Roller - Wacker Neuson

Transcription

www.wackergroup.com
0116743en
0707
Roller
RD 7H
REPAIR MANUAL
0
1
1
6
7
4
3
E
N
004
RD 7H Repair
Foreword
This manual covers machines with Item Number:
0008042, 0009408, 0009487, 0620079
Operating / Parts Information
You must be familiar with the operation of this machine before you
attempt to troubleshoot or repair it. Basic operating and maintenance
procedures are described in the Operator’s Manual supplied with the
machine. 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. If you are missing either of the documents, please
contact Wacker Corporation to order a replacement.
Damage caused by misuse or neglect of the unit should be brought to
the attention of the operator to prevent similar occurrences from
happening in the future.
This manual provides information and procedures to safely repair and
maintain the above Wacker model(s). For your own safety and
protection from injury, carefully read, understand, and observe all
instructions described in this manual. THE INFORMATION
CONTAINED IN THIS MANUAL IS BASED ON MACHINES
MANUFACTURED UP TO THE TIME OF PUBLICATION. WACKER
CORPORATION RESERVES THE RIGHT TO CHANGE ANY
PORTION OF THIS INFORMATION WITHOUT NOTICE.
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Foreword
RD 7H Repair
CALIFORNIA
Proposition 65 Warning:
Diesel engine exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to the State of California
WARNING
to cause cancer and birth defects or other reproductive harm.
All rights, especially copying and distribution rights, are reserved.
Copyright 2007 by Wacker Corporation
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.
Any type of reproduction or distribution not authorized by Wacker
Corporation represents an infringement of valid copyrights, and
violators will be prosecuted. We expressly reserve the right to make
technical modifications, even without due notice, which aim at
improving our machines or their safety standards.
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RD 7H Repair
1.
Safety Information
1.1
1.2
1.3
1.4
1.5
2.
Operating Safety .................................................................................. 9
Operator Safety While Using Internal Combustion Engines ............... 10
Service Safety .................................................................................... 11
Label Locations .................................................................................. 12
Safety and Informational Labels ......................................................... 13
18
Engine ................................................................................................ 18
Roller .................................................................................................. 19
Sound and Vibration Measurements .................................................. 19
Operation
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
4.
8
Technical Data
2.1
2.2
2.3
3.
Table of Contents
20
Controls and Service Locations .......................................................... 20
Before Starting ................................................................................... 22
Engine Throttle Control ...................................................................... 22
Starting the Machine (RD 7H, RD 7H-S) ............................................ 23
Starting the Machine (RD 7H-ES) ...................................................... 24
Cold Weather Starting (RD 7H, RD 7H-S) ......................................... 25
Engine Speed ..................................................................................... 26
Stopping the Machine ......................................................................... 26
Direction and Speed Control .............................................................. 27
Exciter ................................................................................................ 27
Back-Up Stop Pad .............................................................................. 28
Engine Crank ...................................................................................... 28
Parking Brake ..................................................................................... 29
Watering System ................................................................................ 29
Operation on Slopes ........................................................................... 30
Rollovers ............................................................................................ 30
Maintenance
4.1
4.2
4.3
31
Maintenance Schedule ....................................................................... 31
Checking Engine Oil ........................................................................... 32
Changing Engine Oil and Oil Filter ..................................................... 33
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Table of Contents
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
4.23
4.24
5.
Fuel System ........................................................................................34
Engine Air Filter ...................................................................................36
Checking and Adjusting Valve Clearances .........................................37
Engine Cooling System .......................................................................38
Mechanical Oil Pressure Monitoring ....................................................39
Scraper Bars .......................................................................................40
Hydraulic Oil Requirements .................................................................41
Hydraulic Oil Level ..............................................................................42
Changing Hydraulic Fluid and Filter ....................................................43
Direction Lever Adjustment .................................................................44
Lifting ...................................................................................................46
Transporting ........................................................................................46
Pressure Washing the Machine ..........................................................47
Storing the Machine ............................................................................47
Hydraulic Schematic ............................................................................48
Hydraulic Schematic Components ......................................................49
Hydraulic Diagram ...............................................................................50
Hydraulic Diagram Components .........................................................51
RD 7H-ES Electrical Schematic ..........................................................52
RD 7H-ES Electrical Schematic Components .....................................53
General Troubleshooting .....................................................................54
General
5.1
5.2
5.3
5.4
6.
RD 7H Repair
55
Tools ....................................................................................................55
Reference Numbers ( ) ........................................................................55
Ordering Parts .....................................................................................55
Repair Accessories .............................................................................55
Hydraulic System
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
56
Hydraulic System Precautions ............................................................56
Hydraulic System Service Basics ........................................................56
Analyzing Hydraulic Oil Contamination ...............................................57
General Description .............................................................................58
Vibration Circuit ...................................................................................58
Hydraulic Manifold Block .....................................................................59
Drive Circuit .........................................................................................60
Return Line Filter .................................................................................60
6
RD 7H Repair
6.9
6.10
6.11
6.12
6.13
6.14
6.15
7.
70
Description ......................................................................................... 70
Pump Assembly ................................................................................. 71
Replacing the Drive Pump .................................................................. 72
Exciter Pump ...................................................................................... 74
Replacing the Engine ......................................................................... 76
Roller
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
9.
Bleeding the Hydraulic System .......................................................... 61
Hydraulic Diagram .............................................................................. 62
Hydraulic Schematic ........................................................................... 63
Testing Hydraulic Pressures .............................................................. 64
Checking the Vibration Circuit ............................................................ 64
Checking the Drive Circuit .................................................................. 66
Relief Valves ...................................................................................... 68
Power Take-Off
7.1
7.2
7.3
7.4
7.5
8.
Table of Contents
79
Drum - Description ............................................................................. 79
Replacing the Drum ............................................................................ 80
Drum Disassembly and Assembly ...................................................... 84
Replacing the Exciter ......................................................................... 88
Exciter Assembly ................................................................................ 92
Throttle Cable ..................................................................................... 94
Direction Cable ................................................................................... 96
Direction Control Lever ....................................................................... 98
Troubleshooting
9.1
9.2
9.3
9.4
9.5
9.6
100
General ............................................................................................. 100
Vibration System .............................................................................. 101
Troubleshooting the Vibration System ............................................. 102
Drive System .................................................................................... 103
Troubleshooting the Drive System ................................................... 104
Starting System ................................................................................ 107
7
Safety Information
1.
RD 7 /...
Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE and
NOTE callouts which must be followed to reduce the possibility of
personal injury, damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
DANGER
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
WARNING
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
CAUTION
NOTICE: Used without the safety alert symbol, NOTICE indicates a
hazardous situation which, if not avoided, could result in property
damage.
Note: Contains additional information important to a procedure.
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RD 7 /...
1.1
Safety Information
Operating Safety
WARNING
wc_si000115gb.fm
Familiarity and proper training are required for the safe operation of the
machine. Machines operated improperly or by untrained personnel
can be dangerous. Read the operating instructions contained in both
this manual and the engine manual and familiarize yourself with the
location and proper use of all controls. Inexperienced operators should
receive instruction from someone familiar with the machine before
being allowed to operate it.
1.1.1
ALWAYS operate the machine with all safety devices and guards in
place and in working order.
1.1.2
ALWAYS check that all controls are functioning properly immediately
after start-up! DO NOT operate the machine unless all controls operate
correctly.
1.1.3
ALWAYS remain aware of changing surface conditions and use extra
care when operating over uneven ground, on hills, or over soft or
coarse material. The machine could shift or slide unexpectedly.
1.1.4
ALWAYS remain aware of changing positions and the movement of
other equipment and personnel on the job site.
1.1.5
ALWAYS use caution when operating near the edges of pits, trenches
or platforms. Check to be sure that the ground surface is stable enough
to support the weight of the machine with the operator and that there
is no danger of the roller sliding, falling, or tipping.
1.1.6
ALWAYS position yourself safely when operating machine in reverse
or on hills. Leave enough space between yourself and the machine so
you will not be placed in a hazardous position should the machine slide
or tip.
1.1.7
ALWAYS operate the machine with both of your feet on the ground!
DO NOT stand, sit, or ride on machine while in operation.
1.1.8
ALWAYS remain aware of moving parts and keep hands, feet, and
loose clothing away from the moving parts of the machine.
1.1.9
NEVER operate the machine with the fuel cap loose or missing.
9
Safety Information
1.2
RD 7 /...
Operator Safety While Using Internal Combustion Engines
DANGER
Internal combustion engines present special hazards during operation
and fueling. Read and follow the warning instructions in the engine
owner’s manual and the safety guidelines below. Failure to follow the
warnings and safety guidelines could result in severe injury or death.
1.2.1
DO NOT run the machine indoors or in an enclosed area such as a
deep trench unless adequate ventilation, through such items as
exhaust fans or hoses, is provided. Exhaust gas from the engine
contains poisonous carbon monoxide gas; exposure to carbon
monoxide can cause loss of consciousness and may lead to death.
1.2.2
DO NOT smoke while operating the machine.
1.2.3
DO NOT smoke when refueling the engine.
1.2.4
DO NOT refuel a hot or running engine.
1.2.5
DO NOT refuel the engine near an open flame.
1.2.6
DO NOT spill fuel when refueling the engine.
1.2.7
DO NOT run the engine near open flames.
1.2.8
ALWAYS refill the fuel tank in a well-ventilated area.
1.2.9
ALWAYS replace the fuel tank cap after refueling.
1.2.10 DO NOT touch or lean against hot exhaust pipes.
