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Operator’s Manual
Roller
RD 7
EN
Copyright notice
© Copyright 2013 by Wacker Neuson Production Americas LLCAll rights, including copying and distribution rights, are reserved.This publication may be photocopied by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permission from Wacker Neuson Production Americas LLC.Any type of reproduction or distribution not authorized by Wacker Neuson Production Americas LLC represents an infringement of valid copyrights. Violators will be prosecuted.
Trademarks All trademarks referenced in this manual are the property of their respective owners.
Manufacturer Wacker Neuson Production Americas LLCN92W15000 Anthony AvenueMenomonee Falls, WI 53051 U.S.A.Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957www.wackerneuson.com
Original instructions
This Operator’s Manual presents the original instructions. The original language of this Operator’s Manual is American English.
RD 7 Foreword
ForewordSAVE THESE INSTRUCTIONS—This manual contains important instructions for the machine models below. These instructions have been written expressly by Wacker Neuson Production Americas LLC and must be followed during installation, operation, and maintenance of the machines.;
Machine identification
A nameplate listing the model number, item number, revision number, and serial number is attached to this machine. The location of the nameplate is shown above.
Serial number (S/N)
For future reference, record the serial number in the space provided below. You will need the serial number when requesting parts or service for this machine.
Machine documentation
From this point forward in this documentation, Wacker Neuson Production Americas LLC will be referred to as Wacker Neuson.Keep a copy of the Operator’s Manual with the machine at all times. Use the separate Parts Book supplied with the machine to order replacement parts. Refer to the separate Repair Manual for detailed instructions on servicing and repairing the machine.If you are missing any of these documents, please contact Wacker Neuson to order a replacement or visit www.wackerneuson.com. When ordering parts or requesting service information, be prepared to provide the machine model number, item number, revision number, and serial number.
Machine Item NumberRD 7H-ES 0009408, 0620794RD 7H-S 0009487, 0620795RD 7-RAW 0620079, 0620478, 0620596
wc_gr010180
Serial Number:
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Foreword RD 7
Expectations for information in this manualThis manual provides information and procedures to safely operate and maintain the above Wacker Neuson model(s). For your own safety and to reduce the risk of injury, carefully read, understand, and observe all instructions described in this manual. Wacker Neuson expressly reserves the right to make technical modifications, even without notice, which improve the performance or safety standards of its machines.The information contained in this manual is based on machines manufactured up until the time of publication. Wacker Neuson reserves the right to change any portion of this information without notice.The illustrations, parts, and procedures in this manual refer to Wacker Neuson factory-installed components. Your machine may vary depending on the requirements of your specific region.
CALIFORNIA Proposition 65 Warning
Combustion exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
Laws pertaining to spark arresters
NOTICE: State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed to prevent accidental dis-charge of sparks or flames from the engine exhaust. Spark arresters are qualified and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator.
Manufacturer’s approval
This manual contains references to approved parts, attachments, and modifica-tions. The following definitions apply:
Approved parts or attachments are those either manufactured or provided by Wacker Neuson. Approved modifications are those performed by an authorized Wacker Neuson service center according to written instructions published by Wacker Neuson.Unapproved parts, attachments, and modifications are those that do not meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following conse-quences:
Serious injury hazards to the operator and persons in the work areaPermanent damage to the machine which will not be covered under warranty
Contact your Wacker Neuson dealer immediately if you have questions about approved or unapproved parts, attachments, or modifications.
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EC Declaration of Conformity
ManufacturerWacker Neuson Production Americas LLC, N92W15000 Anthony Avenue, Menomonee Falls, Wisconsin 53051 USA
Product
Product
Product category
Product function
Item number
Net installed power
Measured sound power level
Guaranteed sound power level
RD 7H-ES, RD 7H-S
Vibrating Walk-Behind Rollers
To compact asphalt
0620794, 0620795
6.1 kW
106 dB(A)
108 dB(A)
Conformity Assessment ProcedureAccording to 2000/14/EC ANNEX VIII
Notified BodyLloyds Register Verification Limited (Notified Body No 0038)71 Fenchurch Street, London EC3M 4BS, United Kingdom
Directives and StandardsWe hereby declare that this product meets and complies with the relevant regulations and requirements of the following directives and standards:
2006/42/EC, 2000/14/EC, 2005/88/EC, 2004/108/EC, EN 500-1, EN 500-4
Authorized Person for Technical DocumentsLeo Goeschka, Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, 80809 München
Menomonee Falls, WI, USA, 17.03.2015
Paul SinaManager, Product EngineeringFor Wacker Neuson
Dan DomanskiTechnical DirectorFor Wacker Neuson
Original Declaration of Conformity
Keith HerrManaging DirectorFor Wacker Neuson
Table of ContentsRD 7
Foreword 3EC Declaration of Conformity 5
1 Safety Information 9
1.1 Signal Words Used in this Manual ....................................................... 91.2 Machine Description and Intended Use ............................................. 101.3 Safety Guidelines for Operating the Machine ..................................... 111.4 Service Safety .................................................................................... 131.5 Operator Safety while Using Internal Combustion Engines ............... 151.6 Hydraulic Fluid Safety ........................................................................ 16
2 Labels 18
2.1 Label Locations .................................................................................. 182.2 Label Meanings .................................................................................. 19
3 Lifting and Transporting 25
4 Operation 27
4.1 Preparing the Machine for First Use ................................................... 274.2 Control / Component Locations .......................................................... 284.3 Components ....................................................................................... 294.4 Refueling the Machine ........................................................................ 304.5 Exciter ................................................................................................ 314.6 Back-Up Stop Pad .............................................................................. 314.7 Engine Crank ...................................................................................... 314.8 Parking Brake ..................................................................................... 324.9 Watering System ................................................................................ 324.10 Functions of the Engine Throttle Control ............................................ 334.11 Direction and Speed Control .............................................................. 344.12 Before Starting ................................................................................... 354.13 Position of the Operator ..................................................................... 354.14 Starting the Machine (RD 7H, RD 7H-S) ............................................ 364.15 Starting the Machine (RD 7H-ES) ...................................................... 384.16 Cold Weather Starting (RD 7H, RD 7H-S) ......................................... 394.17 Engine Speed ..................................................................................... 424.18 Stopping the Machine ......................................................................... 424.19 Emergency Shutdown Procedure ....................................................... 434.20 Machine Stability ................................................................................ 434.21 Operation on Slopes ........................................................................... 444.22 Rollovers ............................................................................................ 44
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Table of Contents RD 7
5 Maintenance 45
5.1 Periodic Maintenance Schedule ..........................................................455.2 Safety-Related Spare Parts .................................................................465.3 Checking Engine Oil Level ..................................................................485.4 Changing the Engine Oil .....................................................................495.5 Fuel System ........................................................................................515.6 Engine Air Filter ...................................................................................525.7 Checking and Adjusting the Valve Clearances ...................................535.8 Engine Cooling System .......................................................................545.9 Mechanical Oil Pressure Monitoring ....................................................555.10 Scraper Bars .......................................................................................565.11 Water Spray Bars ................................................................................575.12 Hydraulic Oil Requirements .................................................................585.13 Hydraulic Oil Level ..............................................................................595.14 Changing Hydraulic Fluid and Filter ....................................................605.15 Direction Lever Adjustment .................................................................615.16 Pressure Washing the Machine ..........................................................635.17 Storing the Machine ............................................................................635.18 Machine Disposal / Decommissioning .................................................64
6 Troubleshooting 65
7 Technical Data 66
7.1 Engine .................................................................................................667.2 Roller ...................................................................................................677.3 Lubrication ...........................................................................................677.4 Sound and Vibration Specifications .....................................................68
8 AEM Safety Manual 69
9 Schematics 96
9.1 Hydraulic Schematic ............................................................................969.2 Hydraulic Schematic Components ......................................................979.3 Hydraulic Diagram ...............................................................................989.4 Hydraulic Diagram Components .........................................................999.5 RD 7H-ES—Electrical Schematic ......................................................1009.6 RD 7H-ES—Electrical Schematic Components ................................101
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RD 7 Safety Information
1 Safety Information1.1 Signal Words Used in this ManualThis manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE signal words which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service.
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation which, if not avoided, could result in property damage.
Note: A Note contains additional information important to a procedure.
This is the safety alert symbol. It is used to alert you to potential personal hazards.Obey all safety messages that follow this symbol.
DANGERDANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
To avoid death or serious injury from this type of hazard, obey all safety messages that follow this signal word.
WARNINGWARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
To avoid possible death or serious injury from this type of hazard, obey all safety messages that follow this signal word.
CAUTIONCAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
To avoid possible minor or moderate injury from this type of hazard, obey all safety messages that follow this signal word.
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Safety Information RD 7
1.2 Machine Description and Intended UseThis machine is a dual drum vibratory walk-behind roller. The Wacker Neuson Walk-Behind Roller consists of an upper frame to which are mounted a diesel engine, a hydraulic tank, a water tank, and a hydrostatic drive system; and a lower frame which supports two steel drums, an exciter assembly, and a handle. The engine powers the hydraulics that provide machine movement and drum vibration. The vibrating drums smooth and compact the work surface as the machine moves. The operator uses the handle to control machine speed and direction.
This machine is intended to be used for compacting sand, gravel, soil, and asphalt on roadways, walkways, bridges, and parking lots.
This machine has been designed and built strictly for the intended use described above. Using the machine for any other purpose could permanently damage the machine or seriously injure the operator or other persons in the area. Machine damage caused by misuse is not covered under warranty.
The following are some examples of misuse:Using the machine as a ladder, support, or work surfaceUsing the machine to carry or transport passengers or equipmentUsing the machine to tow other machinesUsing the machine to spray liquids other than water (i.e., diesel fuel on asphalt)Operating the machine outside of factory specificationsOperating the machine in a manner inconsistent with all warnings found on the machine and in the Operator’s Manual.
This machine has been designed and built in accordance with the latest global safety standards. It has been carefully engineered to eliminate hazards as far as practicable and to increase operator safety through protective guards and labeling. However, some risks may remain even after protective measures have been taken. They are called residual risks. On this machine, they may include exposure to:
Heat, noise, exhaust, and carbon monoxide from the engineBurns from hot hydraulic fluidFire hazards from improper refueling techniques Fuel and its fumesPersonal injury from improper lifting techniques or operating techniques
To protect yourself and others, make sure you thoroughly read and understand the safety information presented in this manual before operating the machine.
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RD 7 Safety Information
1.3 Safety Guidelines for Operating the MachineOperator training
Before operating the machine:Read and understand the operating instructions contained in all manuals delivered with the machine.Familiarize yourself with the location and proper use of all controls and safety devices. Contact Wacker Neuson for additional training if necessary.
When operating this machine:Do not allow improperly trained people to operate the machine. People operating the machine must be familiar with the potential risks and hazards associated with it.
Operator qualifications
Only trained personnel are permitted to start, operate, and shut down the machine. They also must meet the following qualifications:
have received instruction on how to properly use the machineare familiar with required safety devices
The machine must not be accessed or operated by:childrenpeople impaired by alcohol or drugs
Contact Wacker Neuson for additional training if necessary.
Application area
Be aware of the application area. Keep unauthorized personnel, children, and pets away from the machine.Remain aware of changing positions and the movement of other equipment and personnel in the application area/job site.
Be aware of the application area.Do not operate the machine in areas that contain flammable objects, fuels, or products that produce flammable vapors.
Safety devices, controls, and attachments
Only operate the machine when:All safety devices and guards are in place and in working order.All controls operate correctly.The machine is set up correctly according to the instructions in the Operator’s Manual.The machine is clean.The machine’s labels are legible.
To ensure safe operation of the machine:Do not operate the machine if any safety devices or guards are missing or inoperative.Do not modify or defeat the safety devices. Only use accessories or attachments that are approved by Wacker Neuson.
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Safety Information RD 7
Safe operating practicesWhen operating this machine:Remain aware of the machine’s moving parts. Keep hands, feet, and loose clothing away from the machine’s moving parts.Operate the machine with both of your feet on the ground! Do not stand, sit, or ride on machine while in operation.Remain aware of changing surface conditions and use extra care when operating over uneven ground, on hills, or over soft or coarse material. The machine could shift or slide unexpectedly.Use caution when operating near the edges of pits, trenches or platforms. Check to be sure that the ground surface is stable enough to support the weight of the machine with the operator and that there is no danger of the roller sliding, falling, or tipping. Position yourself safely when operating machine in reverse or on hills. Leave enough space between yourself and the machine so you will not be placed in a hazardous position should the machine slide or tip.
