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Roller

RD 7 /...

OPERATOR’S MANUAL

0154645en 012

1107

0 1 5 4 6 4 5 E N

RD 7 /... Table of Contents

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1. Foreword 5

2. Safety Information 6

2.1 Operating Safety .................................................................................. 72.2 Operator Safety While Using Internal Combustion Engines ................. 82.3 Service Safety ...................................................................................... 92.4 Label Locations .................................................................................. 102.5 Safety and Informational Labels ......................................................... 11

3. Operation 16

3.1 Controls and Service Locations .......................................................... 163.2 Before Starting ................................................................................... 173.3 Engine Throttle Control ...................................................................... 183.4 Starting the Machine (RD 7H, RD 7H-S) ............................................ 183.5 Starting the Machine (RD 7H-ES) ...................................................... 193.6 Cold Weather Starting (RD 7H, RD 7H-S) ......................................... 213.7 Engine Speed ..................................................................................... 223.8 Stopping the Machine ......................................................................... 223.9 Direction and Speed Control .............................................................. 233.10 Exciter ................................................................................................ 233.11 Back-Up Stop Pad .............................................................................. 243.12 Engine Crank ...................................................................................... 243.13 Parking Brake ..................................................................................... 253.14 Watering System ................................................................................ 253.15 Operation on Slopes ........................................................................... 263.16 Rollovers ............................................................................................ 26

4. Maintenance 27

4.1 Maintenance Schedule ....................................................................... 274.2 Checking Engine Oil ........................................................................... 284.3 Changing Engine Oil and Oil Filter ..................................................... 294.4 Fuel System ....................................................................................... 304.5 Engine Air Filter .................................................................................. 324.6 Checking and Adjusting Valve Clearances ........................................ 334.7 Engine Cooling System ...................................................................... 34

Table of Contents RD 7 /...

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4.8 Mechanical Oil Pressure Monitoring ....................................................354.9 Scraper Bars .......................................................................................364.10 Hydraulic Oil Requirements .................................................................374.11 Hydraulic Oil Level ..............................................................................384.12 Changing Hydraulic Fluid and Filter ....................................................394.13 Direction Lever Adjustment .................................................................404.14 Lifting ...................................................................................................424.15 Transporting ........................................................................................424.16 Pressure Washing the Machine ..........................................................434.17 Storing the Machine ............................................................................434.18 Hydraulic Schematic ............................................................................444.19 Hydraulic Schematic Components ......................................................454.20 Hydraulic Diagram ...............................................................................464.21 Hydraulic Diagram Components .........................................................474.22 RD 7H-ES Electrical Schematic ..........................................................484.23 RD 7H-ES Electrical Schematic Components .....................................494.24 General Troubleshooting .....................................................................50

5. Technical Data 51

5.1 Engine .................................................................................................515.2 Roller ...................................................................................................525.3 Sound and Vibration Measurements ...................................................52

Foreword

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CALIFORNIAProposition 65 Warning:

Engine exhaust, some of its constituents, and certain vehiclecomponents, contain or emit chemicals known to the State ofCalifornia to cause cancer and birth defects or other reproductiveharm.

1. ForewordThis manual provides information and procedures to safely operateand maintain this Wacker model. For your own safety and protectionfrom injury, carefully read, understand and observe the safetyinstructions described in this manual.

Keep this manual or a copy of it with the machine. If you lose thismanual or need an additional copy, please contact WackerCorporation. This machine is built with user safety in mind; however,it can present hazards if improperly operated and serviced. Followoperating instructions carefully! If you have questions about operatingor servicing this equipment, please contact Wacker Corporation.

The information contained in this manual was based on machines inproduction at the time of publication. Wacker Corporation reserves theright to change any portion of this information without notice.

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

Copyright 2007 by Wacker Corporation.

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

Any type of reproduction or distribution not authorized by WackerCorporation represents an infringement of valid copyrights and will beprosecuted. We expressly reserve the right to make technicalmodifications, even without due notice, which aim at improving ourmachines or their safety standards.

WARNING

RD 7 /... Safety Information

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2. Safety InformationThis manual contains DANGER, WARNING, CAUTION, NOTICE andNOTE callouts which must be followed to reduce the possibility ofpersonal injury, damage to the equipment, or improper service.

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

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

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

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

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

DANGER

WARNING

CAUTION

Safety Information RD 7 /...

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2.1 Operating Safety

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

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

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

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

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

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

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

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

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

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

WARNING


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2.2 Operator Safety While Using Internal Combustion Engines

Internal combustion engines present special hazards during operationand fueling. Read and follow the warning instructions in the engineOwner’s Manual and the safety guidelines below. Failure to follow thewarnings and safety standards could result in severe injury or death.

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

2.2.2 DO NOT smoke while operating the machine.

2.2.3 DO NOT smoke when refueling the engine.

2.2.4 DO NOT refuel a hot or running engine.

2.2.5 DO NOT refuel the engine near an open flame.

2.2.6 DO NOT spill fuel when refueling the engine.

2.2.7 DO NOT run the engine near open flames.

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

2.2.9 ALWAYS replace the fuel tank cap after refueling.

2.2.10 DO NOT touch or lean against hot exhaust pipes.

2.2.11 DO NOT mix diesel fuel with any other fluids.

DANGER


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2.3 Service Safety

A poorly maintained machine can become a safety hazard! In orderfor the machine to operate safely and properly over a long period oftime, periodic maintenance and occasional repairs are necessary.

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

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

2.3.3 ALWAYS check all external fasteners at regular intervals.

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

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

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

2.3.7 ALWAYS turn the engine off before performing maintenance or makingrepairs.

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

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

WARNING


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2.4 Label Locations

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% � � � � � � � � � � � � � � � & � � � � �


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2.5 Safety and Informational Labels

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

Label Meaning

DANGER!Engines emit carbon monoxide; operate only in well-ventilated area. Read the Operator’s Manual.No sparks, flames, or burning objects near the machine. Shut off the engine before refueling.

WARNING! Hot surface!

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

WARNING!To prevent hearing loss, wear hearing protec-tion when operating the machine.

