws (13) and securethe 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'slifting 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), andnuts (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 controlcable may need to be adjusted. See section Direction LeverAdjustment.

7.5.22 The engine valve clearance may need to be adjusted. See sectionChecking and Adjusting Valve Clearances.

Note: See sealant and torque reference charts in the back of thismanual for the appropriate threadlocking adhesives and torque values.

Before starting the machine, ensure that all tools have been removedfrom the machine and that replacement parts and adjusters are firmlytightened.WARNING

wc_tx000352gb.fm 78

RD 7 /... Repair Roller
8. Roller
8.1 Drum - Description

The front and rear drums operate as static rollers to aid in smoothingand finishing.The front and rear drums are driven by hydraulic motors. Each motoris mounted to a drive hub which is mounted directly to the left side ofeach drum. The drive motor is designed to provide low speeds andhigh 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 rightside and is used to ensure that the machine will not roll when not inuse. The brake is mounted directly to the drum support and is engagedand disengaged by the operator.NOTICE: The parking brake is designed to hold the machine on anincline with the engine off. Do not drive against the parking brake in theengaged position. The brake may bend and damage the machine.Note: Wacker Corporation does not recommend the disassembly orattempted repair of hydraulic components (pumps, motors) by anyoneother than a trained hydraulic repair technician. Repair and rebuildingof hydraulic components may be available from componentmanufacturers. Hydraulic component parts are not available fromWacker Corporation.

wc_tx000353gb.fm 79

Roller RD 7 /... Repair
8.2 Replacing the Drum

RemovalStop the machine, apply the parking brake, and switch off the engine.NOTICE: Before removing the drum, clean and wash the completedrum assembly to remove as much dirt as possible. Be especiallythorough when cleaning the area around the tube and hoseconnections on the motors. This will minimize the chance ofcontamination when opening the hydraulic lines.

Before dismantling the hydraulic connectors or hoses, ensure that allpressure has been relieved from the circuit. Open hose fittings slowly.

8.2.1 Tag and disconnect the hydraulic lines to the drive motor. Cap or plugall open connections. For recommended caps or plugs, see sectionRepair Accessories.

8.2.2 Remove the four screws (1) that secure the porting block (2) to thelower frame. Pull the porting block out to access the three upperhydraulic lines. Tag, disconnect, and cap the three upper hydrauliclines (3) from the porting block.

8.2.3 Attach steel lifting ropes or chains from a suitable crane to themachine's lifting eye (4). Only use slings or chains for hoisting. The ropes, chains, and cranemust have the suitable specified lifting capacity—830 Kg.(1829 lbs.).Do not use improvised slings or chains.NOTICE: Never use any other part of the roller to lift the machine, assevere damage may occur. Do not stand under the machine while it is being lifted or moved.

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.

WARNING

WARNING

WARNING

wc_tx000353gb.fm 80


10

9

10

wc_gr003666

4

8

12

3

11

5

9

7

6

wc_tx000353gb.fm 81


Installation8.2.7 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 thehub 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 securethe drum support (6) to the drum hub assembly (7).

8.2.10 Apply Loctite 243 or an equivalent to the three screws (8) and securethe drum support (9) to the frame. Torque the screws to 120 Nm (88ft.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 (36ft.lbs.).

Before you start the machine, ensure that all tools have been removedfrom the machine and that replacement parts and adjusters are firmlytightened.WARNING

wc_tx000353gb.fm 82


10

9

10

wc_gr003666

4

8

12

3

11

5

9

7

6

wc_tx000353gb.fm 83

8.3 Drum Disassembly and Assembly

Drive-Side Disassembly8.3.1 Remove the drum from the machine. See section Replacing the Drum.

8.3.2 Stand the drum on end with the drive motor (1) facing up.

8.3.3 Note the angle at which the drive motor is mounted. Remove the fourscrews (2) that hold the drive motor and the drum support (3) to theouter drive hub (4a) and remove the drive motor and the drum support.

NOTICE: When removing the drive motor, care must be taken toensure that the splined shaft does not separate from the inside of themotor.