When operating this machine:Do not operate a machine in need of repair.Do not subject the roller to jarring impacts by driving it off curbs or off the back of a truck or trailer.Do not transport the machine while it is running.Do not operate a machine in need of service or repair.
Personal Protective Equipment (PPE)
Wear the following Personal Protective Equipment (PPE) while operating this machine:
Close-fitting work clothes that do not hinder movementSafety glasses with side shieldsHearing protectionSafety-toed footwear
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RD 7 Safety Information
1.4 Service SafetyService training
Before servicing or maintaining the machine:Read and understand the instructions contained in all manuals delivered with the machine.Familiarize yourself with the location and proper use of all controls and safety devices. Only trained personnel shall troubleshoot or repair problems occurring with the machine.Contact Wacker Neuson for additional training if necessary.
When servicing or maintaining this machine:Do not allow improperly trained people to service or maintain the machine. Personnel servicing or maintaining the machine must be familiar with the associated potential risks and hazards.
Precautions Follow the precautions below when servicing or maintaining the machine.Read and understand the service procedures before performing any service to the machine.All adjustments and repairs must be completed before operation. Do not operate the machine with a known problem or deficiency.All repairs and adjustments shall be completed by a qualified technician.Turn off the machine before performing maintenance or making repairs.
Machine modifications
When servicing or maintaining the machine:Use only accessories/attachments that are approved by Wacker Neuson.
When servicing or maintaining the machine:Do not defeat safety devices. Do not modify the machine without the express written approval of Wacker Neuson.
Replacing parts and labels
Replace worn or damaged components.Replace all missing and hard-to-read labels.When replacing electrical components, use components that are identical in rating and performance to the original components.When replacement parts are required for this machine, use only Wacker Neuson replacement parts or those parts equivalent to the original in all types of specifications, such as physical dimensions, type, strength, and material.
Cleaning When cleaning and servicing the machine:Keep the machine clean and free of debris such as leaves, paper, cartons, etc.Keep the labels legible.
When cleaning the machine:Do not clean the machine while it is running.Never use gasoline or other types of fuels or flammable solvents to clean the machine. Fumes from fuels and solvents can become explosive.
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Safety Information RD 7
Personal Protective Equipment (PPE)Wear the following Personal Protective Equipment (PPE) while servicing or maintaining this machine:
Close-fitting work clothes that do not hinder movementSafety glasses with side shieldsHearing protectionSafety-toed footwear
In addition, before servicing or maintaining the machine:Tie back long hair.Remove all jewelry (including rings).
Safe service practices
Check all external fasteners at regular intervals.Some service procedures require that the machine’s battery be disconnected. To reduce the risk of personal injury, read and understand the service procedures before performing any service to the machine.Turn engine off before servicing machine. If the engine has electric start, disconnect negative terminal on battery.Before you start the machine, ensure that all tools have been removed from the machine and that replacement parts and adjusters are firmly tightened.
After Use Stop the engine when the machine is not being operated.Close the fuel valve, if equipped, when machine is not being operated.Ensure that the machine will not tip over, roll, slide, or fall when not being operated.Store the machine in a clean, dry location out of the reach of children.
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RD 7 Safety Information
1.5 Operator Safety while Using Internal Combustion EnginesOperating safety
When running the engine:Keep the area around exhaust pipe free of flammable materials.Check the fuel lines and the fuel tank for leaks and cracks before starting the engine. Do not run the machine if fuel leaks are present or the fuel lines are loose.
When running the engine:Do not smoke while operating the machine.Do not run the engine near sparks or open flames.Do not touch the engine or muffler while the engine is running or immediately after it has been turned off.Do not operate a machine when its fuel cap is loose or missing. Do not start the engine if fuel has spilled or a fuel odor is present. Move the machine away from the spill and wipe the machine dry before starting.
Refueling safety
When refueling the engine:Clean up any spilled fuel immediately.Refill the fuel tank in a well-ventilated area.Replace the fuel tank cap after refueling.Use suitable tools for refueling (for example, a fuel hose or funnel).
When refueling the engine:Do not smoke.Do not refuel a hot or running engine.Do not refuel the engine near sparks or open flames.
WARNINGInternal combustion engines present special hazards during operation and fueling. Failure to follow the warnings and safety standards could result in severe injury or death.
Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below.
DANGERExhaust gas from the engine contains carbon monoxide, a deadly poison. Exposure to carbon monoxide can kill you in minutes.
NEVER operate the machine inside an enclosed area, such as a tunnel, unless adequate ventilation is provided through such items as exhaust fans or hoses.
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Safety Information RD 7
1.6 Hydraulic Fluid SafetySafety instructions
Inspect the hydraulic system thoroughly before operating the machine.Do not touch hydraulic fluid or hydraulic components while the machine is operating. Wait until the machine is cool.Before disconnecting hydraulic fittings or hoses, ensure that all pressure has been bled from the circuit. Set all controls in neutral, turn engine off, and allow the fluids to cool before loosening hydraulic fittings or attaching test gauges.Hydraulic fluid escaping under high pressure may penetrate the skin, cause burns, blind, or cause other serious injuries or infections. Contact a physician immediately for treatment if your skin has been penetrated by hydraulic fluid, even if the wound seems minor.Fluid leaks from small holes are often practically invisible. Do not use your bare hands to check for leaks. Check for leaks using a piece of cardboard or wood.Hydraulic fluid is extremely flammable. Stop the engine immediately if a hydraulic leak is detected.After servicing the hydraulics, make sure all components are reconnected to the proper fittings. Failure to do so may result in damage to the machine and/or injury to a person on or near the machine.
WARNINGPossibility of severe injury. Hydraulic fluid is under high pressure and becomes very hot during operation.
To avoid injury, obey the safety instructions listed below.
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RD 7 Safety Information
Noteswc_si000744gb.fm17
Labels RD 7
2 Labels2.1 Label Locations
wc_gr010241
O
K
P
E
A
R
F
M
L
G
B
C
D
H
JN
Q
S
V
T
U
W
XP
R
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RD 7 Labels
2.2 Label MeaningsA NOTICENo lift point
B Vibration control ON/OFF
C Read and understand the supplied Operator’s Manual before operating the machine. Failure to do so increases the risk of injury to yourself and others.
D
AND
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Labels RD 7
— Check engine oil level.Use SAE10W30.
Check the fuel level.
— Engage parking brake.
— Turn vibration off.
— Place throttle in the FAST position.
— Pull decompression lever up.
— Insert crank handle.
— Rotate crank handle counterclockwise 5X.
— Remove crank handle.
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RD 7 Labels
— Disengage parking brake.E Low sulfur fuel or ultra low sulfur fuel only.
F DANGERAsphyxiation hazard
Engines emit carbon monoxide. Do not run the machine indoors or in an enclosed area unless adequate ventilation, through such items as exhaust fans or hoses, is provided. Read the Operator’s Manual. No sparks, flames, or burning objects near the machine. Stop the engine before refueling.
G CAUTIONUse only clean, filtered diesel fuel
H WARNINGHot surface
J WARNINGHot surface
0178715
STOP
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Labels RD 7
K Tie-down pointL Engine oil drain
M Parking brake
N Throttle control lever:Rabbit = Full or FastTurtle = Idle or Slow
O Key switch, engine start:OffOnStart
P NOTICELifting point
178709
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RD 7 Labels
Q Operator’s Manual must be stored on machine.A replacement Operator’s Manual can be ordered through your local Wacker Neuson dis-tributor.
R WARNINGTo prevent hearing loss, wear hearing protec-tion when operating the machine.
S Water control valve
T Tie-down point
U This machine may be covered by one or more patents.
V Guaranteed sound power level in dB(A).
W Hydraulic oil drain
��
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� � � � � � � # � � � � � � � � � � � � � � ! � �
� � � � � # � $ � � � � � � � � � � � � � � �
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Labels RD 7
X Hydraulic oil reservoir fill
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RD 7 Lifting and Transporting
3 Lifting and TransportingRequirements Lifting equipment (sling or chain) capable of supporting the machine’s weight.
Lifting Follow the procedure below to lift the machine.
1. Stop the engine.
2. Engage the parking brake.
3. Attach a sling or chain to the lifting eye (a) using a suitable hook or shackle.
4. Only use steel ropes or chains for hoisting. Do not use improvised ropes or chains.
NOTICE: Do not use any other part of the roller to lift the machine, as severe damage may occur.
5. Lift the machine as necessary.
Transporting Follow the procedure below to transport the machine.
Before transporting the machine:place blocks in front of and behind each drum.use the front and rear tie-down (c) to secure the machine to the trailer.place the lift handle (b) into the upright position.
NOTICE: Only use the tie-downs to secure the machine. Do not use any other part of the roller to tie the machine down as severe damage to the machine may occur.
WARNINGCrushing hazard. You may be crushed if the lifting devices fail.
Never stand under, or get onto, the machine while it is being lifted or moved.Use only steel ropes or chains for hoisting. Do not use improvised ropes or chains.Use only the designated lifting points to lift the machine.
wc_gr010323
b
c
a
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Lifting and Transporting RD 7
Noteswc_tx003241gb.fm26
RD 7 Operation
4 Operation4.1 Preparing the Machine for First Use1. Make sure all loose packaging materials have been removed from the machine.
2. Check the machine and its components for damage. If there is visible damage, do not operate the machine! Contact your Wacker Neuson dealer immediately for assistance.
3. Take inventory of all items included with the machine and verify that all loose components and fasteners are accounted for.
4. Attach component parts not already attached.
5. Add fluids as needed and applicable, including fuel, engine oil, and battery acid.
6. Move the machine to its operating location.
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Operation RD 7
4.2 Control / Component Locationswc_gr010228
1
2
11114
35
17
18
1920
2122
2324
25
26
28
13
14
3
116
15
9
10
16
7
8
11
12
27
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RD 7 Operation
4.3 ComponentsRef. 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 Shockmount (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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Operation RD 7
4.4 Refueling the MachineRequirements Machine shut downEngine coolMachine/fuel tank level with the groundFresh, clean fuel supply
Procedure Perform the procedure below to refuel the machine.
1. Remove the fuel cap.
2. Fill the fuel tank until the fuel level gauge indicates that the tank is full.
3. Re-install the fuel cap.
Result The procedure to refuel the machine is now complete.
WARNINGFire hazard. Fuel and its vapors are extremely flammable. Burning fuel can cause severe burns.
Keep all sources of ignition away from the machine while refueling.Do not refuel if the machine is positioned in a truck fitted with a plastic bed liner. Static electricity can ignite the fuel or fuel vapors.Refuel only when the machine is outdoors.Clean up spilled fuel immediately.
CAUTIONFire and health hazard. Fuel expands when heated. Expanding fuel in an over-filled tank can lead to spills and leaks.
Do not overfill the fuel tank.
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RD 7 Operation
4.5 ExciterThe exciter provides the vibration and can be used in most applications involving cohesive-type soils with heavy clay content, as well as loose soils and gravel.
NOTICE: DO NOT run the machine over hard surfaces like concrete with the vibration on. Damage to the drum bearings may result.
4.6 Back-Up Stop Pad
A back-up stop pad (a) is mounted to the machine. The back-up stop pad operates in reverse only.
If the machine backs into an obstruction or if the operator becomes trapped between the machine and the obstruction, the pad will be pressed and the machine will stop. With the stop pad activated, the machine can move only in the forward direction.
4.7 Engine Crank
The engine crank is equipped with kick-back damping to protect the operator from injury should the engine backfire. The brief reverse rotation at the handle tube (a) separates the link between the crank lug (b) and the driving dog (c).
STOP
a
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a cb
wc_gr001345
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Operation RD 7
4.8 Parking BrakeIntroduction The parking brake is used to ensure that the machine will not roll when not in use.It engages the weld stops on the drum, therefore movement in either direction is possible before the brake will catch and stop the machine. With the engine on or off, the parking brake is designed to hold the machine if on an incline of 22° (40% grade) or less.
Procedure To disengage the parking brake:
Rotate the handle (a) 90° clockwise until it seats in the shallow detent.
To engage the parking brake:
Rotate the handle (a) 90° counterclockwise until it seats in the deep detent.
