Wacker Neuson RD 7 Series, RD 7H-ES, RD 7H, RD 7-RAW, RD 7H-S Operator's Manual

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Operator’s Manual

Notice d’Emploi

Roller

Rouleau

RD 7

5000185489 17 0911

5000185489

© Copyright 2011 by Wacker Neuson Production Americas LLC All rights, including copying and distribution rights, are reserved. This publication may be photocopied by the original purchaser of the machine. Any

other type of reproduction is prohibited without express written permission from Wacker Neuson 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

Manufacturer

Original instructions

All trademarks referenced in this manual are the property of their respective owners.

Wacker Neuson Production Americas LLC N92W15000 Anthony Avenue Menomonee Falls, WI 53051 U.S.A. Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957 www.wackerneuson.com

This Operator’s Manual presents the original instructions. The original language of this Operator’s Manual is American English.

5000185465 17 0911

RD 7 Foreword

Foreword

Machines covered in this manual

Machine Item Number

RD 7H 0008042 RD 7H-ES 0009408, 0620794 RD 7H-S 0009487, 0620795 RD 7-RAW 0620079, 0620478, 0620596

Machine documentation

Expectations for information in this manual

 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.

 This 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.

CALIFORNIA Proposition 65 Warning

Laws pertaining to spark arresters

Engine exhaust, some of its constituents, and certain vehicle components, contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

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 discharge 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.

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Foreword RD 7

Manufacturer’s approval

This manual contains references to approved parts, attachments, and modifications. 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 consequences:

 Serious injury hazards to the operator and persons in the work area  Permanent 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

Manufacturer

Wacker Neuson Production Americas LLC, N92W15000 Anthony Avenue, Menomonee Falls, Wisconsin USA

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

5,1 kW

107 dB(A)

108 dB(A)

Conformity Assessment Procedure

According to ANNEX VIII

Notified Body

Lloyds Register Quality Assurance Limited (Notified Body No 0088) 71 Fenchurch Street, London EC3M 4BS, United Kingdom

Guidelines and Standards

We hereby declare that this product meets and complies with the relevant regulations and requirements of the following guidelines and standards:

2011-CE-RD7H_en.fm

2006/42/EC, 2000/14/EC, 2004/108/EC, EN 500-1, EN 500-4

Authorized Person for Technical Documents

Axel Häret, Wacker Neuson SE, Preußenstraße 41, 80809 München

Menomonee Falls, WI, USA, 22.08.2011

William Lahner Vice President of Engineering

Paul Sina Manager, Product Engineering

Original Declaration of Conformity

Table of ContentsRD 7

Foreword 3

EC Declaration of Conformity 5

1 Safety Information 9

1.1 Signal Words Used in this Manual ....................................................... 9

1.2 Machine Description and Intended use .............................................. 10

1.3 Operating Safety ................................................................................ 11

1.4 Operator Safety While Using Internal Combustion Engines ............... 13

1.5 Service Safety .................................................................................... 14

2 Labels 16

2.1 Label Locations .................................................................................. 16

2.2 Safety and Informational Labels ......................................................... 17

3 Lifting and Transporting 22

4 Operation 23

4.1 Preparing the Machine for First Use ................................................... 23

4.2 Controls and Service Locations .......................................................... 24

4.3 Position of the Operator ..................................................................... 25

4.4 Refueling the Machine ........................................................................ 26

4.5 Before Starting ................................................................................... 27

4.6 Engine Throttle Control ...................................................................... 27

4.7 Starting the Machine (RD 7H, RD 7H-S) ............................................ 28

4.8 Starting the Machine (RD 7H-ES) ...................................................... 29

4.9 Cold Weather Starting (RD 7H, RD 7H-S) ......................................... 30

4.10 Engine Speed ..................................................................................... 31

4.11 Stopping the Machine ......................................................................... 31

4.12 Direction and Speed Control .............................................................. 32

4.13 Exciter ................................................................................................ 32

4.14 Back-Up Stop Pad .............................................................................. 33

4.15 Engine Crank ...................................................................................... 33

4.16 Parking Brake ..................................................................................... 34

4.17 Watering System ................................................................................ 34

4.18 Machine Stability ................................................................................ 35

4.19 Operation on Slopes ........................................................................... 36

4.20 Rollovers ............................................................................................ 36

4.21 Emergency Shutdown Procedure ....................................................... 37

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Table of Contents RD 7

5 Maintenance 38

5.1 Maintenance Schedule ........................................................................38

5.2 Safety-Related Spare Parts .................................................................39

5.3 Checking Engine Oil ............................................................................41

5.4 Changing Engine Oil and Oil Filter ......................................................42

5.5 Fuel System ........................................................................................43

5.6 Engine Air Filter ...................................................................................45

5.7 Checking and Adjusting Valve Clearances .........................................46

5.8 Engine Cooling System .......................................................................47

5.9 Mechanical Oil Pressure Monitoring ....................................................48

5.10 Scraper Bars .......................................................................................49

5.11 Water Spray Bars ................................................................................50

5.12 Hydraulic Oil Requirements .................................................................51

5.13 Hydraulic Oil Level ..............................................................................52

5.14 Changing Hydraulic Fluid and Filter ....................................................53

5.15 Direction Lever Adjustment .................................................................54

5.16 Pressure Washing the Machine ..........................................................56

5.17 Storing the Machine ............................................................................56

6 Troubleshooting 57

7 Technical Data 58

7.1 Engine .................................................................................................58

7.2 Roller ...................................................................................................59

7.3 Lubrication ...........................................................................................59

7.4 Sound and Vibration Measurements ...................................................60

8 AEM Safety Manual 61

9 Schematics 88

9.1 Hydraulic Schematic ............................................................................88

9.2 Hydraulic Schematic Components ......................................................89

9.3 Hydraulic Diagram ...............................................................................90

9.4 Hydraulic Diagram Components .........................................................91

9.5 RD 7H ES—Electrical Schematic ........................................................92

9.6 RD 7H-ES—Electrical Schematic Components ..................................93

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RD 7 Safety Information

1 Safety Information

1.1 Signal Words Used in this Manual

This 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.

This is the safety alert symbol. It is used to alert you to potential personal hazards. f Obey all safety messages that follow this symbol.

DANGER

DANGER 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.

WARNING

WARNING 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 mes-

sages that follow this signal word.

CAUTION!

CAUTION 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.

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.

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Safety Information RD 7

1.2 Machine Description and Intended use

This 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 surface

• Using the machine to carry or transport passengers or equipment

• Using the machine to tow other machines

• Using the machine to spray liquids other than water (i.e., diesel fuel on asphalt)

• Operating the machine outside of factory specifications

• Operating 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 engine

• Burns from hot hydraulic fluid

• Fire hazards from improper refueling techniques

• Fuel and its fumes

• Personal injury from improper lifting techniques or operating techniques

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RD 7 Safety Information

To protect yourself and others, make sure you thoroughly read and understand the safety information presented in this manual before operating the machine.

1.3 Operating Safety

Familiarity and proper training are required for the safe operation of the machine. Machines operated improperly or by untrained personnel can be hazardous. Read the operating instructions contained in this

WARNING

Operator qualifications

manual and the engine manual, and familiarize yourself with the location and proper use of all controls. Inexperienced operators should receive instruction from someone familiar with the machine before being allowed to operate it.

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 machine

• are familiar with required safety devices

The machine must not be accessed or operated by:

• children

• people impaired by alcohol or drugs

Contact Wacker Neuson for additional training if necessary.

Personal Protective Equipment (PPE)

Wear the following Personal Protective Equipment (PPE) while operating this machine:

• Close-fitting work clothes that do not hinder movement

• Safety glasses with side shields

• Hearing protection

• Safety-toed footwear

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

1.3.2 Always operate machine with all safety devices and guards in place and in working order. Do not modify or defeat safety devices. Do not operate machine if any safety devices or guards are missing or inoperative.

1.3.3 ALWAYS check that all controls are functioning properly immediately after start-up! DO NOT operate the machine unless all controls operate correctly.

1.3.4 ALWAYS remain aware of changing surface conditions and use extra care when operating over uneven ground, on hills, or over soft or coarse material. The machine could shift or slide unexpectedly.

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Safety Information RD 7

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

1.3.6 ALWAYS position yourself safely when operating machine in reverse or on hills. Leave enough space between yourself and the machine so you will not be placed in a hazardous position should the machine slide or tip.

1.3.7 Make sure that all other persons are at a safe distance from the machine. Stop the machine if people step into the working area of the machine.

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

1.3.9 ALWAYS remain aware of changing positions and the movement of other equipment and personnel on the job site.

Do not use a cellphone or send text messages while operating this machine.

Do not subject the roller to jarring impacts by driving it off curbs or off the back of a truck or trailer.

1.3.10 NEVER operate the machine with the fuel cap loose or missing. Do not operate the machine with unapproved accessories or

attachments. Do not transport the machine while it is running.

1.3.11 Never leave the machine running unattended.

1.3.12 Do not use accessories or attachments that are not recommended by Wacker Neuson. Damage to equipment and injury to the user may result.

1.3.13 Do not touch the engine or muffler while the engine is on or immediately after it has been turned off. These areas get hot and may cause burns.

1.3.14 Do not operate a machine in need of service or repair.

1.3.15 ALWAYS do periodic maintenance as recommended in the Operator’s Manual.

1.3.16 Store the machine properly when it is not being used. The machine should be stored in a clean, dry location out of the reach of children.

1.3.17 Do not use a cellphone or send text messages while operating this machine.

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RD 7 Safety Information

1.4 Operator Safety While Using Internal Combustion Engines

WARNING

Internal combustion engines present special hazards during operation and fueling. Failure to follow the warnings and safety standards could result in severe injury or death. f Read and follow the warning instructions in the engine owner’s manual and the

safety guidelines below.

DANGER

Exhaust gas from the engine contains carbon monoxide, a deadly poison. Exposure to carbon monoxide can kill you in minutes.

f 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.

Operating 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.

• Do not smoke.

• Do not refuel a hot or running engine.

• Do not refuel the engine near sparks or open flames.

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Safety Information RD 7

1.5 Service Safety

A poorly maintained machine can become a safety hazard! In order

for the machine to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary.

WARNING

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 movement

• Safety glasses with side shields

• Hearing protection

• Safety-toed footwear

In addition, before servicing or maintaining the machine:

• Tie back long hair.

• Remove all jewelry (including rings).