8.3.4 Remove the retaining ring (5) that secures the outer drive hub (4a) tothe shaft of the inner drive hub (6a).

8.3.5 Remove the retaining ring (7) holding the roller bearing (8) in the outerdrive hub (4a).

8.3.6 Press the roller bearing from the outer drive hub.

8.3.7 Remove the seals (12 & 13) from the outer drive hub.

To remove inner drive hub (6a) from the drum:8.3.8 Remove the four screws (9a).8.3.9 Remove the two plug screws (10) and washers (11) to expose the

puller holes. Install two M12 screws into the puller holes. Turn the M12screws until the inner drive hub (6a) is pulled free of the drum.

Drive-Side Assembly8.3.10 On newer machines (9408 rev. 108+; 9487 rev. 106+), place the V-ring

(17) onto the inner drive hub (6a). 8.3.11 Apply Loctite 243 or an equivalent to the four screws (9a). Then, using

the screws, mount the inner drive hub to the drum. Torque the screwsto 120 Nm (89 ft.lbs.).

8.3.12 Install the shaft seal (12) into the outer drive hub (4a). 8.3.13 Press the bearing (8) into the outer drive hub and secure it with the

retaining ring (7).8.3.14 Secure the seal (13) to the outer drive hub (4a) using high-temperature

RTV.

8.3.15 Place the outer drive hub (4a) over the shaft of the inner drive hub (6a).Make sure the seal (13) lays flat on the inner drive hub. Secure theouter drive hub to the inner drive hub with the retaining ring (5).

wc_tx000353gb.fm 84

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 toensure splined shaft does not separate from inside of motor.

wc_gr003664

1

4b

9a

9b

17

17

6a

6b

11

1110

10

13

13

12

12

144a

8

87

7

5

5

3

2

wc_tx000353gb.fm 85


Non-Drive Side Disassembly8.3.17 Remove the drum’s drive-side drive motor and components.

8.3.18 Stand the drum on end with the non-drive side facing up.

8.3.19 Remove the retaining ring (5) that secures the outer drive hub (4b) tothe shaft of the inner drive hub (6b).

8.3.20 Remove the retaining ring (7) that secures the roller bearing (8) in theouter drive hub (4b).

8.3.21 Press the roller bearing from the outer drive hub.

8.3.22 Remove the seals (12 & 13) from the outer drive hub.

To remove inner drive hub (6b) from the drum:8.3.23 Remove the four screws (9b).8.3.24 Remove the two plug screws and washers to expose the puller holes.

In their place, install two M12 screws. Turn the M12 screws until theinner drive hub (6b) is pulled free of the drum.

Non-Drive Side Assembly8.3.25 On newer machines (9408 rev. 108+; 9487 rev. 106+), place the V-ring

(17) onto the inner drive hub (6b). 8.3.26 Apply Loctite 243 or an equivalent to the four screws (9b). Then, using

the screws, mount the inner drive hub to the drum. Torque the screwsto 120 Nm (89 ft.lbs.).

8.3.27 Install the shaft seal (12) into the outer drive hub (4b). 8.3.28 Press the bearing (8) into the outer drive hub and secure it with the

retaining ring (7).8.3.29 Secure the seal (13) to the outer drive hub (4b) using high-temperature

RTV.

8.3.30 Place the outer drive hub (4b) over the shaft of the inner drive hub (6b).Make sure the seal (13) lays flat on the inner drive hub. Secure theouter drive hub to the inner drive hub with the retaining ring (5).

wc_tx000353gb.fm 86


wc_gr003664

1

4b

9a

9b

17

17

6a

6b

11

1110

10

13

13

12

12

144a

8

87

7

5

5

3

2

wc_tx000353gb.fm 87

8.4 Replacing the Exciter

RemovalNOTICE: Before removing the exciter, clean and wash the completeexciter assembly to remove as much dirt as possible. Be especiallythorough when cleaning the area around the tube and hoseconnections on the motors. This will minimize the chance ofcontamination when opening hydraulic lines.

8.4.1 Remove top cover (1) by removing six screws (2).8.4.2 Drain water tank by disconnecting hose (3) from fitting (4).8.4.3 Remove water tank (5) by removing two screws (6) attaching tank to

frame and remove the screw (7) and washer (8) from the bracketlocated under the water tank.