NOTICE: Do not drive against the parking brake in the engaged position. The brake may bend and damage the machine.
4.9 Watering System
The RD 7 is equipped with a water control valve which allows the roller to be used wet or dry, and a sprinkler system to distribute the water evenly across the drums. The water is gravity-fed to the sprinklers when the control valve is in the OPEN (horizontal) position (a).
wc_gr001343
a
wc_gr010230
a
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RD 7 Operation
4.10 Functions of the Engine Throttle ControlThe engine throttle control has three positions.
Ref. Position Function
a High Starting and running the machine
b Low Periods of long idling
c Off Stopping the machine
wc_gr010207
a
b
c
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Operation RD 7
4.11 Direction and Speed ControlIntroduction Travel direction and speed are controlled by the forward/reverse control lever (a).Direction From the neutral position: To move forward, push the control lever away from the operator.To move in reverse, pull the control lever towards the operator.
Speed Speed is varied by the movement of the control lever. The farther the lever is pushed in either direction, the faster the roller will travel in that direction.
wc_gr010227
b
a
WARNINGPossible loss of machine control. A loose grip on the handle may cause it to pivot rapidly during operation.
Hold the handle with both hands while operating the machine. See Position of the Operator.
WARNINGPossible loss of machine control. If the linkage separates from the directional lever while the machine is running, the roller could “run away” and cause injury.
If the linkage separates, set the throttle control (b) to the OFF position.
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RD 7 Operation
4.12 Before StartingBefore starting the machine, check the following:Engine oil levelAir cleaner maintenance indicatorFuel levelHydraulic fluid levelWater tank level
4.13 Position of the Operator
Safe and efficient use of this machine is the operator’s responsibility. Full control of the machine is not possible unless the operator maintains the proper working position at all times.
While operating this machine, the operator must:stand or walk behind the machine, facing forward with the handle directly aheadhold the handle with one hand and activate the control lever with the other hand
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Operation RD 7
4.14 Starting the Machine (RD 7H, RD 7H-S)Requirements Fuel in the tank.Procedure Perform the procedure below to start the machine.
1. Check that the exciter (a) is in the OFF position.
2. Set the throttle control (b) to the high idle position.
3. Turn the decompression lever (c) until stop (c1) is reached. In this position, the automatic decompression system is heard to engage.
4. Insert the engine crank (d) into the guide sleeve (e).5. Turn the crank five turns to build up pressure for the engine to fire.
This procedure continues on the next page.
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c1
c0 c
ba
de
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RD 7 Operation
Continued from the previous page.6. Stand alongside the engine, facing the back of the machine (f) and grasp the crank with both hands. Firmly hold the crank to maintain contact all the time between the starting handle and the engine.
7. Turn the engine crank slowly until the pawl engages the rachet, then increase the turning force to build up speed.
Note: The highest speed must be reached when the decompression lever (c) returns to the (c0) position.
8. As soon as the engine has started, pull the engine crank out of the guide sleeve. Note: If backfiring occurs when starting the engine because the crank handle was not turned firmly enough, the brief reverse rotation at the handle tube separates the link between the crank lug and the driving dog.
9. If the engine begins to run backwards after backfiring (smoke emerges from air cleaner), release the crank handle immediately and stop the engine.
10. To restart the engine, wait until it has come to a standstill, then repeat the starting procedures.
11. Allow engine to warm up for a few minutes before operating machine.
WARNINGPersonal injury hazard. Injury may result if the engine should backfire.
Stand alongside the engine, facing the back of the machine. Do not stand in any other position.Maintain turning force during the entire hand starting operation.
wc_gr010214
f
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Operation RD 7
4.15 Starting the Machine (RD 7H-ES)Requirements Fuel in the tank.Procedure Perform the procedure below to start the machine.
1. Check that the exciter (a) is in the OFF position.
2. Set the throttle control (b) to the high idle position.
3. Turn the ignition switch (c) to start the engine.
NOTICE When the key is in the ON position, an alarm will sound. The alarm is a reminder to turn the key to the OFF position when the machine is not in use. Failure to do this will result in a dead battery.Do not crank the engine starter for more than 15 seconds at one time. Cranking the engine longer than 15 seconds could lead to starter damage. Allow 30 seconds between cranking attempts.
Note: The alarm will stop when proper oil pressure is reached.
4. Allow the engine to warm up for a few minutes before operating the machine.
wc_gr010217
c
b
a
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RD 7 Operation
4.16 Cold Weather Starting (RD 7H, RD 7H-S)Requirements Fuel in the tankFree-flowing lubricating oil
Procedure Perform the procedure below to start the machine at temperatures below approximately -5°C (23°F). Always turn the engine over to ensure that it rotates freely.
1. Check that the exciter switch (a) is in the OFF position.
2. Set the throttle control (b) to the high idle position.
3. Move the decompression lever (c) to a position that is approximately halfway between (c0) and (c1).
4. Insert the engine crank (d) into the guide sleeve (e).5. Turn the engine over with the engine crank until it is felt to rotate more freely
(10–20 turns of the engine crank).
This procedure continues on the next page.
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c1
c0 c
f
ba
de
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Operation RD 7
Continued from the previous page.6. Clean around the cover of the metering device (f), then:remove the cover (g)fill with free-flowing lubricating oil (h) until the level reaches the upper rimpress the cover on firmly
Note: Two filling operations in succession are needed.
7. Turn the decompression lever until limit stop (c1).8. Stand alongside the engine, facing the back of the machine (j) and grasp the
engine crank with both hands. Hold the engine crank firmly to maintain contact between the starting handle and the engine.
9. Turn the handle slowly until the pawl engages the rachet, then increase the turning force to build up speed.
Note: The highest speed must be reached when the decompression lever (c) returns to the (c0) position.
This procedure continues on the next page.
wc_gr010225
g
f
h
WARNINGPersonal injury hazard. Injury may result if the engine should backfire.
Stand alongside the engine, facing the back of the machine. Do not stand in any other position.Maintain turning force during the entire hand-starting operation.
wc_gr010234
j
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RD 7 Operation
Continued from the previous page.10.As soon as the engine has started, pull the starting handle out of the guide sleeve.
Note: If backfiring occurs when starting the engine because the crank handle was not turned firmly enough, the brief reverse rotation at the handle tube separates the link between the crank lug and the driving dog.
11.If the engine begins to run backwards after backfiring (smoke emerges from air cleaner), release the crank handle immediately and stop the engine.
12.To restart the engine, wait until it has come to a standstill, then repeat the starting procedures.
13.Allow engine to warm up for a few minutes before operating machine.
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Operation RD 7
4.17 Engine SpeedDuring operation, run the engine at full throttle. This ensures maximum exciter speed and will produce the best compaction.
4.18 Stopping the MachineProcedure Perform the following procedure to stop the machine.
1. Place the exciter switch (a) in the OFF position.
2. Close the water control valve (b).3. Set the throttle control (c) to the OFF position to stop the engine.
4. On electric-start machines, turn the engine switch (d) to the OFF position.
5. Apply the parking brake.
6. Clean the scraper bars before storing the machine.
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d
ca
b
CAUTIONPossible loss of machine control. If the throttle control fails, the engine may get stuck in high idle.
Pull up on the decompression lever to stop the engine.Decompression lever may be hot. Wear protective gloves to prevent injury.
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RD 7 Operation
4.19 Emergency Shutdown ProcedureIf a breakdown or accident occurs while the machine is operating, follow the procedure below:
1. Stop the engine.
2. Close the fuel valve.
3. Allow the machine to cool.
4. Contact the rental yard or machine owner for further instructions.
4.20 Machine Stability
Surface conditions
Pay attention to changing surface conditions while operating the machine. Adjust speed and travel direction as necessary to maintain safe operation.
Machine stability and traction may be severely reduced when operating on uneven or rough terrain, rocky soils, or wet or loosely packed surface material. The machine may suddenly tip, sink, or fall when moved onto surfaces that have been newly filled with earth.
Travel speed A fast moving machine is more likely to tip or fall over while making turns or changing direction.
Reduce travel speed before turning the machine.
Drum overhang
The machine can tip suddenly if more than half of the drum width extends beyond the edge of the elevated surface.
Reduce travel speed and watch the drum position carefully when operating along the edge of an elevated surface.Keep as much of the drum on the elevated surface as possible.
Vibrating on a compacted surface
Activating the vibratory system on a fully compacted surface may cause the drums to rebound and momentarily lose contact with the ground. If this occurs while the machine is on an incline, the machine may slide.
If the drums rebound on the compacted surface, reduce vibration speed or stop vibration entirely.
WARNINGCrushing hazards. Certain job site conditions or operating practices may adversely affect machine stability.
Follow the instructions below to reduce the risk of tipping or falling incidents.
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Operation RD 7
4.21 Operation on SlopesWhen operating on slopes or hills, special care must be taken to reduce the risk of personal injury or damage to the machine. Always operate the machine up and down hills rather than from side to side. For safe operation and for protection of the engine, continuous duty use should be restricted to slopes of 22° (40% grade) or less.
Do not operate the machine sideways on slopes. The machine may roll over, even on stable ground.
4.22 RolloversProper operation of the machine on slopes will prevent rollovers. Read and follow Safety instructions in “Operating Safety” and “Operation on Slopes”. If a machine rollover does occur, care must be taken to prevent damage to the engine. In this position, oil from the engine crankcase can flow into the combustion chamber, which can severely damage the engine next time it is started. If the machine has rolled on its side, immediate steps should be taken to right the machine.
NOTICE: To prevent damage to the engine after a rollover, the machine must NOT be started, AND it must be serviced to remove any oil that may have been trapped in the combustion chambers. Contact your local Wacker Neuson dealer for instructions or servicing.
WARNING
22°40%
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RD 7 Maintenance
5 Maintenance5.1 Periodic Maintenance ScheduleThe table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and equipment.
Refer to the engine manufacturer’s manual for more information.
Dailybefore
starting
Afterfirst
25 hr1
Every250hr
Every500hr
Every1000
hr
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.2
Change hydraulic system return line filter.
Check and adjust scraper bars.
Check linkage components.3
Clean battery terminals (RD 7H-ES).
Change hydraulic oil and filter.1For new or reconditioned engines.CAUTION: DO NOT tighten cylinder head fastenings.2Change after first 100 hours.3Maintain linkages more frequently in dusty environments. Lubricating linkages is not recommended. However, if necessary, use a dry lubricant that does not attract dust.
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Maintenance RD 7
5.2 Safety-Related Spare PartsOverview This machine is equipped with a back-up stop pad to enhance operator safety. Foryour convenience, we have provided the following diagram and list of replacement parts for this safety-related feature.
For a complete list of spare parts for this machine, contact your Wacker Neuson dealer or visit www.wackerneuson.com.
Upper handle diagram
28
20
77
141137132
15
145137132
16
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RD 7 Maintenance
Upper handle parts listRef. Part No. Qty. Description Measurement and Torque
15 0112307 1 Handle
16 0155442 1 Rod
20 0112351 1 Spring
28 0155441 1 Disc
77 0112391 2 Bearing 20 x 20
132 0010367 4 Lock nut M8
137 0010622 10 Flat washer B8,4
141 0011310 2 Hex head screw M8 x 8525 Nm / 18 ft.lbs
145 0011346 2 Hex head screw M8 x 6525 Nm / 18 ft.lbs
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Maintenance RD 7
5.3 Checking Engine Oil LevelEngine oil levelStop the machine, switch off the engine and apply the parking brake.
Check the oil with the machine standing on a level surface.
1. Clean around the dipstick.
2. Check the oil level on the extended dipstick (a). If necessary, top up to the “max” mark.
The engine may be hot enough to cause burns! Allow the engine to cool prior to servicing.
WARNING
wc_gr001348
a
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RD 7 Maintenance
5.4 Changing the Engine OilPrerequisites Before changing the oil:Run the machine to warm the oil. Park the machine on a flat level surface. Set all controls in neutral, stop the engine, apply the parking brake, and allow the engine and fluids to cool.
.
Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid that drains off. Dispose of this liquid in accordance with environmental protection legislation.
Procedure 1. Unscrew the oil drain plug and allow the oil to drain into a 1–1.5 liter (1–1.5 quarts) container.
2. Clean the oil drain plug and attach a new seal to it.
3. Reinstall the drain plug.
4. Unscrew the filler cap of the oil filter housing. Check the condition of the O-ring (a) on the filler cap and replace it if it is damaged.