1.2.11 DO NOT mix diesel fuel with any other fluids.
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RD 7 /...
1.3
Safety Information
Service Safety
WARNING
wc_si000115gb.fm
Poorly maintained machines 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.
1.3.1
DO NOT modify the machine without the express written approval of
the manufacturer.
1.3.2
DO NOT open hydraulic lines or loosen hydraulic connections while
the engine is running! Hydraulic fluid under pressure can penetrate the
skin, cause burns, blind, or create other potentially dangerous
hazards. Set all controls in neutral and turn engine off before loosening
the hydraulic lines.
1.3.3
ALWAYS check all external fasteners at regular intervals.
1.3.4
ALWAYS keep the area around the muffler free of debris such as
leaves, paper, cartons, etc. A hot muffler could ignite the debris and
start a fire.
1.3.5
ALWAYS keep the machine clean and labels legible. Replace all
missing and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
1.3.6
ALWAYS replace the safety devices and guards after repairs and
maintenance.
1.3.7
ALWAYS turn engine off before performing maintenance or making
repairs.
1.3.8
ALWAYS make sure slings, chains, hooks, ramps, jacks and other
types of lifting devices are attached securely and have enough weightbearing capacity to lift or hold the machine safely. Always remain
aware of the location of other people around when lifting the machine.
1.3.9
ALWAYS turn the engine off before servicing the machine. If the
engine has electric start, disconnect the negative terminal on the
battery before servicing the machine.
11
Safety Information
Label Locations
O P E
S T O
R E P
M A N
T H R
D IS T
D IE
A N
W E
E R
S IC
Ö R
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R A T
R E D
L A C
U A L
O U G
R IB
O R 'S
O N M
E M E N
C A N
H Y O
U T O R
B E T R IE B S
D E R M A S C
R D E N . Z U R
S A T Z B Ü C H
H B IT T E A N
T L IC H E N W
M A
A C
T O
B E
U R
.
N U A L M U S T B E
H IN E .
P E R A T O R 'S
O R D E R E D
L O C A L W A C K E R
V O R
H IN E
B E S
E R N
IH R
A C K
S C H R IF
A U F B E
T E L L U N
W E N D E
E N
E R H Ä N
T M U S S
W A H R T
G V O N
N S IE
D L E R .
E L
S E
C O
W A
P E
A D
M A N U
R R E T
N T A C
C K E R
D IR U
IC IO N
L A
E T
C O
W A
P O
E X
N O
R E
N T
C K
U R
E M
N
A L D
E N ID
T E A
M A S
E J E
A L .
T IC E D
M U N IE
A C T E R
E R L E
C O M M
P L A IR E
E O
O E
S U
C E
M P
'E M
S U
L E
P L U
A N
S U
P E R A C IO N D E B E
N L A M A Q U IN A .
D IS T R IB U ID O R
R C A N O P A R A
L A R
P L O I D O
R L A M A
D IS T R IB
S P R O C
D E R U N
P P L E M E
IT
C H IN E .
U T E U R
H E
N T A IR E .
1 1 5 0 9 6
1.4
RD 7 /...
RD 7 /...
1.5
Safety Information
Safety and Informational Labels
Wacker machines use international pictorial labels where needed.
These labels are described below:
Label
Meaning
DANGER!
Engines emit carbon monoxide; operate only
in well-ventilated area. Read the Operator’s
Manual.
No sparks, flames, or burning objects near the
machine. Shut off the engine before refueling.
WARNING!
Hot surface!
WARNING!
Read and understand the supplied Operator’s
Manual before operating the machine. Failure
to do so increases the risk of injury to yourself
or others.
WARNING!
To prevent hearing loss, wear hearing protection when operating the machine.
Guaranteed sound power level in dB(A).
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Safety Information
RD 7 /...
Label
Meaning
CAUTION!
Use only clean, filtered diesel fuel.
D IE
A N
W E
E R
S IC
Ö R
R A T
R E D
L A C
U A L
O U G
R IB
O R 'S
O N M
E M E N
C A N
H Y O
U T O R
B E T R IE B S
D E R M A S C
R D E N . Z U R
S A T Z B Ü C H
H B IT T E A N
T L IC H E N W
M A
A C
T O
B E
U R
.
N U A L
H IN E .
P E R A
O R D E
L O C A
V O R
H IN E
B E S
E R N
IH R
A C K
M U S T B E
T O R 'S
R E D
L W A C K E R
S C H R IF
A U F B E
T E L L U N
W E N D E
E N
E R H Ä N
T M
W A
G
N S
U S S
H R T
V O N
IE
D L E R .
E L
S E
C O
W A
P E
A D
M A N U
R E T
N T A C
C K E R
D IR U
IC IO N
R
L A N O
E T R E
C O N T
W A C K
P O U R
E X E M
A L D
E N ID
T E A
M A S
N E J E
A L .
T IC E D
M U N IE
A C T E R
E R L E
C O M M
P L A IR E
E O
O E
S U
C E
M P
'E M P
S U R
L E D
P L U S
A N D
S U P
P E R
N L A
D IS T
R C A
L A R
A C IO
M A Q
R IB U
N O P
L O I D O
L A M A
IS T R IB
P R O C
E R U N
P L E M E
N
Operator’s Manual must be stored on
machine. A replacement Operator’s Manual
can be ordered through your local Wacker distributor.
D E B E
U IN A .
ID O R
A R A
IT
C H IN E .
U T E U R
H E
1 1 5 0 9 6
O P E
S T O
R E P
M A N
T H R
D IS T
N T A IR E .
Water control valve.
Vibration control ON/OFF.
No lift point.
(one of two)
CAUTION!
Lifting point.
Tie-down point.
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RD 7 /...
Label
Safety Information
Meaning
Engine oil drain.
Hydraulic oil reservoir fill tube.
Hydraulic oil drain.
Key switch, engine start:
Off
On
Start
This machine may be covered by one or more
patents.
A nameplate listing the model number, item
number, revision number, and serial number is
attached to each unit. Please record the information found on this plate 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.
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Safety Information
Label
RD 7 /...
Meaning
Check engine oil level.
Use SAE10W30.
Check the fuel level.
Engage parking brake.
Turn vibration off.
Pull engine throttle out.
Pull decompression lever up.
Insert crank handle.
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RD 7 /...
Label
Safety Information
Meaning
Rotate crank handle counterclockwise 5X.
Remove crank handle.
Disengage parking brake.
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Technical Data
2.
RD 7 /...
Technical Data
2.1
Engine
Item No.
RD 7H
0008042
RD 7H-S
0009487
RD 7-RAW
0620079
RD 7H-ES
0009408
Engine
Engine type
One cylinder, 4-stroke, air cooled, diesel engine
Engine make
Hatz
Engine model
1D41S
Operating power
kW (Hp)
Operating speed
rpm
Valve clearance (cold)
intake:
exhaust:
Battery
Air cleaner
Engine lubrication
Engine oil capacity
Fuel
5.1 (6.9) @ 2600 rpm
2600
mm (in.)
V
1D41S VAR I
0.10 (0.004)
0.20–0.25 (0.008–0.010)
—
12 VDC
Dry pleated-paper element
type
SAE15W40
oil grade
l (qt.)
1.2 (1.25)
type
No. 2 diesel
Fuel tank capacity
l (gal.)
5.0 (1.3)
Fuel consumption
l (gal.)/
hr.
1.67 (0.44)
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—
RD 7 /...
2.2
Technical Data
Roller
Item No.
RD 7H
0008042
RD 7H-ES
0009408
RD 7H-S
0009487
RD 7-RAW
0620079
Roller
Overall dimensions handle up (l x w x h)
mm
(in.)
1225 x 700 x 2215
(48.3 x 27.5 x 87.2)
Overall Dimensions handle down (l x w x h)
mm
(in.)
2630 x 700 x 1165
(103.5 x 27.5 x 46)
Operating weight
kg (lbs.)
810 (1785)
830 (1829)
Area capacity
m2 (ft.2)/hr.
2613 (28115)
Forward speed (max)
km/h (mph)
0-4.0 (0-2.5)
Reverse speed (max)
km/h (mph)
0-2.0 (0-1.2)
Vibration frequency
55 (3300)
Hz (vpm)
Hydraulic system lubrication
810 (1785)
SAE 10W30 hydraulic oil*
type
Hydraulic system capacity
l (gal.)
Gradeability with vibration
%
25
Gradeability without vibration
%
40
30 (8)
*See “Hydraulic Oil Requirements”
2.3
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 (LWA) = 108 dB(A).
These sound values were determined according to ISO 3744 for the
sound power level (LWA) and ISO 6081 for the sound pressure level
(LpA) at the operator’s location.
The weighted effective acceleration value, determined according to
ISO 8662 Part 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.
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Operation
3.
RD 7 /...
Operation
3.1
Controls and Service Locations
Ref. Description
Ref.
Description
1
Handle locking pin
15
Crank guide sleeve
2
Tie-down location
16
Fuel tank fill cap
3
Scraper bar (4 total)
17
Top cover
4
Water control valve
18
Hydraulic tank (under front cover)
5
Shock mount (4 total)
19
Hydraulic tank fill port (under top cover)
6
Parking brake
20
Hydraulic tank sightglass (through slots)
7
Back-up stop pad
21
Fuel tank
8
Forward/reverse control lever
22
Front cover
9
Exciter control lever
23
Lifting eye
10
Water tank fill cap
24
Operator’s Manual holder
11
Crank storage location
25
Water tank
12
Throttle control
26
Battery
13
Air cleaner indicator
27
Ignition switch
14
Oil dipstick
28
Alarm
wc_tx000294gb.fm
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RD 7 /...
wc_tx000294gb.fm
Operation
21
Operation
3.2
RD 7 /...
Before Starting
Before starting the machine, check the following:
3.3
•
Engine oil level
•
Air cleaner maintenance indicator
•
Fuel level
•
Hydraulic fluid level
•
Water tank level
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.
c1
a
c
b
d
wc_gr001338
wc_tx000294gb.fm
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RD 7 /...
3.4
Operation
Starting the Machine (RD 7H, RD 7H-S)
See Graphic: wc_gr001338, wc_gr001339, wc_gr001340
3.4.1
Check that the exciter (a) is in the OFF position.
3.4.2
Pull the throttle control (c) up to open engine throttle.
3.4.3
Turn the decompression lever (f) until stop (f1) is reached. In this
position, the automatic decompression system is heard to engage.
3.4.4
Insert the crank (d) into the guide sleeve (b).
3.4.5
Turn the crank 5 turns to build up pressure for the engine to fire.
3.4.6
Stand alongside the engine, facing the back of the machine (e) and
grasp the tubular grip with both hands.
Do not stand in any other position! Injury may result if the engine
should backfire!
WARNING
3.4.7
Turn the handle slowly until the pawl engages the rachet, then
increase the turning force to build up speed.
Note: The highest speed must be reached when the decompression
lever (f) returns to the (f0) position.
3.4.8
As soon as the engine has started, pull the starting handle out of the
guide sleeve.
WARNING
You must hold the tubular grip firmly to maintain contact all the time
between the starting handle and the engine. Maintain turning force
during the entire hand starting operation.
Note: If backfiring occurs when starting the engine because the crank
handle was not turned firmly enough, the brief reverse rotation at the
handle tube separates the link between the crank lug and the driving
dog.
3.4.9
If the engine begins to run backwards after backfiring (smoke emerges
from air cleaner), release the crank handle immediately and stop the
engine.
3.4.10
To restart the engine, wait until it has come to a standstill, then repeat
the starting procedures.
3.4.11
Allow engine to warm up for a few minutes before operating machine.
e
f1
g
f
f0
wc_gr001339
wc_tx000294gb.fm
23
wc_gr001340
Operation
3.5
RD 7 /...
Starting the Machine (RD 7H-ES)
3.5.1
Check that the exciter (a) is in the OFF position.
3.5.2
Pull the throttle control (b) up to open the engine throttle.
3.5.3
Turn the ignition switch (c) to start the engine.
CAUTION
.
When the key is in the ON position, an alarm will sound. The alarm is
a reminder to turn the key to the OFF position when the machine is not
in use. Failure to do this will result in a dead battery.
Note: The alarm will stop when proper oil pressure is reached.
Do not crank the engine starter for more than 15 seconds at one time.
Longer cranking cycles could lead to starter damage.
WARNING
3.5.4
wc_tx000294gb.fm
Allow the engine to warm up for a few minutes before operating the
machine.
24
RD 7 /...
3.6
Operation
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.
3.6.1
Check that the exciter switch (a) is in the OFF position.
3.6.2
Pull the throttle control (c) up to open the engine throttle.
3.6.3
Move the decompression lever (f) to a position that is approximately
halfway between f0 and f1.
3.6.4
Insert the crank (d) into the guide sleeve (b).
3.6.5
Turn the crank 10 turns (rotations) to build up pressure for the engine
to fire.
3.6.6
Clean around the cover of the metering device (g), then:
3.6.7
•
remove the cover
•
fill with lubricating oil until the level reaches the upper rim
•
press the cover on firmly.
Start the engine as normal. See section Starting the Machine.
c1
a
c
b
d
wc_gr001338
e
f1
g
f
f0
wc_gr001339
wc_tx000294gb.fm
wc_gr001340
25
Operation
3.7
RD 7 /...
Engine Speed
During operation, run the engine at full throttle (2800 rpm). This
ensures maximum exciter speed and will produce the best
compaction.
3.8
Stopping the Machine
3.8.1
Place the exciter switch (a) in the OFF position.
3.8.2
Close the water control valve.
3.8.3
Push the throttle control (b) to the minimum position to stop the engine.
3.8.4
On electric start machines, turn the engine switch (c) to the OFF
position.
3.8.5
Apply the parking brake.
3.8.6
Clean the scraper bars before storing the machine.
NOTICE: Should the engine ever speed out of control and not stop 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
26
RD 7 /...
3.9
Operation
Direction and Speed Control
Travel direction and speed are controlled by the movable lever (a)
inside the handle. From the neutral position, the handle is 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
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
this occurring, the throttle (b1) must be pushed in to stop the engine.
b1
a
wc_gr001341
3.10 Exciter
The exciter provides the vibration and can be used in most applications
involving cohesive-type soils with heavy clay content, as well as loose
soils and gravel.
NOTICE: DO NOT run the machine over hard surfaces like concrete
or compacted asphalt with the vibration on. Damage to the drum
bearings may result.
wc_tx000294gb.fm
27
Operation
RD 7 /...
3.11 Back-Up Stop Pad
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.
a
STOP
wc_gr001342
3.12 Engine Crank
The engine crank is equipped with kick-back damping to protect the
operator from injury should the engine backfire. The brief reverse
rotation at the handle tube (a) separates the link between the crank lug
(b) and the driving dog (c).
a
c
b
wc_gr001345
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28
RD 7 /...
Operation
3.13 Parking Brake
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.
a
wc_gr001343
3.14 Watering System
The RD 7 is equipped with a water control valve which allows the roller
to be used wet or dry, and a sprinkler system to distribute the water
evenly across the drums. The water is gravity fed to the sprinklers
when the control valve is in the OPEN (horizontal) position (a).
a
wc_gr001344
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29
Operation
RD 7 /...
3.15 Operation on Slopes
See Graphic: wc_gr001346 and wc_gr001347
When operating on slopes or hills, special care must be taken 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
22˚
40%
wc_gr001346
wc_gr001347
3.16 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 dealer for instructions or servicing.
wc_tx000294gb.fm
30
RD 7 /...
4.
Maintenance
Maintenance
4.1
Maintenance Schedule
Daily
before
starting
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.