8.4.4 Drain the hydraulic oil. See section Changing Hydraulic Fluid and Filter- steps 1-4.

8.4.5 Tag and disconnect the three hydraulic hoses (9) from the excitermotor (10) and the three hoses (11) from the porting block (12). Before dismantling the hydraulic connectors or hoses, ensure that allpressure has been relieved from the circuit. Open hose fittings slowly.Note: In the interests of environmental protection, place a plastic sheetand a container under the machine to collect the liquid which drains off,and dispose of properly.

8.4.6 Remove both the front and rear plates (13) from the upper frame (14)by removing the two screws (15) on each plate.

8.4.7 Remove the shock mount screws (16) and washers (17) that securethe shock mounts (18) to the lower frame (19).

8.4.8 Support the machine by attaching a sling or chain to the lifting eye (20)using a suitable hook or shackle. Each lifting device must havecapacity of at least 1000 lbs. (454 Kg.).

Only use slings or chains for hoisting. The sling or chain must have thesuitable specified lifting capacity. Do not use improvised slings orchains. Do not stand under the machine while it is being hoisted or moved.NOTICE: Never use any other part of the roller to lift the machine, assevere damage may occur.

8.4.9 Remove the upper mass of the machine by using central lifting eye(20).

8.4.10 Remove the inner scraper bar (21) by removing the two center screws(22) and washers (23).

WARNING

WARNING

wc_tx000353gb.fm 88

8.4.11 Remove the four screws (24) and washers (25) that mount the exciter
assembly (26) to the lower frame (19).

wc_gr003667

a

C

A D

B

54

3

78

20

6

1513

1513

14

12

1716

26

27 18

25

24

19

21

2322

12

11

9

10

c

cb

b

wc_tx000353gb.fm 89

Installation
8.4.12 Place the exciter assembly (25) on the frame. Rock the housing on theframe 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 theframe between the threaded holes.

8.4.14 Apply Loctite 243 or an equivalent to the screws (24). Mount the exciterassembly to frame using the four screws (24) and the washers (25).Torque the screws in the pattern A, B, C, D. (a) following thissequence:

• 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 entirelength 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 thescrews to 86Nm. (63 ft.lbs).

8.4.19 Re-install both the front and the rear plates (13) and the screws (15) toupper frame (14).

8.4.20 Reconnect the three hydraulic hoses (9) to the exciter motor (10) andthe three hoses (11) to the porting block (12).

8.4.21 Fill the hydraulic tank with hydraulic oil (SAE 10W 30) until the oil levelis visible halfway up the sightglass. Run the engine briefly, then stopthe engine and check for leaks. Check the level in the sightglass, andtop 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 thismanual for appropriate threadlocking adhesives and torque values.


wc_tx000353gb.fm 90


wc_gr003667

a

C

A D

B

54

3

78

20

6

1513

1513

14

12

1716

26

27 18

25

24

19

21

2322

12

11

9

10

c

cb

b

wc_gr003667

a

C

A D

B

54

3

78

20

6

1513

1513

14

12

1716

26

27 18

25

24

19

21

2322

12

11

9

10

c

cb

b

wc_tx000353gb.fm 91

8.5 Exciter Assembly

Disassembly8.5.1 Remove the exciter assembly from the frame. See section Replacing

the Exciter.

8.5.2 Remove the four screws (1) that secure the exciter motor (2) to thecover plate (3) and remove the exciter motor.

8.5.3 Remove the ten screws (4) that secure the cover plates (3 & 8) to theexciter housing (5) and remove the cover plates.

8.5.4 Press the bearings (6a & 6b) and the shaft (7) as a unit from thehousing. Inspect the bearings for damage and replace them ifnecessary.

Assembly8.5.5 Press the non-motor side bearing (6b) into the exciter housing (5).8.5.6 Turn the housing on end with the motor side facing up, insert the shaft

(7) with the splined end facing up and press it into the lower bearing.

8.5.7 Press the motor side bearing (6a) into the housing and over the shaft.

8.5.8 Apply Loctite 243 or an equivalent to the ten screws (4) and secure thecover plates (3 & 8) to the housing. Torque the screws to 10 Nm (7ft.lbs.).