1.5.1 ALWAYS check all external fasteners at regular intervals.

1.5.2 Do not modify the machine without the express written approval of the manufacturer.

1.5.3 Do not attempt to clean or service the machine while it is running. Rotating parts can cause severe injury.

1.5.4 Do not use gasoline or other types of fuels or flammable solvents to clean parts, especially in enclosed areas. Fumes from fuels and solvents can become explosive.

1.5.5 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.

1.5.6 ALWAYS make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices are attached securely and have enough weight-bearing capacity to lift or hold the machine safely. Always remain aware of the location of other people in the area when lifting the machine.

1.5.7 ALWAYS turn the engine off before servicing the machine. If the engine has electric start, disconnect the negative terminal on the battery before servicing the machine.

1.5.8 Keep the area around the muffler free of debris such as leaves, paper, cartons, etc. A hot muffler could ignite the debris and start a fire.

1.5.9 Do not tip the machine for cleaning or for any other reason.

1.5.10 DO NOT open hydraulic lines or loosen hydraulic connections while the engine is running! Hydraulic fluid under pressure can penetrate the skin, cause burns, blind, or create other potentially dangerous hazards. Set all controls in neutral and turn engine off before loosening the hydraulic lines.

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RD 7 Safety Information

1.5.11 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.

1.5.12 Always make sure hose connections have been reconnected back to the correct fitting. Failure to do so may result in damage to the machine and/or injury to person on or near the machine.

1.5.13 All adjustments and repairs MUST be completed before operation. Do not operate the machine with a known problem or deficiency! All repairs and adjustments should be completed by a qualified technician.

1.5.14 Before you start the machine, ensure that all tools have been removed from the machine and that replacement parts and adjusters are firmly tightened.

1.5.15 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.

1.5.16 Keep the machine clean and labels legible. Replace all missing and hard-toread labels. Labels provide important operating instructions and warn of dangers and hazards.

1.5.17 ALWAYS replace safety devices and guards after repairs and maintenance.

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Labels RD 7

2Labels

2.1 Label Locations

B, F, U

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RD 7 Labels

STOP

2.2 Safety and Informational Labels

Wacker Neuson machines use international pictorial labels where needed. These labels are described below.

Label Meaning

A DANGER!

Asphyxiation hazard.

Engines emit carbon monoxide.

0178715

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.

B WARNING!

Hot surface

C WARNING!

Read and understand the supplied Operator’s Manual before operating the machine. Failure to do so increases the risk of injury to yourself and others.

D WARNING!

To prevent hearing loss, wear hearing protection when operating the machine.

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Labels RD 7

Label Meaning

E Guaranteed sound power level in

dB(A).

F CAUTION!

Use only clean, filtered diesel fuel.

L O C A L W A C K E R

N G V O N

E L M A N U A L D E O P E R A C I O N D E B E S E R R E T E N I D O E N L A M A Q U I N A . C O N T A C T E A S U D I S T R IB U I D O R W A C K E R M A S C E R C A N O P P E D I R U N E J E M P L A R A D I C I O N A L .

L A N O T I C E D ' E M P L O I D O I T E T R E M U N I E S U R L A M A C H I N E . C O N T A C T E R L E D I S T R I W A C K E R L E P L U S P R O C H E P O U R C O M M A N D E R U N E X E M P L A I R E S U P P L E M E N T A I R E .

B U T E U R

A R A

machine. A replacement Operator’s Manual can be ordered through your

1 1 5 0 9 6

local Wacker Neuson distributor.

G Operator’s Manual must be stored on

O P E R A T O R ' S M A N U A L M U S T B E S T O R E D O N M A C H I N E . R E P L A C E M E N T O P E R A T O R ' S M A N U A L C A N B E O R D E R E D T H R O U G H Y O U R D I S T R I B U T O R .

D I E B E T R I E B S V O R S C H R I F T M U S S A N D E R M A S C H I N E A U F B E W A H R T W E R D E N . Z U R B E S T E L L U E R S A T Z B Ü C H E R N W E N D E N S IE S I C H B IT T E A N I H R E N Ö R T L I C H E N W A C K E R H Ä N D L E R .

H Water control valve.

J Vibration control ON/OFF.

K NOTICE

No lift point.

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RD 7 Labels

Label Meaning

L NOTICE

Lifting point.

M Tie-down point.

N Engine oil drain.

O Hydraulic oil reservoir fill tube.

P Hydraulic oil drain.

Q Key switch, engine start:

Off On Start

R This machine may be covered by one

or more patents.

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Labels RD 7

Label Meaning

S A nameplate listing the model number,

item number, revision number, and serial number is attached to each unit. Please record the information found on this nameplate so it will be available should the nameplate become lost or damaged. When ordering parts or requesting service information, you will always be asked to specify the model number, item number, revision number, and serial number of the unit.

Check engine oil level. Use SAE10W30.

Check the fuel level.

Engage parking brake.

Turn vibration off.

Pull engine throttle out.

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RD 7 Labels

Label Meaning

Pull decompression lever up.

Insert crank handle.

Rotate crank handle counterclockwise 5X.

Remove crank handle.

Disengage parking brake.

U Low sulfur fuel or ultra low sulfur fuel

only.

V Parking brake.

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Lifting and Transporting RD 7

3 Lifting and Transporting

WARNING

Crushing and machine damage hazards. Improper lifting techniques can cause the machine to fall.

f Observe the safety guidelines below when lifting and transporting the machine.

Lifting

• Attach a sling or chain to the lifting eye

shackle. Each lifting device must have capacity of at least 650 Kg (1430 lbs).

• Only use steel ropes or chains for hoisting. The rope or chain must

have the suitable specified lifting capacity of 650 Kg (1430 lbs). Do not use improvised ropes or chains.

NOTICE: Never use any other part of the roller to lift the machine, as

severe damage may occur.

• Do not stand under, or get onto, the machine while it is being hoisted

or moved.

(a)

using a suitable hook or

Transporting

Before transporting the machine:

• place blocks in front of and behind each drum.

• use the front and rear tie-downs

• place the lift handle

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.

trailer.

(c)

to secure the machine to the

(b)

into the upright position.

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RD 7 Operation

4 Operation

4.1 Preparing the Machine for First Use

Preparing for first use

To prepare your machine for first use:

4.1.1 Make sure all loose packaging materials have been removed from the machine.

4.1.2 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.

4.1.3 Take inventory of all items included with the machine and verify that all loose components and fasteners are accounted for.

4.1.4 Attach component parts not already attached.

4.1.5 Add fluids as needed and applicable, including fuel, engine oil, and battery acid.

4.1.6 Move the machine to its operating location.

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Operation RD 7

4.2 Controls and Service Locations

Ref. Description Ref. Description

1 Handle locking pin 15 Crank guide sleeve 2 Tie-down location 16 Fuel tank fill cap 3 Scraper bar (4 total) 17 Top cover 4 Water control valve 18 Hydraulic tank (under front cover) 5 Shock mount (4 total) 19 Hydraulic tank fill port (under top cover) 6 Parking brake 20 Hydraulic tank sightglass (through slots) 7 Back-up stop pad 21 Fuel tank 8 Forward/reverse control lever 22 Front cover

9 Exciter control lever 23 Lifting eye 10 Water tank fill cap 24 Operator’s Manual holder 11 Crank storage location 25 Water tank 12 Throttle control 26 Battery 13 Air cleaner indicator 27 Ignition switch 14 Oil dipstick 28 Alarm

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RD 7 Operation

4.3 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 ahead

• grasp the handle with one hand

• activate the control levers with the other hand

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Operation RD 7

4.4 Refueling the Machine

Requirements

• Machine shut down

• Engine cool

• Machine/fuel tank level with the ground

• Fresh, clean fuel supply

Procedure

Perform the procedure below to refuel the machine.

WARNING

Fire hazard. Fuel and its vapors are extremely flammable. Burning fuel can cause severe burns.

f Keep all sources of ignition away from the machine while refueling. f 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.

f Refuel only when the machine is outdoors. f Clean up spilled fuel immediately.

4.4.1 Remove the fuel cap.

4.4.2 Fill the fuel tank until the fuel level gauge indicates that the tank is full.

CAUTION

Fire and health hazard. Fuel expands when heated. Expanding fuel in an over-filled tank can lead to spills and leaks.

f Do not overfill the fuel tank.

4.4.3 Reinstall the fuel cap.

Result

The procedure to refuel the machine is now complete.

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RD 7 Operation

4.5 Before Starting

Before starting the machine, check the following:

• Engine oil level

• Air cleaner maintenance indicator

• Fuel level

• Hydraulic fluid level

• Water tank level

4.6 Engine Throttle Control

See Graphic: wc_gr001338

The engine throttle control (c) is pulled out to start the engine. Press in on the rubber button (c1) with your thumb while pulling the control out. The control will stay at any position, and can be fine-tuned by twisting the control in or out.

To stop the engine, push the throttle control all the way in by pressing on the rubber button with the heel of your hand.

wc_gr001338

wc_tx000294gb.fm 27

Operation RD 7

4.7 Starting the Machine (RD 7H, RD 7H-S)

See Graphic: wc_gr001338, wc_gr001339, wc_gr001340

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

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

4.7.3 Turn the decompression lever (f) until stop (f1) is reached. In this position, the automatic decompression system is heard to engage.

4.7.4 Insert the crank (d) into the guide sleeve (b).

4.7.5 Turn the crank 5 turns to build up pressure for the engine to fire.

4.7.6 Stand alongside the engine, facing the back of the machine (e) and grasp the tubular grip with both hands.

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

WARNING

4.7.7 Turn the handle slowly until the pawl engages the rachet, then increase the turning force to build up speed.

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

4.7.8 As soon as the engine has started, pull the starting handle out of the guide sleeve.

You must hold the tubular grip firmly to maintain contact all the time between the starting handle and the engine. Maintain turning force

WARNING

during the entire hand starting operation.

Note: If backfiring occurs when starting the engine because the crank handle was not turned firmly enough, the brief reverse rotation at the handle tube separates the link between the crank lug and the driving dog.

4.7.9 If the engine begins to run backwards after backfiring (smoke emerges from air cleaner), release the crank handle immediately and stop the engine.

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

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

wc_gr001339

wc_gr001340

28 wc_tx000294gb.fm

RD 7 Operation

4.8 Starting the Machine (RD 7H-ES)

See Graphic: wc_gr001529

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

4.8.2 Pull the throttle control (b) up to open the engine throttle.

4.8.3 Turn the ignition switch (c) to start the engine. . When the key is in the ON position, an alarm will sound. The alarm is

a reminder to turn the key to the OFF position when the machine is not

CAUTION

WARNING

4.8.4 Allow the engine to warm up for a few minutes before operating the

in use. Failure to do this will result in a dead battery. Note: The alarm will stop when proper oil pressure is reached.