This procedure continues on the next page.
WARNINGBurn hazard. Engine and exhaust pipe become extremely hot during operation.
Stop the engine and allow the machine to cool before changing the engine oil.
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a
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Maintenance RD 7
Continued from the previous page.5. Remove the used filter element. Install a new filter element with the “TOP” mark facing up.
6. Add engine oil up to the “MAX” mark on the dipstick; approximately 1.1–1.2 liters (1–1¼ quarts).
7. Wet the O-ring and threads of the filler plug with high-temperature grease available from your Hatz Dealer. Then, reinstall the filler plug.
8. Run the engine for two minutes. Turn off the engine and check the engine oil level again. Add engine oil as necessary.
9. Make sure that there is no oil leakage past the filler cap.
WARNINGMost used oil contains small amounts of materials that can cause cancer and other health problems if inhaled, ingested, or left in contact with skin for prolonged periods of time.
Take steps to avoid inhaling or ingesting used engine oil. Wash skin thoroughly after exposure to used engine oil.
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RD 7 Maintenance
5.5 Fuel SystemFuel tank water trapThe interval at which you should check the water trap depends upon the amount of water in the fuel. The normal interval is one week.
Stop the machine, switch off the engine, and apply the parking brake.
1. Remove the cover from the roller to allow access to the fuel tank water trap.
2. Loosen the hex screw (a) until only 2 threads are holding it in place.
3. Trap the drops of water that emerge in a transparent container.Note: Since water has a higher specific gravity than diesel fuel, the water emerges first. The two substances separate at a clearly visible line.
4. When only diesel fuel emerges, retighten the hex screw.
NOTICE: Diesel fuel destroys shock mounts. Clean up fuel spillage immediately.
Changing the fuel filter cartridge
Fuel filter maintenance intervals depend on the purity of the diesel fuel used. If your fuel is dirty, perform this operation at 250 hours.
Stop the machine, switch off the engine, and apply the parking brake.
Explosion hazard! Diesel fuel is flammable and must be treated withthe necessary caution. Do not smoke near the machine. Avoid sparksand open flames.
1. Remove the cover from the roller to allow access to the fuel filter.
2. Place a suitable container under the fuel filter to trap escaping fuel.
3. Close the fuel supply line.
4. Pull the fuel supply line (b) off of the fuel filter trap (c) at both sides, and insert the new filter.
NOTICE: Keep the area clean to prevent dirt from entering the fuel lines.
5. Make sure the fuel filter is oriented with the arrow in the direction of fuel flow.
6. Open the fuel supply line until fuel begins to flow.
7. Run the engine briefly to check the fuel filter and lines for leaks.
WARNING
ac
b
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Maintenance RD 7
5.6 Engine Air FilterChecking the air cleaner blockage indicator1. 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.
2. In dusty operating conditions, check the rubber bellows several times per day.Cleaning or replacing the engine air filterThe engine may be hot enough to cause burns! Allow the engine to cool prior to servicing.
3. Loosen the wing nut (b) and remove it. Also remove the air cleaner cover (c).Note: The decompression lever will also come off.
4. Pull out the filter cartridge (e).5. Check that the valve plate (f) for the air blockage indicator is clean and in good
condition.Cleaning dry dirt from the filter cartridge
6. Blow through the filter cartridge from the inside using a compressed air gun.
7. Continue until all dust has been removed.
NOTICE: Only use filtered, dry compressed air. Do not exceed an air pressure of more than 5 bar (70 psi). Keep the nozzle at a distance of 150 mm (6 in.) from the element.
Cleaning wet or oily dirt from the filter
8. Change the filter cartridge.
NOTICE: Always trace and correct the cause of wet or oily contamination of a filter element.
Checking the filter cartridge
9. Hold the element up to a light or pass a lamp through the middle to check the condition of the element folds (g).
10.Check that the sealing surface (d) is in good condition.
NOTICE: If there is even slight damage to the paper filter element or the sealing surface, replace the filter cartridge.
WARNING
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RD 7 Maintenance
5.7 Checking and Adjusting the Valve ClearancesStop the machine, apply the parking brake and switch off the engine.
1. Make sure that the compression lever is in position “0”. See section Starting the Machine.
2. Remove the cylinder head cover and the gasket.
3. Turn the engine over in the normal direction of rotation until compression is felt.
4. Check the inlet valve clearance between the rocker and the valve stem using a feeler gauge (a).
5. If the valve clearance is incorrect, loosen the hex nut (c).Note: See section Technical Data for valve clearances.
6. Turn the adjusting screw (b) with a screwdriver until the feeler gauge (a) can just be pulled through between the rocker and the valve stem with slight resistance to its movement after the nut (c) has been retightened.
7. Repeat this adjustment with the outlet valve.
8. Place a new gasket under the cylinder head cover, reinstall the cylinder head cover, and tighten down the screws uniformly.
9. Run the engine briefly and make sure that the cylinder head cover is not leaking.
b
wc_gr001353
a b
c
b c
de
fg
wc_gr001352
a b c
d
e
fg
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Maintenance RD 7
5.8 Engine Cooling SystemStop the machine, apply the parking brake and switch off the engine. The engine must be allowed to cool down before cleaning.
Dry contamination
1. Clean all air guide elements and the complete cooling air zones (a) on the cylinder head and the cylinder and flywheel blades without making them wet. Blow them dry with compressed air.
Moist or oily contamination
2. Clean the entire area with a solvent or cold cleaner according to its manufacturer's instructions, then spray down with a high pressure water jet. Blow them dry with compressed air.
3. Trace the source of oil leaks causing greasy dirt. Repair the leaks, seeking advice of your Hatz dealer if necessary.
4. After cleaning, run the engine to dry it out and to prevent the formation of rust.
wc_gr001354
a
a
a
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RD 7 Maintenance
5.9 Mechanical Oil Pressure MonitoringThe 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.
1. Add fuel.
2. Check the engine oil level.
3. To activate the oil pressure monitor, press the lever (a).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 are mentioned on the label (b) placed on the engine.
NOTICE: Even with the mechanical oil pressure control monitoring the oil level, it must be checked every 8–15 operating hours.
a
wc_gr002338
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Maintenance RD 7
5.10 Scraper BarsCheck the four scraper bars (a) for wear. Replace the scraper bars as needed.Cleaning the scraper bars
The scraper bars should be cleaned daily after use or as often as needed to remove built-up dirt, mud, and tar.
Use a high-pressure water jet and a strong brush if needed.
wc_gr001355
a
a a
a
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RD 7 Maintenance
5.11 Water Spray BarsBackground Clogged or dirty spray bars can prevent water from spraying onto the drums. If water spray is noticeably reduced or absent even though there is water in the tank, then clean the spray bars.
Procedure Follow the procedure below to clean the spray bars.
1. The spray bars (a) are located behind the drum scrapers.
2. Start the machine. Activate the spray system and check for free flow of water through each spray hole (b).
3. If any of the spray holes are blocked, use a small pointed object (i.e. a stiff piece of wire) to remove the blockage.
4. Rinse the spray bars with clean water and dry with a soft, clean cloth.
NOTICE: The cap (c) and fitting (d) are not removable.
wc_gr007078
a
ab
a
c
d
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Maintenance RD 7
5.12 Hydraulic Oil RequirementsWacker Neuson recommends the use of a premium grade, petroleum-based hydraulic oil with anti-wear and anti-foam characteristics. Good anti-wear oils contain additives to reduce oxidation, prevent foaming, and provide for good water separation. These oils offer superior motor and pump life.
When selecting hydraulic oil for your machine, be sure to specify anti-wear properties. Wacker Neuson offers a premium grade hydraulic oil for use in this machine.
Avoid mixing different brands and grades of hydraulic oils.
Oil Viscosity Most hydraulic oils are available in different viscosities. The SAE number for an oil is used strictly to identify viscosity. It does not indicate the type of oil (engine, hydraulic, gear, etc.). The higher the SAE number, the thicker the oil.
For normal applications use a good non-detergent, anti-wear, hydraulic oil with a viscosity rating of SAE 10W30.
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RD 7 Maintenance
5.13 Hydraulic Oil LevelA hydraulic oil level sightglass (a) is located on the hydraulic tank and is visible through the slots on the top cover.
Check the oil level with the machine standing on a level surface. The oil level should be at the halfway mark on the sightglass. If the level is low, remove the top cover and top up with hydraulic oil as necessary.
If hydraulic oil continually needs to be added, inspect the hoses and connections for possible leaks. Repair hydraulic leaks immediately to prevent damage to the hydraulic components.
a
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Maintenance RD 7
5.14 Changing Hydraulic Fluid and FilterStop the machine, switch off the engine, and apply the parking brake with the machine standing on a level surface.Note: In the interests of environmental protection, place plastic sheeting and a container under the machine to collect the liquid which drains off. Dispose of this liquid properly.
1. Remove the top cover of the roller.
2. Remove the drain plug (b) from the end of the drain hose that is attached to the hydraulic tank.
3. Allow the hydraulic oil to drain into a suitable container.
4. When all the oil has drained out, reinstall the drain plug back into the hose and secure it in place.
5. Place a plastic bag around the filter (a) to contain any oil spillage.
6. Unscrew the old hydraulic filter.
7. Install the new hydraulic filter. Screw the new hydraulic filter on by hand, making sure that it is not cross-threaded.
NOTICE: Use only original spare parts.
8. Tighten the hydraulic filter using both hands.
9. Fill the hydraulic tank with hydraulic oil until the level is visible halfway up the sightglass.
10.Run the engine briefly, then stop the engine and check for leaks.
11.Check the oil level in the sightglass, and top up if necessary.
a
b
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RD 7 Maintenance
5.15 Direction Lever AdjustmentThe forward/reverse control lever should have long forward travel and short reverse travel. If the lever appears out of adjustment, it can be re-adjusted as follows:
1. Start the engine. Place the forward/reverse control lever in the NEUTRAL position (N). Confirm that the machine does not creep. If the machine does creep, turn the large adjusting nut (4) on the spring-loaded, cable centering device (5) so that the machine does not creep.
2. Stop the engine.
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 full FORWARD position, the drive pump control arm should rotate, in the direction shown, as far as possible. If the drive pump control arm rotates as far as possible, no further adjustment is required.If the drive pump control arm does not rotate as far as possible, continue.
4. Disconnect the clevis (1) from the pivot (2).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 FORWARD position, adjust the clevis and lock nut (8) so that it can hold the drive pump control arm in the fully rotated position. Reattach the clevis to the pivot.
Note: If the adjustment cannot be made with the clevis alone, adjust the linkage (10).
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.
7. Turn off the engine.
8. Adjust the nut (4) on the spring-loaded, cable centering device as needed so that the machine remains stationary when the control lever is in the NEUTRAL position. Start the engine and recheck for machine creeping/movement. It may take several attempts to find the correct position. Loosen the nuts (6) holding the cable (3) to the bracket (7) and reposition the cable if necessary.
The maximum allowable reverse travel speed is 2 km/hr. Do not adjust the direction control lever so that reverse travel speed is greater than 2 km/hr. (1.2 mph).
CAUTION
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Maintenance RD 7
2
10
9
r
nf1 2
3
45
7
8
6
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RD 7 Maintenance
5.16 Pressure Washing the MachineWhen pressure washing the machine, avoid using harsh chemicals and only use moderate water pressure (35–70 MPa [500–1000 psi]) .
Avoid direct pressure to the following components: EngineHydraulicWater tank/plastic partsHosesLabels
5.17 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).
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Maintenance RD 7
5.18 Machine Disposal / DecommissioningIntroduction This machine must be properly decommissioned at the end of its service life.Responsible disposal prevents toxic chemicals and materials from harming the environment. This machine contains several components that may be considered hazardous waste in many areas:
Operating fluids, including fuel, engine oil, grease, and hydraulic fluidBatteries
Before decommissioning this machine, read and follow local safety and environmental regulations pertaining to the disposal of construction equipment.
Preparation Perform the following tasks to prepare the machine for disposal.Move the machine to a protected location where it will not pose any safety hazards and cannot be accessed by unauthorized individuals.Ensure that the machine cannot be operated from the time of final shutdown to disposal.Drain all fluids, including fuel, engine oil, and hydraulic fluid. Seal any fluid leaks.Remove the battery.