Note: The orientation of the cover plate (3) must be as shown in orderto install the exciter motor properly.

8.5.9 Apply Loctite 243 or an equivalent to the four screws (1) and securethe exciter motor (2) to the cover plate (3). Torque the screws to 10 Nm(7 ft.lbs.).

8.5.10 Install the exciter assembly into the frame. See section Replacing theExciter.

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2

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6b

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7

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8.6 Throttle Cable

Removal8.6.1 Remove the setscrew (1) holding the throttle cable (2) to the cam on

the engine.

8.6.2 Loosen the nut (3) and remove the cable support (4). 8.6.3 Pull the sleeve (5) from the cable support and remove the cable.

8.6.4 Loosen the nut (6) that secures the throttle control (7) to the bracket(8).Installation

8.6.5 Feed the throttle cable (2) through the bracket (8), sleeve (5) and cablesupport (4).

8.6.6 Press the sleeve into the cable support and mount the cable supportto bracket (9). Tighten the nut (3).

8.6.7 Feed the cable through the throttle pin (10). Before securing the cablewith the setscrew (1), adjust so that the machine runs at the specifiedspeed (rpm) at full throttle. See section Technical Data.

8.6.8 Secure the throttle control (7) to the bracket (8). Tighten the nut (6). Before starting the machine, ensure that all tools have been removedfrom the machine and that replacement parts and adjusters are firmlytightened.WARNING

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wc_gr001517

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4

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7

86

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10

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8.7 Direction Cable

Removal8.7.1 Remove the four screws (8) that secure the covers (9) to expose the

handle linkage.

8.7.2 Remove the clevis (1) from the pivot bracket (2). Unscrew the clevisfrom the spring-loaded, cable centering device (5).

8.7.3 Remove the small locknut (11) from the end of the cable.

8.7.4 Loosen the nut (4) on the spring-loaded, cable centering device (5). 8.7.5 Unscrew the spring-loaded, cable centering device from the cable (3).8.7.6 Loosen the nut (6) that mounts the cable to the bracket (7).8.7.7 Remove the cable ball end (10) from the pivot plate. Unscrew the cable

ball end from the cable.

8.7.8 Loosen the nut on the cable that secures the cable to the handlebracket (12) and remove the cable.

Installation8.7.9 Feed the cable (3) through the handle frame. Screw the cable end into

the cable ball end (10).8.7.10 Mount the cable ball end to the pivot plate.

8.7.11 Mount the cable to the handle bracket (12).8.7.12 Remove the small locknut (11) from the end of the cable. Then, feed

the cable into the spring-loaded, cable centering device (5). Screw thespring-loaded, cable centering device onto the end of the cable untilthe cable bottoms out. Re-install the locknut.

8.7.13 Screw the clevis (1) onto the cable end.

8.7.14 Tighten the nut (4) on the spring-loaded, cable centering device.

8.7.15 Mount the cable to the bracket (7). Tighten the nut (6). 8.7.16 Attach the clevis (1) to the pivot bracket (2).8.7.17 Before mounting the covers, the cable needs to be adjusted properly.

See section Direction Lever Adjustment.


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wc_gr003670

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45

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8.8 Direction Control Lever

Removal8.8.1 Remove the four screws (1) that secure the covers (2) to the handle

frame (3) and remove the covers.

8.8.2 Disconnect the cable ball end (4) from the pivot plate (5).8.8.3 Remove the screw (6) holding the lever assembly to the frame.

8.8.4 Remove the shaft (7) and the spring (8).8.8.5 Remove the pivot hub (9) from the pivot plate (5) by disconnecting the

retaining ring (10). Press the bearing (11) from the pivot hub.

8.8.6 Press the pin (12) from the direction handle (13).8.8.7 Press the bearing (14) from the direction handle.

To remove plunger shaft:8.8.8 Unscrew the plunger (16) from the shaft end (17).8.8.9 Slide the spring (18) off of the shaft and pull the shaft through the guide

handle (19).8.8.10 Press the two bearings (20) from the guide handle.

Installation8.8.11 Press the bearing (14) into the direction handle (13).

Note: Make sure the bearing is flush with the backside of the directionhandle.