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

machine.

wc_tx000294gb.fm 29

Operation RD 7

4.9 Cold Weather Starting (RD 7H, RD 7H-S)

See Graphic: wc_gr001338, wc_gr001339, wc_gr001340

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

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

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

4.9.3 Move the decompression lever (f) to a position that is approximately halfway between f0 and f1.

4.9.4 Insert the crank (d) into the guide sleeve (b).

4.9.5 Turn the crank 10 turns (rotations) to build up pressure for the engine to fire.

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

• remove the cover

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

• press the cover on firmly.

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

wc_gr001338

wc_gr001339

wc_gr001340

30 wc_tx000294gb.fm

RD 7 Operation

4.10 Engine Speed

During operation, run the engine at full throttle. This ensures maximum exciter speed and will produce the best compaction.

4.11 Stopping the Machine

See Graphic: wc_gr001529

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

4.11.2 Close the water control valve.

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

4.11.4 On electric start machines, turn the engine switch (c) to the OFF position.

4.11.5 Apply the parking brake.

4.11.6 Clean the scraper bars before storing the machine. NOTICE: Should the engine ever speed out of control and not stop by

using the throttle control, pulling up on the decompression lever, which could be hot to the touch, will stop the engine.

wc_tx000294gb.fm 31

Operation RD 7

4.12 Direction and Speed Control

See Graphic: wc_gr001341

Travel direction and speed are controlled by the movable lever (a) inside the handle. From the neutral position, the handle is pushed away from the operator to travel forward, and towards the operator to travel in reverse.

Keep both hands on the handle while operating the machine. The handle may pivot rapidly while in operation and cause injury.

WARNING

Speed is varied by the movement of the lever; the farther the lever is pushed in either direction, the faster the roller will travel in that direction.

If the linkage separates from the directional lever while the machine is running, the roller could “run away” and cause injury. In the event of

WARNING

this occurring, the throttle (b1) must be pushed in to stop the engine.

4.13 Exciter

wc_gr001341

The exciter provides the vibration and can be used in most applications involving cohesive-type soils with heavy clay content, as well as loose soils and gravel.

NOTICE: DO NOT run the machine over hard surfaces like concrete or compacted asphalt with the vibration on. Damage to the drum bearings may result.

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RD 7 Operation

4.14 Back-Up Stop Pad

See Graphic: wc_gr001342

A back-up stop pad (a) is mounted to the rear section of the machine behind the control panel. The back-up stop pad operates in reverse only.

If the machine backs into an obstruction or if the operator becomes trapped behind it, the pad will be pressed forward and stop the machine. The machine can move only in the forward direction when the handle is brought back through the neutral position.

STOP

4.15 Engine Crank

See Graphic: wc_gr001345

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).

wc_gr001342

wc_tx000294gb.fm 33

wc_gr001345

Operation RD 7

4.16 Parking Brake

See Graphic: wc_gr001343

The parking brake is used to ensure that the machine will not roll when not in use. It engages the weld stops on the drum, therefore a small amount of movement is possible before the brake will catch and stop the machine.

To disengage the parking brake:

Rotate the handle (a) 90° clockwise and bring it to rest in a shallow detent.

To engage the parking brake: Rotate the handle (a) 90° counterclockwise and allow it to rest in the

deep detent. NOTICE: The parking brake is designed to hold the machine on an

incline with the engine off. Do not drive against the parking brake in the engaged position. The brake may bend and damage the machine.

4.17 Watering System

See Graphic: wc_gr001344

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

wc_gr001344

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RD 7 Operation

4.18 Machine Stability

WARNING

Crushing 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.

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 sur-

faces 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.

wc_tx000294gb.fm 35

Operation RD 7

4.19 Operation on Slopes

See Graphic: wc_gr001346 and wc_gr001347

When operating on slopes or hills, special care must be taken to reduce the risk of personal injury or damage to the machine. Always operate the machine up and down hills rather than from side to side. For safe operation and for protection of the engine, continuous duty use should be restricted to slopes of 22° (40% grade) or less.

NEVER operate the machine sideways on slopes. The machine may roll over, even on stable ground.

WARNING

4.20 Rollovers

Proper operation of the machine on slopes will prevent rollovers. Read and follow Safety instructions in “Operating Safety” and “Operation on Slopes”. If a machine rollover does occur, care must be taken to prevent damage to the engine. In this position, oil from the engine crankcase can flow into the combustion chamber, which can severely damage the engine next time it is started. If the machine has rolled on its side, immediate steps should be taken to right the machine.

NOTICE: To prevent damage to the engine after a rollover, the machine must NOT be started, AND it must be serviced to remove any oil that may have been trapped in the combustion chambers. Contact your local Wacker Neuson dealer for instructions or servicing.

22˚ 40%

wc_gr001346

wc_gr001347

36 wc_tx000294gb.fm

RD 7 Operation

4.21 Emergency Shutdown Procedure

If a breakdown or accident occurs while the machine is operating, follow the procedure below:

4.21.1 Stop the engine.

4.21.2 Close the fuel valve.

4.21.3 Allow the machine to cool.

4.21.4 Contact the rental yard or machine owner for further instructions.

wc_tx000294gb.fm 37

Maintenance RD 7

5 Maintenance

5.1 Maintenance Schedule

The 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.

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.

Daily

before

starting

After

first

25 hrs.*



Every

250

hrs.





Every

500

hrs.

Every

1200

hrs.

Clean cooling system.



Replace fuel filter.

Clean or replace air filter.

Change hydraulic system return line filter.

Check and adjust scraper bars.

**Check linkage components.

Clean battery terminals (RD 7H-ES).

Change hydraulic oil and filter.

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

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

38 wc_tx000295gb.fm



RD 7 Maintenance

5.2 Safety-Related Spare Parts

Overview

This machine is equipped with a back-up stop pad to enhance operator safety. For your 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

145 137 132

141 137 132

wc_gr007050

wc_tx000295gb.fm 39

Maintenance RD 7

Upper handle parts list

Ref. Part No. Qty. Description

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 85

145 0011346 2 Hex head screw M8 x 65

Measurement and Torque

25 Nm / 18 ft.lbs

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RD 7 Maintenance

5.3 Checking Engine Oil

See Graphic: wc_gr001348

Engine oil level

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

5.3.1 Clean around the dipstick.

5.3.2 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

wc_tx000295gb.fm 41

Maintenance RD 7

5.4 Changing Engine Oil and Oil Filter

See Graphic: wc_gr001349

Before changing the oil:

5.4.1 Run the machine to warm the oil.

5.4.2 Park the machine on a flat level surface.

5.4.3 Set all controls in neutral, stop the engine, apply the parking brake, and allow the engine and fluids to cool.

Burn hazard! Avoid contact with the engine oil when draining the engine. Hot oil can burn!

CAUTION

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.

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

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

5.4.6 Reinstall the drain plug.

5.4.7 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.

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

5.4.9 Add engine oil up to the “MAX” mark on the dipstick; approximately

1.1–1.2 liters (1–1¼ quarts).

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

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

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

wc_gr001349

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RD 7 Maintenance

WARNING

Most 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.

f Take steps to avoid inhaling or ingesting used engine oil. f Wash skin thoroughly after exposure to used engine oil.

5.5 Fuel System

See Graphic: wc_gr001351

Fuel tank water trap

The interval at which you should check the water trap depends upon the amount of water in the fuel. The normal interval is one week.

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

5.5.1 Remove the cover from the roller to allow access to the fuel tank water trap.

5.5.2 Loosen the hex screw (a) until only 2 threads are holding it in place.

5.5.3 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.

5.5.4 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 with

the necessary caution. Do not smoke near the machine. Avoid sparks

WARNING

and open flames.

5.5.5 Remove the cover from the roller to allow access to the fuel filter.

5.5.6 Place a suitable container under the fuel filter to trap escaping fuel.

5.5.7 Close the fuel supply line.

5.5.8 Pull the fuel supply line (b) off of the fuel filter trap (c) at both sides, and insert the new filter.

wc_tx000295gb.fm 43

Maintenance RD 7

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

5.5.9 Make sure the fuel filter is oriented with the arrow in the direction of fuel flow.

5.5.10 Open the fuel supply line until fuel begins to flow.

5.5.11 Run the engine briefly to check the fuel filter and lines for leaks.

wc_gr001351

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RD 7 Maintenance

5.6 Engine Air Filter

See Graphic: wc_gr001352

Checking the air cleaner blockage indicator

5.6.1 Briefly run the engine at full speed. If the rubber bellows is pulled in and obscures the green zone (a), clean or replace the air filter.

5.6.2 In dusty operating conditions, check the rubber bellows several times per day.

Cleaning or replacing the engine air filter

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

WARNING

5.6.3 Loosen the wing nut (b) and remove it. Also remove the air cleaner cover (c).

Note: The decompression lever will also come off.

5.6.4 Pull out the filter cartridge (e).

5.6.5 Check that the valve plate (f) for the air blockage indicator is clean and in good condition.

Cleaning dry dirt from the filter cartridge

5.6.6 Blow through the filter cartridge from the inside using a compressed air gun.

5.6.7 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

5.6.8 Change the filter cartridge. NOTICE: Always trace and correct the cause of wet or oily

contamination of a filter element.

Checking the filter cartridge

5.6.9 Hold the element up to a light or pass a lamp through the middle to check the condition of the element folds (g).

5.6.10 Check that the sealing surface (d) is in good condition. NOTICE: If there is even slight damage to the paper filter element or

the sealing surface, replace the filter cartridge.

wc_tx000295gb.fm 45

Maintenance RD 7

5.7 Checking and Adjusting Valve Clearances

See Graphic: wc_gr001353

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

5.7.1 Make sure that the compression lever is in position “0”. See section

Starting the Machine.

5.7.2 Remove the cylinder head cover and the gasket.

5.7.3 Turn the engine over in the normal direction of rotation until compression is felt.

5.7.4 Check the inlet valve clearance between the rocker and the valve stem using a feeler gauge (a).

5.7.5 If the valve clearance is incorrect, loosen the hex nut (c). Note: See section Technical Data for valve clearances.

5.7.6 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.

5.7.7 Repeat this adjustment with the outlet valve.

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

5.7.9 Run the engine briefly and make sure that the cylinder head cover is not leaking.

wc_gr001353

wc_gr001352

46 wc_tx000295gb.fm

RD 7 Maintenance

5.8 Engine Cooling System

See Graphic: wc_gr001354

Stop the machine, apply the parking brake and switch off the engine. The engine must be allowed to cool down before cleaning.