Guaranteed sound power level in dB(A).


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CAUTION! Use only clean, filtered diesel fuel.

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

Water control valve.

Vibration control ON/OFF.

No lift point.(one of two)

CAUTION! Lifting point.

Tie-down point.

Label Meaning

��

� � � � � � � � � � � � � � � � � � � � � �

� � � � � � � � � � � � � � � � � � � � � � � � �

� � � � � � � � � � � � � � � � � � � � �

� � � � � � � � � � � � � � � � � � �

� � � � � � � � � � � � � � � � �

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Engine oil drain.

Hydraulic oil reservoir fill tube.

Hydraulic oil drain.

Key switch, engine start:OffOnStart

This machine may be covered by one or more patents.

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

Label Meaning


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Check engine oil level. Use SAE10W30.

Check the fuel level.

Engage parking brake.

Turn vibration off.

Pull engine throttle out.

Pull decompression lever up.

Insert crank handle.

Label Meaning


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Rotate crank handle counterclockwise 5X.

Remove crank handle.

Disengage parking brake.

Label Meaning

RD 7 /... Operation

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3. Operation

3.1 Controls and Service Locations

Ref. Description Ref. Description

1 Handle locking pin 15 Crank guide sleeve

2 Tie-down location 16 Fuel tank fill cap

3 Scraper bar (4 total) 17 Top cover

4 Water control valve 18 Hydraulic tank (under front cover)

5 Shock mount (4 total) 19 Hydraulic tank fill port (under top cover)

6 Parking brake 20 Hydraulic tank sightglass (through slots)

7 Back-up stop pad 21 Fuel tank

8 Forward/reverse control lever 22 Front cover

9 Exciter control lever 23 Lifting eye

10 Water tank fill cap 24 Operator’s Manual holder

11 Crank storage location 25 Water tank

12 Throttle control 26 Battery

13 Air cleaner indicator 27 Ignition switch

14 Oil dipstick 28 Alarm

Operation RD 7 /...

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3.2 Before Starting

Before starting the machine, check the following:

• Engine oil level

• Air cleaner maintenance indicator

RD 7 /... Operation

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• Fuel level

• Hydraulic fluid level

• Water tank level

3.3 Engine Throttle Control

See Graphic: wc_gr001338

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

3.4 Starting the Machine (RD 7H, RD 7H-S)See Graphic: wc_gr001338, wc_gr001339, wc_gr001340

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

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

c

c1a

b

dwc_gr001338

Operation RD 7 /...

wc_tx000294gb.fm 19

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

3.4.4 Insert the crank (d) into the guide sleeve (b).3.4.5 Turn the crank 5 turns to build up pressure for the engine to fire.

3.4.6 Stand alongside the engine, facing the back of the machine (e) andgrasp the tubular grip with both hands.

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

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

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

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

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

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

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

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

3.5 Starting the Machine (RD 7H-ES)See Graphic: wc_gr001529

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

WARNING

WARNING

wc_gr001339

e

f0

f1

g

f

wc_gr001340

RD 7 /... Operation

wc_tx000294gb.fm 20

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

3.5.3 Turn the ignition switch (c) to start the engine.

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

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

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

CAUTION

WARNING

Operation RD 7 /...

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

See Graphic: wc_gr001338, wc_gr001339, wc_gr001340

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

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

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

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

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

to fire.

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

• remove the cover

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

• press the cover on firmly.

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

c

c1a

b

dwc_gr001338

wc_gr001339

e

f0

f1

g

f

wc_gr001340

RD 7 /... Operation

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3.7 Engine Speed

During operation, run the engine at full throttle (2800 rpm). Thisensures maximum exciter speed and will produce the bestcompaction.

3.8 Stopping the Machine


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

3.8.2 Close the water control valve.

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

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

3.8.5 Apply the parking brake.

3.8.6 Clean the scraper bars before storing the machine.

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

Operation RD 7 /...

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3.9 Direction and Speed Control


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

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

3.10 Exciter

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

WARNING

WARNING

b1

a

wc_gr001341

RD 7 /... Operation

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3.11 Back-Up Stop Pad


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

3.12 Engine Crank


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

STOP

wc_gr001342

a

wc_gr001345

a b c

Operation RD 7 /...

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3.13 Parking Brake


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

3.14 Watering System


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

wc_gr001343a

a

wc_gr001344

RD 7 /... Operation

wc_tx000294gb.fm 26

3.15 Operation on Slopes

See Graphic: wc_gr001346 and wc_gr001347

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

3.16 Rollovers

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

WARNING

22˚40%

wc_gr001346 wc_gr001347

Maintenance RD 7 /...

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4. Maintenance

4.1 Maintenance Schedule

Dailybefore

starting

Afterfirst

25 hrs.*

Every250hrs.

Every500hrs.

Every1200hrs.

Check engine oil level.

Check air cleaner maintenance indicator.

Check the water trap.

Check hydraulic oil level.

Clean the scraper bars.

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

Check tappet clearance.

Examine screw connections.

Replace engine oil and filter.

Check and adjust valve clearances.

Clean cooling system.

Replace fuel filter.

Clean or replace air filter.

Change hydraulic system return line filter.

Check and adjust scraper bars.

**Check linkage components.

Clean battery terminals (RD 7H-ES).

Change hydraulic oil and filter.

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

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

RD 7 /... Maintenance

wc_tx000295gb.fm 28

4.2 Checking Engine Oil


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

4.2.1 Clean around the dipstick.

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

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

WARNING

a

wc_gr001348


wc_tx000295gb.fm 29

4.3 Changing Engine Oil and Oil Filter


Before changing the oil:

4.3.1 Run the machine to warm the oil.

4.3.2 Park the machine on a flat level surface.

4.3.3 Turn off the engine and apply the parking brake.

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

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

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

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

4.3.6 Reinstall the drain plug.

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

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

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

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

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

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

CAUTION

wc_gr001349

a


wc_tx000295gb.fm 30

4.4 Fuel SystemSee Graphic: wc_gr001351

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

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

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

4.4.3 Trap the drops of water that emerge in a transparent container.

Note: Since water has a higher specific gravity than diesel fuel, thewater emerges first. The two substances separate at a clearly visibleline.