After
first
25 hrs.*
Check tappet clearance.

Examine screw connections.

Replace engine oil and filter.

Every
250
hrs.
Every
500
hrs.

Check and adjust valve clearances.

Clean cooling system.

Replace fuel filter.

Clean or replace air filter.

Change hydraulic system return line filter.

Check and adjust scraper bars.

**Check linkage components.

Clean battery terminals (RD 7H-ES).

Change hydraulic oil and filter.

*For new or reconditioned engines.
CAUTION: DO NOT tighten cylinder head fastenings.
** Maintain linkages more frequently in dusty environments. Lubricating linkages is not
recommended. However, if necessary, use a dry lubricant that does not attract dust.
wc_tx000295gb.fm
Every
1200
hrs.
31
Maintenance
4.2
RD 7 /...
Checking Engine Oil
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.
4.2.1
Clean around the dipstick.
4.2.2
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
a
wc_gr001348
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32
RD 7 /...
4.3
Maintenance
Changing Engine Oil and Oil Filter
Before changing the oil:
4.3.1
Run the machine to warm the oil.
4.3.2
Park the machine on a flat level surface.
4.3.3
Turn off the engine and apply the parking brake.
Burn hazard! Avoid contact with the engine oil when draining 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.
4.3.4
Unscrew the oil drain plug and allow the oil to drain into a 1–1.5 liter
(1–1.5 quarts) container.
4.3.5
Clean the oil drain plug and attach a new seal to it.
4.3.6
Reinstall the drain plug.
4.3.7
Unscrew the filler cap of the oil filter housing. Check the condition of
the O-ring (a) on the filler cap and replace it if it is damaged.
4.3.8
Remove the used filter element. Install a new filter element with the
“TOP” mark facing up.
4.3.9
Add engine oil up to the “MAX” mark on the dipstick; approximately
1.1–1.2 liters (1–1¼ quarts).
4.3.10
Wet the O-ring and threads of the filler plug with high-temperature
grease available from your Hatz Dealer. Then, reinstall the filler plug.
4.3.11
Run the engine for two minutes. Turn off the engine and check the
engine oil level again. Add engine oil as necessary.
4.3.12
Make sure that there is no oil leakage past the filler cap.
a
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33
Maintenance
4.4
RD 7 /...
Fuel System
Fuel tank water trap
The interval at which you should check the water trap depends upon
the amount of water in the fuel. The normal interval is one week.
Stop the machine, switch off the engine, and apply the parking brake.
4.4.1
Remove the cover from the roller to allow access to the fuel tank water
trap.
4.4.2
Loosen the hex screw (a) until only 2 threads are holding it in place.
4.4.3
Trap the drops of water that emerge in a transparent container.
Note: Since water has a higher specific gravity than diesel fuel, the
water emerges first. The two substances separate at a clearly visible
line.
4.4.4
When only diesel fuel emerges, retighten the hex screw.
NOTICE: Diesel fuel destroys shock mounts. Clean up fuel spillage
immediately.
WARNING
Changing the fuel filter cartridge
Fuel filter maintenance intervals depend on the purity of the diesel fuel
used. If your fuel is dirty, perform this operation at 250 hours.
Stop the machine, switch off the engine, and apply the parking brake.
Danger of explosion! Diesel fuel is flammable and must be treated with
the necessary caution. Do not smoke near the machine. Avoid sparks
and open flames.
4.4.5
Remove the cover from the roller to allow access to the fuel filter.
4.4.6
Place a suitable container under the fuel filter to trap escaping fuel.
4.4.7
Close the fuel supply line.
4.4.8
Pull the fuel supply line (b) off of the fuel filter trap (c) at both sides, and
insert the new filter.
NOTICE: Keep the area clean to prevent dirt from entering the fuel
lines.
4.4.9
Make sure the fuel filter is oriented with the arrow in the direction of fuel
flow.
4.4.10 Open the fuel supply line until fuel begins to flow.
4.4.11 Run the engine briefly to check the fuel filter and lines for leaks.
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34
RD 7 /...
Maintenance
b
a
c
wc_gr001351
wc_tx000295gb.fm
35
Maintenance
4.5
RD 7 /...
Engine Air Filter
Checking the air cleaner blockage indicator
4.5.1
Briefly run the engine at full speed. If the rubber bellows is pulled in and
obscures the green zone (a), clean or replace the air filter.
4.5.2
In dusty operating conditions, check the rubber bellows several 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
4.5.3
Loosen the wing nut (b) and remove it. Also remove the air cleaner
cover (c).
Note: The decompression lever will also come off.
4.5.4
Pull out the filter cartridge (e).
4.5.5
Check that the valve plate (f) for the air blockage indicator is clean and
in good condition.
Cleaning dry dirt from the filter cartridge
4.5.6
Blow through the filter cartridge from the inside using a compressed air
gun.
4.5.7
Continue until all dust has been removed.
NOTICE: Only use filtered, dry compressed air. Do not exceed an air
pressure of more than 5 bar (70 psi). Keep the nozzle at a distance of
150 mm (6 in.) from the element.
Cleaning wet or oily dirt from the filter
4.5.8
Change the filter cartridge.
NOTICE: Always trace and correct the cause of wet or oily
contamination of a filter element.
Checking the filter cartridge
4.5.9
Hold the element up to a light or pass a lamp through the middle to
check the condition of the element folds (g).
4.5.10 Check that the sealing surface (d) is in good condition.
NOTICE: If there is even slight damage to the paper filter element or
the sealing surface, replace the filter cartridge.
wc_tx000295gb.fm
36
RD 7 /...
4.6
Maintenance
Checking and Adjusting Valve Clearances
Stop the machine, apply the parking brake and switch off the engine.
4.6.1
Make sure that the compression lever is in position “0”. See section
Starting the Machine.
4.6.2
Remove the cylinder head cover and the gasket.
4.6.3
Turn the engine over in the normal direction of rotation until
compression is felt.
4.6.4
Check the inlet valve clearance between the rocker and the valve stem
using a feeler gauge (a).
4.6.5
If the valve clearance is incorrect, loosen the hex nut (c).
Note: See section Technical Data for valve clearances.
4.6.6
Turn the adjusting screw (b) with a screwdriver until the feeler gauge
(a) can just be pulled through between the rocker and the valve stem
with slight resistance to its movement after the nut (c) has been
retightened.
4.6.7
Repeat this adjustment with the outlet valve.
4.6.8
Place a new gasket under the cylinder head cover, reinstall the
cylinder head cover, and tighten down the screws uniformly.
4.6.9
Run the engine briefly and make sure that the cylinder head cover is
not leaking.
a
b
c
wc_gr001353
d
e
a
c
b
g
f
wc_gr001352
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37
Maintenance
4.7
RD 7 /...
Engine Cooling System
The engine must be allowed to cool down before cleaning.
Dry contamination
4.7.1
Clean all air guide elements and the complete cooling air zones (a) on
the cylinder head and the cylinder and flywheel blades without making
them wet. Blow them dry with compressed air.
Moist or oily contamination
4.7.2
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.
4.7.3
Trace the source of oil leaks causing greasy dirt. Repair the leaks,
seeking advice of your Hatz dealer if necessary.
4.7.4
After cleaning, run the engine to dry it out and to prevent the formation
of rust.
a
a
a
wc_gr001354
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38
RD 7 /...
4.8
Maintenance
Mechanical Oil Pressure Monitoring
The mechanical oil pressure monitor should be activated:
•
when first filling, or after running the fuel tank dry.
•
if the engine shut down automatically because the lubricating oil
supply was inadequate.
•
after freeing it by turning it at low temperatures.
4.8.1
Add fuel.
4.8.2
Check the engine oil level.
4.8.3
To activate the oil pressure monitor, press the lever (a).
4.8.4
Re-assemble all the parts repositioned or removed. Check that the
capsule elements make a good seal.
Note: Instructions to activate the mechanical oil pressure control are
mentioned on the label (b) placed on the engine.
Even with the mechanical oil pressure control monitoring the oil level,
it must be checked every 8–15 operating hours.
CAUTION
wc_tx000295gb.fm
39
Maintenance
4.9
RD 7 /...
Scraper Bars
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.
a
a
a
wc_gr001355
wc_tx000295gb.fm
40
RD 7 /...
Maintenance
4.10 Hydraulic Oil Requirements
Wacker recommends the use of a premium grade, petroleum-based
hydraulic oil with anti-wear and anti-foam characteristics. Good antiwear 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 offers a premium grade hydraulic oil for use
in this machine.
•
Wacker Hydraulic Oil - P/N 85094
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
41
Maintenance
RD 7 /...
4.11 Hydraulic Oil Level
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.
a
wc_gr001356
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42
RD 7 /...
Maintenance
4.12 Changing Hydraulic Fluid and Filter
Stop the machine, switch off the engine, and apply the parking brake
with the machine standing on a level surface.
Note: In the interests of environmental protection, place plastic
sheeting and a container under the machine to collect the liquid which
drains off. Dispose of this liquid properly.
4.12.1
Remove the top cover of the roller.
4.12.2
Remove the drain plug (b) from the end of the drain hose that is
attached to the hydraulic tank.
4.12.3
Allow the hydraulic oil to drain into a suitable container.
4.12.4
When all the oil has drained out, reinstall the drain plug back into the
hose and secure it in place.
4.12.5
Place a plastic bag around the filter (a) to contain any oil spillage.
4.12.6
Unscrew the old hydraulic filter.
4.12.7
Install the new hydraulic filter. Screw the new hydraulic filter on by
hand, making sure that it is not cross-threaded.
NOTICE: Use only original spare parts.
4.12.8
Tighten the hydraulic filter using both hands.
4.12.9
Fill the hydraulic tank with hydraulic oil until the level is visible halfway
up the sightglass.
4.12.10 Run the engine briefly, then stop the engine and check for leaks.
4.12.11 Check the oil level in the sightglass, and top up if necessary.
a
b
wc_gr001357
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43
Maintenance
RD 7 /...
4.13 Direction Lever Adjustment
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:
4.13.1 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.
4.13.2 Stop the engine.
4.13.3 Place the forward/reverse control lever in the full FORWARD position
(F). Check the rotation of the drive pump control arm (9). In the full
FORWARD position, the drive pump control arm should rotate, in the
direction shown, as far as possible.
•
If the drive pump control arm rotates as far as possible, no further
adjustment is required.
•
If the drive pump control arm does not rotate as far as possible,
continue.
4.13.4 Disconnect the clevis (1) from the pivot (2).
4.13.5 Rotate the pivot so that the drive pump control arm rotates as far as
possible. With the forward/reverse control lever in the full 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).
4.13.6 Start the engine and check the NEUTRAL position of the control lever.
•
If the machine remains stationary, no further adjustment is
required.
•
If the machine creeps forwards or backwards, continue.
4.13.7 Turn off the engine.
4.13.8 Adjust the nut (4) on the spring-loaded, cable centering device 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.
4.13.9 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
2 km/hr. (1.2 mph).
CAUTION