Dry contamination

5.8.1 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

5.8.2 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.

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

5.8.4 After cleaning, run the engine to dry it out and to prevent the formation of rust.

wc_gr001354

wc_tx000295gb.fm 47

Maintenance RD 7

5.9 Mechanical Oil Pressure Monitoring

See Graphic: wc_gr002338

The mechanical oil pressure monitor should be activated:

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

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

• after freeing it by turning it at low temperatures.

5.9.1 Add fuel.

5.9.2 Check the engine oil level.

5.9.3 To activate the oil pressure monitor, press the lever (a).

5.9.4 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.

CAUTION

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

48 wc_tx000295gb.fm

RD 7 Maintenance

5.10 Scraper Bars

See Graphic: wc_gr001355

Check the four scraper bars (a) for wear. Replace the scraper bars as needed.

Cleaning the scraper bars

The scraper bars should be cleaned daily after use or as often as needed to remove built-up dirt, mud, and tar.

Use a high-pressure water jet and a strong brush if needed.

wc_gr001355

wc_tx000295gb.fm 49

Maintenance RD 7

5.11 Water Spray Bars

Background

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.

5.11.1 The spray bars (a) are located behind the drum scrapers.

wc_gr007078

5.11.2 Start the machine. Activate the spray system and check for free flow of water through each spray hole (b).

5.11.3 If any of the spray holes are blocked, stop the machine and use a small pointed object (i.e. a stiff piece of wire) to remove the blockage.

5.11.4 Rinse the spray bars with clean water and dry with a soft, clean cloth.

NOTICE: The cap (c) and fitting (d) are not removable.

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RD 7 Maintenance

5.12 Hydraulic Oil Requirements

Wacker Neuson recommends the use of a premium grade, petroleumbased hydraulic oil with anti-wear and anti-foam characteristics. Good anti-wear oils contain additives to reduce oxidation, prevent foaming, and provide for good water separation. These oils offer superior motor and pump life.

When selecting hydraulic oil for your machine, be sure to specify antiwear properties. Wacker Neuson offers a premium grade hydraulic oil for use in this machine.

Avoid mixing different brands and grades of hydraulic oils.

Oil Viscosity

Most hydraulic oils are available in different viscosities. The SAE number for an oil is used strictly to identify viscosity. It does not indicate the type of oil (engine, hydraulic, gear, etc.). The higher the SAE number, the thicker the oil.

For normal applications use a good non-detergent, anti-wear, hydraulic oil with a viscosity rating of SAE 10W30.

wc_tx000295gb.fm 51

Maintenance RD 7

5.13 Hydraulic Oil Level

See Graphic: wc_gr001356

A hydraulic oil level sightglass (a) is located on the hydraulic tank and is visible through the slots on the top cover.

Check the oil level with the machine standing on a level surface. The oil level should be at the halfway mark on the sightglass. If the level is low, remove the top cover and top up with hydraulic oil as necessary.

If hydraulic oil continually needs to be added, inspect the hoses and connections for possible leaks. Repair hydraulic leaks immediately to prevent damage to the hydraulic components.

wc_gr001356

52 wc_tx000295gb.fm

RD 7 Maintenance

5.14 Changing Hydraulic Fluid and Filter

See Graphic: wc_gr001357

Stop the machine, switch off the engine, and apply the parking brake with the machine standing on a level surface.

Note: In the interests of environmental protection, place plastic sheeting and a container under the machine to collect the liquid which drains off. Dispose of this liquid properly.

5.14.1 Remove the top cover of the roller.

5.14.2 Remove the drain plug (b) from the end of the drain hose that is attached to the hydraulic tank.

5.14.3 Allow the hydraulic oil to drain into a suitable container.

5.14.4 When all the oil has drained out, reinstall the drain plug back into the hose and secure it in place.

5.14.5 Place a plastic bag around the filter (a) to contain any oil spillage.

5.14.6 Unscrew the old hydraulic filter.

5.14.7 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.

5.14.8 Tighten the hydraulic filter using both hands.

5.14.9 Fill the hydraulic tank with hydraulic oil until the level is visible halfway up the sightglass.

5.14.10 Run the engine briefly, then stop the engine and check for leaks.

5.14.11 Check the oil level in the sightglass, and top up if necessary.

wc_tx000295gb.fm 53

Maintenance RD 7

5.15 Direction Lever Adjustment

See Graphic: wc_gr003672

The forward/reverse control lever should have long forward travel and short reverse travel. If the lever appears out of adjustment, it can be readjusted as follows:

5.15.1 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 springloaded, cable centering device (5) so that the machine does not creep.

5.15.2 Stop the engine.

5.15.3 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.

5.15.4 Disconnect the clevis (1) from the pivot (2).

5.15.5 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).

5.15.6 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.

5.15.7 Turn off the engine.

5.15.8 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.

5.15.9 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

CAUTION

2 km/hr. (1.2 mph).

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RD 7 Maintenance

wc_tx000295gb.fm 55

Maintenance RD 7

5.16 Pressure Washing the Machine

When 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:

• Engine

• Hydraulic

• Water tank/Plastic parts

• Hoses

• Labels

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 cyl-

inders.

• Remove the battery from the machine and charge it periodically

(RD 7H-ES).

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RD 7 Troubleshooting

6 Troubleshooting

Problem / Symptom Reason / Remedy

Engine does not start • Fuel tank empty.

• Wrong type of fuel.

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

• Fuel system not primed.

• Fuel filter restricted or plugged. Replace filter.

• Check/adjust valve clearance.

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

• Air cleaner element plugged.

• Check/adjust decompression device.

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

• Starter motor defective (RD 7H-ES).

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

• Key switch defective (RD 7H-ES).

Engine stops by itself • Fuel tank empty.

• Fuel filter plugged.

• Fuel lines broken or loose.

No vibration • Valve damaged.

• Exciter assembly damaged.

• Exciter motor coupling damaged or broken.

• Exciter motor damaged.

• Pump damaged.

No travel or Travel only in one direction

• Control cable loose or broken.

• Drive motor damaged.

• Drive pump damaged.

• Defective relief valve or valves.

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Technical Data RD 7

7 Technical Data

7.1 Engine

Engine Power Rating

Net power rating per ISO 3046/1-IFN. Actual power output may vary due to conditions of specific use.

Item No.

Engine type One cylinder, 4-stroke, air cooled, diesel engine

Engine make Hatz

Engine model 1D41S 1D41S VAR I

Max. rated power @ rated speed

Operating speed rpm 2600

Valve clearance (cold) intake: exhaust:

Battery V — 12 VDC —

Air cleaner type Dry pleated-paper element

Engine lubrication

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

kW (Hp)

mm (in.) 0.10 (0.004)

oil grade

RD 7H RD 7H-ES RD 7H-S

Engine

5.1 (6.9) @ 2600 rpm

0.20–0.25 (0.008–0.010)

SAE15W40

Fuel type No. 2 diesel

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

Fuel consumption

Item No.

Battery V — 12 VDC —

Air cleaner type Dry pleated-paper element

Fuel type No. 2 diesel

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

Fuel consumption

l (gal.)/hr.

1.67 (0.44)

RD 7-RAW

1.67 (0.44)

58 wc_td000115gb.fm

RD 7 Technical Data

7.2 Roller

Item No.

Overall dimensions handle up (l x w x h)

Overall Dimensions handle down (l x w x h)

Operating weight Area capacity Forward speed (max) Reverse speed (max) Vibration frequency Hydraulic system lubrication Hydraulic system capacity Gradeability with vibration Gradeability without vibration

Roller

mm (in.)

kg (lbs.)

m2 (ft.2)/hr.

km/h (mph)

Hz (vpm)

type

l (gal.)

RD 7H RD 7H-ES

RD 7H-S

RD 7-RAW

1225 x 700 x 2215

(48.3 x 27.5 x 87.2)

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

810 (1785) 830 (1829) 810 (1785)

2613 (28115)

0-4.0 (0-2.5) 0-2.0 (0-1.2)

55 (3300)

SAE 10W30 hydraulic oil*

30 (8)

25 40

*See “Hydraulic Oil Requirements”

7.3 Lubrication

Item No.

Hydraulic System

Exciter Rear Drum Drive Bearing

Front Drum Drive Bearing

type

L (gal)

type

qty.

type

RD 7

Lubrication

Premium grade, anti-wear hydraulic fluid 10W30

21.6 (5.7)

Mobil XHP222 Mobil XHP222

2-3 shots with hand-held grease gun

Sealed Bearings—No lubrication required

wc_td000115gb.fm 59

Technical Data RD 7

7.4 Sound and Vibration Measurements

The 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 (L

) = 108 dB(A).

These sound values were determined according to ISO 3744 for the sound power level (L

) 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/sec2.

60 wc_td000115gb.fm

NOTICE OF COPYRIGHT PROTECTION

AEM Safety Manuals are protected as a copyrighted work with ownership duly registered with the Copyright Office, Washington, D.C. Any reproduction, translation, decompiling or other use of an AEM Safety Manual, or portion thereof, or the creation of deriv-

ative works based on an AEM Safety Manual,without the prior written approval of AEM, is expressly prohibited. Copyright infringement can result in civil and criminal sanctions, damages and other penalties being imposed.

Revised 6/02, 9/04

SAFETY ALERT SYMBOL

This Safety Alert Symbol means ATTENTION is involved!

The Safety Alert Symbol identifies important safety messages on machines, safety signs, in manuals, or elsewhere.When you see this symbol, be alert to the possibility of personal injury or death. Follow the 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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WORD OF EXPLANATION................................................................................ 2

FOREWORD.......................................................................................................... 4

A WORD TO THE USER ...................................................................................... 5

FOLLOW A SAFETY PROGRAM ...................................................................... 6

PREPARE FOR SAFE OPERATION.................................................................... 9

START SAFELY....................................................................................................15

WORK SAFELY .................................................................................................. 18

PARK & SHUTDOWN SAFELY ...................................................................... 23

LOAD & UNLOAD MACHINE SAFELY ........................................................ 25

TRANSPORTING SAFELY .............................................................................. 26

PERFORM MAINTENANCE SAFELY ............................................................ 28

SPECIAL OPERATING AND MAINTENANCE PRECAUTIONS................ 43

TEST YOUR KNOWLEDGE ............................................................................ 47

A FINAL WORD TO THE USER ...................................................................... 48

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WORD OF EXPLANATION

The following is a partial list of reference material on safe operating practices:

U.S. Department of Labor publishes safety and health regulations and standards under the authority of the Occupational Safety and Health Act for the general construction and mining industries. Its address is: U.S. Department of Labor, 200 Constitution Avenue, NW,Washington, DC 20210.