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

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

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

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

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

4.4.7 Close the fuel supply line.

4.4.8 Pull the fuel supply line (b) off of the fuel filter trap (c) at both sides, andinsert the new filter.

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

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

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

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

WARNING


wc_tx000295gb.fm 31

a

b

c

wc_gr001351


wc_tx000295gb.fm 32

4.5 Engine Air Filter


Checking the air cleaner blockage indicator4.5.1 Briefly run the engine at full speed. If the rubber bellows is pulled in and

obscures the green zone (a), clean or replace the air filter.

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

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

4.5.3 Loosen the wing nut (b) and remove it. Also remove the air cleanercover (c).Note: The decompression lever will also come off.

4.5.4 Pull out the filter cartridge (e).4.5.5 Check that the valve plate (f) for the air blockage indicator is clean and

in good condition.

Cleaning dry dirt from the filter cartridge4.5.6 Blow through the filter cartridge from the inside using a compressed air

gun.

4.5.7 Continue until all dust has been removed.

NOTICE: Only use filtered, dry compressed air. Do not exceed an airpressure of more than 5 bar (70 psi). Keep the nozzle at a distance of150 mm (6 in.) from the element.Cleaning wet or oily dirt from the filter

4.5.8 Change the filter cartridge.

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

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

4.5.10 Check that the sealing surface (d) is in good condition.

NOTICE: If there is even slight damage to the paper filter element orthe sealing surface, replace the filter cartridge.

WARNING


wc_tx000295gb.fm 33

4.6 Checking and Adjusting Valve ClearancesSee Graphic: wc_gr001353

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

4.6.1 Make sure that the compression lever is in position “0”. See sectionStarting the Machine.

4.6.2 Remove the cylinder head cover and the gasket.

4.6.3 Turn the engine over in the normal direction of rotation untilcompression is felt.

4.6.4 Check the inlet valve clearance between the rocker and the valve stemusing a feeler gauge (a).

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

4.6.6 Turn the adjusting screw (b) with a screwdriver until the feeler gauge(a) can just be pulled through between the rocker and the valve stemwith slight resistance to its movement after the nut (c) has beenretightened.

4.6.7 Repeat this adjustment with the outlet valve.

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

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

a b

c

wc_gr001353

a b c

de

fg

wc_gr001352


wc_tx000295gb.fm 34

4.7 Engine Cooling System


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

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

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

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

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

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

a

a

a

wc_gr001354


wc_tx000295gb.fm 35

4.8 Mechanical Oil Pressure Monitoring


The mechanical oil pressure monitor should be activated:

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

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

• after freeing it by turning it at low temperatures.

4.8.1 Add fuel.

4.8.2 Check the engine oil level.

4.8.3 To activate the oil pressure monitor, press the lever (a).4.8.4 Re-assemble all the parts repositioned or removed. Check that the

capsule elements make a good seal.

Note: Instructions to activate the mechanical oil pressure control arementioned on the label (b) placed on the engine.

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

CAUTION


wc_tx000295gb.fm 36

4.9 Scraper Bars


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

wc_gr001355

a

a a


wc_tx000295gb.fm 37

4.10 Hydraulic Oil Requirements

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

• Wacker Hydraulic Oil - P/N 85094

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


wc_tx000295gb.fm 38

4.11 Hydraulic Oil Level


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

a

wc_gr001356


wc_tx000295gb.fm 39

4.12 Changing Hydraulic Fluid and FilterSee Graphic: wc_gr001357

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

4.12.1 Remove the top cover of the roller.

4.12.2 Remove the drain plug (b) from the end of the drain hose that isattached to the hydraulic tank.

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

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

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

4.12.6 Unscrew the old hydraulic filter.

4.12.7 Install the new hydraulic filter. Screw the new hydraulic filter on byhand, making sure that it is not cross-threaded.

NOTICE: Use only original spare parts.

4.12.8 Tighten the hydraulic filter using both hands.

4.12.9 Fill the hydraulic tank with hydraulic oil until the level is visible halfwayup the sightglass.

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

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

ab

wc_gr001357


wc_tx000295gb.fm 40

4.13 Direction Lever Adjustment


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

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

4.13.2 Stop the engine.

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

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

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

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

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

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

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

• If the machine creeps forwards or backwards, continue.

4.13.7 Turn off the engine.

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

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


wc_tx000295gb.fm 41

wc_gr003672

1 2F N

R7

63

45

8

9

10

2


wc_tx000295gb.fm 42

4.14 Lifting


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

4.15 Transporting


Before transporting the machine:

• place blocks in front of and behind each drum.

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

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

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

WARNING

WARNING

a

wc_gr001359wc_gr001360

a

b


wc_tx000295gb.fm 43

4.16 Pressure Washing the Machine

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

• Engine

• Hydraulic

• Water tank/Plastic parts

• Hoses

• Labels

4.17 Storing the Machine

If the machine is to be stored for more than 30 days:

• Drain the fuel tank and the water tank.

• Open the water valve and drain water from the sprinkling system.

• Change the oil.

• Clean the entire roller and engine compartment.

• Remove dirt from the engine cooling fins.

• Cover the roller and place it in a dry, protected area.

• Remove the diesel injectors and put a little oil into the engine cylinders.