wc_tx000295gb.fm
44
RD 7 /...
Maintenance
8
1
2
F
N
R
7
5
4
3
6
9
10
2
wc_gr003672
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45
Maintenance
RD 7 /...
4.14 Lifting
Attach a sling or chain to the lifting eye (a) using a suitable hook or
shackle. Each lifting device must have capacity of at least 650 Kg
(1430 lbs).
Only use steel ropes or chains for hoisting. The rope or chain must
have the suitable specified lifting capacity of 650 Kg (1430 lbs). Do not
WARNING use improvised ropes or chains.
NOTICE: Never use any other part of the roller to lift the machine, as
severe damage may occur.
Do not stand under, or get onto, the machine while it is being hoisted
or moved.
WARNING
a
a
b
wc_gr001360
wc_gr001359
4.15 Transporting
Before transporting the machine:
•
place blocks in front of and behind each drum.
•
use the front and rear tie-downs (b) to secure the machine to the
trailer
•
place the lift handle (a) into the upright position.
NOTICE: Only use the tie-downs to secure the machine. Do not use
any other part of the roller to tie the machine down as severe damage
to the machine may occur.
wc_tx000295gb.fm
46
RD 7 /...
Maintenance
4.16 Pressure Washing the Machine
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
4.17 Storing the Machine
If the machine is to be stored for more than 30 days:
wc_tx000295gb.fm
•
Drain the fuel tank and the water tank.
•
Open the water valve and drain water from the sprinkling system.
•
Change the oil.
•
Clean the entire roller and engine compartment.
•
Remove dirt from the engine cooling fins.
•
Cover the roller and place it in a dry, protected area.
•
Remove the diesel injectors and put a little oil into the engine
cylinders.
•
Remove the battery from the machine and charge it periodically
(RD 7H-ES).
47
Maintenance
RD 7 /...
4.18 Hydraulic Schematic
2
P
3
1
206 bar
3000 psi
15
14
13
12
200 bar
2900 psi
100 bar
1450 psi
11
10
5
4
8
10 micron
7
16
6
wc_gr003636
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48
RD 7 /...
Maintenance
4.19 Hydraulic Schematic Components
Ref.
Description
Ref.
Description
1
Exciter relief valve
9
Charge pump
2
Exciter control valve
10
Exciter pump
3
Exciter motor
11
Drive pump
4
Rear drive motor
12
Charge pressure relief valve
5
Front drive motor
13
Internal drive pump relief valves
6
Return filter
14
Porting block
7
Suction filter
15
Manifold
8
Pump assembly
16
Tank
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49
Maintenance
RD 7 /...
4.20 Hydraulic Diagram
16
15
1
7
6
8
11
(9)
(12)
10
2
13
3
5
14
4
wc_gr003637
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50
RD 7 /...
Maintenance
4.21 Hydraulic Diagram Components
Ref.
Description
Ref.
Description
1
9
Charge pump
2
10
Exciter pump
3
Exciter motor
11
Drive pump
4
Rear drive motor
12
5
Front drive motor
13
6
Return filter
14
Porting block
7
Suction filter
15
Manifold
8
Pump assembly
16
Tank
wc_tx000295gb.fm
51
Maintenance
RD 7 /...
4.22 RD 7H-ES Electrical Schematic
Br
R
P
8
B
1 2 3 4 5 6
6 5 4 3 2 1
4
0
1
3
wc_gr003663
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52
RD 7 /...
Maintenance
4.23 RD 7H-ES Electrical Schematic Components
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
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53
Maintenance
RD 7 /...
4.24 General Troubleshooting
Problem / Symptom
Engine does not start
Reason / Remedy
• 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.
wc_tx000295gb.fm
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RD 7 /... Repair
5.
General
General
5.1
Tools
Because all possible problems encountered while repairing the
machine cannot be anticipated, it is up to the mechanic to use common
sense and good judgement in tool selection.
The use of any special tools is recommended only for those operations
where the use of conventional tools proves inadequate.
Before substituting another tool or procedure, you should be satisfied
that neither personal injury nor damage to the component will result.
5.2
Reference Numbers ( )
Repair procedures contain reference numbers enclosed in
parentheses ( ). These numbers refer to the item numbers shown on
the assembly drawings and other detailed drawings. They are included
to aid the mechanic in identifying parts and assembling components.
5.3
Ordering Parts
The repair procedures contained in this manual do not include part
numbers. For parts replacement information, refer to the Parts Book
originally supplied with the machine.
If the original Parts Book has been lost, a replacement may be ordered
from Wacker Corporation. When ordering a replacement Parts Book,
please list the model number, item number, revision level, and serial
number of the machine. Parts Books are also available on the Wacker
Corporation Web site. See www.wackergroup.com. Enter the site as a
visitor.
5.4
Repair Accessories
In order to avoid contamination of the hydraulic system while repair
work involving hydraulic hoses is performed, the following plastic caps
and plugs for fitting ends are available:
Part
Number
Description
(Male)
Part
Number
Description
(Female)
0111709 Plug-fitting, #4
0111714 Cap-fitting, #4
0111713 Plug-fitting, #4, flare end
0111718 Cap-fitting, #4, flare end
wc_tx000350gb.fm
55
Hydraulic System
6.
RD 7 /... Repair
Hydraulic System
6.1
Hydraulic System Precautions
WARNING
6.2
Escaping hydraulic oil under pressure, even a pinhole size leak, can
penetrate body tissue, causing serious injury, and possible death. If oil
is injected into your skin, you must be treated immediately by a doctor
familiar with this kind of injury.
•
Always use a board or cardboard when checking for hydraulic oil
leaks.
•
Relieve the hydraulic pressure before working on the machine.
•
Personal injury can result from contact with hot hydraulic oil.
•
Use extreme care and wear appropriate clothing, such as gloves
and safety glasses, when working with hot hydraulic oil.
Hydraulic System Service Basics
Many hydraulic system problems may be rectified by basic service and
maintenance tasks. Before attempting in-depth service procedures,
carry out the basic hydraulic service procedures listed below.
wc_tx000351gb.fm
•
Top off the hydraulic oil supply with the correct type and grade of
oil.
•
Clean and tighten all the hydraulic fittings. Check the hoses for
holes and/or leaks. Air within the hydraulic system can greatly
affect machine performance.
•
Check/change the hydraulic filter. Particles and debris in the filter
are signs of failing component(s). Change the hydraulic oil and
clean all components if there is debris found in the filter. Locate
and replace the failing component(s) before operating the
machine.
•
Carry out hydraulic tests with the machine/hydraulic oil warm.
Start and operate the machine at high idle for several minutes
before conducting troubleshooting procedures. The hydraulic oil
should be between 37.4–48.6°C (100–120°F).
56
RD 7 /... Repair
6.3
Hydraulic System
Analyzing Hydraulic Oil Contamination
If the hydraulic oil becomes contaminated, premature component
failure could occur. Contaminated oil can also contribute to
overheating. When inspecting the hydraulic oil filter for contamination,
the type of contamination can help determine the probable cause of
problems.
•
Bronze colored particles suggest a pump or motor port plate
failure.
•
Shiny steel particles suggest pump or motor piston failure.
•
Rubber particles indicate a seal failure or a hose failure.
•
Aluminum particles suggest a steering and/or charge pump
failure.
If any particles are found in the hydraulic filter element, all components
of the hydraulic oil system must be cleaned. Do not use any damaged
components. Remove the damaged components and replace them
with new ones.
wc_tx000351gb.fm
57
Hydraulic System
6.4
RD 7 /... Repair
General Description
The hydraulic system is powered by two pumps mounted in tandem
and driven directly by the engine crankshaft through a flex coupling.
Internal relief valves within the drive pump protect the drive motors and
components of the drive system.
A relief valve (1) is located on the vibration manifold block.
The hydraulic system is protected by a return line filter which removes
particles down to 10 microns and includes a by-pass relief valve to aid
in cold weather start-up and to protect the system, should the filter be
clogged.
The hydraulic tank is equipped with a strainer at the fill port to trap large
objects or particles which may accidentally fall into the tank when
adding hydraulic fluid. Additional system protection is provided by a
suction filter mounted in-line with the exciter pump inlet.
6.5
Vibration Circuit
The vibration system is an open-loop series circuit driven by a fixed
displacement, gear-type pump. Components of the vibration circuit
include: the gear-type pump, a manifold block, a 3000-psi relief valve,
a control valve, and the exciter motor.
The vibration circuit is controlled by the exciter control valve. This valve
is operated by an ON/OFF lever located on the handle. Supply oil from
the pump enters the manifold where it is directed to the exciter control
valve. When the lever is in the OFF position, the exciter control valve
is open, allowing oil to pass through the system without driving the
exciter motor. When switched to the ON position, the exciter control
valve closes and oil from the pump is directed to the exciter motor
which drives the eccentric weight between the drums. The relief valve
(1), connected to the manifold, limits system pressure to 3000 psi (206
bar).
wc_tx000351gb.fm
58
RD 7 /... Repair
6.6
Hydraulic System
Hydraulic Manifold Block
1
2
3
4
7
5
6
Ref.
Description
Ref.
wc_gr001503
Description
1
Relief valve (3000 psi [206 bar])
5
Exciter motor return line
2
Exciter control pressure lines
6
Porting block return line
3
Exciter pump pressure line
7
Filter bypass return line
4
Exciter motor pressure line
-
---
wc_tx000351gb.fm
59
Hydraulic System
6.7
RD 7 /... Repair
Drive Circuit
The drive system is a closed-loop circuit consisting of: a drive pump, a
manifold, two relief valves, and front and rear drive motors arranged in
series. Both drive motors rotate at the same speed.
The drive pump is a variable displacement, piston-type pump with an
integral charge pump. Charge pressure is maintained at 100 psi (7 bar)
through an internal relief valve.
The drive pump is manually actuated by the control lever mounted to
the end of the handle. When the control lever is shifted forward, oil is
directed from the high-pressure side of the drive pump to the manifold
block, and downstream to both the front and rear drive motors. Return
flow from the drive motors is directed back through the manifold and
returns to the low-pressure side of the drive pump.
When operating in reverse, the high- and low-pressure sides of the
drive pump are reversed.
System pressure is limited to 2900 psi (200 bar) by two relief valves in
the drive pump.
6.8
Return Line Filter
The oil returning from the vibration function is directed out of the
manifold to a return line filter. A back pressure valve located at the
return line filter is used to protect the system. When pressure from the
exciter circuit exceeds 14.5 psi (1 bar), the valve opens and the oil
flows directly to the tank.
wc_tx000351gb.fm
60
RD 7 /... Repair
6.9
Hydraulic System
Bleeding the Hydraulic System
6.9.1
Fill the hydraulic system with clean hydraulic oil until it is visible in the
sightglass. Do not reuse used hydraulic oil.
6.9.2
Disconnect the line (1) from drive pump. Fill the pump case with
hydraulic oil through the open connection. Reconnect the line.
6.9.3
Start the engine and run the machine at full throttle. Move the control
slowly back and forth from forward to reverse for a short time to bleed