8.8.12 Apply Loctite 271 or an equivalent to the pin (12) and press it into thedirectional handle 22 ±0.25 mm (0.90 ±0.01 in).

8.8.13 Press the bearing (11) into the pivot hub (9). Note: Make sure the bearing is flush with the front side of the pivot hub.

8.8.14 Insert the pivot hub into the pivot plate (5) and secure it with theretaining ring (10).

8.8.15 Slide the spring over the shaft.

8.8.16 Insert the shaft (7) through the spring (8), pivot hub (9) and directionhandle (13), and mount to the handle frame (3) using the screw (6) andnut (15).

8.8.17 Reattach the cable ball end (4) to the pivot plate (5).8.8.18 Apply Loctite 243 or an equivalent to the four screws (1) and install the

covers (2) to the handle frame. Torque the screw to 18 ft.lbs. (25 Nm).

To install the plunger shaft:8.8.19 Press the two bearings (20) into the guide handle (19).

wc_tx000353gb.fm 98

Note: Make sure the bearings are flush with both sides of the guidehandle.
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 screwthe plunger (16) onto the end of the shaft.


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Troubleshooting RD 7 /... Repair
9. Troubleshooting
9.1 General

The troubleshooting charts which follow provide basic guidelines tohelp you diagnose and remedy equipment problems. Keep in mind thatevery possible problem cannot be anticipated. Should questions ariseduring the service or repair of this equipment please contact WackerCorporation for assistance.Before removing any parts or making adjustments, conduct a visualinspection of the machine and check for:

9.1.1 Dirty air and fuel filters.

9.1.2 Rocks or dirt obstructing the movement of the drums, and scraper barassemblies.

9.1.3 Leaks in the hydraulic lines and fittings.

9.1.4 Low oil levels in the engine crankcase, exciter and hydraulic tank.

9.1.5 Loose mounting hardware on the pumps or motors.

9.1.6 Broken linkage and cables.

wc_tx000354gb.fm 100

RD 7 /... Repair Troubleshooting
9.2 Vibration System

No vibration. • Vibration valve not on or defective. Check function of the valve and replace it if necessary.

• Exciter motor or bearings seized. Check exciter motor & bearings.

• Exciter pump failure. Check exciter system pressure. Replace the exciter pump if necessary.

Vibration slow. • Engine speed too low. Run engine at full speed. Check engine rpm and vibration vpm.

• Exciter motor and/or bearing binding. Remove exciter motor. Rotate motor and shafts by hand.

• Exciter pump failure. Check exciter system pressure. Replace the exciter pump if necessary.

• Exciter motor worn. Check vibration speed and operating pressure.


9.3 Troubleshooting the Vibration System
The exciter pump is designed to put out a constant flow of oil at a setengine speed. This ensures that the vibration frequency remainssteady. When troubleshooting the exciter circuit, the vibration speedshould be measured along with the operating and relief pressures tohelp 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 oilup to normal operating temperatures.

9.3.2 Check the engine rpm using a tachometer. The engine must berunning at the correct rpm to accurately measure vibration.

9.3.3 Position the roller on a rubber mat and start vibration. Hold thevibrotach (P/N 53397) against the outer rim on the drum and measurethe vibration speed.

9.3.4 The vibration speed along with the operating and relief valve pressurescan be used to determine the condition of the exciter system as shownin the chart below.

If the exciter is binding (causing high operating pressures), it will benecessary to disconnect and remove the exciter motor from thehousing to determine if the binding is occurring in the exciter bearingsor in the motor. Turn the motor shaft and exciter shaft by hand andcheck that they turn freely.

N = Normal, L = Low, H = High

Engine rpm vpm minimum

2700–2900 3300

OperatingPressure

Pump ReliefPressure Exciter Speed Probable Cause

N N N System OK.

H N N or L Exciter bearings or motor binding.

N or L N L Exciter motor worn.

L L LExciter pump damaged or worn, relief valve defective or needs adjusting.


9.4 Drive System

Machine does not climb grade.

• Drums spinning. Ground material loose or slippery.

• Grade too steep. Measure angle of grade.

• Relief pressure low or relief valve defective. Check relief pressure. Replace or adjust relief valve.