• Remove the battery from the machine and charge it periodically (RD 7H-ES).


wc_tx000295gb.fm 44

4.18 Hydraulic Schematic

7

16 6

8

10

11

13200 bar2900 psi

12100 bar1450 psi

5 4

1206 bar3000 psi

2

15

14

3P

10 micron

wc_gr003636


wc_tx000295gb.fm 45

4.19 Hydraulic Schematic Components



1 Exciter relief valve 9 Charge pump

2 Exciter control valve 10 Exciter pump

3 Exciter motor 11 Drive pump

4 Rear drive motor 12 Charge pressure relief valve

5 Front drive motor 13 Internal drive pump relief valves

6 Return filter 14 Porting block

7 Suction filter 15 Manifold

8 Pump assembly 16 Tank


wc_tx000295gb.fm 46

4.20 Hydraulic Diagram

wc_gr003637

15

28

11(9)(12)

1

10

6

7

16

3

14

4

5

13


wc_tx000295gb.fm 47

4.21 Hydraulic Diagram Components



1 Exciter relief valve 9 Charge pump

2 Exciter control valve 10 Exciter pump

3 Exciter motor 11 Drive pump

4 Rear drive motor 12 Charge pressure relief valve

5 Front drive motor 13 Internal drive pump relief valves

6 Return filter 14 Porting block

7 Suction filter 15 Manifold

8 Pump assembly 16 Tank


wc_tx000295gb.fm 48

4.22 RD 7H-ES Electrical Schematic

wc_gr003663

1 2 3 4 5 62 13456

41

3

Br

P

B

R

0

8


wc_tx000295gb.fm 49

4.23 RD 7H-ES Electrical Schematic Components



1 Key switch 5 Starter

2 15 Amp fuse 6 Regulator

3 Alternator 7 Alarm

4 Battery 8 Oil pressure switch

Wire Colors

B Black R Red Y Yellow Or Orange

G Green T Tan Br Brown Pr Purple

L Blue V Violet Cl Clear Sh Shield

P Pink W White Gr Gray LL Light blue


wc_tx000295gb.fm 50

4.24 General Troubleshooting

Problem / Symptom Reason / Remedy

Engine does not start • Fuel tank empty.

• Wrong type of fuel.

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

• Fuel system not primed.

• Fuel filter restricted or plugged. Replace filter.

• Check/adjust valve clearance.

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

• Air cleaner element plugged.

• Check/adjust decompression device.

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

• Starter motor defective (RD 7H-ES).

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

• Key switch defective (RD 7H-ES).

Engine stops by itself • Fuel tank empty.

• Fuel filter plugged.

• Fuel lines broken or loose.

No vibration • Valve damaged.

• Exciter assembly damaged.

• Exciter motor coupling damaged or broken.

• Exciter motor damaged.

• Pump damaged.

No travelorTravel only in one direction

• Control cable loose or broken.

• Drive motor damaged.

• Drive pump damaged.

• Defective relief valve or valves.

Technical Data RD 7 /...

wc_td000115gb.fm 51

5. Technical Data

5.1 Engine

Item No.

RD 7H0008042

RD 7H-ES0009408

RD 7H-S0009487

RD 7-RAW 06200790620478

Engine

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

Engine make Hatz

Engine model 1D41S 1D41S VAR I

Operating power kW (Hp) 5.1 (6.9) @ 2600 rpm

Operating speed rpm 2600

Valve clearance (cold) intake: exhaust:

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

Battery V — 12 VDC —

Air cleaner type Dry pleated-paper element

Engine lubrication oil grade SAE15W40

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

Fuel type No. 2 diesel

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

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

RD 7 /... Technical Data

wc_td000115gb.fm 52

5.2 Roller

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

Item No.

RD 7H0008042

RD 7H-ES0009408

RD 7H-S0009487

RD 7-RAW06200790620478

Roller

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

mm(in.)

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

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

mm(in.)

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

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

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

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

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

Vibration frequency Hz (vpm) 55 (3300)

Hydraulic system lubrication type SAE 10W30 hydraulic oil*

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

Gradeability with vibration % 25

Gradeability without vibration % 40

*See “Hydraulic Oil Requirements”

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

NOTICE OF COPYRIGHT PROTECTIONAEM Safety Manuals are protected as a copyrighted work withownership duly registered with the Copyright Office,Washington,D.C.Any reproduction, translation, decompiling or other use of anAEM Safety Manual, or portion thereof, or the creation of deriv-

ative works based on an AEM Safety Manual,without the prior writ-ten approval of AEM, is expressly prohibited. Copyright infringe-ment can result in civil and criminal sanctions, damages and otherpenalties being imposed.

Copyright © 1978 AEM (Association of Equipment Manufacturers)Former Copyright © CIMA (Construction Industry Manufacturer Association)

Revised 6/02, 9/04

SAFETY ALERT SYMBOLThis Safety Alert Symbol meansATTENTION is involved!

The Safety Alert Symbol identifies important safetymessages on machines, safety signs, in manuals, orelsewhere.When you see this symbol, be alert tothe possibility of personal injury or death. Followthe instructions in the safety message.

Why is SAFETY important to YOU?

3 BIG REASONS:• Accidents KILL or DISABLE• Accidents COST• Accidents CAN BE AVOIDED

KE40246P2 6/9/05 3:16 PM Page i

WORD OF EXPLANATION................................................................................ 2

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

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

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

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

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

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

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

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

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

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

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

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

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

1

KE40246P2 6/9/05 3:16 PM Page 1

WORD OF EXPLANATION

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

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

SAE - Society of Automotive Engineers, Inc., 400Commonwealth Drive,Warrendale, PA 15096,publishes a list, "Operator Precautions," SAE J153MAY, 1987.

Association of Equipment Manufacturers,111 East Wisconsin Avenue, Milwaukee,WI USA53202, publishes the Roller Compactor SafetyManual and other safety-related material.

2

KE40246P2 6/9/05 3:16 PM Page 2

3

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

Regardless of which machine you operate, it isYOUR responsibility to study and understand thisSafety Manual, and to see that a copy remainswith your machine.The manual begins with your“safety homework,” takes you step-by-stepthrough your working day, and ends withmaintenance operations.

Manufacturers produce machines with manybuilt-in safety features. Employers provideaccident prevention programs.Yet, the ultimateresponsibility to operate and maintain yourmachine with the skill, care and knowledgeessential for safety is YOURS.

Do not operate your machine until you have beentrained in the use of all operating controls andunderstand the handling characteristics of themachine.

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

WORD OF EXPLANATION

KE40246P2 6/9/05 3:16 PM Page 3

4

This safety manual is intended to point out some ofthe basic situations which may be encounteredduring the normal operation and maintenance ofyour machine, and to suggest possible ways ofdealing with these conditions.