Disposal Perform the following tasks to dispose of the machine.Disassemble the machine and separate all parts by material type.Dispose of recyclable parts as specified by local regulations.Dispose of all non-hazardous components that cannot be recycled.Dispose of waste fuel, engine oil, and hydraulic fluid in accordance with local environmental protection regulations.
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RD 7 Troubleshooting6 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.
Technical Data RD 7
7 Technical Data7.1 Engine Engine Power
RatingNet power rating per ISO 3046/1-IFN. Actual power output may vary due to conditions of specific use.
Item No. RD 7H-ES RD 7H-S
Engine
Engine type One cylinder, 4-stroke, air cooled, diesel engine
Engine make Hatz
Engine model 1D42S
Max. rated power @ rated speed kW (hp) 6.1 (8.2) @ 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 10W30 SG, SF/CC, CD
Engine oil capacity L (qt) 1.2 (1.25)
Fuel type No. 2 dieselLow sulfur or ultra-low sulfur only
Fuel tank capacity L (gal) 5.0 (1.3)
Fuel consumption L (gal)/hr 1.63 (0.43)
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RD 7 Technical Data
7.2 Roller7.3 Lubrication
Item No. RD 7H-ES RD 7H-S RD 7-RAW
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 (lb) 830 (1829) 810 (1786) —
Area capacity m2 (ft2)/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”
Item No. RD 7
Lubrication
Hydraulic System typeL (gal)
Premium grade, anti-wear hydraulic fluid 10W30
21.6 (5.7)
Exciter type Mobil XHP222
Rear Drum Drive Bearing typeqty.
Mobil XHP2222-3 shots with hand-held grease gun
Front Drum Drive Bearing type Sealed Bearings—No lubrication required
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Technical Data RD 7
7.4 Sound and Vibration SpecificationsThe required sound specification, Paragraph 1.7.4.f of 89/392/EEC Machinery 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 the sound power level (LWA) and ISO 11204 for the sound pressure level (LpA) at the operator’s location.
The weighted effective acceleration value, determined according to ISO 5349-1, is approximately:
Hands = 9.66 m/s2.
The sound and vibration measurements were obtained with the machine operating on hard asphalt at maximum RPM and top speed.
HAV Uncertainties
Hand-transmitted vibration was measured per ISO 5349-1. This measurement includes an uncertainty of 1.5 m/s2.
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NOTICE OF COPYRIGHT PROTECTIONAEM Safety Manuals are protected as a copyrighted work withownership duly registered with the Copyright Office,Washington,D.C.Any reproduction, translation, decompiling or other use of anAEM Safety Manual, or portion thereof, or the creation of deriv-
ative works based on an AEM Safety Manual,without the prior writ-ten approval of AEM, is expressly prohibited. Copyright infringe-ment can result in civil and criminal sanctions, damages and otherpenalties being imposed.
SAFETY ALERT SYMBOLThis Safety Alert Symbol meansATTENTION is involved!
The Safety Alert Symbol identifies important safetymessages on machines, safety signs, in manuals, orelsewhere.When you see this symbol, be alert tothe possibility of personal injury or death. Followthe instructions in the safety message.
Why is SAFETY important to YOU?
3 BIG REASONS:• Accidents KILL or DISABLE• Accidents COST• Accidents CAN BE AVOIDED
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Copyright © 1978 AEM (Association of Equipment Manufacturers)Former Copyright © CIMA (Construction Industry Manufacturer Association)
Revised 6/02, 9/04
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WORD OF EXPLANATION............................................................................
FOREWORD......................................................................................................
A WORD TO THE USER ..................................................................................
FOLLOW A SAFETY PROGRAM ..................................................................
PREPARE FOR SAFE OPERATION................................................................
START SAFELY.................................................................................................
WORK SAFELY ................................................................................................
PARK & SHUTDOWN SAFELY ....................................................................
LOAD & UNLOAD MACHINE SAFELY ......................................................
TRANSPORTING SAFELY ............................................................................
PERFORM MAINTENANCE SAFELY ..........................................................
SPECIAL OPERATING AND MAINTENANCE PRECAUTIONS..............
TEST YOUR KNOWLEDGE ..........................................................................
A FINAL WORD TO THE USER ....................................................................
WORD OF EXPLANATION
The following is a partial list of reference material on safe operating practices:
U.S. Department of Labor publishes safety andhealth regulations and standards under theauthority of the Occupational Safety and Health Actfor the general construction and mining industries.Its address is: U.S. Department of Labor, 200Constitution Avenue, NW,Washington, DC 20210.
SAE - Society of Automotive Engineers, Inc., 400Commonwealth Drive,Warrendale, PA 15096,publishes a list, "Operator Precautions," SAE J153MAY, 1987.
Association of Equipment Manufacturers,111 East Wisconsin Avenue, Milwaukee,WI USA53202, publishes the Roller Compactor SafetyManual and other safety-related material.
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WORD OF EXPLANATION
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This Safety Manual covers many different types ofroller compactors … including steel wheel rollers,vibratory rollers, rubber-tired rollers, segmentedpad/sheepsfoot soil compactors and landfill compactors.These may be either self-propelled ride-on, walk-behind or towed rollers.They may beused for the compaction of asphalt, soil, landfill orother materials. Excluded from coverage are vibratory plates and hand rammers.
Regardless of which machine you operate, it isYOUR responsibility to study and understand thisSafety Manual, and to see that a copy remainswith your machine.The manual begins with your“safety homework,” takes you step-by-stepthrough your working day, and ends withmaintenance operations.
Manufacturers produce machines with manybuilt-in safety features. Employers provideaccident prevention programs.Yet, the ultimateresponsibility to operate and maintain yourmachine with the skill, care and knowledgeessential for safety is YOURS.
Do not operate your machine until you have beentrained in the use of all operating controls andunderstand the handling characteristics of themachine.
REMEMBER — SAFETY … YOURS AND THAT OFTHOSE AROUND YOU … IS UP TO YOU!
This safety manual is intended to point out some ofthe basic situations which may be encounteredduring the normal operation and maintenance ofyour machine, and to suggest possible ways ofdealing with these conditions.
Additional precautions may be necessary, dependingon application, machine type, configuration andattachments used, and conditions at the work-siteor in the maintenance area.The manufacturer has nodirect control over machine application, operation,inspection, lubrication or maintenance.Therefore, itis your responsibility to use good safe practices inthese areas.
The information provided in this manual supplementsthe specific information about your machine that iscontained in the manufacturer's manual(s). Otherinformation which may affect the safe operation ofyour machine may be contained on safety signs, or ininsurance requirements, employer's safety programs,safety codes, local, state/provincial and federal laws,rules and regulations.
If you do not understand any of this information, orif errors or contradictions seem to exist, consult withyour supervisor before operating your machine.
IMPORTANT: If you do not have themanufacturer's manual(s) for your particularmachine, get a replacement manual from youremployer, equipment dealer, or manufacturerof your machine. Keep this safety manual andthe manufacturer's manual(s) with yourmachine.
Unauthorized modifications of machines createhazards. Machines should not be modified or alteredunless prior approval is obtained from the manufacturer.
FOREWORD
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A WORD TO THE USER
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It is your responsibility to read and understand thissafety manual and the manufacturer's manual(s)before operating your machine.This safety manualtakes you step-by-step through your working day.
Remember that YOU are the key to safety. Goodsafety practices not only protect you but also protect the people around you. Study this manualand the manufacturer's manual(s) for your specificmachine. Make them a working part of your safetyprogram. Keep in mind that this safety manual iswritten for only this type of machine. Practice allother usual and customary safe working precautions,and above all — (FIG. 1)
REMEMBER — SAFETY IS UP TO YOU
YOU CAN PREVENTSERIOUS INJURY OR DEATH
KNOW THE RULES
Every employer is concerned about safety. Safeoperation and proper maintenance of your machinecan prevent accidents. KNOW the rules — LIVE bythem. (FIG. 2)
When starting work at a new site, check with thedesignated safety coordinator for specific safetyinstructions. DON’T LEARN SAFETY THE HARDWAY.
Know the meaning of all hand signals, signal flags,signs and markings.
Know the traffic rules used at the work site. Knowwho the signal person is; watch and obey their signals.
Know where the fire extinguishers and first aid kitsare kept and how to use them. Know where to getproper aid and assistance when needed.
Use common sense to avoid accidents. If an accident does occur, be prepared to react to itquickly and effectively. NEVER PANIC.
Know how to use the emergency communicationssystem to summon help when necessary.
FOLLOW A SAFETY PROGRAM
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FOLLOW A SAFETY PROGRAM
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KNOW WHAT IT IS?
Consult your supervisor for specific instructions ona job, and the personal safety equipment required.For instance, you may need:• Hard Hat• Safety Shoes• Eye Protection• Face Protection• Heavy Gloves• Reflector Vests• Hearing Protection• Respirators
Do not wear loose clothing or any accessory — flopping cuffs, untied shoelaces, dangling necktiesand scarves, rings, wrist watches, or other jewelry— that can catch on protruding or moving parts orcontrols. Long hair should be securely bound toprevent entanglement with moving parts. (FIG. 3)
BE ALERT!
Know where to get assistance. Know how to use afirst aid kit and fire extinguisher or fire suppressionsystem. (FIG. 4)
BE AWARE!
Take advantage of training programs offered.
Safety programs require that one person at eachjobsite be assigned the overall responsibility andauthority for safety. Know who that person is,and COMMUNICATE.
Know what the jobsite rules are, and FOLLOW THERULES. Be safety conscious, responsible and reliable.Think about safety BEFORE something happens.
Report unsafe conditions to a supervisor immediately!
BE CAREFUL!
Human error is caused by many factors:carelessness, fatigue, overload, preoccupation,incompatibility between operator and the machine,drugs, and alcohol to name a few. Eliminate thesefactors BEFORE accidents occur. Damage to themachine can be fixed in a short period of time, butinjury, or death has a lasting effect.
FOR YOUR SAFETY AND SAFETY OFOTHERS, ENCOURAGE YOUR FELLOWWORKERS TO ACT SAFELY.
FOLLOW A SAFETY PROGRAM
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LEARN TO BE SAFE
READ the operator’s manual. If one has not beenprovided, GET ONE AND STUDY IT BEFOREOPERATING THE MACHINE. If you have anyquestions contact the manufacturer.Know the positions and understand the functionsof all controls before attempting to operate amachine. Know the meaning of all identificationsymbols on your controls and gauges. (FIG. 5)Know the location of the emergency shut-downcontrol if the machine is so equipped.Know the capabilities and limitations of themachine … such as speed, breaking and steering.Know the operational and transport dimensionsof your machine to avoid inadvertently hittingsomething during operation or transporting.Carefully read and follow the instructions on allsafety signs on the machine. Keep safety signs ingood condition. Replace missing or damagedsafety signs.
NEVER operate a machine which is new to youwithout first being instructed in its proper operation.
CHECK IT OUT!
Always conduct a pre-shift inspection before operatingany machine. Know what safety devices your machineis equipped with … and see that each item is securelyin place and in operating condition. (FIG. 6)
For example:• Safety Blocks and Locks• Other Locking Devices• Lights• Alarms• Horn• Guards and Shields• Shut-Down Devices• First Aid Kit• Fire Extinguishers
TIRES
Inspect pneumatic tires (if so equipped) fordamage, wear, and proper inflation. Never operatewith over-inflated or under-inflated tires. (FIG. 7)
Check that all wheel lug nuts are present and tight.
NEVER START OR OPERATE A MACHINEKNOWN OR SUSPECTED TO BE DEFECTIVEOR MALFUNCTIONING.
PREPARE FOR SAFE OPERATION
KNOW YOUR MACHINE
Never operate a machine for which you are nottrained or qualified.
Familiarize yourself with pedals, controls andinstruments – their locations and function.
To handle controls without slipping, wipe themclean of oil and grease.
Remove tools, supplies and other materials fromthe working areas and machine walkways – andkeep these areas free of trash.
Make sure the items you do carry are not looseor in the way.
ARE REPAIRS MADE?
If your daily check uncovers any item that needsattention – repair, replacement, or adjustment –report it to your supervisor and tag the machineon the start switch and/or other appropriate,prominent location. A minor malfunction couldbe a sign of a more serious problem if themachine is operated.
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PREPARE FOR SAFE OPERATION
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FIRE PREVENTION
Never allow flammable fluids or materials tocontact hot surfaces.