SAE - Society of Automotive Engineers, Inc., 400 Commonwealth Drive,Warrendale, PA 15096, publishes a list, "Operator Precautions," SAE J153 MAY, 1987.

Association of Equipment Manufacturers, 111 East Wisconsin Avenue, Milwaukee,WI USA 53202, publishes the Roller Compactor Safety Manual and other safety-related material.

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This Safety Manual covers many different types of roller compactors … including steel wheel rollers, vibratory rollers, rubber-tired rollers, segmented pad/sheepsfoot soil compactors and landfill compactors.These may be either self-propelled ride-on, walk-behind or towed rollers.They may be used for the compaction of asphalt, soil, landfill or other materials. Excluded from coverage are vibratory plates and hand rammers.

Regardless of which machine you operate, it is YOUR responsibility to study and understand this Safety Manual, and to see that a copy remains with your machine.The manual begins with your “safety homework,” takes you step-by-step through your working day, and ends with maintenance operations.

Manufacturers produce machines with many built-in safety features. Employers provide accident prevention programs.Yet, the ultimate responsibility to operate and maintain your machine with the skill, care and knowledge essential for safety is YOURS.

Do not operate your machine until you have been trained in the use of all operating controls and understand the handling characteristics of the machine.

REMEMBER — SAFETY … YOURS AND THAT OF THOSE AROUND YOU … IS UP TO YOU!

WORD OF EXPLANATION

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This safety manual is intended to point out some of the basic situations which may be encountered during the normal operation and maintenance of your machine, and to suggest possible ways of dealing with these conditions.

Additional precautions may be necessary, depending on application, machine type, configuration and attachments used, and conditions at the work-site or in the maintenance area.The manufacturer has no direct control over machine application, operation, inspection, lubrication or maintenance.Therefore, it is your responsibility to use good safe practices in these areas.

The information provided in this manual supplements the specific information about your machine that is contained in the manufacturer's manual(s). Other information which may affect the safe operation of your machine may be contained on safety signs, or in insurance 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, or if errors or contradictions seem to exist, consult with your supervisor before operating your machine.

IMPORTANT: If you do not have the manufacturer's manual(s) for your particular machine, get a replacement manual from your employer, equipment dealer, or manufacturer of your machine. Keep this safety manual and the manufacturer's manual(s) with your machine.

Unauthorized modifications of machines create hazards. Machines should not be modified or altered unless prior approval is obtained from the manufacturer.

FOREWORD

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It is your responsibility to read and understand this safety manual and the manufacturer's manual(s) before operating your machine.This safety manual takes you step-by-step through your working day.

Remember that YOU are the key to safety. Good safety practices not only protect you but also protect the people around you. Study this manual and the manufacturer's manual(s) for your specific machine. Make them a working part of your safety program. Keep in mind that this safety manual is written for only this type of machine. Practice all other usual and customary safe working precautions, and above all — (FIG. 1)

REMEMBER — SAFETY IS UP TO YOU

YOU CAN PREVENT

SERIOUS INJURY OR DEATH

A WORD TO THE USER

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KNOW THE RULES

Every employer is concerned about safety. Safe operation and proper maintenance of your machine can prevent accidents. KNOW the rules — LIVE by them. (FIG. 2)

When starting work at a new site, check with the designated safety coordinator for specific safety instructions. DON’T LEARN SAFETY THE HARD WAY.

Know the meaning of all hand signals, signal flags, signs and markings.

Know the traffic rules used at the work site. Know who the signal person is; watch and obey their signals.

Know where the fire extinguishers and first aid kits are kept and how to use them. Know where to get proper aid and assistance when needed.

Use common sense to avoid accidents. If an accident does occur, be prepared to react to it quickly and effectively. NEVER PANIC.

Know how to use the emergency communications system to summon help when necessary.

FOLLOW A SAFETY PROGRAM

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KNOW WHAT IT IS?

Consult your supervisor for specific instructions on a 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 neckties and scarves, rings, wrist watches, or other jewelry — that can catch on protruding or moving parts or controls. Long hair should be securely bound to prevent entanglement with moving parts. (FIG. 3)

FOLLOW A SAFETY PROGRAM

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BE ALERT!

Know where to get assistance. Know how to use a first aid kit and fire extinguisher or fire suppression system. (FIG. 4)

BE AWARE!

Ta ke advantage of training programs offered.

Safety programs require that one person at each jobsite be assigned the overall responsibility and authority for safety. Know who that person is, and COMMUNICATE.

Know what the jobsite rules are, and FOLLOW THE RULES. 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 these factors BEFORE accidents occur. Damage to the machine can be fixed in a short period of time, but injury, or death has a lasting effect.

FOR YOUR SAFETY AND SAFETY OF OTHERS, ENCOURAGE YOUR FELLOW WORKERS TO ACT SAFELY.

FOLLOW A SAFETY PROGRAM

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LEARN TO BE SAFE

READ the operator’s manual. If one has not been provided, GET ONE AND STUDY IT BEFORE OPERATING THE MACHINE. If you have any questions contact the manufacturer.

Know the positions and understand the functions of all controls before attempting to operate a machine. Know the meaning of all identification symbols on your controls and gauges. (FIG. 5)

Know the location of the emergency shut-down control if the machine is so equipped.

Know the capabilities and limitations of the machine … such as speed, breaking and steering.

Know the operational and transport dimensions of your machine to avoid inadvertently hitting something during operation or transporting.

Carefully read and follow the instructions on all safety signs on the machine. Keep safety signs in good condition. Replace missing or damaged safety signs.

PREPARE FOR SAFE OPERATION

NEVER operate a machine which is new to you without first being instructed in its proper operation.

CHECK IT OUT!

Always conduct a pre-shift inspection before operating any machine. Know what safety devices your machine is equipped with … and see that each item is securely in 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

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TIRES

Inspect pneumatic tires (if so equipped) for damage, wear, and proper inflation. Never operate with over-inflated or under-inflated tires. (FIG. 7)

Check that all wheel lug nuts are present and tight.

NEVER START OR OPERATE A MACHINE KNOWN OR SUSPECTED TO BE DEFECTIVE OR MALFUNCTIONING.

PREPARE FOR SAFE OPERATION

KNOW YOUR MACHINE

Never operate a machine for which you are not trained or qualified.

Familiarize yourself with pedals, controls and instruments – their locations and function.

To handle controls without slipping, wipe them clean of oil and grease.

Remove tools, supplies and other materials from the working areas and machine walkways – and keep these areas free of trash.

Make sure the items you do carry are not loose or in the way.

ARE REPAIRS MADE?

If your daily check uncovers any item that needs attention – repair, replacement, or adjustment – report it to your supervisor and tag the machine on the start switch and/or other appropriate, prominent location. A minor malfunction could be a sign of a more serious problem if the machine is operated.

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FIRE PREVENTION

Never allow flammable fluids or materials to contact 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.After repairs are made, clean the machine before you operate it.

Inspect electrical wiring for worn or damaged insulation. Install new wiring if wires are damaged.

PREPARE FOR SAFE OPERATION

Because ether or other starting fluids are flammable, do not smoke when using them.Always follow the instructions on the container and in the operator’s manual for your machine. (See page 19.)

Batteries produce explosive gases. Keep open flame or sparks away. See the manufacturer’s instructions when servicing the batteries, when using jumper cables or when using a battery charger. (See pages 36 and 37.)

Remove all trash or debris from the machine. Make sure that oily rags or other flammable material are not stored on the machine. (FIG. 8)

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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 affecting driving 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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Before starting, carefully inspect your machine for any evidence of physical damage such as cracking, bending or deformation of plates or welds. Check for cracking or flaking of paint, which may indicate an excessive strain or dangerous crack in the material below. Check for loose, broken or missing parts such as Roll-Over Protective Structure (ROPS) support brackets, vibration isolators, and nuts and bolts. If potentially serious problems are found, do not operate the machine until appropriate repairs are completed.

Check the level of all fluids … brake, transmission, power steering, engine coolant, hydraulic system, and others. Fill low reservoirs only to the proper level.

Check the various systems (hydraulic, cooling, etc.) for leaks. (FIG. 11) Inspect all plugs, filler caps and fittings for tell-tale signs of leaks.ALWAYS use a flashlight or shielded trouble light when checking … Never an open flame. Repair any leaks, or have them repaired by authorized service personnel. (See pages 28 through 42 for additional service cautions.)

Check the fuel level and, if low, fill the tank with the proper grade of clean fuel before extended operation (following the instructions on page 34).

A stalled or faltering engine can result in a real hazard when operating on grades, in traffic or in heavily congested areas.

NEVER smoke when checking fuel level or refueling.

PREPARE FOR SAFE OPERATION

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BE SURE THE WORK AREA IS SAFE

Before beginning operation, thoroughly check the area for any unusual conditions that could be dangerous. (FIG. 12) Check for hidden holes, drop-offs or overhead obstacles that could be dangerous. Check the clearance under overhead power and phone lines. LOOK UP AS WELL AS DOWN.

Be observant of other workmen, bystanders and other machines in the area. Be especially careful if trenches, lightpoles, tiles, buildings, etc. are within the effective range of a vibratory compactor. IMPROPER OPERATION COULD RESULT IN DAMAGE OR INJURY.

Remember, the danger of sliding and/or tipping on steep slopes is always present … regardless of how heavy or “stable” your machine may appear to be.When operating under these conditions, the use of ROPS and seat belts reduces the hazard to operating personnel.

PREPARE FOR SAFE OPERATION

FIG. 12

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Walk around your machine once more just prior to mounting it – checking for people and objects that might be in the way – then MOUNT PROPERLY USING STEPS AND HANDHOLDS PROVIDED.

Always use seat belts if your machine is equipped with a ROPS.

Just before starting, check all controls … such as forward and reverse, steering, transmission and throttle to be sure they are in the correct start-up position. (FIG. 13) The parking brake should be applied during the start-up operation.

Check for proper functioning of all operating and shut-down controls.

START CORRECTLY

Know the PROPER starting procedure for your machine. Follow the manufacturer’s operation manual … to the letter.

Then, start your engine.

START SAFELY

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IMMEDIATELY AFTER STARTING THE ENGINE …

• Observe gauges, instruments, and warning lights to

ensure that they are functioning and their readings are within the normal operating range. (FIG. 14)

• Be sure work area is safe for test operation of the

various 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 unusual

odors; 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 on level ground if possible.