Additional precautions may be necessary, dependingon application, machine type, configuration andattachments used, and conditions at the work-siteor in the maintenance area.The manufacturer has nodirect control over machine application, operation,inspection, lubrication or maintenance.Therefore, itis your responsibility to use good safe practices inthese areas.

The information provided in this manual supplementsthe specific information about your machine that iscontained in the manufacturer's manual(s). Otherinformation which may affect the safe operation ofyour machine may be contained on safety signs, or ininsurance requirements, employer's safety programs,safety codes, local, state/provincial and federal laws,rules and regulations.

If you do not understand any of this information, orif errors or contradictions seem to exist, consult withyour supervisor before operating your machine.

IMPORTANT: If you do not have themanufacturer's manual(s) for your particularmachine, get a replacement manual from youremployer, equipment dealer, or manufacturerof your machine. Keep this safety manual andthe manufacturer's manual(s) with yourmachine.

Unauthorized modifications of machines createhazards. Machines should not be modified or alteredunless prior approval is obtained from the manufacturer.

FOREWORD

KE40246P2 6/9/05 3:16 PM Page 4

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

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

REMEMBER — SAFETY IS UP TO YOU

YOU CAN PREVENTSERIOUS INJURY OR DEATH

5

A WORD TO THE USER

KE40246P2 6/9/05 3:16 PM Page 5

6

KNOW THE RULES

Every employer is concerned about safety. Safeoperation and proper maintenance of your machinecan prevent accidents. KNOW the rules — LIVE bythem. (FIG. 2)

When starting work at a new site, check with thedesignated safety coordinator for specific safetyinstructions. DON’T LEARN SAFETY THE HARDWAY.

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

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

Know where the fire extinguishers and first aid kitsare kept and how to use them. Know where to getproper aid and assistance when needed.

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

Know how to use the emergency communicationssystem to summon help when necessary.

FOLLOW A SAFETY PROGRAM

KE40246P2 6/9/05 3:16 PM Page 6

7

KNOW WHAT IT IS?

Consult your supervisor for specific instructions ona job, and the personal safety equipment required.For instance, you may need:• Hard Hat• Safety Shoes• Eye Protection• Face Protection• Heavy Gloves• Reflector Vests• Hearing Protection• Respirators

Do not wear loose clothing or any accessory — flopping cuffs, untied shoelaces, dangling necktiesand scarves, rings, wrist watches, or other jewelry— that can catch on protruding or moving parts orcontrols. Long hair should be securely bound toprevent entanglement with moving parts. (FIG. 3)


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8

BE ALERT!

Know where to get assistance. Know how to use afirst aid kit and fire extinguisher or fire suppressionsystem. (FIG. 4)

BE AWARE!

Take advantage of training programs offered.

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

Know what the jobsite rules are, and FOLLOW THERULES. Be safety conscious, responsible and reliable.Think about safety BEFORE something happens.

Report unsafe conditions to a supervisor immediately!

BE CAREFUL!

Human error is caused by many factors:carelessness, fatigue, overload, preoccupation,incompatibility between operator and the machine,drugs, and alcohol to name a few. Eliminate thesefactors BEFORE accidents occur. Damage to themachine can be fixed in a short period of time, butinjury, or death has a lasting effect.

FOR YOUR SAFETY AND SAFETY OFOTHERS, ENCOURAGE YOUR FELLOWWORKERS TO ACT SAFELY.


KE40246P2 6/9/05 3:16 PM Page 8

LEARN TO BE SAFE

READ the operator’s manual. If one has not beenprovided, GET ONE AND STUDY IT BEFOREOPERATING THE MACHINE. If you have anyquestions contact the manufacturer.Know the positions and understand the functionsof all controls before attempting to operate amachine. Know the meaning of all identificationsymbols on your controls and gauges. (FIG. 5)Know the location of the emergency shut-downcontrol if the machine is so equipped.Know the capabilities and limitations of themachine … such as speed, breaking and steering.Know the operational and transport dimensionsof your machine to avoid inadvertently hittingsomething during operation or transporting.Carefully read and follow the instructions on allsafety signs on the machine. Keep safety signs ingood condition. Replace missing or damagedsafety signs.

9

PREPARE FOR SAFE OPERATION

NEVER operate a machine which is new to youwithout first being instructed in its proper operation.

CHECK IT OUT!

Always conduct a pre-shift inspection before operatingany machine. Know what safety devices your machineis equipped with … and see that each item is securelyin place and in operating condition. (FIG. 6)

For example:• Safety Blocks and Locks• Other Locking Devices• Lights• Alarms• Horn• Guards and Shields• Shut-Down Devices• First Aid Kit• Fire Extinguishers

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TIRES

Inspect pneumatic tires (if so equipped) fordamage, wear, and proper inflation. Never operatewith over-inflated or under-inflated tires. (FIG. 7)

Check that all wheel lug nuts are present and tight.

NEVER START OR OPERATE A MACHINEKNOWN OR SUSPECTED TO BE DEFECTIVEOR MALFUNCTIONING.

10


KNOW YOUR MACHINE

Never operate a machine for which you are nottrained or qualified.

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

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

Remove tools, supplies and other materials fromthe working areas and machine walkways – andkeep these areas free of trash.

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

ARE REPAIRS MADE?

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

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FIRE PREVENTION

Never allow flammable fluids or materials tocontact hot surfaces.

Never refuel:• When engine is running• While smoking• Near open flames or sparks• In poorly ventilated area

Never overfill fuel tank or fluid reservoirs.Clean up spills immediately.

Replace fuel cap securely after filling.

Check for fuel, oil and hydraulic fluid leaks.Replace worn or damaged hoses/tubes.Afterrepairs are made, clean the machine before youoperate it.

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

11


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

Batteries produce explosive gases. Keep open flameor sparks away. See the manufacturer’s instructionswhen servicing the batteries, when using jumpercables or when using a battery charger. (See pages36 and 37.)