• Drive pump or drive motors damaged or worn. Consult Wacker Corporation.

Machine does not travel or travels slowly or erratically.

• Engine speed too low. Run engine at full throttle. Check engine rpm.

• Hydraulic fluid cold or wrong type. Allow fluid to warm up. Check fluid against specifications.

• Control cable ends disconnected or broken. Check cable and connections. Repair or replace as required.

• Control lever pin sheared. Check and repair.

• Drive bearings seized. Inspect drive bearings. Check bearing lubrication.

• Drive pump worn or defective. Consult Wacker Corporation. Replace pump.

• Drive motor worn. Consult Wacker Corporation. Replace motor.

• Relief valve pressure low. Check and adjust relief valve.

• Air trapped in hydraulic oil. Check suction hose. Tighten connections or replace.


9.5 Troubleshooting the Drive System

Checking for bindingHigh operating pressures indicate binding in the drive system. Bindingcan occur in the drive motor or may be the result of a poor or failingdrive bearing located on the right side of the drum. To check for binding:

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

9.5.2 Remove the drum. See section Replacing the Drum.

9.5.3 Attempt to lift the drum by the drum support (1). If a metallic click orclang can be heard and there is any play in the bearing, the bearing isfailing; replace it.

9.5.4 Remove the drive motor (2) from the drum support.

NOTICE: When removing the drive motor, care must be taken toensure that the splined shaft does not separate from the inside of themotor.

9.5.5 Attempt to turn the drum hub by hand. If you cannot turn the drum hubby hand, the bearing is binding; replace it.

9.5.6 Attempt to turn the drive motor shaft by hand. If the drive motor shaftbinds, rebuild or replace the drive motor.



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Checking Drive MotorsFailure of the drive circuit to reach operating pressures is normallycaused by a worn or damaged drive pump, although the problem couldalso 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 (1430lbs.). NOTICE: Use only the lifting eye of the roller to lift the machine. Usingany 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 therevolutions of each drum as they spin. Look for a significant differencein the speed of one drum over the other. Conduct the same test in withthe direction lever in the full REVERSE position. If one drum spinsfaster than the other in both directions, the motor spinning the slowdrum may have failed.

By checking the flow from the drive motor case drain hoses, one cantell if the drive motor seals are functioning. When new, the drive motorswill 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 drivemotor.

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 leverin the full FORWARD position, collect all the oil that drains from thedrive 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 sothat the rear drum is up against an abutment such as a brick wall orconcrete barricade.

9.5.17 With the throttle at full and the forward/reverse control lever in the fullREVERSE position, collect all oil that drains from the drive motor overa one-minute time period.

WARNING


• 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.

9.6 Starting System


Engine turns over but will not start or starts hard.

• Fuel tank is empty. Fill fuel tank.

• Wrong type of fuel. Use correct fuel type.

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

• Fuel filter restricted or plugged. Replace fuel filter.

• Incorrect valve clearance. Check/adjust valve clearance.

• Air cleaner element plugged. Check and replace air filter.

• Vibration switch on, loading down hydraulic system. Turn switch off.

• Hydraulic oil or engine oil too heavy. Check specifications and fill with correct oil.

• Temperature is too cold. Warm engine. Change engine oil to a higher grade.


Notes

Threadlockers and Sealants


Threadlocking adhesives and sealants are specified throughout thismanual by a notation of “S” plus a number (S#) and should be usedwhere indicated. Threadlocking compounds normally break down attemperatures above 175°C (350°F). If a screw or bolt is hard toremove, heat it using a small propane torch to break down the sealant.When applying sealants, follow instructions on container. The sealantslisted are recommended for use on Wacker equipment.