air trapped in the drive circuit.
6.9.4
Check the hydraulic oil level and add oil as required.
Note: If the drive pump chatters or operation is noisy, turn the machine
off and check for air leaks in the inlet line of the charge pump.
1
wc_gr001504
wc_tx000351gb.fm
61
Hydraulic System
RD 7 /... Repair
6.10 Hydraulic Diagram
P
1
3
1
21 mPa
3000 PSI
2
2
12
13
10 mPa
1450 PSI
20 mPa
2900 PSI
5
4
11
9
10
8
10 micron
7
16
6
Ref.
Description
Ref.
wc_gr001361
Description
1
9
Charge pump
2
10
Exciter pump
3
Exciter motor
11
Drive pump
4
Rear drive motor
12
5
Front drive motor
13
6
Return filter
14
Porting block
7
Suction filter
15
Manifold
8
Pump assembly
16
Tank
wc_tx000351gb.fm
62
RD 7 /... Repair
Hydraulic System
6.11 Hydraulic Schematic
16
15
1
7
6
8
11
(9)
(12)
10
2
13
3
5
14
4
wc_gr003637
wc_tx000351gb.fm
63
Hydraulic System
RD 7 /... Repair
6.12 Testing Hydraulic Pressures
Before making pressure checks:
6.12.1 Inspect the machine for hydraulic leaks.
6.12.2 Check the level of hydraulic oil in the tank.
6.12.3 Check the engine operating speed at full throttle.
6.12.4 Run the machine for 5-10 minutes before testing to allow time for the
hydraulic system to warm up.
Note: There are no designated test ports on the hydraulic block. Use
pressure fittings and adapters designed for use with Wacker hydraulic
test equipment.
Before opening the hydraulic connections, shut the engine off and
make sure all controls are in neutral.
WARNING
6.13 Checking the Vibration Circuit
Test the vibration circuit with the machine on soil or gravel. If testing is
done indoors, position the machine on a heavy mat or old tires to
absorb the vibration.
NOTICE: Do not run vibration on concrete.
6.13.1 Remove the vibration pressure line (1) from the hydraulic manifold (2).
6.13.2 Install a #6 T-fitting (f) and a test fitting (d) into the manifold. Install a
5000 psi gauge (a) to the test fitting.
6.13.3 Start the engine and run the machine at full throttle with the forward/
reverse control in neutral.
6.13.4 Switch the vibration on. The gauge will read relief pressure
momentarily as the exciter starts and then will fall to normal operating
pressure as the exciter reaches full speed.
If it is not possible to read the relief valve pressure accurately,
disconnect the exciter motor inlet line (3) on the manifold. Cap off and
plug open line connections both on the manifold and on the line. Start
the engine and run the test. If the pump is in working condition, the
gauge will immediately come up to relief valve pressure and remain
there.
wc_tx000351gb.fm
64
RD 7 /... Repair
Hydraulic System
1
a
d
f
b
e
c
2
3
wc_gr001505
Ref.
wc_tx000351gb.fm
Description
Part No.
Part No.
10 mPa (1000 psi)
0077999
30 mPa (5000 psi)
0078000
a
Pressure gauges
b
Gauge adapter
0078005
-
c
Hose
0078002
-
d
Test fitting
0089203
-
e
Hex nut
ORFS adapter
#6 0087227
#6 0087228
#8 0116798
#8 0116799
f
T-Fitting
#6 0083412
#8 0029099
65
Hydraulic System
RD 7 /... Repair
6.14 Checking the Drive Circuit
Operating Pressure
Check operating pressures with the machine on a firm, level surface.
6.14.1 Remove the drive pressure line (3) from the hydraulic pump (1).
6.14.2 Install a #6 T-fitting (2) and a test fitting (4) into the pump. Install a
5000-psi gauge onto the test fitting.
6.14.3 Start the engine and run it at full throttle.
6.14.4 Shift the control lever into either forward or reverse and read the
operating pressure.
Note: Operating pressures will increase significantly when running the
machine uphill, off road or against an object.
Relief Pressure
6.14.5 Block in front of and behind both drums to prevent the machine from
moving, or dead head the machine against a solid concrete abutment.
Make sure the blocks are large enough so that the machine will not
climb over them during testing.
WARNING
6.14.6 Install a 5000-psi gauge in the test fitting (4).
6.14.7 Start the engine and run the machine at full throttle. Shift the control
slowly into forward or reverse until the pressure on the gauge tops out.
This is the forward or reverse relief valve pressure.
Note: Make sure the drums do not spin.
wc_tx000351gb.fm
66
RD 7 /... Repair
Hydraulic System
1
2
3
4
wc_gr001506
Normal Operating
Relief Valve
Pressure bar (psi) Pressure bar (psi)
wc_tx000351gb.fm
Forward
69 (1000)
200 (2900)
Reverse
41 (600)
200 (2900)
Exciter
69 (1000)
206 (3000)
67
Hydraulic System
RD 7 /... Repair
6.15 Relief Valves
The relief valves are preset at the factory and normally do not require
further adjustment. Any valve adjustment is done by shims. However,
adjusting relief valves is not recommended, as shims are not spare
parts. Replace the complete relief valve.
NOTICE: Do not increase pressures above machine specifications!
Higher pressures can damage pumps and motors.
Drive Circuit Reliefs
Current machines have relief valves (1) built into the drive pump.
These relief valves are preset at 2900 psi (200 bar) and do not require
further adjustment unless they are operating at below the
recommended setting.
Exciter Relief Pressure
DO NOT remove the plug or attempt to set the valve while the engine
is running or the system is under pressure!
WARNING
6.15.1 Turn off the engine.
6.15.2 Remove the water tank (7) to access the vibration manifold. To do so,
remove the two screws attaching the tank to the frame and remove the
screw (8) and the washer (9) from the bracket located under the water
tank. Also remove the hose (10) and fitting (11).
6.15.3 Remove the plug (3) or the retaining ring (12) and from the end of the
valve (2) to access the adjusting screw.
6.15.4 Use a 1/4-inch Allen wrench (4) and turn the adjusting screw in or out
as necessary.
6.15.5 Re-install the plug or the cap and retaining ring.
6.15.6 Start the engine and recheck the pressure.
6.15.7 If the valve needs further adjustment, turn off the engine and adjust it
again. Continue this process until the correct pressure (206 bar [3000
psi]) is set.
wc_tx000351gb.fm
68
RD 7 /... Repair
Hydraulic System
7
11
10
9
8
4
2
1
12
13
3
wc_gr003668
wc_tx000351gb.fm
69
Power Take-Off
7.
RD 7 /... Repair
Power Take-Off
7.1
Description
The pumps used to power the hydraulic system are driven directly by
the engine through a flywheel coupling or a clutch (1), depending on
the age of the machine. The pumps are connected along their shafts
through a solid mounted coupling (2).
The exciter pump (3) is a fixed displacement, gear-type pump. It
provides a constant flow of oil to the vibration circuit. A constant flow
of oil equates to a constant speed.
The drive pump (4) is a variable displacement, axial piston pump. A
variable flow of oil equates to a variable travel speed. The more flow
there is, the faster the travel speed. Flow through the drive pump is
controlled by the angle of the pump’s swash plate. The pump’s swash
plate is controlled through the movement of a lever attached to the
pump’s control shaft (5). This provides for infinitely variable speeds
between 0 (zero) and the top speed of 4.0 km/hr. (2.5 mph) forward,
and 2.0 km/hr. (1.2 mph) reverse.
Note: Wacker Corporation does not recommend the disassembly or
attempted repair of hydraulic components (pumps, motors) by anyone
other than a trained hydraulic repair technician. Repair and rebuilding
of hydraulic components may be available from component
manufacturers. Hydraulic component parts are not available from
Wacker Corporation.
wc_tx000352gb.fm
70
RD 7 /... Repair
7.2
Power Take-Off
Pump Assembly
3
2
4
5
1
wc_gr001509
wc_tx000352gb.fm
71
Power Take-Off
7.3
RD 7 /... Repair
Replacing the Drive Pump
Removal
NOTICE: The failure of a drive pump and/or motor, caused by factors
other than normal wear, can contaminate the drive circuit with metal
particles.
7.3.1
WARNING
WARNING
Thoroughly clean the pump and the hose connections.
Danger of burns! The pump may be hot—care must be taken when
removing hydraulic components and oil. Hot oil can burn!
Before dismantling the hydraulic connectors or the hoses, ensure that
all pressure has been relieved from the circuit. Open the hose fittings
slowly.
7.3.2
Tag and disconnect the hose lines (1) from the pump. Cap or plug all
open connections. For recommended caps or plugs, see Repair
Accessories.
7.3.3
Remove the support bracket (2) from the exciter pump (3). Save the
locknuts (4) and washers (5) for installation.
7.3.4
Remove the two locknuts (6) that secure the exciter pump to the drive
pump (7) and remove the drive pump.
7.3.5
Remove two mounting screws (8) holding the drive pump to the
engine/pump adapter.
7.3.6
Remove the control lever (9), hydraulic fittings (10), O-ring (11) and
coupling (12) and transfer them to the new pump.
Installation
7.3.7
Install the new pump and fasten it to the engine/pump adapter. Secure
the mounting screws (8) using Loctite 271 or an equivalent highstrength threadlocker.
7.3.8
Install the exciter pump (3) to the new drive pump using the locknuts
(6).
7.3.9
Install the support bracket (2) to the exciter pump using the locknuts
(4) and the washers (5).
7.3.10 Reconnect the hose lines (1) to the fittings (10).
7.3.11 Bleed the drive circuit.
NOTICE: It is recommended that the drive circuit be flushed after a
pump failure to remove any contaminants which may be trapped in the
lines.
wc_tx000352gb.fm
72
RD 7 /... Repair
WARNING
Power Take-Off
Before you start the machine, ensure that all tools have been removed
from the machine and that the replacement parts and adjusters are
firmly tightened.
1
10
8
1
7
12
9
10
5
11
4
3
1
6
2
wc_tx000352gb.fm
wc_gr001510
73
Power Take-Off
7.4
RD 7 /... Repair
Exciter Pump
Removal
7.4.1
WARNING
WARNING
Thoroughly clean the pump and the hose connections.
Danger of burns! The pump may be hot—care must be taken when
removing hydraulic components and oil. Hot oil can burn!
slowly.
7.4.2
Tag and disconnect hose lines (1) from exciter pump (3). Cap or plug
all open connections. For recommended caps or plugs, see section
Repair Accessories.
7.4.3
Remove the support bracket (2) from the exciter pump (3). Save the
locknuts (4) and the washers (5) for installation.
7.4.4
Remove the two locknuts (6) that secure the exciter pump to the drive
pump (7) and remove the exciter pump.
7.4.5
Remove the O-ring (8), coupling (9) and fitting (10) and transfer them
to the new pump.
Installation
7.4.6
Install the new exciter pump (3) to the drive pump (7) using the
locknuts (6).
7.4.7
Install the support bracket (2) to the exciter pump using the locknuts
(4) and washers (5).
7.4.8
Reconnect the hose lines (1) to the fitting (10).
7.4.9
Bleed the hydraulic system before starting. See section Bleeding the
Hydraulic System.
WARNING
wc_tx000352gb.fm
from the machine and that replacement parts and adjusters are firmly
tightened.
74
RD 7 /... Repair
Power Take-Off
1
7
9
5
8
4
1
3
6
10
2
wc_tx000352gb.fm
wc_gr001511
75
Power Take-Off
7.5
RD 7 /... Repair
Replacing the Engine
Removal
WARNING
slowly.
7.5.1
Tag and disconnect all the hoses that are attached to the engine. Also
disconnect the throttle cable.
7.5.2
Remove the pump support bracket (2) at the front of the hydraulic
pumps (3).
7.5.3
Remove the exhaust pipe (4).
7.5.4
Attach steel lifting ropes or chains from a suitable crane to the engine's
lifting eye.
Note: The engine lifting eye (104439) was originally packaged with the
HATZ Engine Manual. To install lifting eye, remove the throttle bracket
(5) and the mount lifting eye in its place.
7.5.5
Remove the screws (6), washers (7), and nuts (8) that mount the
engine to the frame.
7.5.6
Leaving the pumps mounted to the engine, lift the engine slightly to
check that it is correctly balanced.
7.5.7
Lift and remove the engine from the machine.
Do not stand under or get near the engine while it is being lifted or
moved.
WARNING
wc_tx000352gb.fm