Remove all trash or debris from the machine. Makesure that oily rags or other flammable material arenot stored on the machine. (FIG. 8)

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PREPARING TO ROAD THE MACHINE

Know what conditions you will likely encounter:• Insufficient clearances• Traffic congestion• Type of surface• Steep grades• Restricted visibility

Determine appropriate warnings to be used. (FIG. 9)Know whether you will need to be escorted.

If the machine is to travel on a road or highway,refer to the manufacturer’s manual(s) for instructions.Become familiar with local laws and ordinances affectingdriving on highways. Use “slow moving vehicle” emblem.Make sure flags, lights, and warning signs are in place.

Select the proper gear before negotiating steep grades. (FIG. 10)

12


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Before starting, carefully inspect your machine forany evidence of physical damage such as cracking,bending or deformation of plates or welds. Check forcracking or flaking of paint, which may indicate anexcessive strain or dangerous crack in the materialbelow. Check for loose, broken or missing parts suchas Roll-Over Protective Structure (ROPS) supportbrackets, vibration isolators, and nuts and bolts. Ifpotentially serious problems are found, do notoperate the machine until appropriate repairs arecompleted.

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

Check the various systems (hydraulic, cooling, etc.)for leaks. (FIG. 11) Inspect all plugs, filler caps andfittings for tell-tale signs of leaks.ALWAYS use aflashlight or shielded trouble light when checking …Never an open flame. Repair any leaks, or have themrepaired by authorized service personnel. (See pages28 through 42 for additional service cautions.)

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

A stalled or faltering engine can result in a realhazard when operating on grades, in traffic or inheavily congested areas.

NEVER smoke when checking fuel level or refueling.

13


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BE SURE THE WORK AREA IS SAFE

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

Be observant of other workmen, bystanders andother machines in the area. Be especially careful iftrenches, lightpoles, tiles, buildings, etc. are withinthe effective range of a vibratory compactor.IMPROPER OPERATION COULD RESULT INDAMAGE OR INJURY.

Remember, the danger of sliding and/or tipping onsteep slopes is always present … regardless ofhow heavy or “stable” your machine may appear tobe.When operating under these conditions, theuse of ROPS and seat belts reduces the hazard tooperating personnel.

14


FIG. 12

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Walk around your machine once more just prior tomounting it – checking for people and objects thatmight be in the way – then MOUNT PROPERLYUSING STEPS AND HANDHOLDS PROVIDED.

Always use seat belts if your machine is equippedwith a ROPS.

Just before starting, check all controls … such asforward and reverse, steering, transmission andthrottle to be sure they are in the correct start-upposition. (FIG. 13) The parking brake should beapplied during the start-up operation.

Check for proper functioning of all operating andshut-down controls.

START CORRECTLY

Know the PROPER starting procedure for yourmachine. Follow the manufacturer’s operationmanual … to the letter.

Then, start your engine.

15

START SAFELY

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IMMEDIATELY AFTER STARTING THE ENGINE …

• Observe gauges, instruments, and warning lights toensure that they are functioning and their readingsare within the normal operating range. (FIG. 14)

• Be sure work area is safe for test operation of thevarious controls and attachments.

• Operate all controls: make certain they operate properly, and “feel” right.Accustom yourself to the“feel” of your machine.

• Listen for any unusual noises; smell for any unusualodors; look for any signs of trouble.

• Check all warning and safety devices and indicators.

• If safety-related defects or malfunctions are detected, shut down the machine. Correct it, or notify your supervisor. DO NOT OPERATE UNTIL CORRECTED.

Check operation of service and parking brakes onlevel ground if possible.

Check service brakes (including hydrostatic brakes,if so equipped) in both forward and reverseoperation (FIG. 15) ACCORDING TO THEMANUFACTURERS INSTRUCTIONS.

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

16

START SAFELY

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COLD WEATHER OPERATION

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

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

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

BOOSTER CABLE INSTRUCTIONS

1. Connect positive (+) cable to positive post ofdischarged battery.

2. Connect other end of same cable to same markedpost of booster battery.

3. Connect negative (-) cable to other post of booster battery.

4. Make final connection on stalled vehicle away frombattery, either on vehicle frame or engine block.

5. Start vehicle and remove cables in reverse order of connection.

17

START SAFELY

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REMEMBER THESE RULES

When roading or operating a machine, always stayin the operator’s station. NEVER mount or dismounta machine that is moving. Maintain control of yourmachine at all times.

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

Constantly check your total work area forpotential hazards.

Never JUMP on or off your machine. Use the stepsand handholds provided to mount or dismountsafely. Maintain three point contact when mountingor dismounting.(FIG. 17)

• Never use controls or levers as hand holds.• Never jump off the machine.

Look, listen and smell for possible malfunctions. Ifmalfunctioning controls or erratic operation aredetected, correct or report them immediately.DO NOT OPERATE THE MACHINE UNTILCORRECTED.

Prevent asphyxiation. If you must operate in abuilding or other enclosed area, or if yourmachine is equipped with an enclosed cab, be cer-tain there is adequate ventilation.

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

18

WORK SAFELY

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

NEVER allow unqualified or unauthorized personnelto operate your machine.

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

NEVER abuse your machine. Misuse or abuse cancause an accident.

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

Give the right-of-way to loaded equipment on haulroads. Maintain a safe distance from personnel, motorvehicles and other machines.

Your safety, and the safety of those around you, isdetermined by the care and judgment YOU use whileoperating your machine.

19

WORK SAFELY

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20

WORKING ON SLOPES

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

ALWAYS use seat belts IF your machine is equippedwith a ROPS.

NEVER allow the engine or machine to overspeed.

When climbing or descending steep grades,ALWAYSselect the proper gear BEFORE starting on the slope,to assure adequate power or engine breaking.

If your machine has a gear shift, select a low gear.If your machine has a hydrostatic drive, the speedcontrol should be in the slow travel position, closeto neutral … NEVER in the fully displaced position.

On machines that have a gear shift AND a hydrostaticcontrol, BOTH controls must be in their slow travelposition.