TYPE( ) = Europe COLOR USAGE

PART NO. –SIZE

Loctite 222Hernon 420Omnifit 1150 (50M)

Purple Low strength, for locking threads smaller than 6 mm (1/4”).Hand tool removable.Temp. range: -54 to 149°C (-65 to 300°F)

73287 - 10 ml


Blue Medium strength, for locking threads larger than 6 mm (1/4”).Hand tool removable.Temp. range: -54 to 149°C (-65 to 300°F)

29311 - .5 ml17380 - 50 ml

Loctite 271/277Hernon 427Omnifit 1550 (220M)

Red High strength, for all threads up to 25 mm (1”).Heat parts before disassembly.Temp. range: -54 to 149°C (-65 to 300°F)

29312 - .5 ml26685 - 10 ml73285 - 50 ml

Loctite 290Hernon 431Omnifit 1710 (230LL)

Green Medium to high strength, for locking preassembled threads and for sealing weld porosity (wicking).Gaps up to 0.13 mm (0.005”)Temp. range: -54 to 149°C (-65 to 300°F)

28824 - .5 ml25316 - 10 ml

Loctite 609Hernon 822Omnifit 1730 (230L)

Green Medium strength retaining compound for slip or press fit of shafts, bearings, gears, pulleys, etc.Gaps up to 0.13 mm (0.005”) Temp. range: -54 to 149°C (-65 to 300°F)

29314 - .5 ml


Brown Hydraulic sealantTemp. range: -54 to 149°C (-65 to 300°F)

79356 - 50 ml

Loctite 592Hernon 920Omnifit 790

White Pipe sealant with Teflon for moderate pressures.Temp. range: -54 to 149°C (-65 to 300°F)

26695 - 6 ml73289 - 50 ml

Loctite 515Hernon 910Omnifit 10

Purple Form-in-place gasket for flexible joints.Fills gaps up to 1.3 mm (0.05”)Temp. range: -54 to 149°C (-65 to 300°F)

70735 - 50 ml


Threadlockers and Sealants (continued)

Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container. The sealants listed are recommended for use on Wacker equipment.

TYPE( ) = Europe COLOR USAGE

PART NO. –SIZE

Loctite 496Hernon 110Omnifit Sicomet 7000

Clear Instant adhesive for bonding rubber, metal and plastics; general purpose.For gaps up to 0.15 mm (0.006”)Read caution instructions before using.Temp. range: -54 to 82°C (-65 to 180°F)

52676 - 1oz.

Loctite Primer THernon Primer 10Omnifit VC Activator

AerosolSpray

Fast curing primer for threadlocking, retaining and sealing compounds. Must be used with stainless steel hardware. Recommended for use with gasket sealants.

2006124-6 oz.

Torque Values

Torque Values

Metric Fasteners (DIN)

TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE

Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch

M3 1.2 *11 1.6 *14 2.1 *19 5.5 7/32 2.5 –

M4 2.9 *26 4.1 *36 4.9 *43 7 9/32 3 –

M5 6.0 *53 8.5 6 10 7 8 5/16 4 –

M6 10 7 14 10 17 13 10 – 5 –

M8 25 18 35 26 41 30 13 1/2 6 –

M10 49 36 69 51 83 61 17 11/16 8 –

M12 86 63 120 88 145 107 19 3/4 10 –

M14 135 99 190 140 230 169 22 7/8 12 –

M16 210 155 295 217 355 262 24 15/16 14 –

M18 290 214 405 298 485 357 27 1-1/16 14 –

M20 410 302 580 427 690 508 30 1-1/4 17 –

1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm

8.8 10.9 12.9

Torque Values

Torque Values (continued)

Inch Fasteners (SAE)

Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch

No.4 0.7 *6 1.0 *14 1.4 *12 5.5 1/4 – 3/32

No.6 1.4 *12 1.9 *17 2.4 *21 8 5/16 – 7/64

No.8 2.5 *22 3.5 *31 4.7 *42 9 11/32 – 9/64

No.10 3.6 *32 5.1 *45 6.8 *60 – 3/8 – 5/32

1/4 8.1 6 12 9 16 12 – 7/16 – 3/32

5/16 18 13 26 19 33 24 13 1/2 – 1/4

3/8 31 23 45 33 58 43 – 9/16 – 5/16

7/16 50 37 71 52 94 69 16 5/8 – 3/8

1/2 77 57 109 80 142 105 19 3/4 – 3/8

9/16 111 82 156 115 214 158 – 13/16 – –

5/8 152 112 216 159 265 195 24 15/16 – 1/2

3/4 271 200 383 282 479 353 – 1-1/8 – 5/8

1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm

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

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