7.5.8
Remove the hydraulic pumps (3) and the pump adapter (9). On older
versions (10a), loosen the screw (15) and remove the coupler (14)
from the shaft. A pry bar between the coupler and the shaft may be
needed. Remove the six screws (11) that secure the flywheel coupling
to the engine and remove the flywheel coupling.
7.5.9
On newer versions (10b), the pump mounts directly into the clutch.
Remove the two screws (16) and washers (17) that secure the clutch
to the engine and remove the clutch.
76
RD 7 /... Repair
Power Take-Off
5
10b
11
4
16
14
15
6
7
17
9
13
1
10a
3
12
2
8
wc_gr001512
wc_tx000352gb.fm
77
Power Take-Off
RD 7 /... Repair
Installation
7.5.10 Apply Loctite 243 or an equivalent to the six screws (11) and secure
the flywheel coupling (10) to the engine. Torque the screws to 18 ft.lbs.
(25 Nm).
7.5.11 Apply Loctite 243 or an equivalent to the screw (15) and secure the
coupler (14) to the pump shaft. Torque the screw to 45 ft.lbs. (60 Nm).
7.5.12 Apply Loctite 243 or an equivalent to the ten screws (12) and secure
the pump adapter (9) to the engine. Torque the screws to 51 ft.lbs. (69
Nm).
7.5.13 Apply Loctite 243 or an equivalent to the two screws (13) and secure
the hydraulic pump (3) to the engine. Torque the screws to 36 ft.lbs.
(49 Nm).
7.5.14 Attach steel lifting ropes or chains from a suitable crane to the engine's
lifting eye. Lift the engine and place it into the machine.
7.5.15 Install the pump support bracket (2) onto the hydraulic pump.
7.5.16 Mount the engine to the frame reusing the screws (6), washers (7), and
nuts (8).
7.5.17 Attach the pump support bracket to the frame.
7.5.18 Attach the exhaust pipe (4) to the engine.
7.5.19 Attach all hose lines to the pumps.
7.5.20 Attach all electrical wiring and throttle cable to the engine.
7.5.21 Attach the control lever bracket (1) to the drive pump. The drive control
cable may need to be adjusted. See section Direction Lever
Adjustment.
7.5.22 The engine valve clearance may need to be adjusted. See section
Checking and Adjusting Valve Clearances.
WARNING
wc_tx000352gb.fm
Note: See sealant and torque reference charts in the back of this
manual for the appropriate threadlocking adhesives and torque values.
Before starting the machine, ensure that all tools have been removed
tightened.
78
RD 7 /... Repair
8.
Roller
Roller
8.1
Drum - Description
The front and rear drums operate as static rollers to aid in smoothing
and finishing.
The front and rear drums are driven by hydraulic motors. Each motor
is mounted to a drive hub which is mounted directly to the left side of
each drum. The drive motor is designed to provide low speeds and
high torques without the need for any type of speed reduction gears,
belts, or pulleys.
A mechanical parking brake is attached to the rear drum on the right
side and is used to ensure that the machine will not roll when not in
use. The brake is mounted directly to the drum support and is engaged
and disengaged by the operator.
NOTICE: The parking brake is designed to hold the machine on an
incline with the engine off. Do not drive against the parking brake in the
engaged position. The brake may bend and damage the machine.
Note: Wacker Corporation does not recommend the disassembly or
attempted repair of hydraulic components (pumps, motors) by anyone
other than a trained hydraulic repair technician. Repair and rebuilding
of hydraulic components may be available from component
manufacturers. Hydraulic component parts are not available from
Wacker Corporation.
wc_tx000353gb.fm
79
Roller
8.2
RD 7 /... Repair
Replacing the Drum
Removal
Stop the machine, apply the parking brake, and switch off the engine.
NOTICE: Before removing the drum, clean and wash the complete
drum assembly to remove as much dirt as possible. Be especially
thorough when cleaning the area around the tube and hose
connections on the motors. This will minimize the chance of
contamination when opening the hydraulic lines.
Before dismantling the hydraulic connectors or hoses, ensure that all
pressure has been relieved from the circuit. Open hose fittings slowly.
WARNING
8.2.1
Tag and disconnect the hydraulic lines to the drive motor. Cap or plug
all open connections. For recommended caps or plugs, see section
Repair Accessories.
8.2.2
Remove the four screws (1) that secure the porting block (2) to the
lower frame. Pull the porting block out to access the three upper
hydraulic lines. Tag, disconnect, and cap the three upper hydraulic
lines (3) from the porting block.
8.2.3
Attach steel lifting ropes or chains from a suitable crane to the
machine's lifting eye (4).
WARNING
Only use slings or chains for hoisting. The ropes, chains, and crane
must have the suitable specified lifting capacity—830 Kg.(1829 lbs.).
Do not use improvised slings or chains.
Do not stand under the machine while it is being lifted or moved.
WARNING
Lift the machine so that it is 6 mm (0.25 in.) off the ground.
wc_tx000353gb.fm
8.2.4
On the nondrive-motor side of the machine, remove the four screws (5)
that secure the drum support (6) to the hub assembly (7).
8.2.5
On the drive-motor side of the machine, remove the three screws (8)
that secure the drum support (9) to the frame.
8.2.6
Slide the drum (10) from the frame.
80
RD 7 /... Repair
Roller
4
3
2
1
10
8
9
6
11
5
10
7
9
wc_gr003666
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81
Roller
RD 7 /... Repair
Installation
8.2.7
If the non-drive-motor-side drum support (6) was removed, reinstall it.
Be sure to include the shims (11) during re-installation.
8.2.8
Position the drum (10) under the machine frame. Align the holes in the
hub assembly with the holes in the nondrive-motor side drum support
(6).
8.2.9
Apply Loctite 243 or an equivalent to the four screws (5) and secure
the drum support (6) to the drum hub assembly (7).
8.2.10 Apply Loctite 243 or an equivalent to the three screws (8) and secure
the drum support (9) to the frame. Torque the screws to 120 Nm (88
ft.lbs.).
8.2.11 Reconnect all hydraulic hoses to the drive motors.
8.2.12 Reconnect all hydraulic hoses (3) to the porting block (2).
8.2.13 Apply Loctite 243 or an equivalent to the four screws (1) and secure
the porting block to the lower frame. Torque the screws to 49 Nm (36
ft.lbs.).
WARNING
wc_tx000353gb.fm
tightened.
82
RD 7 /... Repair
Roller
4
3
2
1
10
8
9
6
11
5
10
7
9
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Roller
8.3
RD 7 /... Repair
Drum Disassembly and Assembly
Drive-Side Disassembly
8.3.1
Remove the drum from the machine. See section Replacing the Drum.
8.3.2
Stand the drum on end with the drive motor (1) facing up.
8.3.3
Note the angle at which the drive motor is mounted. Remove the four
screws (2) that hold the drive motor and the drum support (3) to the
outer drive hub (4a) and remove the drive motor and the drum support.
NOTICE: When removing the drive motor, care must be taken to
ensure that the splined shaft does not separate from the inside of the
motor.
8.3.4
Remove the retaining ring (5) that secures the outer drive hub (4a) to
the shaft of the inner drive hub (6a).
8.3.5
Remove the retaining ring (7) holding the roller bearing (8) in the outer
drive hub (4a).
8.3.6
Press the roller bearing from the outer drive hub.
8.3.7
Remove the seals (12 & 13) from the outer drive hub.
To remove inner drive hub (6a) from the drum:
8.3.8
Remove the four screws (9a).
8.3.9
Remove the two plug screws (10) and washers (11) to expose the
puller holes. Install two M12 screws into the puller holes. Turn the M12
screws until the inner drive hub (6a) is pulled free of the drum.
Drive-Side Assembly
8.3.10 On newer machines (9408 rev. 108+; 9487 rev. 106+), place the V-ring
(17) onto the inner drive hub (6a).
8.3.11 Apply Loctite 243 or an equivalent to the four screws (9a). Then, using
the screws, mount the inner drive hub to the drum. Torque the screws
to 120 Nm (89 ft.lbs.).
8.3.12 Install the shaft seal (12) into the outer drive hub (4a).
8.3.13 Press the bearing (8) into the outer drive hub and secure it with the
retaining ring (7).
8.3.14 Secure the seal (13) to the outer drive hub (4a) using high-temperature
RTV.
8.3.15 Place the outer drive hub (4a) over the shaft of the inner drive hub (6a).
Make sure the seal (13) lays flat on the inner drive hub. Secure the
outer drive hub to the inner drive hub with the retaining ring (5).
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RD 7 /... Repair
8.3.16
Roller
Apply Loctite 243 or an equivalent to the four screws (2). Align the
drum support (3), O-ring (14), and drive motor (1) (at the correct angle)
with the outer drive hub (4a) and secure them with the four screws (2).
Torque the screws to 86 Nm (63 ft.lbs.).
NOTICE: When installing the drive motor, care must be taken to
ensure splined shaft does not separate from inside of motor.
4b
9b
5
7
8
12
9a
13
17
10
11
6b
13
6a
12
11
17
10
14
4a
8
7
5
3
1
2
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Roller
RD 7 /... Repair
Non-Drive Side Disassembly
8.3.17 Remove the drum’s drive-side drive motor and components.
8.3.18 Stand the drum on end with the non-drive side facing up.
8.3.19 Remove the retaining ring (5) that secures the outer drive hub (4b) to
the shaft of the inner drive hub (6b).
8.3.20 Remove the retaining ring (7) that secures the roller bearing (8) in the
outer drive hub (4b).
8.3.21 Press the roller bearing from the outer drive hub.
8.3.22 Remove the seals (12 & 13) from the outer drive hub.
To remove inner drive hub (6b) from the drum:
8.3.23 Remove the four screws (9b).
8.3.24 Remove the two plug screws and washers to expose the puller holes.
In their place, install two M12 screws. Turn the M12 screws until the
inner drive hub (6b) is pulled free of the drum.
Non-Drive Side Assembly
8.3.25 On newer machines (9408 rev. 108+; 9487 rev. 106+), place the V-ring
(17) onto the inner drive hub (6b).
8.3.26 Apply Loctite 243 or an equivalent to the four screws (9b). Then, using
the screws, mount the inner drive hub to the drum. Torque the screws
to 120 Nm (89 ft.lbs.).
8.3.27 Install the shaft seal (12) into the outer drive hub (4b).
8.3.28 Press the bearing (8) into the outer drive hub and secure it with the
retaining ring (7).
8.3.29 Secure the seal (13) to the outer drive hub (4b) using high-temperature
RTV.
8.3.30 Place the outer drive hub (4b) over the shaft of the inner drive hub (6b).
Make sure the seal (13) lays flat on the inner drive hub. Secure the
outer drive hub to the inner drive hub with the retaining ring (5).
wc_tx000353gb.fm
86
RD 7 /... Repair
Roller
4b
9b
5
7
8
12
9a
13
17
10
11
6b
13
6a
12
11
17
10
14
4a
8
7
5
3
1
2
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Roller
8.4
RD 7 /... Repair
Replacing the Exciter
Removal
NOTICE: Before removing the exciter, clean and wash the complete
exciter assembly to remove as much dirt as possible. Be especially
thorough when cleaning the area around the tube and hose
connections on the motors. This will minimize the chance of
contamination when opening hydraulic lines.
8.4.1
Remove top cover (1) by removing six screws (2).
8.4.2
Drain water tank by disconnecting hose (3) from fitting (4).
8.4.3
Remove water tank (5) by removing two screws (6) attaching tank to
frame and remove the screw (7) and washer (8) from the bracket
located under the water tank.
8.4.4
Drain the hydraulic oil. See section Changing Hydraulic Fluid and Filter
- steps 1-4.
8.4.5
Tag and disconnect the three hydraulic hoses (9) from the exciter
motor (10) and the three hoses (11) from the porting block (12).
WARNING
Before dismantling the hydraulic connectors or hoses, ensure that all
pressure has been relieved from the circuit. Open hose fittings slowly.
Note: In the interests of environmental protection, place a plastic sheet