ALWAYS be sure that manually operated gear typetransmissions are fully engaged BEFORE starting ontoa grade. DO NOT attempt to change the gear selectionwhile traveling on a grade. See the manufacturer’smanual for specific instructions.

WORK SAFELY

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21

Avoid operating your machine too close to anoverhang, deep ditch or hole. If your machineinadvertently gets close to a tipping conditionor drop-off, STOP and get off the machineafter applying the parking brake … plan yourmoves carefully before proceeding. Reversal isoften the best move.

Be alert to potential caving edges, falling rocksand slides.

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

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

Always travel slowly over rough terrain andhillsides. Maintain a speed consistent with theworking conditions.

WORK SAFELY

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22

When traveling on a public road, obey all trafficregulations and be sure that the proper clearanceflags, lights and warning signs … such as the “slowmoving vehicle” emblem … are used. (FIG. 22)

NEVER speed … and NEVER coast in neutral.

When roading the machine know your approxi-mate stopping distance at any given speed.

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

Always look in all directions before reversingyour direction of travel.

Use EXTRA caution when working in closequarters or when traveling through congestedareas. Courtesy pays off.

WORK SAFELY

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23

PARK SAFELY

Park in an off the road area, out of traffic, or asinstructed. If necessary to park in a traffic lane, usethe appropriate flags, barriers, flares, lights andwarning signals. Provide advance warning signals inthe traffic lane to warn approaching traffic.

Park on level ground whenever possible. (FIG. 25)When not possible, position the machine at right

angles to the slope. Make sure the machine is on afirm footing, and that there is no danger of sliding.Do NOT leave your machine until you are sure it issafely blocked in both directions and parkingbrakes firmly applied. (FIG. 24)

Lower the blade and all other hydraulicallyoperated attachments (if so equipped ) to theground.

PARK AND SHUT DOWN SAFELY

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24

SHUT DOWN PROPERLY

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

Follow the manufacturer’s operation manual forYOUR machine. Remove the key(s) to preventunauthorized starting and movement, and positionand lock any antivandalism devices.

DISMOUNT PROPERLY

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

NEVER jump off your machine. (FIG. 26) Afterstopping, use the steps and handholds provided todismount safely. Maintain three point contact whendismounting.

PARK AND SHUT DOWN SAFELY

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25

Loading and unloading machines always involvespotential hazards. EXTREME CAUTION SHOULDBE USED.

Know the correct loading and unloading proceduresfor your machine.

All machines are not loaded and unloaded thesame way.The procedures recommended by themanufacturer should always be followed.

Several precautions are applicable to all machines:

• NEVER load or unload machine by yourself.• Keep all non-essential personnel clear of loading

and unloading area.• Load and unload on a level surface.• ALWAYS use ramps of adequate size and strength.

Be sure ramps are sufficiently wide, and long enough to provide a safe loading slope.

• NEVER use ramps that are cracked, damaged, or of questionable strength. (FIG. 27)

• Be sure that the ramps are securely positioned and fastened, and that the two sides are at the same level as one another.

• The ramp surface must provide adequate traction.Be sure the surface is clean and free of grease,oil, ice, and loose material.

• The hauling vehicle should be blocked to prevent movement during loading or unloading of the machine.

• For proper tie-down instructions, see the manufacturer’s manual.

LOAD AND UNLOAD MACHINE SAFELY

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26

GENERAL

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

NEVER attempt to tow a trailer or machine if thehitching devices are of insufficient or questionablecapacity, improperly matched in size or shape, orpositioned at improper heights.

When towing a machine equipped with portabilityor transport wheels,ALWAYS follow themanufacturer’s towing instructions.

BEFORE TOWING

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

ALWAYS make sure the hitch is properly andsecurely locked.

ALWAYS use safety chains between the haulingvehicle and tailer or towed machine. Be sure thechains are properly and securely connected … atBOTH ends. Cross the chains under the tonguewhen connecting to the hauling vehicle.

ALWAYS make sure electrical and otherconnections between the hauling vehicle and traileror towed machine are properly and securely made.After connecting, check the lights for properoperation. If the towed trailer or machine isequipped with brakes operable from the haulingvehicle, check to make sure they are operatingproperly.

ALWAYS be sure the portability or transportwheels, on machines so equipped, are LOCKEDin the lowered position.

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

TRANSPORTING SAFELY

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27

TOWING

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

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

NEVER travel at speeds above those recommended bythe manufacturer.

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

When necessary to disconnect and park a trailer ortowed machine,ALWAYS select a location that is leveland, if possible, one where children are unlikely to bepresent. BEFORE disconnecting a trailer, chock the frontAND rear of the wheels, and block under the tongue.

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

TRANSPORTING SAFELY

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28

GENERAL

Maintenance work can be hazardous if not done ina careful manner. All personnel should realize thehazards and strictly follow safe practices.

NEVER perform any work on the equipment unlessauthorized to do so. (FIG. 29) Before performing anymaintenance or repair work, consult the InstructionManual. Follow the manufacturer’s recommendedprocedures.

BEFORE any maintenance work is begun, reviewLOCKOUT/TAGOUT procedures. LOCKOUTcontrols and/or energy source and place a warninglabel to alert workers of shutdown.

PRIOR to removal of LOCKOUT/TAGOUT, theequipment must be fully operational and all personnelaccounted for. Except in cases of emergency, theremoval of the LOCKOUT/ TAGOUT should be doneby the initiating person prior to the return to start-up.

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

REPLACE all missing or broken guards and panels.

USE proper nonflammable cleaning solvents. Followsolvent manufacturer’s instructions.

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

PERFORM MAINTENANCE SAFELY

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

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29


CLOTHING AND PERSONAL PROTECTIVE ITEMS

Keep hands and clothing well away from engine fan and moving parts while engine is running.

ALWAYS wear appropriate safety glasses, goggles or face shield when working. (FIG. 30) Proper eyeprotection can keep flying particles from grinding,drilling or hammering operations, or fluids such asfuel, solvents, lubricants and brake fluids, fromdamaging your eyes. Normal glasses do NOTprovide adequate protection.