Never refuel:• When engine is running• While smoking• Near open flames or sparks• In poorly ventilated area
Never overfill fuel tank or fluid reservoirs.Clean up spills immediately.
Replace fuel cap securely after filling.
Check for fuel, oil and hydraulic fluid leaks.Replace worn or damaged hoses/tubes.Afterrepairs are made, clean the machine before youoperate it.
Inspect electrical wiring for worn or damagedinsulation. Install new wiring if wires are damaged.
Because ether or other starting fluids are flammable,do not smoke when using them.Always follow theinstructions on the container and in the operator’smanual for your machine. (See page 19.)
Batteries produce explosive gases. Keep open flameor sparks away. See the manufacturer’s instructionswhen servicing the batteries, when using jumpercables or when using a battery charger. (See pages36 and 37.)
Remove all trash or debris from the machine. Makesure that oily rags or other flammable material arenot stored on the machine. (FIG. 8)
PREPARING TO ROAD THE MACHINE
Know what conditions you will likely encounter:• Insufficient clearances• Traffic congestion• Type of surface• Steep grades• Restricted visibility
Determine appropriate warnings to be used. (FIG. 9)Know whether you will need to be escorted.
If the machine is to travel on a road or highway,refer to the manufacturer’s manual(s) for instructions.Become familiar with local laws and ordinances affectingdriving on highways. Use “slow moving vehicle” emblem.Make sure flags, lights, and warning signs are in place.
Select the proper gear before negotiating steep grades. (FIG. 10)
PREPARE FOR SAFE OPERATION
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PREPARE FOR SAFE OPERATION
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Before starting, carefully inspect your machine forany evidence of physical damage such as cracking,bending or deformation of plates or welds. Check forcracking or flaking of paint, which may indicate anexcessive strain or dangerous crack in the materialbelow. Check for loose, broken or missing parts suchas Roll-Over Protective Structure (ROPS) supportbrackets, vibration isolators, and nuts and bolts. Ifpotentially serious problems are found, do notoperate the machine until appropriate repairs arecompleted.
Check the level of all fluids … brake, transmission,power steering, engine coolant, hydraulic system, andothers. Fill low reservoirs only to the proper level.
Check the various systems (hydraulic, cooling, etc.)for leaks. (FIG. 11) Inspect all plugs, filler caps andfittings for tell-tale signs of leaks.ALWAYS use aflashlight or shielded trouble light when checking …Never an open flame. Repair any leaks, or have themrepaired by authorized service personnel. (See pages28 through 42 for additional service cautions.)
Check the fuel level and, if low, fill the tank with theproper grade of clean fuel before extended operation(following the instructions on page 34).
A stalled or faltering engine can result in a realhazard when operating on grades, in traffic or inheavily congested areas.
NEVER smoke when checking fuel level or refueling.
BE SURE THE WORK AREA IS SAFE
Before beginning operation, thoroughly check thearea for any unusual conditions that could bedangerous. (FIG. 12) Check for hidden holes,drop-offs or overhead obstacles that could bedangerous. Check the clearance under overheadpower and phone lines. LOOK UP AS WELL ASDOWN.
Be observant of other workmen, bystanders andother machines in the area. Be especially careful iftrenches, lightpoles, tiles, buildings, etc. are withinthe effective range of a vibratory compactor.IMPROPER OPERATION COULD RESULT INDAMAGE OR INJURY.
Remember, the danger of sliding and/or tipping onsteep slopes is always present … regardless ofhow heavy or “stable” your machine may appear tobe.When operating under these conditions, theuse of ROPS and seat belts reduces the hazard tooperating personnel.
PREPARE FOR SAFE OPERATION
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FIG. 12
15
START SAFELY
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Walk around your machine once more just prior tomounting it – checking for people and objects thatmight be in the way – then MOUNT PROPERLYUSING STEPS AND HANDHOLDS PROVIDED.
Always use seat belts if your machine is equippedwith a ROPS.
Just before starting, check all controls … such asforward and reverse, steering, transmission andthrottle to be sure they are in the correct start-upposition. (FIG. 13) The parking brake should beapplied during the start-up operation.
Check for proper functioning of all operating andshut-down controls.
START CORRECTLY
Know the PROPER starting procedure for yourmachine. Follow the manufacturer’s operationmanual … to the letter.
Then, start your engine.
IMMEDIATELY AFTER STARTING THE ENGINE …
• Observe gauges, instruments, and warning lights toensure that they are functioning and their readingsare within the normal operating range. (FIG. 14)
• Be sure work area is safe for test operation of thevarious controls and attachments.
• Operate all controls: make certain they operate properly, and “feel” right.Accustom yourself to the“feel” of your machine.
• Listen for any unusual noises; smell for any unusualodors; look for any signs of trouble.
• Check all warning and safety devices and indicators.
• If safety-related defects or malfunctions are detected, shut down the machine. Correct it, or notify your supervisor. DO NOT OPERATE UNTIL CORRECTED.
Check operation of service and parking brakes onlevel ground if possible.
Check service brakes (including hydrostatic brakes,if so equipped) in both forward and reverseoperation (FIG. 15) ACCORDING TO THE
If an unsafe condition cannot be remedied immediately, notify your supervisor and tag themachine on the start switch and/or other appropriate, prominent location. (See page 28 forLockout/Tagout procedure.) No machine should be operated if any part is not in safe operating condition. Make certain that any unsafecondition has been satisfactorily remedied.
START SAFELY
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MANUFACTURERS INSTRUCTIONS.
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START SAFELY
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COLD WEATHER OPERATION
Consult the engine manufacturer’s operation manualfor proper cold weather starting procedure.
When using cold weather starting aids, be sure tofollow the engine manufacturer’s instructions.(FIG. 16)
After starting, operate all systems slowly and gentlyuntil properly warmed up.
BOOSTER CABLE INSTRUCTIONS
1. Connect positive (+) cable to positive post ofdischarged battery.
2. Connect other end of same cable to same markedpost of booster battery.
3. Connect negative (-) cable to other post of booster battery.
4. Make final connection on stalled vehicle away frombattery, either on vehicle frame or engine block.
5. Start vehicle and remove cables in reverse order of connection.
REMEMBER THESE RULES
When roading or operating a machine, always stayin the operator’s station. NEVER mount or dismounta machine that is moving. Maintain control of yourmachine at all times.
ALWAYS operate your machine slowly until fullyfamiliarized with it’s operation.
Constantly check your total work area forpotential hazards.
Never JUMP on or off your machine. Use the stepsand handholds provided to mount or dismountsafely. Maintain three point contact when mountingor dismounting.(FIG. 17)
• Never use controls or levers as hand holds.• Never jump off the machine.
Look, listen and smell for possible malfunctions. Ifmalfunctioning controls or erratic operation aredetected, correct or report them immediately.DO NOT OPERATE THE MACHINE UNTILCORRECTED.
Prevent asphyxiation. If you must operate in abuilding or other enclosed area, or if yourmachine is equipped with an enclosed cab, be cer-tain there is adequate ventilation.
WORK SAFELY
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Use extra care when refueling. (See page 34 forspecial precautions.)
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WORK SAFELY
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For maximum safety on machines with more thanone operator’s position, operate from the positiongiving the greatest visibility of potential hazards.
NEVER allow unqualified or unauthorized personnelto operate your machine.
NEVER allow other personnel to ride on yourmachine unless appropriate seating is provided …and then only if authorized to do so.
NEVER abuse your machine. Misuse or abuse cancause an accident.
NEVER enter or place any part of your body in the“hinge area” or other “pinch” areas of an articulatedmachine while the engine is running, or when there isany chance another person might start the machine.(FIG. 18)
Give the right-of-way to loaded equipment on haulroads. Maintain a safe distance from personnel, motorvehicles and other machines.
Your safety, and the safety of those around you, isdetermined by the care and judgment YOU use whileoperating your machine.
WORKING ON SLOPES
When working on slopes, avoid sidehill travel whenever possible … rather operate up and downthe slope. (FIG. 19 & 20) Remember the danger ofsliding and/or tipping on steep slopes is always present … regardless of how heavy or “stable” yourmachine may appear to be.
ALWAYS use seat belts IF your machine is equippedwith a ROPS.
NEVER allow the engine or machine to overspeed.
When climbing or descending steep grades,ALWAYSselect the proper gear BEFORE starting on the slope,to assure adequate power or engine breaking.
If your machine has a gear shift, select a low gear.If your machine has a hydrostatic drive, the speedcontrol should be in the slow travel position, closeto neutral … NEVER in the fully displaced position.
On machines that have a gear shift AND a hydrostaticcontrol, BOTH controls must be in their slow travelposition.
ALWAYS be sure that manually operated gear typetransmissions are fully engaged BEFORE starting ontoa grade. DO NOT attempt to change the gear selection
WORK SAFELY
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while traveling on a grade. See the manufacturer’smanual for specific instructions.
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WORK SAFELY
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Avoid operating your machine too close to anoverhang, deep ditch or hole. If your machineinadvertently gets close to a tipping conditionor drop-off, STOP and get off the machineafter applying the parking brake … plan yourmoves carefully before proceeding. Reversal isoften the best move.
Be alert to potential caving edges, falling rocksand slides.
Check for overhead obstacles that could bedangerous. LOOK UP AS WELL AS DOWN.(FIG. 21)
Be alert to obstacles and excessively roughterrain. Back away from them and go around.
Always travel slowly over rough terrain andhillsides. Maintain a speed consistent with theworking conditions.
When traveling on a public road, obey all trafficregulations and be sure that the proper clearanceflags, lights and warning signs … such as the “slowmoving vehicle” emblem … are used. (FIG. 22)
NEVER speed … and NEVER coast in neutral.
When roading the machine know your approxi-mate stopping distance at any given speed.
NEVER turn corners at excessively high speeds.(FIG. 23)
Always look in all directions before reversingyour direction of travel.
Use EXTRA caution when working in closequarters or when traveling through congestedareas. Courtesy pays off.
WORK SAFELY
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PARK AND SHUT DOWN SAFELY
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PARK SAFELY
Park in an off the road area, out of traffic, or asinstructed. If necessary to park in a traffic lane, usethe appropriate flags, barriers, flares, lights andwarning signals. Provide advance warning signals inthe traffic lane to warn approaching traffic.
Park on level ground whenever possible. (FIG. 25)When not possible, position the machine at right
angles to the slope. Make sure the machine is on afirm footing, and that there is no danger of sliding.Do NOT leave your machine until you are sure it issafely blocked in both directions and parkingbrakes firmly applied. (FIG. 24)
Lower the blade and all other hydraulicallyoperated attachments (if so equipped ) to theground.
SHUT DOWN PROPERLY
Know the proper shut-down procedure for yourmachine.As with the starting procedure, this varieswith the type and model of machine.
Follow the manufacturer’s operation manual forYOUR machine. Remove the key(s) to preventunauthorized starting and movement, and positionand lock any antivandalism devices.
DISMOUNT PROPERLY
NEVER dismount from your machine until it is fullystopped and the engine is shut off.
NEVER jump off your machine. (FIG. 26) Afterstopping, use the steps and handholds provided todismount safely. Maintain three point contact whendismounting.
PARK AND SHUT DOWN SAFELY
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LOAD AND UNLOAD MACHINE SAFELY
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Loading and unloading machines always involvespotential hazards. EXTREME CAUTION SHOULDBE USED.
Know the correct loading and unloading proceduresfor your machine.
All machines are not loaded and unloaded thesame way.The procedures recommended by themanufacturer should always be followed.
Several precautions are applicable to all machines:
• NEVER load or unload machine by yourself.• Keep all non-essential personnel clear of loading
and unloading area.• Load and unload on a level surface.• ALWAYS use ramps of adequate size and strength.
Be sure ramps are sufficiently wide, and long enough to provide a safe loading slope.
• NEVER use ramps that are cracked, damaged, or of questionable strength. (FIG. 27)
• Be sure that the ramps are securely positioned and fastened, and that the two sides are at the same level as one another.
• The ramp surface must provide adequate traction.Be sure the surface is clean and free of grease,oil, ice, and loose material.
• The hauling vehicle should be blocked to prevent movement during loading or unloading of the machine.
• For proper tie-down instructions, see the manufacturer’s manual.
GENERAL
When towing a machine on a trailer, or a machineequipped with “portability or transport wheels”,ALWAYS use a hauling vehicle of sufficient weight,horsepower and braking capacity to maintainproper control.