Check service brakes (including hydrostatic brakes, if so equipped) in both forward and reverse operation (FIG. 15) ACCORDING TO THE MANUFACTURERS INSTRUCTIONS.

If an unsafe condition cannot be remedied immediately, notify your supervisor and tag the machine on the start switch and/or other appropriate, prominent location. (See page 28 for Lockout/Tagout procedure.) No machine should be operated if any part is not in safe operating condition. Make certain that any unsafe condition has been satisfactorily remedied.

START SAFELY

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COLD WEATHER OPERATION

Consult the engine manufacturer’s operation manual for proper cold weather starting procedure.

When using cold weather starting aids, be sure to follow the engine manufacturer’s instructions. (FIG. 16)

After starting, operate all systems slowly and gently until properly warmed up.

BOOSTER CABLE INSTRUCTIONS

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.

START SAFELY

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REMEMBER THESE RULES

When roading or operating a machine, always stay in the operator’s station. NEVER mount or dismount a machine that is moving. Maintain control of your machine at all times.

ALWAYS operate your machine slowly until fully familiarized with it’s operation.

Constantly check your total work area for potential hazards.

Never JUMP on or off your machine. Use the steps and handholds provided to mount or dismount safely. Maintain three point contact when mounting or dismounting.(FIG. 17)

• Never use controls or levers as hand holds.

• Never jump off the machine.

Look, listen and smell for possible malfunctions. If malfunctioning controls or erratic operation are detected, correct or report them immediately. DO NOT OPERATE THE MACHINE UNTIL CORRECTED.

Prevent asphyxiation. If you must operate in a building or other enclosed area, or if your machine is equipped with an enclosed cab, be certain there is adequate ventilation.

Use extra care when refueling. (See page 34 for special precautions.)

WORK SAFELY

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For maximum safety on machines with more than one operator’s position, operate from the position giving the greatest visibility of potential hazards.

NEVER allow unqualified or unauthorized personnel to operate your machine.

NEVER allow other personnel to ride on your machine unless appropriate seating is provided … and then only if authorized to do so.

NEVER abuse your machine. Misuse or abuse can cause an accident.

NEVER enter or place any part of your body in the “hinge area” or other “pinch” areas of an articulated machine while the engine is running, or when there is any chance another person might start the machine. (FIG. 18)

Give the right-of-way to loaded equipment on haul roads. Maintain a safe distance from personnel, motor vehicles and other machines.

Your safety, and the safety of those around you, is determined by the care and judgment YOU use while operating your machine.

WORK SAFELY

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WORKING ON SLOPES

When working on slopes, avoid sidehill travel whenever possible … rather operate up and down the slope. (FIG. 19 & 20) Remember the danger of sliding and/or tipping on steep slopes is always present … regardless of how heavy or “stable” your machine may appear to be.

ALWAYS use seat belts IF your machine is equipped with a ROPS.

NEVER allow the engine or machine to overspeed.

When climbing or descending steep grades,ALWAYS select 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 speed control should be in the slow travel position, close to neutral … NEVER in the fully displaced position.

On machines that have a gear shift AND a hydrostatic control, BOTH controls must be in their slow travel position.

ALWAYS be sure that manually operated gear type transmissions are fully engaged BEFORE starting onto a grade. DO NOT attempt to change the gear selection while traveling on a grade. See the manufacturer’s manual for specific instructions.

WORK SAFELY

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Avoid operating your machine too close to an overhang, deep ditch or hole. If your machine inadvertently gets close to a tipping condition or drop-off, STOP and get off the machine after applying the parking brake … plan your moves carefully before proceeding. Reversal is often the best move.

Be alert to potential caving edges, falling rocks and slides.

Check for overhead obstacles that could be dangerous. LOOK UP AS WELL AS DOWN. (FIG. 21)

Be alert to obstacles and excessively rough terrain. Back away from them and go around.

Always travel slowly over rough terrain and hillsides. Maintain a speed consistent with the working conditions.

WORK SAFELY

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When traveling on a public road, obey all traffic regulations and be sure that the proper clearance flags, lights and warning signs … such as the “slow moving vehicle” emblem … are used. (FIG. 22)

NEVER speed … and NEVER coast in neutral.

When roading the machine know your approximate stopping distance at any given speed.

NEVER turn corners at excessively high speeds. (FIG. 23)

Always look in all directions before reversing your direction of travel.

Use EXTRA caution when working in close quarters or when traveling through congested areas. Courtesy pays off.

WORK SAFELY

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PARK SAFELY

Park in an off the road area, out of traffic, or as instructed. If necessary to park in a traffic lane, use the appropriate flags, barriers, flares, lights and warning signals. Provide advance warning signals in the 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 a firm footing, and that there is no danger of sliding. Do NOT leave your machine until you are sure it is safely blocked in both directions and parking brakes firmly applied. (FIG. 24)

Lower the blade and all other hydraulically operated attachments (if so equipped ) to the ground.

PARK AND SHUT DOWN SAFELY

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SHUT DOWN PROPERLY

Know the proper shut-down procedure for your machine. As with the starting procedure, this varies with the type and model of machine.

Follow the manufacturer’s operation manual for YOUR machine. Remove the key(s) to prevent unauthorized starting and movement, and position and lock any antivandalism devices.

DISMOUNT PROPERLY

NEVER dismount from your machine until it is fully stopped and the engine is shut off.

NEVER jump off your machine. (FIG. 26) After stopping, use the steps and handholds provided to dismount safely. Maintain three point contact when dismounting.

PARK AND SHUT DOWN SAFELY

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Loading and unloading machines always involves potential hazards. EXTREME CAUTION SHOULD BE USED.

Know the correct loading and unloading procedures for your machine.

All machines are not loaded and unloaded the same way.The procedures recommended by the manufacturer 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.

LOAD AND UNLOAD MACHINE SAFELY

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GENERAL

When towing a machine on a trailer, or a machine equipped with “portability or transport wheels”, ALWAYS use a hauling vehicle of sufficient weight, horsepower and braking capacity to maintain proper control.

NEVER attempt to tow a trailer or machine if the hitching devices are of insufficient or questionable capacity, improperly matched in size or shape, or positioned at improper heights.

When towing a machine equipped with portability or transport wheels, ALWAYS follow the manufacturer’s towing instructions.

BEFORE TOWING

When connecting a trailer to a hauling vehicle, block under the trailer’s tongue before attempting to make the connection. NEVER attempt to lift heavy tongues or move heavy trailers by hand. NEVER get any part of your body under the tongue when hitching or unhitching.

ALWAYS make sure the hitch is properly and securely locked.

ALWAYS use safety chains between the hauling vehicle and tailer or towed machine. Be sure the chains are properly and securely connected … at BOTH ends. Cross the chains under the tongue when connecting to the hauling vehicle.

ALWAYS make sure electrical and other connections between the hauling vehicle and trailer or towed machine are properly and securely made. After connecting, check the lights for proper operation. If the towed trailer or machine is equipped with brakes operable from the hauling vehicle, check to make sure they are operating properly.

ALWAYS be sure the portability or transport wheels, on machines so equipped, are LOCKED in the lowered position.

Check ALL tires for proper pressure, excessive or abnormal wear, and potentially dangerous cuts, bruises or bulges. Have any problems corrected before proceeding.

TRANSPORTING SAFELY

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TOWING

ALWAYS use EXTRA care when towing a trailer or machine… when maneuvering in tight places, when backing (visibility is reduced, and jackknifing must be avoided), and when towing on steep grades.

Know and obey all local, state and federal laws and regulations.

NEVER travel at speeds above those recommended by the manufacturer.

NEVER allow anyone to ride on a trailer or towed machine. (FIG. 28)

When necessary to disconnect and park a trailer or towed machine,ALWAYS select a location that is level and, if possible, one where children are unlikely to be present. BEFORE disconnecting a trailer, chock the front AND rear of the wheels, and block under the tongue.

See pages 23 through 24 for parking, shut-down procedures and roading machine for transport.

TRANSPORTING SAFELY

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GENERAL

Maintenance work can be hazardous if not done in a careful manner. All personnel should realize the hazards and strictly follow safe practices.

NEVER perform any work on the equipment unless authorized to do so. (FIG. 29) Before performing any maintenance or repair work, consult the Instruction Manual. Follow the manufacturer’s recommended procedures.

BEFORE any maintenance work is begun, review LOCKOUT/TAGOUT procedures. LOCKOUT controls and/or energy source and place a warning label to alert workers of shutdown.

PRIOR to removal of LOCKOUT/TAGOUT, the equipment must be fully operational and all personnel accounted for. Except in cases of emergency, the removal of the LOCKOUT/ TAGOUT should be done by the initiating person prior to the return to start-up.

BEFORE doing any major work, or work on the electrical system, disconnect the batteries.

REPLACE all missing or broken guards and panels.

USE proper nonflammable cleaning solvents. Follow solvent manufacturer’s instructions.

ALWAYS remove all flammable materials in the vicinity of welding and/or burning operations.

PERFORM MAINTENANCE SAFELY

BURNING OR WELDING in the vicinity of acoustical material may release hazardous fumes.

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PERFORM MAINTENANCE SAFELY

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 eye protection can keep flying particles from grinding, drilling or hammering operations, or fluids such as fuel, solvents, lubricants and brake fluids, from damaging your eyes. Normal glasses do NOT provide adequate protection.

ALWAYS wear a hard hat and safety shoes. (FIG. 30) ALWAYS wear hearing protectors when exposed to high noise levels for extended periods.ALWAYS wear a respirator when painting or exposed to dusty conditions. ALWAYS keep your pockets free of loose objects which can fall out and drop into

machinery. (FIG. 31) Heavy gloves should be worn for many operations.

EXHAUST FUMES

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, use an exhaust pipe extension. If you do not have an exhaust pipe extension, be positive the area is adequately ventilated. (FIG. 32)

HEAVY PARTS

Handle tools and heavy parts sensibly – with regard for yourself and other persons. Lower items – don’t throw or drop them.

ALWAYS use proper hoisting equipment for lifting heavy loads.

KE40246P3 6/9/05 3:19 PM Page 29

• 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 transmission in 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.

PERFORM MAINTENANCE SAFELY

KE40246P3 6/9/05 3:19 PM Page 30

Before beginning welding or burning operations, drain fuel lines and tank and move all flammable material to a safe distance, and be certain a fire extinguisher is readily available.When welding fuel tanks, either gasoline OR diesel,ALWAYS drain the tank, fill with water, and leave cap off during the welding operation.