and a container under the machine to collect the liquid which drains off,
and dispose of properly.
8.4.6
Remove both the front and rear plates (13) from the upper frame (14)
by removing the two screws (15) on each plate.
8.4.7
Remove the shock mount screws (16) and washers (17) that secure
the shock mounts (18) to the lower frame (19).
8.4.8
Support the machine by attaching a sling or chain to the lifting eye (20)
using a suitable hook or shackle. Each lifting device must have
capacity of at least 1000 lbs. (454 Kg.).
WARNING
8.4.9
Only use slings or chains for hoisting. The sling or chain must have the
suitable specified lifting capacity. Do not use improvised slings or
chains.
Do not stand under the machine while it is being hoisted or moved.
Remove the upper mass of the machine by using central lifting eye
(20).
8.4.10 Remove the inner scraper bar (21) by removing the two center screws
(22) and washers (23).
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RD 7 /... Repair
8.4.11
Roller
Remove the four screws (24) and washers (25) that mount the exciter
assembly (26) to the lower frame (19).
5
4
3
20
8
7
6
15
13
15
13
14
1
2
26
18
27
C
B
A
D
a
b
17
16
c
b
c
19
25
24
10
21
11
12
23
22
9
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Roller
RD 7 /... Repair
Installation
8.4.12 Place the exciter assembly (25) on the frame. Rock the housing on the
frame to determine if a corner needs to be shimmed. Place shims (27)
as needed between the frame and the housing.
8.4.13 Lay a bead of Loctite 515 or equivalent on the milled surface (b) of the
frame between the threaded holes.
8.4.14 Apply Loctite 243 or an equivalent to the screws (24). Mount the exciter
assembly to frame using the four screws (24) and the washers (25).
Torque the screws in the pattern A, B, C, D. (a) following this
sequence:
•
Step 1 - tighten by hand
•
Step 2 - 54 Nm (40 ft.lbs.)
•
Step 3 - 120 Nm (88 ft.lbs.)
•
Step 4 - recheck 120 Nm (88 ft.lbs.)
8.4.15 Fill in the space between the exciter and the frame, along the entire
length of the exciter (c), with Silicone.
8.4.16 Install the scraper bar (21) with two screws (22) and washers (23).
8.4.17 Position the upper mass of the machine over the lower mass by using
the central lifting eye (20).
8.4.18 Apply Loctite 243 or an equivalent to the screws (16) and secure the
shock mounts (18) with the washers (17) and the screws. Torque the
screws to 86Nm. (63 ft.lbs).
8.4.19 Re-install both the front and the rear plates (13) and the screws (15) to
upper frame (14).
8.4.20 Reconnect the three hydraulic hoses (9) to the exciter motor (10) and
the three hoses (11) to the porting block (12).
8.4.21 Fill the hydraulic tank with hydraulic oil (SAE 10W 30) until the oil level
is visible halfway up the sightglass. Run the engine briefly, then stop
the engine and check for leaks. Check the level in the sightglass, and
top off if necessary.
8.4.22 Install the water tank (5) with the three screws (6 & 7) and washer (8).
8.4.23 Install the top cover (1) with the six screws (2).
8.4.24 Reconnect the water hose (3) to the fitting (4).
WARNING
wc_tx000353gb.fm
Note: See sealant and torque reference charts in the back of this
manual for appropriate threadlocking adhesives and torque values.
tightened.
90
RD 7 /... Repair
Roller
5
4
3
20
8
7
6
15
13
15
13
14
1
2
26
18
27
C
B
A
D
a
b
17
16
c
b
c
19
25
24
10
21
11
12
23
22
9
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Roller
8.5
RD 7 /... Repair
Exciter Assembly
Disassembly
8.5.1
Remove the exciter assembly from the frame. See section Replacing
the Exciter.
8.5.2
Remove the four screws (1) that secure the exciter motor (2) to the
cover plate (3) and remove the exciter motor.
8.5.3
Remove the ten screws (4) that secure the cover plates (3 & 8) to the
exciter housing (5) and remove the cover plates.
8.5.4
Press the bearings (6a & 6b) and the shaft (7) as a unit from the
housing. Inspect the bearings for damage and replace them if
necessary.
Assembly
8.5.5
Press the non-motor side bearing (6b) into the exciter housing (5).
8.5.6
Turn the housing on end with the motor side facing up, insert the shaft
(7) with the splined end facing up and press it into the lower bearing.
8.5.7
Press the motor side bearing (6a) into the housing and over the shaft.
8.5.8
Apply Loctite 243 or an equivalent to the ten screws (4) and secure the
cover plates (3 & 8) to the housing. Torque the screws to 10 Nm (7
ft.lbs.).
Note: The orientation of the cover plate (3) must be as shown in order
to install the exciter motor properly.
8.5.9
Apply Loctite 243 or an equivalent to the four screws (1) and secure
the exciter motor (2) to the cover plate (3). Torque the screws to 10 Nm
(7 ft.lbs.).
8.5.10 Install the exciter assembly into the frame. See section Replacing the
Exciter.
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RD 7 /... Repair
Roller
6b
4
6a
8
5
4
1
3
7
2
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Roller
8.6
RD 7 /... Repair
Throttle Cable
Removal
8.6.1
Remove the setscrew (1) holding the throttle cable (2) to the cam on
the engine.
8.6.2
Loosen the nut (3) and remove the cable support (4).
8.6.3
Pull the sleeve (5) from the cable support and remove the cable.
8.6.4
Loosen the nut (6) that secures the throttle control (7) to the bracket
(8).
Installation
wc_tx000353gb.fm
8.6.5
Feed the throttle cable (2) through the bracket (8), sleeve (5) and cable
support (4).
8.6.6
Press the sleeve into the cable support and mount the cable support
to bracket (9). Tighten the nut (3).
8.6.7
Feed the cable through the throttle pin (10). Before securing the cable
with the setscrew (1), adjust so that the machine runs at the specified
speed (rpm) at full throttle. See section Technical Data.
8.6.8
Secure the throttle control (7) to the bracket (8). Tighten the nut (6).
WARNING
tightened.
94
RD 7 /... Repair
Roller
5
8
4
6
3
7
10
1
2
9
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Roller
8.7
RD 7 /... Repair
Direction Cable
Removal
8.7.1
Remove the four screws (8) that secure the covers (9) to expose the
handle linkage.
8.7.2
Remove the clevis (1) from the pivot bracket (2). Unscrew the clevis
from the spring-loaded, cable centering device (5).
8.7.3
Remove the small locknut (11) from the end of the cable.
8.7.4
Loosen the nut (4) on the spring-loaded, cable centering device (5).
8.7.5
Unscrew the spring-loaded, cable centering device from the cable (3).
8.7.6
Loosen the nut (6) that mounts the cable to the bracket (7).
8.7.7
Remove the cable ball end (10) from the pivot plate. Unscrew the cable
ball end from the cable.
8.7.8
Loosen the nut on the cable that secures the cable to the handle
bracket (12) and remove the cable.
Installation
8.7.9
Feed the cable (3) through the handle frame. Screw the cable end into
the cable ball end (10).
8.7.10 Mount the cable ball end to the pivot plate.
8.7.11 Mount the cable to the handle bracket (12).
8.7.12 Remove the small locknut (11) from the end of the cable. Then, feed
the cable into the spring-loaded, cable centering device (5). Screw the
spring-loaded, cable centering device onto the end of the cable until
the cable bottoms out. Re-install the locknut.
8.7.13 Screw the clevis (1) onto the cable end.
8.7.14 Tighten the nut (4) on the spring-loaded, cable centering device.
8.7.15 Mount the cable to the bracket (7). Tighten the nut (6).
8.7.16 Attach the clevis (1) to the pivot bracket (2).
8.7.17 Before mounting the covers, the cable needs to be adjusted properly.
See section Direction Lever Adjustment.
WARNING
wc_tx000353gb.fm
tightened.
96
RD 7 /... Repair
Roller
11
1
2
7
5
4
10
3
6
9
8
10
1
11
3
wc_gr003670
12
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97
Roller
8.8
RD 7 /... Repair
Direction Control Lever
Removal
8.8.1
Remove the four screws (1) that secure the covers (2) to the handle
frame (3) and remove the covers.
8.8.2
Disconnect the cable ball end (4) from the pivot plate (5).
8.8.3
Remove the screw (6) holding the lever assembly to the frame.
8.8.4
Remove the shaft (7) and the spring (8).
8.8.5
Remove the pivot hub (9) from the pivot plate (5) by disconnecting the
retaining ring (10). Press the bearing (11) from the pivot hub.
8.8.6
Press the pin (12) from the direction handle (13).
8.8.7
Press the bearing (14) from the direction handle.
To remove plunger shaft:
8.8.8
Unscrew the plunger (16) from the shaft end (17).
8.8.9
Slide the spring (18) off of the shaft and pull the shaft through the guide
handle (19).
8.8.10 Press the two bearings (20) from the guide handle.
Installation
8.8.11 Press the bearing (14) into the direction handle (13).
Note: Make sure the bearing is flush with the backside of the direction
handle.
8.8.12 Apply Loctite 271 or an equivalent to the pin (12) and press it into the
directional handle 22 ±0.25 mm (0.90 ±0.01 in).
8.8.13 Press the bearing (11) into the pivot hub (9).
Note: Make sure the bearing is flush with the front side of the pivot hub.
8.8.14 Insert the pivot hub into the pivot plate (5) and secure it with the
retaining ring (10).
8.8.15 Slide the spring over the shaft.
8.8.16 Insert the shaft (7) through the spring (8), pivot hub (9) and direction
handle (13), and mount to the handle frame (3) using the screw (6) and
nut (15).
8.8.17 Reattach the cable ball end (4) to the pivot plate (5).
8.8.18 Apply Loctite 243 or an equivalent to the four screws (1) and install the
covers (2) to the handle frame. Torque the screw to 18 ft.lbs. (25 Nm).
To install the plunger shaft:
8.8.19 Press the two bearings (20) into the guide handle (19).
wc_tx000353gb.fm
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RD 7 /... Repair
Roller
Note: Make sure the bearings are flush with both sides of the guide
handle.
8.8.20
Insert the shaft (17) through the guide handle. Slide the spring (18)
over the shaft.
8.8.21
Apply Loctite 243 or an equivalent to the threads of the shaft and screw
the plunger (16) onto the end of the shaft.
WARNING
tightened.
14
12
2
15
3
5
4
13
19
10
11
9
8
7
18
6
16
2
17
20
1
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Troubleshooting
9.
RD 7 /... Repair
Troubleshooting
9.1
General
The troubleshooting charts which follow provide basic guidelines to
help you diagnose and remedy equipment problems. Keep in mind that
every possible problem cannot be anticipated. Should questions arise
during the service or repair of this equipment please contact Wacker
Corporation for assistance.
Before removing any parts or making adjustments, conduct a visual
inspection of the machine and check for:
wc_tx000354gb.fm
9.1.1
Dirty air and fuel filters.
9.1.2
Rocks or dirt obstructing the movement of the drums, and scraper bar
assemblies.
9.1.3
Leaks in the hydraulic lines and fittings.
9.1.4
Low oil levels in the engine crankcase, exciter and hydraulic tank.
9.1.5
Loose mounting hardware on the pumps or motors.
9.1.6
Broken linkage and cables.
100
RD 7 /... Repair
9.2
Troubleshooting
Vibration System
Problem / Symptom
No vibration.
Reason / Remedy
• Vibration valve not on or defective. Check function of
the valve and replace it if necessary.
• Exciter motor or bearings seized. Check exciter
motor & bearings.
• Exciter pump failure. Check exciter system pressure.
Replace the exciter pump if necessary.
Vibration slow.
• Engine speed too low. Run engine at full speed.
Check engine rpm and vibration vpm.
• Exciter motor and/or bearing binding. Remove
exciter motor. Rotate motor and shafts by hand.
• Exciter pump failure. Check exciter system pressure.
Replace the exciter pump if necessary.
• Exciter motor worn. Check vibration speed and
operating pressure.
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Troubleshooting
9.3
RD 7 /... Repair