NEVER attempt to tow a trailer or machine if thehitching devices are of insufficient or questionablecapacity, improperly matched in size or shape, orpositioned at improper heights.
When towing a machine equipped with portabilityor transport wheels,ALWAYS follow themanufacturer’s towing instructions.
BEFORE TOWING
When connecting a trailer to a hauling vehicle,block under the trailer’s tongue before attemptingto make the connection. NEVER attempt to liftheavy tongues or move heavy trailers by hand.NEVER get any part of your body under thetongue when hitching or unhitching.
ALWAYS make sure the hitch is properly andsecurely locked.
ALWAYS use safety chains between the haulingvehicle and tailer or towed machine. Be sure thechains are properly and securely connected … atBOTH ends. Cross the chains under the tonguewhen connecting to the hauling vehicle.
ALWAYS make sure electrical and otherconnections between the hauling vehicle and traileror towed machine are properly and securely made.After connecting, check the lights for properoperation. If the towed trailer or machine isequipped with brakes operable from the haulingvehicle, check to make sure they are operatingproperly.
ALWAYS be sure the portability or transportwheels, on machines so equipped, are LOCKEDin the lowered position.
Check ALL tires for proper pressure, excessiveor abnormal wear, and potentially dangerous cuts,bruises or bulges. Have any problems correctedbefore proceeding.
TRANSPORTING SAFELY
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TOWING
ALWAYS use EXTRA care when towing a trailer ormachine… when maneuvering in tight places, when backing(visibility is reduced, and jackknifing must be avoided), andwhen towing on steep grades.
Know and obey all local, state and federal laws and regulations.
NEVER travel at speeds above those recommended bythe manufacturer.
NEVER allow anyone to ride on a trailer or towedmachine. (FIG. 28)
When necessary to disconnect and park a trailer ortowed machine,ALWAYS select a location that is leveland, if possible, one where children are unlikely to bepresent. BEFORE disconnecting a trailer, chock the frontAND rear of the wheels, and block under the tongue.
See pages 23 through 24 for parking, shut-downprocedures and roading machine for transport.
GENERAL
Maintenance work can be hazardous if not done ina careful manner. All personnel should realize thehazards and strictly follow safe practices.
NEVER perform any work on the equipment unlessauthorized to do so. (FIG. 29) Before performing anymaintenance or repair work, consult the InstructionManual. Follow the manufacturer’s recommendedprocedures.
BEFORE any maintenance work is begun, reviewLOCKOUT/TAGOUT procedures. LOCKOUTcontrols and/or energy source and place a warninglabel to alert workers of shutdown.
PRIOR to removal of LOCKOUT/TAGOUT, theequipment must be fully operational and all personnelaccounted for. Except in cases of emergency, theremoval of the LOCKOUT/ TAGOUT should be doneby the initiating person prior to the return to start-up.
BEFORE doing any major work, or work on theelectrical system, disconnect the batteries.
REPLACE all missing or broken guards and panels.
USE proper nonflammable cleaning solvents. Followsolvent manufacturer’s instructions.
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ALWAYS remove all flammable materials in thevicinity of welding and/or burning operations.
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CLOTHING AND PERSONAL PROTECTIVE ITEMS
Keep hands and clothing well away from engine fan and moving parts while engine is running.
ALWAYS wear appropriate safety glasses, goggles or face shield when working. (FIG. 30) Proper eyeprotection can keep flying particles from grinding,drilling or hammering operations, or fluids such asfuel, solvents, lubricants and brake fluids, fromdamaging your eyes. Normal glasses do NOTprovide adequate protection.
ALWAYS wear a hard hat and safety shoes. (FIG. 30)ALWAYS wear hearing protectors when exposed tohigh noise levels for extended periods.ALWAYS weara respirator when painting or exposed to dustyconditions. ALWAYS keep your pockets free ofloose objects which can fall out and drop into
machinery. (FIG. 31) Heavy gloves should be wornfor many operations.
EXHAUST FUMES
Engine exhaust fumes can cause sickness or death.If it is necessary to run an engine in an enclosedarea, use an exhaust pipe extension. If you do nothave an exhaust pipe extension, be positive the areais adequately ventilated. (FIG. 32)
HEAVY PARTS
HEAVY PARTS
Handle tools and heavy parts sensibly – with regardfor yourself and other persons. Lower items – don’tthrow or drop them.
ALWAYS use proper hoisting equipment for liftingheavy loads.
• Keep machine in proper adjustment at all times.Serious injury could result if adjustments are neglected.
• Whenever possible,AVOID working on a machine with the engine running. If the engine must be run to make checks or adjustments, put the transmissionin neutral, set the parking brake and chock the drum and wheels securely ... front and rear ... to prevent movement in either direction.
• Personnel can be caught by moving parts when the guards are removed for access in making repairs.A repair or maintenance job is not complete until guards, plates and other safety devices have been replaced.
• NEVER put your fingers in open gears or reach through the spokes of a gear.
• Before working on the fuel system, close the fuel shut-off valve. NEVER smoke or use open flames near the machine while working on the fuel system.
• Remove and store all tools before resuming operation.
• Before working in the pivot or “pinch” area of an articulated machine, securely attach the steering frame lock to prevent the machine from turning.(FIG. 33) Enter this area only when necessary.
• Connect any other safety locks provided before proceeding with the work.
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Before beginning welding or burning operations, drainfuel lines and tank and move all flammable material to asafe distance, and be certain a fire extinguisher is readilyavailable.When welding fuel tanks, either gasoline ORdiesel,ALWAYS drain the tank, fill with water, and leavecap off during the welding operation.
All guards, plates and other safety devices mustbe properly replaced before the machine isreturned to service or serious injury to you or otherpersonnel may result.
AVOID burning or welding near acoustical materialwhenever possible, as hazardous fumes may bereleased. If unavoidable, make sure the area is adequatelyventilated, and that a fire extinguisher is ready available.
ALWAYS use authorized replacement parts that meetthe machine manufacturer’s specifications.
JACKING AND BLOCKING
ALWAYS lower all movable attachments to the groundor to their lowest position before servicing a machine.
If a machine must be raised for servicing or repairs,ALWAYS block the machine securely. Use axle stands orother rigid supports of ample capacity. NEVER rely solelyon the jacks for support. If necessary to work under amachine, be absolutely certain it is adequately supported.(FIG. 34)
WARNING: Never use concrete blocks for supports.They can collapse under even light loads.
When jacking up a machine, use a SUITABLE jack,placed in the proper position, on a solid foundation.
Before working on a machine, chock the drum andwheels securely … front and rear … in such a manneras to prevent movement in EITHER direction. Securelyattach the steering frame lock to prevent the machinefrom turning.
FIRE PREVENTION
Whenever possible use a nonflammable solvent toclean parts. Do not use gasoline or other fluids thatgive off harmful vapors.
If flammable fluids, such as diesel fuel, must be used,extinguish open flames or sparks and do not smoke.
Store dangerous fluids in a suitable place, in approvedcontainers which are clearly marked. NEVER smokein areas where flammable fluids are used or stored.(FIG. 35)
Use proper nonflammable cleaning solvents. Followsolvent manufacturer’s instructions for use.
Always remove all flammable material in the vicinityof welding and/or burning operations.
ALWAYS keep the floor in the work area clean anddry. Oily, greasy floors can easily lead to falls. Wetspots, especially near electrical equipment, can behazardous. (FIG. 35)
Know where fire extinguishers are kept – how theyoperate – and for what type of fire they are intended.
Check readiness of any fire detectors and firesuppression systems.
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FIRE PREVENTION CHECKLIST (FIG. 36)
• Remove debris such as rags, coal dust, oil, leaves,pine needles.
• Check and repair fuel and hydraulic leaks.
• Check and repair damaged wiring.
• Prevent hose and electrical wire harness abrasion.
• Tighten loose clamps and fittings.
• Secure loose wiring.
• Make sure guards and protective covers are in place.
• Make sure fire extinguisher is available and operable.
REFUELING (FIG. 37)
Precautions
When refueling, the following precautions must be followed:
• Add proper type and grade of fuel only when machine is not running and machine is parked with no one in the cab.
• Fuel in a well-ventilated area.
• Turn off all electrical switches.
• Turn off cab heaters.
• Open lights, lighted smoking materials, flames, or spark producing devices shall be kept at a safe distance while refueling.
• Keep fuel nozzle in contact with tank being filled,or provide a ground to prevent static sparks from igniting fuel.
• Do not spill fuel on hot surfaces.
• Any spillage shall be cleaned immediately.
• Do not start engine until fuel cap is secured to the fuel tank and people are clear of the machine.
• ALWAYS make sure fuel, oil, hydraulic fluid and water are added to their proper tanks.
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SERVICING COOLING SYSTEM
When checking coolant level:• Stop the engine and let the engine and radiator
cool before checking. (FIG. 38)
If an overheated engine requires a shutdown:• Wait for the radiator to cool. The hot
pressurized coolant can cause burn injuries. Neveradd coolant to an overheated system.
• Overheating is a symptom of trouble. Stop the engine and have the trouble corrected before serious damage occurs.
• If it is necessary to check an overheated engine use a heavy cloth, gloves, heavy clothing and safety glasses or goggles to protect yourself. Stand to the side, turn your face away, and slightly loosen the cap.Wait until the sound stops before removing the cap.
SERVICING BATTERIES
Always wear safety glasses and gloves whenworking with batteries.
Before removing a battery, turn off all electricalequipment, then disconnect the negative (-)battery cable first. Before installing a battery,turn off all electrical equipment, then connectthe positive (+) battery cable first.
To prevent sparking at the posts when usinga battery charger, always turn the charger off ordisconnect it from its power source beforeconnecting or disconnecting charger leads tobattery posts. Caps on all cells should be lefton and the vent caps would be covered witha wet cloth.
Do not short across the battery terminals.The spark could ignite the gases.
BOOSTER CABLE INSTRUCTIONS (FIG.39)
1.Connect positive (+) cable to positive post of discharged battery.
2.Connect other end of same cable to same marked post of booster battery.
3.Connect negative (-) cable to other post of booster battery.
4.Make final connection on stalled vehicle away from battery, either on vehicle frame or engine block.
5.Start vehicle and remove cables in reverse order of connection.
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BATTERY SERVICING
To prevent a battery explosion: (Fig. 40)
• Maintain the electrolyte at the recommended level. Check level frequently. Add distilled water to batteries only before starting up, neverwhen shutting down.With electrolyte at the proper level, less space is available for gases toaccumulate in the battery.
• Use a flashlight to check the electrolyte level.Never use a flame. (Fig. 41)
• Do not short across the battery terminals.The spark could ignite the gases.
Battery acid will burn skin, eat holes in clothing,and may cause blindness if splashed into eyes. Ifyou spill acid on yourself flush skin immediatelywith lots of water. Apply baking soda to help neu-tralize the acid. If acids gets in your eyes, flushimmediately with large amounts of water andseek proper medical treatment immediately.
When servicing batteries, remember that alead-acid storage battery generates (when chargingor discharging) hydrogen and oxygen – a veryexplosive mixture.A spark of flame could ignitethese gases.
HYDRAULIC SYSTEMS
NOTE: Hydraulic Systems have “special features”.Some of the features affecting your safety are listedbelow.
Pressure can be maintained in hydraulic and aircircuits long after the engine has been shut down.This pressure can cause hydraulic fluid or itemssuch as pipe plugs to “shoot out” at high speed ifpressure is not released correctly. Release systempressure before attempting to make adjustmentsor repairs.
Consult the manufacturer’s instructions for correctprocedure.
Before disconnecting hydraulic fluid lines, be sureyou:• Shut off engine.
• Always release any air pressure (supercharge) on the hydraulic reservoir.
• Move pedals and control levers repeatedly through their operating ranges to relieve all pressures.
Pressurized hydraulic fluid can penetrate theskin and cause serious injury. Therefore, be sureall connections are tight and that lines, pipes, andhoses are in good condition before starting theengine.
Fluid escaping from a small hole can be almostinvisible. Use a piece of cardboard or wood,instead of your hands, to search for suspectedleaks. (FIG. 42)
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HYDRAULIC SYSTEMS (CONT’D)
If you are struck by escaping hydraulic fluidunder pressure, serious injury can occur ifproper medical treatment is not administeredimmediately.