All guards, plates and other safety devices must be properly replaced before the machine is returned to service or serious injury to you or other

personnel may result.

AVOID burning or welding near acoustical material whenever possible, as hazardous fumes may be released. If unavoidable, make sure the area is adequately ventilated, and that a fire extinguisher is ready available.

ALWAYS use authorized replacement parts that meet the machine manufacturer’s specifications.

JACKING AND BLOCKING

ALWAYS lower all movable attachments to the ground or 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 or other rigid supports of ample capacity. NEVER rely solely on the jacks for support. If necessary to work under a machine, 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 and wheels securely … front and rear … in such a manner as to prevent movement in EITHER direction. Securely attach the steering frame lock to prevent the machine from turning.

PERFORM MAINTENANCE SAFELY

KE40246P3 6/9/05 3:19 PM Page 31

FIRE PREVENTION

Whenever possible use a nonflammable solvent to clean parts. Do not use gasoline or other fluids that give 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 approved containers which are clearly marked. NEVER smoke in areas where flammable fluids are used or stored. (FIG. 35)

Use proper nonflammable cleaning solvents. Follow solvent manufacturer’s instructions for use.

Always remove all flammable material in the vicinity of welding and/or burning operations.

ALWAYS keep the floor in the work area clean and dry. Oily, greasy floors can easily lead to falls. Wet spots, especially near electrical equipment, can be hazardous. (FIG. 35)

Know where fire extinguishers are kept – how they operate – and for what type of fire they are intended.

Check readiness of any fire detectors and fire suppression systems.

PERFORM MAINTENANCE SAFELY

KE40246P3 6/9/05 3:19 PM Page 32

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.

PERFORM MAINTENANCE SAFELY

KE40246P3 6/9/05 3:19 PM Page 33

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.

PERFORM MAINTENANCE SAFELY

KE40246P3 6/9/05 3:19 PM Page 34

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. Never add 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.

PERFORM MAINTENANCE SAFELY

KE40246P3 6/9/05 3:19 PM Page 35

SERVICING BATTERIES

Always wear safety glasses and gloves when

working with batteries.

Before removing a battery, turn off all electrical equipment, then disconnect the negative (-) battery cable first. Before installing a battery, turn off all electrical equipment, then connect the positive (+) battery cable first.

To prevent sparking at the posts when using a battery charger, always turn the charger off or disconnect it from its power source before connecting or disconnecting charger leads to battery posts. Caps on all cells should be left on and the vent caps would be covered with a 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.

PERFORM MAINTENANCE SAFELY

KE40246P3 6/9/05 3:19 PM Page 36

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, never when shutting down.With electrolyte at the proper level, less space is available for gases to accumulate 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. If you spill acid on yourself flush skin immediately with lots of water. Apply baking soda to help neutralize the acid. If acids gets in your eyes, flush immediately with large amounts of water and seek proper medical treatment immediately.

When servicing batteries,remember that a lead-acid storage battery generates (when charging or discharging) hydrogen and oxygen – a very explosive mixture.A spark of flame could ignite these gases.

PERFORM MAINTENANCE SAFELY

KE40246P3 6/9/05 3:19 PM Page 37

HYDRAULIC SYSTEMS

NOTE: Hydraulic Systems have “special features”.

Some of the features affecting your safety are listed below.

Pressure can be maintained in hydraulic and air circuits long after the engine has been shut down. This pressure can cause hydraulic fluid or items such as pipe plugs to “shoot out” at high speed if pressure is not released correctly. Release system pressure before attempting to make adjustments or repairs.

Consult the manufacturer’s instructions for correct procedure.

Before disconnecting hydraulic fluid lines, be sure you:

• 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 the skin and cause serious injury. Therefore, be sure all connections are tight and that lines, pipes, and hoses are in good condition before starting the engine.

Fluid escaping from a small hole can be almost invisible. Use a piece of cardboard or wood, instead of your hands, to search for suspected leaks. (FIG. 42)

PERFORM MAINTENANCE SAFELY

KE40246P3 6/9/05 3:19 PM Page 38

HYDRAULIC SYSTEMS (CONT’D)

If you are struck by escaping hydraulic fluid under pressure, serious injury can occur if

proper medical treatment is not administered immediately.

During operation, hydraulic fluid and air in an unvented hydraulic tank becomes heated and will tend to expand.This will raise the pressure inside an unvented hydraulic tank. If the filler cap is removed rapidly, the pressure in the tank can force the oil out of the tank very rapidly. The hydraulic fluid may be very hot and may cause severe burns. Always relieve tank pressure before removing the cap completely. Consult the manufacturer’s instructions for the correct procedure.

When adding fluid to any system, be sure to use the fluid recommended by the manufacturer. Certain fluids, when mixed, may destroy seals causing loss of control and possible personal injury.

Keep hydraulic relief valve settings set to the manufacturer’s recommendations. Excessive pressures could result in structural or hydraulic failures. Low pressure could result in loss of control. Either condition could cause

personal injury or death.

Be sure the engine is stopped and machine is

properly locked out and controls tagged, before working on a machine. Only run engine when it is essential, as in the case of pressure adjustments, lubrication, or tests. Follow the manufacturer’s recommendations when making adjustments. Never resume operation until satisfactory adjustments have been made. The operator must follow the mechanic’s instructions when adjustments are being made or machine is being serviced.

PERFORM MAINTENANCE SAFELY

KE40246P3 6/9/05 3:19 PM Page 39

TIRE INSPECTION

Recommended air pressure must be maintained in every tire. Daily checks assure that inflation is correct. If your periodic check discloses a tire that is continuously losing air, a leak is indicated and must 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.

PERFORM MAINTENANCE SAFELY

KE40246P3 6/9/05 3:19 PM Page 40

PNEUMATIC TIRES

Changing tires or adding air can be a hazardous business. Special tools and procedures are required for changing off-highway tires.

Explosion and separation of a tire and/or rim parts can cause serious injury or death. (FIG. 44) Always follow the manufacturer’s recommendations or see your tire supplier.

PERFORM MAINTENANCE SAFELY

TIRE PRESSURE

Check tire pressure before starting operation. An air pressure rise during operation is normal and should NOT be reduced. Overloads or overspeeds may produce increased tire pressures due to heat. Never bleed tires. Reduce your load – or speed – or stop until tires cool.

ADD AIR

From a distance – with air chuck clipped on the tire valve – and with extension hose that permits you to stand behind tread. (FIG. 45) Always use a tire cage or equivalent for protection.

KE40246P3 6/9/05 3:19 PM Page 41

ROPS (Roll-Over Protective Structures)

Periodically inspect ROPS for cracks and loose mounting hardware.

Replace all missing, deteriorated or worn rubber parts.

If it becomes necessary to remove a ROPS, reinstall it only on the same machine, in its original position. (FIG. 46)

NEVER alter the ROPS in any way without the written approval of the manufacturer.

NEVER cut holes in or weld on ROPS without the manufacturer’s approval.

NEVER attempt to repair a damaged ROPS – it must be replaced with a new unit, approved for that machine.

Periodically inspect seat belts for wear, tear, deterioration or 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 is exposed to a flame or excessive heat.

Maintenance and repair of air conditioners … except for very minor repairs or servicing … must be done only by an experienced air conditioner or refrigeration technician. (FIG. 47)

PERFORM MAINTENANCE SAFELY

KE40246P3 6/9/05 3:19 PM Page 42

PARKING AND TRANSPORTING

ALWAYS select a level area to park in and, if possible, one where children are unlikely to be present.ALWAYS chock the front AND rear of the roller … even if leaving the machine unattended for short periods.

ALWAYS use EXTRA care when towing a roller … when maneuvering in tight places, when backing (visibility is reduced, and jackknifing must be avoided), and when operating on grades. NEVER operate a towed roller on steep grades or side slopes, as the possibility of tipping or loss of control is greater when towing a roller.

NEVER allow anyone to ride on a towed roller. And, unless absolutely necessary, never permit anyone in the “pinch” area between the towing vehicle and the towed roller.

When necessary to disconnect and park a towed roller, ALWAYS select a location which is level and, if possible, one where children are unlikely to be present. BEFORE disconnecting, ALWAYS chock the front AND rear of the roll, and block under the tongue.

Extreme care should be exercised when loading or unloading a walk-behind roller. It is generally best to stand behind and to one side rather than directly behind a machine being propelled up or down a ramp.

If the roller is designed to hang from the tailgate of a vehicle when being transported, ALWAYS be certain the hook brackets meet the roller manufacturer’s specifications.

Special precautions must also be exercised when loading or unloading, transporting or servicing a towed roller. Consult your manufacturer’s manual for specific details.

SPECIAL OPERATING AND MAINTENANCE PRECAUTIONS

KE40246P3 6/9/05 3:19 PM Page 43

FOR TOWED ROLLERS

Most general safety precautions covered earlier in this manual are also applicable to towed roller operation. Many other SPECIAL precautions must, however, be taken. Study your manufacturer’s manual(s) relative to special considerations when towing. If you have questions or concerns, consult the manufacturer or your dealer.

ALWAYS use a tow tractor of sufficient weight, drawbar horsepower and braking capacity to properly control the towed roller. Proper weight balance and distribution is also essential.

ALWAYS block under the tongue of the towed roller BEFORE attempting to connect it to the towing vehicles or machine. NEVER attempt to lift heavy tongues or move towed rollers by hand. NEVER get any part of your body under the tongue when hitching or unhitching.

ALWAYS make sure the hitch pin is of the proper size, and securely locked in place before towing. (FIG. 48) If safety chains are provided, make sure they are properly and securely connected … at BOTH ends. Cross the chains under the tongue when connecting to the towing vehicle. If electrical or hydraulic connections are required, make sure the connections are properly and securely made.

SPECIAL OPERATING AND MAINTENANCE PRECAUTIONS

KE40246P3 6/9/05 3:19 PM Page 44

FOR LANDFILL COMPACTORS

General

Operators of landfill compactors should carefully handle fill materials that could be picked up and thrown by the wheels, become lodged in the machine, or that are highly flammable.

Frequent checks should be made for wire, cable or other material wound around the axle members. Remove them immediately.

Tr avel with the blade as low as possible.

Maintain good operator visibility – keep all mesh and windows free of accumulated materials that reduce visibility.

When parking the machine,ALWAYS lower the blade.

FIRE PROTECTION

Maintain fire extinguishers and fire protective systems in good working order. ALWAYS recharge extinguishers, or replace with a fully charged unit immediately after use.