Troubleshooting the Vibration System
The exciter pump is designed to put out a constant flow of oil at a set
engine speed. This ensures that the vibration frequency remains
steady. When troubleshooting the exciter circuit, the vibration speed
should be measured along with the operating and relief pressures to
help determine the cause of any problems.
To measure vibration speed:
9.3.1
Start the machine and run it for several minutes to bring hydraulic oil
up to normal operating temperatures.
9.3.2
Check the engine rpm using a tachometer. The engine must be
running at the correct rpm to accurately measure vibration.
9.3.3
Position the roller on a rubber mat and start vibration. Hold the
vibrotach (P/N 53397) against the outer rim on the drum and measure
the vibration speed.
9.3.4
Engine rpm
vpm minimum
2700–2900
3300
The vibration speed along with the operating and relief valve pressures
can be used to determine the condition of the exciter system as shown
in the chart below.
If the exciter is binding (causing high operating pressures), it will be
necessary to disconnect and remove the exciter motor from the
housing to determine if the binding is occurring in the exciter bearings
or in the motor. Turn the motor shaft and exciter shaft by hand and
check that they turn freely.
Operating
Pressure
Pump Relief
Pressure
Exciter Speed
N
N
N
H
N
N or L
N or L
N
L
Exciter motor worn.
L
L
L
Exciter pump damaged or worn,
relief valve defective or needs
adjusting.
N = Normal, L = Low, H = High
wc_tx000354gb.fm
102
Probable Cause
System OK.
Exciter bearings or motor
binding.
RD 7 /... Repair
9.4
Troubleshooting
Drive System
Problem / Symptom
Reason / Remedy
Machine does not climb
grade.
• Drums spinning. Ground material loose or slippery.
• Grade too steep. Measure angle of grade.
• Relief pressure low or relief valve defective. Check
relief pressure. Replace or adjust relief valve.
• Drive pump or drive motors damaged or worn.
Consult Wacker Corporation.
Machine does not travel or
travels slowly or erratically.
• Engine speed too low. Run engine at full throttle.
Check engine rpm.
• Hydraulic fluid cold or wrong type. Allow fluid to
warm up. Check fluid against specifications.
• Control cable ends disconnected or broken. Check
cable and connections. Repair or replace as
required.
• Control lever pin sheared. Check and repair.
• Drive bearings seized. Inspect drive bearings.
Check bearing lubrication.
• Drive pump worn or defective. Consult Wacker
Corporation. Replace pump.
• Drive motor worn. Consult Wacker Corporation.
Replace motor.
• Relief valve pressure low. Check and adjust relief
valve.
• Air trapped in hydraulic oil. Check suction hose.
Tighten connections or replace.
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Troubleshooting
9.5
RD 7 /... Repair
Troubleshooting the Drive System
Checking for binding
High operating pressures indicate binding in the drive system. Binding
can occur in the drive motor or may be the result of a poor or failing
drive bearing located on the right side of the drum.
To check for binding:
9.5.1
Stop the machine, apply the parking brake, and switch off the machine.
9.5.2
Remove the drum. See section Replacing the Drum.
9.5.3
Attempt to lift the drum by the drum support (1). If a metallic click or
clang can be heard and there is any play in the bearing, the bearing is
failing; replace it.
9.5.4
Remove the drive motor (2) from the drum support.
NOTICE: When removing the drive motor, care must be taken to
ensure that the splined shaft does not separate from the inside of the
motor.
wc_tx000354gb.fm
9.5.5
Attempt to turn the drum hub by hand. If you cannot turn the drum hub
by hand, the bearing is binding; replace it.
9.5.6
Attempt to turn the drive motor shaft by hand. If the drive motor shaft
binds, rebuild or replace the drive motor.
104
RD 7 /... Repair
Troubleshooting
1
1
2
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Troubleshooting
RD 7 /... Repair
Checking Drive Motors
Failure of the drive circuit to reach operating pressures is normally
caused by a worn or damaged drive pump, although the problem could
also be the result of a badly worn motor.
To check drive motor operation:
9.5.7
WARNING
Stop the machine, apply the parking brake, and switch off the machine.
The lifting devices must have the capacity of at least 650 kg (1430
lbs.).
NOTICE: Use only the lifting eye of the roller to lift the machine. Using
any other part of the machine may severely damage the machine.
9.5.8
Lift the machine so that the drums are 12 mm (0.5 in.) off the ground.
Support the machine as necessary so that it is secure in this position.
9.5.9
Place a reference mark on each drum with tape or chalk.
9.5.10 Start the engine.
9.5.11 Place the direction lever in the full FORWARD position. Count the
revolutions of each drum as they spin. Look for a significant difference
in the speed of one drum over the other. Conduct the same test in with
the direction lever in the full REVERSE position. If one drum spins
faster than the other in both directions, the motor spinning the slow
drum may have failed.
By checking the flow from the drive motor case drain hoses, one can
tell if the drive motor seals are functioning. When new, the drive motors
will let pass a very slow drip.
9.5.12 Position the machine so that the front drum is up against an abutment,
such as a brick wall or concrete barricade.
9.5.13 Turn off the engine and disconnect the drain line from the front drive
motor.
9.5.14 Position the hose from the front drive motor into a graduated container.
9.5.15 Start the engine. With the throttle at full and the direction control lever
in the full FORWARD position, collect all the oil that drains from the
drive motor over a one-minute time period.
•
If the drive motor drains approximately 40 ml (1.3 oz.) of hydraulic
oil per minute or less, it is operating properly.
•
If the drive motor drains 80 ml (2.6 oz.) or more of hydraulic oil
per minute, it has failed; rebuild or replace the drive motor.
9.5.16 Test the rear drive motor in a similar fashion: Position the machine so
that the rear drum is up against an abutment such as a brick wall or
concrete barricade.
9.5.17 With the throttle at full and the forward/reverse control lever in the full
REVERSE position, collect all oil that drains from the drive motor over
a one-minute time period.
wc_tx000354gb.fm
106
RD 7 /... Repair
9.6
Troubleshooting
•
If the drive motor drains approximately 40 ml (1.3 oz.) of hydraulic
oil per minute or less, it is operating properly.
•
If the drive motor drains 80 ml (2.6 oz.) or more of hydraulic oil
per minute, it has failed; rebuild or replace the drive motor.
Starting System
Problem / Symptom
Engine turns over but will not
start or starts hard.
Reason / Remedy
• Fuel tank is empty. Fill fuel tank.
• Wrong type of fuel. Use correct fuel type.
• Old fuel. Drain tank, change fuel filter and fill with
fresh fuel.
• Fuel filter restricted or plugged. Replace fuel filter.
• Incorrect valve clearance. Check/adjust valve
clearance.
• Air cleaner element plugged. Check and replace air
filter.
• Vibration switch on, loading down hydraulic system.
Turn switch off.
• Hydraulic oil or engine oil too heavy. Check
specifications and fill with correct oil.
• Temperature is too cold. Warm engine. Change
engine oil to a higher grade.
wc_tx000354gb.fm
107
Troubleshooting
RD 7 /... Repair
Notes
wc_tx000354gb.fm
108
Threadlockers and Sealants
Threadlocking adhesives and sealants are specified throughout this
manual by a notation of “S” plus a number (S#) and should be used
where indicated. Threadlocking compounds normally break down at
temperatures above 175°C (350°F). If a screw or bolt is hard to
remove, heat it using a small propane torch to break down the sealant.
When applying sealants, follow instructions on container. The sealants
listed are recommended for use on Wacker equipment.
TYPE
( ) = Europe
Loctite 222
Hernon 420
Omnifit 1150 (50M)
COLOR USAGE
Purple Low strength, for locking threads smaller
than 6 mm (1/4”).
Hand tool removable.
Temp. range: -54 to 149°C (-65 to 300°F)
Blue
Medium strength, for locking threads
Loctite 243
Hernon 423
larger than 6 mm (1/4”).
Omnifit 1350 (100M)
Hand tool removable.
Loctite 271/277
Red
High strength, for all threads up to 25 mm
Hernon 427
(1”).
Omnifit 1550 (220M)
Heat parts before disassembly.
Loctite 290
Green Medium to high strength, for locking
Hernon 431
preassembled threads and for sealing
Omnifit 1710 (230LL)
weld porosity (wicking).
Gaps up to 0.13 mm (0.005”)
Loctite 609
Green Medium strength retaining compound for
Hernon 822
slip or press fit of shafts, bearings, gears,
Omnifit 1730 (230L)
pulleys, etc.
Gaps up to 0.13 mm (0.005”)
Loctite 545
Brown Hydraulic sealant
Hernon 947
Omnifit 1150 (50M)
Loctite 592
White
Pipe sealant with Teflon for moderate
Hernon 920
pressures.
Omnifit 790
Loctite 515
Purple Form-in-place gasket for flexible joints.
Hernon 910
Fills gaps up to 1.3 mm (0.05”)
Omnifit 10
PART NO. –
SIZE
73287 - 10 ml
29311 - .5 ml
17380 - 50 ml
29312 - .5 ml
26685 - 10 ml
73285 - 50 ml
28824 - .5 ml
25316 - 10 ml
29314 - .5 ml
79356 - 50 ml
26695 - 6 ml
73289 - 50 ml
70735 - 50 ml
Threadlockers and Sealants (continued)
Threadlocking adhesives and sealants are specified throughout this
manual by a notation of “S” plus a number (S#) and should be used
where indicated. Threadlocking compounds normally break down at
temperatures above 175°C (350°F). If a screw or bolt is hard to
remove, heat it using a small propane torch to break down the sealant.
When applying sealants, follow instructions on container. The sealants
listed are recommended for use on Wacker equipment.
TYPE
( ) = Europe
COLOR USAGE
Loctite 496
Clear
Instant adhesive for bonding rubber, metal
Hernon 110
and plastics; general purpose.
Omnifit Sicomet 7000
For gaps up to 0.15 mm (0.006”)
Read caution instructions before using.
Loctite Primer T
Aerosol Fast curing primer for threadlocking,
Hernon Primer 10
Spray
retaining and sealing compounds. Must
Omnifit VC Activator
be used with stainless steel hardware.
Recommended for use with gasket
sealants.
PART NO. –
SIZE
52676 - 1oz.
2006124-6 oz.
Torque Values
Torque Values
Metric Fasteners (DIN)
TORQUE VALUES (Based on Bolt Size and Hardness)
8.8
10.9
WRENCH SIZE
12.9
Size
Nm
ft.lb.
Nm
ft.lb.
Nm
ft.lb.
Metric
Inch
Metric
Inch
M3
1.2
*11
1.6
*14
2.1
*19
5.5
7/32
2.5
–
M4
2.9
*26
4.1
*36
4.9
*43
7
9/32
3
–
M5
6.0
*53
8.5
6
10
7
8
5/16
4
–
M6
10
7
14
10
17
13
10
–
5
–
M8
25
18
35
26
41
30
13
1/2
6
–
M10
49
36
69
51
83
61
17
11/16
8
–
M12
86
63
120
88
145
107
19
3/4
10
–
M14
135
99
190
140
230
169
22
7/8
12
–
M16
210
155
295
217
355
262
24
15/16
14
–
M18
290
214
405
298
485
357
27
1-1/16
14
–
M20
410
302
580
427
690
508
30
1-1/4
17
–
1 ft.lb. = 1.357 Nm
* = in.lb.
1 inch = 25.4 mm
Torque Values
Torque Values (continued)
Inch Fasteners (SAE)
Size
Nm
ft.lb.
Nm
ft.lb.
Nm
ft.lb.
Metric
Inch
Metric
Inch
No.4
0.7
*6
1.0
*14
1.4
*12
5.5
1/4
–
3/32
No.6
1.4
*12
1.9
*17
2.4
*21
8
5/16
–
7/64
No.8
2.5
*22
3.5
*31
4.7
*42
9
11/32
–
9/64
No.10
3.6
*32
5.1
*45
6.8
*60
–
3/8
–
5/32
1/4
8.1
6
12
9
16
12
–
7/16
–
3/32
5/16
18
13
26
19
33
24
13
1/2
–
1/4
3/8
31
23
45
33
58
43
–
9/16
–
5/16
7/16
50
37
71
52
94
69
16
5/8
–
3/8
1/2
77
57
109
80
142
105
19
3/4
–
3/8
9/16
111
82
156
115
214
158
–
13/16
–
–
5/8
152
112
216
159
265
195
24
15/16
–
1/2
3/4
271
200
383
282
479
353
–
1-1/8
–
5/8
1 ft.lb. = 1.357 Nm
* = in.lb.
1 inch = 25.4 mm
Wacker Construction Equipment AG
·
Preußenstraße 41
· D-80809 München
· Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90
Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957
Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. +852 2406 60 32 · Fax: +852 2406 60 21