During operation, hydraulic fluid and air in anunvented hydraulic tank becomes heatedand will tend to expand.This will raise thepressure inside an unvented hydraulic tank. Ifthe filler cap is removed rapidly, the pressure inthe tank can force the oil out of the tank veryrapidly. The hydraulic fluid may be veryhot and may cause severe burns. Alwaysrelieve tank pressure before removing the capcompletely. Consult the manufacturer’sinstructions for the correct procedure.
When adding fluid to any system, be sure touse the fluid recommended by the manufacturer.Certain fluids, when mixed, may destroy sealscausing loss of control and possible personalinjury.
Keep hydraulic relief valve settings set tothe manufacturer’s recommendations. Excessivepressures could result in structural orhydraulic failures. Low pressure could result inloss of control. Either condition could causepersonal injury or death.
Be sure the engine is stopped and machine isproperly locked out and controls tagged, beforeworking on a machine. Only run engine when it isessential, as in the case of pressure adjustments,lubrication, or tests. Follow the manufacturer’srecommendations when making adjustments.Never resume operation until satisfactoryadjustments have been made. The operatormust follow the mechanic’s instructions whenadjustments are being made or machine isbeing serviced.
TIRE INSPECTION
Recommended air pressure must be maintainedin every tire. Daily checks assure that inflation iscorrect. If your periodic check discloses a tire thatis continuously losing air, a leak is indicated andmust be repaired. (FIG. 43)
During your pressure checks, also inspect for:
• Objects wedged between or embedded in tires.
• Missing valve caps and wheel lugs.
• Cuts, tears, and breaks that may need repair.
• Abnormal or uneven wear.
• Damaged or poor fitting rim or rim flanges.
• Projecting body hardware, loose fender bolts,spring clips – anything that could contact a tire.
Do not burn or weld on wheels or rims.
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PNEUMATIC TIRES
Changing tires or adding air can be a hazardousbusiness. Special tools and procedures arerequired for changing off-highway tires.
Explosion and separation of a tire and/or rim partscan cause serious injury or death. (FIG. 44) Alwaysfollow the manufacturer’s recommendations orsee your tire supplier.
TIRE PRESSURE
Check tire pressure before starting operation.An air pressure rise during operation is normaland should NOT be reduced. Overloads or over-speeds may produce increased tire pressures dueto heat. Never bleed tires. Reduce your load – orspeed – or stop until tires cool.
ADD AIR
From a distance – with air chuck clipped on thetire valve – and with extension hose that permitsyou to stand behind tread. (FIG. 45) Always use atire cage or equivalent for protection.
ROPS (Roll-Over Protective Structures)
Periodically inspect ROPS for cracks and loose mountinghardware.
Replace all missing, deteriorated or worn rubber parts.
If it becomes necessary to remove a ROPS, reinstall it onlyon the same machine, in its original position. (FIG. 46)
NEVER alter the ROPS in any way without the writtenapproval of the manufacturer.
NEVER cut holes in or weld on ROPS without themanufacturer’s approval.
NEVER attempt to repair a damaged ROPS – it must bereplaced with a new unit, approved for that machine.
Periodically inspect seat belts for wear, tear, deteriorationor excessive dirt. Replace them if necessary.
AIR CONDITIONERS
NEVER attempt to weld on or near air conditioners.Poisonous gas may be formed when refrigerant gas isexposed to a flame or excessive heat.
Maintenance and repair of air conditioners … except forvery minor repairs or servicing … must be done only byan experienced air conditioner or refrigeration technician.
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(FIG. 47)
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PARKING AND TRANSPORTING
ALWAYS select a level area to park in and, ifpossible, one where children are unlikely to bepresent.ALWAYS chock the front AND rear ofthe roller … even if leaving the machine unattendedfor short periods.
ALWAYS use EXTRA care when towing a roller …when maneuvering in tight places, when backing(visibility is reduced, and jackknifing must beavoided), and when operating on grades. NEVERoperate a towed roller on steep grades or sideslopes, as the possibility of tipping or loss of controlis greater when towing a roller.
NEVER allow anyone to ride on a towed roller.And, unless absolutely necessary, never permitanyone in the “pinch” area between the towingvehicle and the towed roller.
When necessary to disconnect and park a towedroller,ALWAYS select a location which is leveland, if possible, one where children are unlikelyto be present. BEFORE disconnecting, ALWAYSchock the front AND rear of the roll, and blockunder the tongue.
Extreme care should be exercised when loadingor unloading a walk-behind roller. It is generallybest to stand behind and to one side rather thandirectly behind a machine being propelled up ordown a ramp.
If the roller is designed to hang from the tailgateof a vehicle when being transported, ALWAYS becertain the hook brackets meet the rollermanufacturer’s specifications.
Special precautions must also be exercised whenloading or unloading, transporting or servicing atowed roller. Consult your manufacturer’smanual for specific details.
FOR TOWED ROLLERS
Most general safety precautions covered earlier inthis manual are also applicable to towed rolleroperation. Many other SPECIAL precautions must,however, be taken. Study your manufacturer’smanual(s) relative to special considerations whentowing. If you have questions or concerns, consultthe manufacturer or your dealer.
ALWAYS use a tow tractor of sufficient weight,drawbar horsepower and braking capacity toproperly control the towed roller. Proper weightbalance and distribution is also essential.
ALWAYS block under the tongue of the towedroller BEFORE attempting to connect it to thetowing vehicles or machine. NEVER attempt tolift heavy tongues or move towed rollers by hand.NEVER get any part of your body under the tonguewhen hitching or unhitching.
ALWAYS make sure the hitch pin is of the propersize, and securely locked in place before towing.(FIG. 48) If safety chains are provided, make surethey are properly and securely connected … atBOTH ends. Cross the chains under the tonguewhen connecting to the towing vehicle. If electrical
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or hydraulic connections are required, make surethe connections are properly and securely made.
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FOR LANDFILL COMPACTORS
General
Operators of landfill compactors should carefullyhandle fill materials that could be picked up andthrown by the wheels, become lodged in themachine, or that are highly flammable.
Frequent checks should be made for wire, cable orother material wound around the axle members.Remove them immediately.
Travel with the blade as low as possible.
Maintain good operator visibility – keep all meshand windows free of accumulated materials thatreduce visibility.
When parking the machine,ALWAYS lower the blade.
FIRE PROTECTION
Maintain fire extinguishers and fire protectivesystems in good working order. ALWAYS rechargeextinguishers, or replace with a fully charged unitimmediately after use.
Check for, and remove, any waste material accumulation above belly pans and behindprotective doors and grills.Accumulations are a fire hazard. (FIG. 49)
FOR WALK-BEHIND ROLLERS
Start-Up
NEVER attempt to operate a walk-behind rollerbefore being thoroughly familiar with the manufacturer’s operating instructions. If you have any questions or uncertainty, consult themanufacturer and/or his dealer BEFORE attemptingto operate it.
ALWAYS follow the manufacturer’s instructionsfor starting the engine.All controls MUST be inthe correct position BEFORE attempting to startthe engine ( for example, the shift lever must bein neutral).
Starting fluid is NOT recommended when handstarting an engine.The engine may kick back.
OPERATION
When operating a walk-behind roller, ALWAYSexercise extreme care to avoid having your feet orclothing caught under the dolly wheels or roll.When possible, stand behind and to one side ofthe machine rather than directly behind it.Particular care must be exercised when operatingnear obstructions, on slippery surfaces, grades and
NEVER ride on a walk-behind roller unless it isdesigned to accommodate riders and anappropriate seat is provided.
NEVER attempt to shift on a grade if the rollerhas a mechanical transmission.
NEVER operate a walk-behind roller in unshoredtrenches or near steep, unsupported banks.Thevibrations could cause a cave-in.
Uneven grades can cause the handle to raise orlower unexpectedly, striking the unwary operator.(FIG. 50)
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side slopes. (ALWAYS wear slip resistant safetyshoes or boots.)
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Do you understand this AEM SAFETY MANUAL ANDITEMS SUCH AS …
• Your safety program?• Your machine manufacturer’s manual(s)?• Proper clothing and personal safety equipment?• Your machine’s controls, warning signs and devices,
and safety equipment?• How to properly inspect, mount, and start your
machine?• How to check your machine for proper operation?• Your work area and any special hazards that may exist?
• Proper operating procedures?• Proper parking, shutdown, and dismounting
procedures?• Proper maintenance procedures?• Proper loading and unloading procedures for
transporting?• Under what conditions you should not operate
your machine?
If you do not understand any of these items, consultwith your supervisor BEFORE operating your machine!
Remember that YOU are the key to safety. Goodsafety practices not only protect you but protect thepeople around you.
You have read this safety manual and the manufacturer’smanual(s) for your specific machine. Make them a workingpart of your safety program. Keep in mind that this safetymanual is written for only this type of machine.
Practice all other usual and customary safe workingprecautions, and above all –
REMEMBERSAFETY IS UP TO YOU
YOU CAN PREVENT SERIOUSINJURY OR DEATH
A FINAL WORD TO THE USER
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NOTICE OF COPYRIGHT PROTECTIONAEM Safety Manuals are protected as a copyrighted work withownership duly registered with the Copyright Office,Washington,D.C.Any reproduction, translation, decompiling or other use of anAEM Safety Manual, or portion thereof, or the creation of deriv-
ative works based on an AEM Safety Manual,without the prior writ-ten approval of AEM, is expressly prohibited. Copyright infringe-ment can result in civil and criminal sanctions, damages and otherpenalties being imposed.
Copyright © 1978 AEM (Association of Equipment Manufacturers)Former Copyright © CIMA (Construction Industry Manufacturer Association)
Revised 6/02, 9/04
SAFETY ALERT SYMBOLThis Safety Alert Symbol meansATTENTION is involved!
The Safety Alert Symbol identifies important safetymessages on machines, safety signs, in manuals, orelsewhere.When you see this symbol, be alert tothe possibility of personal injury or death. Followthe instructions in the safety message.
Why is SAFETY important to YOU?
3 BIG REASONS:• Accidents KILL or DISABLE• Accidents COST• Accidents CAN BE AVOIDED
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Notes:
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Schematics RD 7
9 Schematics9.1 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_tx003245gb.fm96
RD 7 Schematics
9.2 Hydraulic Schematic Components
Ref. Description Ref. Description
1 Exciter relief valve 9 Charge pump
2 Exciter control valve 10 Exciter pump
3 Exciter motor 11 Drive pump
4 Rear drive motor 12 Charge pressure relief valve
5 Front drive motor 13 Internal drive pump relief valves
6 Return filter 14 Porting block
7 Suction filter 15 Manifold
8 Pump assembly 16 Tank
wc_tx003245gb.fm97
Schematics RD 7
9.3 Hydraulic Diagramwc_gr003637
15
28
11(9)(12)
1
10
6
7
16
3
14
4
5
13
wc_tx003245gb.fm98
RD 7 Schematics
9.4 Hydraulic Diagram ComponentsRef. Description Ref. Description
1 Exciter relief valve 9 Charge pump
2 Exciter control valve 10 Exciter pump
3 Exciter motor 11 Drive pump
4 Rear drive motor 12 Charge pressure relief valve
5 Front drive motor 13 Internal drive pump relief valves
6 Return filter 14 Porting block
7 Suction filter 15 Manifold
8 Pump assembly 16 Tank
wc_tx003245gb.fm99
Schematics RD 7
9.5 RD 7H-ES—Electrical Schematicwc_gr003663
1 2 3 4 5 62 13456
41
3
Br
P
B
R
0
8
wc_tx003245gb.fm100
RD 7 Schematics
9.6 RD 7H-ES—Electrical Schematic ComponentsRef. Description Ref. Description
1 Key switch 5 Starter
2 15 Amp fuse 6 Regulator
3 Alternator 7 Alarm
4 Battery 8 Oil pressure switch
Wire Colors
B Black R Red Y Yellow Or Orange
G Green T Tan Br Brown Pr Purple
L Blue V Violet Cl Clear Sh Shield
P Pink W White Gr Gray LL Light blue
wc_tx003245gb.fm101
Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, D-80809 München, Tel.: +49-(0)89-3 54 02-0 Fax: +49 - (0)89-3 54 02-390Wacker Neuson Production Americas LLC, N92W15000 Anthony Ave., Menomonee Falls, WI 53051
Tel. : (262) 255-0500 Fax: (262) 255-0550 Tel.: (800) 770-0957Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
Tel: (852) 3605 5360, Fax: (852) 2758 0032