Check for, and remove, any waste material accumulation above belly pans and behind protective doors and grills.Accumulations are a fire hazard. (FIG. 49)

SPECIAL OPERATING AND MAINTENANCE PRECAUTIONS

KE40246P3 6/9/05 3:19 PM Page 45

FOR WALK-BEHIND ROLLERS

Start-Up

NEVER attempt to operate a walk-behind roller before being thoroughly familiar with the manufacturer’s operating instructions. If you have any questions or uncertainty, consult the manufacturer and/or his dealer BEFORE attempting to operate it.

ALWAYS follow the manufacturer’s instructions for starting the engine. All controls MUST be in the correct position BEFORE attempting to start the engine ( for example, the shift lever must be in neutral).

Starting fluid is NOT recommended when hand starting an engine. The engine may kick back.

OPERATION

When operating a walk-behind roller, ALWAYS exercise extreme care to avoid having your feet or clothing caught under the dolly wheels or roll. When possible, stand behind and to one side of the machine rather than directly behind it. Particular care must be exercised when operating near obstructions, on slippery surfaces, grades and side slopes. (ALWAYS wear slip resistant safety shoes or boots.)

NEVER ride on a walk-behind roller unless it is designed to accommodate riders and an appropriate seat is provided.

NEVER attempt to shift on a grade if the roller has a mechanical transmission.

NEVER operate a walk-behind roller in unshored trenches or near steep, unsupported banks.The vibrations could cause a cave-in.

Uneven grades can cause the handle to raise or lower unexpectedly, striking the unwary operator. (FIG. 50)

SPECIAL OPERATING AND MAINTENANCE PRECAUTIONS

KE40246P3 6/9/05 3:19 PM Page 46

Do you understand this AEM SAFETY MANUAL AND ITEMS 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, consult with your supervisor BEFORE operating your machine!

TEST YOUR KNOWLEDGE

KE40246P3 6/9/05 3:19 PM Page 47

Remember that YOU are the key to safety. Good safety practices not only protect you but protect the people around you.

You have read this safety manual and the manufacturer’s manual(s) for your specific machine. Make them a working part of your safety program. Keep in mind that this safety manual is written for only this type of machine.

Practice all other usual and customary safe working precautions, and above all –

REMEMBER

SAFETY IS UP TO YOU

YOU CAN PREVENT SERIOUS

INJURY OR DEATH

A FINAL WORD TO THE USER

KE40246P3 6/9/05 3:19 PM Page 48

KE40246P1 6/9/05 3:14 PM Page 1

Notes:

wc_tx001856gb.fm 87

Schematics RD 7

9 Schematics

9.1 Hydraulic Schematic

100 bar

1450 psi

206 bar

3000 psi

200 bar

2900 psi

10 micron

wc_gr003636

88 wc_tx001856gb.fm

RD 7 Schematics

9.2 Hydraulic Schematic Components

See Graphic: wc_gr003636

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_tx001856gb.fm 89

Schematics RD 7

9.3 Hydraulic Diagram

11 (9) (12)

wc_gr003637

90 wc_tx001856gb.fm

RD 7 Schematics

9.4 Hydraulic Diagram Components

See Graphic: wc_gr003637

Ref. Description Ref. Description

wc_tx001856gb.fm 91

Schematics RD 7

9.5 RD 7H ES—Electrical Schematic

123456

213456

wc_gr003663

92 wc_tx001856gb.fm

RD 7 Schematics

9.6 RD 7H-ES—Electrical Schematic Components

See Graphic: wc_gr003663

Ref. Description Ref. Description

1 Key switch 5 Starter

2 15 Amp fuse 6 Regulator

3 Alternator 7 Alarm

4 Battery 8 Oil pressure switch

Wire Colors

B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue

wc_tx001856gb.fm 93

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 02-390

Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.

Wacker Neuson Production Americas LLC, N92W15000 Anthony Ave., Menomonee Falls, WI 53051

Tel. : (262) 255-0500 Fax: (262) 255-0550 Tel.: (800) 770-0957

Tel: (852) 3605 5360, Fax: (852) 2758 0032

Notice d’Emploi

Rouleau

RD 7

5000185473 17 0911

réservés. Cette publication pourra être photocopiée par l’acheteur initial de la

machine. Tout autre type de reproduction est interdit sans l’autorisation écrite expresse de Wacker Neuson Production Americas LLC.

Tout type de reproduction ou de distribution non autorisé par Wacker Neuson Production Americas LLC représente une violation des copyrights en vigueur. Les contrevenants feront l’objet de poursuites.

Marques commerciales

Fabricant

Version traduite des instructions

Toutes les marques commerciales qui apparaissent dans ce manuel sont la propriété de leur détenteur respectif.

Wacker Neuson Production Americas LLC N92W15000 Anthony Avenue Menomonee Falls, WI 53051, États-Unis Tél. : (262) 255-0500 · Télécopieur : (262) 255-0550 · Tél. : (800) 770-

0957 www.wackerneuson.com

Cette notice d’emploi est une version traduite des instructions originales. La version originale est en anglais américain.

RD 7 Avant-Propos

Avant-Propos

Machines abordées dans le présent manue

Machine N° d'article

RD 7H 0008042 RD 7H-ES 0009408, 0620794 RD 7H-S 0009487, 0620795 RD 7-RAW 0620079, 0620478, 0620596

Documentation de la machine

Informations attendues dans ce manuel

 À partir de ce point, dans cette documentation, les produits Wacker Neuson

Production Americas LLC porteront l'appellation Wacker Neuson.

 Il convient de toujours garder un exemplaire de la Notice d’emploi avec

la machine.

 Utiliser la Liste des pièces de rechange fournie avec la machine pour

commander des pièces de rechange.

 Pour des instructions détaillées sur la maintenance et la réparation de la

machine, se reporter au Manuel de réparation.

 S’il manque un de ces documents, prendre contact avec Wacker Neuson

Corporation pour en commander un nouveau ou consulter www.wackerneuson.com.

 Pour commander des pièces de rechange ou rechercher des renseignements

relatifs à l’entretien, il faut toujours être prêt à fournir le numéro de modèle, le numéro de référence, le niveau de révision et le numéro de série de la machine.

 Ce manuel fournit des informations et renseigne sur les procédures à suivre

pour utiliser et entretenir en toute sécurité le ou les modèles Wacker Neuson ci-dessus. Par mesure de sécurité et pour réduire les risques de blessure, lire attentivement, bien assimiler et observer les consignes décrites dans ce manuel.

 Wacker Neuson se réserve expressément le droit d’apporter des modifications

techniques, y compris sans préavis, pour améliorer le niveau de performance ou de sécurité de ses machines.

 Les informations contenues dans ce manuel portent sur les machines

fabriquées au moment de la mise sous presse. Wacker Neuson se réserve le droit de modifier toute information sans préavis.

Lois relatives aux étouffeurs d’étincelles

Attention : Les codes de l’inspection du travail et les codes des ressources pub-

liques stipulent que dans certaines localités, les pare-étincelles doivent être utilisés sur des moteurs à combustion interne qui utilisent des hydrocarbures. Un pareétincelles est un appareil mis au point pour éviter une émission inopinée d’étincelles ou de flammes émanant de l’échappement du moteur. A cet égard, les pareétincelles sont définis et évalués par le Service Forestier des Etats-Unis.

Afin d’être conforme aux lois locales en matière de pare-étincelles, consulter le distributeur du moteur ou l’inspecteur du travail de votre localité.

wc_tx001345fr.fm FR-3

Avant-Propos RD 7

Autorisation du fabricant

Ce manuel contient plusieurs références à des pièces, des accessoires et des modifications approuvées. Les définitions suivantes s’appliquent :

 Les pièces et accessoires approuvés sont ceux fabriqués ou fournis par

Wacker Neuson.

 Les modifications approuvées sont celles effectuées par un centre de SAV

Wacker Neuson agréé conformément aux instructions écrites publiées par Wacker Neuson.

 Les pièces, accessoires et modifications non approuvés sont ceux qui ne

remplissent pas les critères approuvés.

Les pièces, accessoires et modifications non approuvés pourront avoir les conséquences suivantes :

 Blessures graves pour l’opérateur et les personnes dans la zone de travail  Dégâts irréversibles pour la machine non couverts par la garantie

Contacter immédiatement un revendeur Wacker Neuson pour toute question sur les pièces, accessoires et modifications approuvés et non approuvés.

FR-4 wc_tx001345fr.fm

Wacker Neuson RD 7 Series, RD 7H-ES, RD 7H, RD 7-RAW, RD 7H-S Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Foreword

1 Safety Information

1.1 Signal Words Used in this Manual

1.2 Machine Description and Intended use

1.3 Operating Safety

1.4 Operator Safety While Using Internal Combustion Engines

1.5 Service Safety

2Labels

2.1 Label Locations

2.2 Safety and Informational Labels

3 Lifting and Transporting

4 Operation

4.1 Preparing the Machine for First Use

4.2 Controls and Service Locations

4.3 Position of the Operator

4.4 Refueling the Machine

4.5 Before Starting

4.6 Engine Throttle Control

4.7 Starting the Machine (RD 7H, RD 7H-S)

4.8 Starting the Machine (RD 7H-ES)

4.9 Cold Weather Starting (RD 7H, RD 7H-S)

4.10 Engine Speed

4.11 Stopping the Machine

4.12 Direction and Speed Control

4.13 Exciter

4.14 Back-Up Stop Pad

4.15 Engine Crank

4.16 Parking Brake

4.17 Watering System

4.18 Machine Stability

4.19 Operation on Slopes

4.20 Rollovers

4.21 Emergency Shutdown Procedure

5 Maintenance

5.1 Maintenance Schedule

5.2 Safety-Related Spare Parts

5.3 Checking Engine Oil

5.4 Changing Engine Oil and Oil Filter

5.5 Fuel System

5.6 Engine Air Filter

5.7 Checking and Adjusting Valve Clearances

5.8 Engine Cooling System

5.9 Mechanical Oil Pressure Monitoring

5.10 Scraper Bars

5.11 Water Spray Bars

5.12 Hydraulic Oil Requirements

5.13 Hydraulic Oil Level

5.14 Changing Hydraulic Fluid and Filter

5.15 Direction Lever Adjustment

5.16 Pressure Washing the Machine

5.17 Storing the Machine

6 Troubleshooting

7 Technical Data

7.1 Engine

7.2 Roller

7.3 Lubrication

7.4 Sound and Vibration Measurements

9 Schematics

9.1 Hydraulic Schematic

9.2 Hydraulic Schematic Components

9.3 Hydraulic Diagram

9.4 Hydraulic Diagram Components

Avant-Propos