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

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

EXHAUST FUMES

Engine exhaust fumes can cause sickness or death.If it is necessary to run an engine in an enclosedarea, use an exhaust pipe extension. If you do nothave an exhaust pipe extension, be positive the areais adequately ventilated. (FIG. 32)

HEAVY PARTS

HEAVY PARTS

Handle tools and heavy parts sensibly – with regardfor yourself and other persons. Lower items – don’tthrow or drop them.

ALWAYS use proper hoisting equipment for liftingheavy loads.

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30

• Keep machine in proper adjustment at all times.Serious injury could result if adjustments are neglected.

• Whenever possible,AVOID working on a machine with the engine running. If the engine must be run to make checks or adjustments, put the transmissionin neutral, set the parking brake and chock the drum and wheels securely ... front and rear ... to prevent movement in either direction.

• Personnel can be caught by moving parts when the guards are removed for access in making repairs.A repair or maintenance job is not complete until guards, plates and other safety devices have been replaced.

• NEVER put your fingers in open gears or reach through the spokes of a gear.

• Before working on the fuel system, close the fuel shut-off valve. NEVER smoke or use open flames near the machine while working on the fuel system.

• Remove and store all tools before resuming operation.

• Before working in the pivot or “pinch” area of an articulated machine, securely attach the steering frame lock to prevent the machine from turning.(FIG. 33) Enter this area only when necessary.

• Connect any other safety locks provided before proceeding with the work.


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31

Before beginning welding or burning operations, drainfuel lines and tank and move all flammable material to asafe distance, and be certain a fire extinguisher is readilyavailable.When welding fuel tanks, either gasoline ORdiesel,ALWAYS drain the tank, fill with water, and leavecap off during the welding operation.

All guards, plates and other safety devices mustbe properly replaced before the machine isreturned to service or serious injury to you or otherpersonnel may result.

AVOID burning or welding near acoustical materialwhenever possible, as hazardous fumes may bereleased. If unavoidable, make sure the area is adequatelyventilated, and that a fire extinguisher is ready available.

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

JACKING AND BLOCKING

ALWAYS lower all movable attachments to the groundor to their lowest position before servicing a machine.

If a machine must be raised for servicing or repairs,ALWAYS block the machine securely. Use axle stands orother rigid supports of ample capacity. NEVER rely solelyon the jacks for support. If necessary to work under amachine, be absolutely certain it is adequately supported.(FIG. 34)

WARNING: Never use concrete blocks for supports.They can collapse under even light loads.

When jacking up a machine, use a SUITABLE jack,placed in the proper position, on a solid foundation.

Before working on a machine, chock the drum andwheels securely … front and rear … in such a manneras to prevent movement in EITHER direction. Securelyattach the steering frame lock to prevent the machinefrom turning.


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32

FIRE PREVENTION

Whenever possible use a nonflammable solvent toclean parts. Do not use gasoline or other fluids thatgive off harmful vapors.

If flammable fluids, such as diesel fuel, must be used,extinguish open flames or sparks and do not smoke.

Store dangerous fluids in a suitable place, in approvedcontainers which are clearly marked. NEVER smokein areas where flammable fluids are used or stored.(FIG. 35)

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

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

ALWAYS keep the floor in the work area clean anddry. Oily, greasy floors can easily lead to falls. Wetspots, especially near electrical equipment, can behazardous. (FIG. 35)

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

Check readiness of any fire detectors and firesuppression systems.


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33

FIRE PREVENTION CHECKLIST (FIG. 36)

• Remove debris such as rags, coal dust, oil, leaves,pine needles.

• Check and repair fuel and hydraulic leaks.

• Check and repair damaged wiring.

• Prevent hose and electrical wire harness abrasion.

• Tighten loose clamps and fittings.

• Secure loose wiring.

• Make sure guards and protective covers are in place.

• Make sure fire extinguisher is available and operable.


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34

REFUELING (FIG. 37)

Precautions

When refueling, the following precautions must be followed:

• Add proper type and grade of fuel only when machine is not running and machine is parked with no one in the cab.

• Fuel in a well-ventilated area.

• Turn off all electrical switches.

• Turn off cab heaters.

• Open lights, lighted smoking materials, flames, or spark producing devices shall be kept at a safe distance while refueling.

• Keep fuel nozzle in contact with tank being filled,or provide a ground to prevent static sparks from igniting fuel.

• Do not spill fuel on hot surfaces.

• Any spillage shall be cleaned immediately.

• Do not start engine until fuel cap is secured to the fuel tank and people are clear of the machine.

• ALWAYS make sure fuel, oil, hydraulic fluid and water are added to their proper tanks.


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35

SERVICING COOLING SYSTEM

When checking coolant level:• Stop the engine and let the engine and radiator

cool before checking. (FIG. 38)

If an overheated engine requires a shutdown:• Wait for the radiator to cool. The hot

pressurized coolant can cause burn injuries. Neveradd coolant to an overheated system.

• Overheating is a symptom of trouble. Stop the engine and have the trouble corrected before serious damage occurs.

• If it is necessary to check an overheated engine use a heavy cloth, gloves, heavy clothing and safety glasses or goggles to protect yourself. Stand to the side, turn your face away, and slightly loosen the cap.Wait until the sound stops before removing the cap.


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36

SERVICING BATTERIES

Always wear safety glasses and gloves whenworking with batteries.

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

To prevent sparking at the posts when usinga battery charger, always turn the charger off ordisconnect it from its power source beforeconnecting or disconnecting charger leads tobattery posts. Caps on all cells should be lefton and the vent caps would be covered witha wet cloth.

Do not short across the battery terminals.The spark could ignite the gases.

BOOSTER CABLE INSTRUCTIONS (FIG.39)

1.Connect positive (+) cable to positive post of discharged battery.

2.Connect other end of same cable to same marked post of booster battery.

3.Connect negative (-) cable to other post of booster battery.

4.Make final connection on stalled vehicle away from battery, either on vehicle frame or engine block.

5.Start vehicle and remove cables in reverse order of connection.


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37

BATTERY SERVICING

To prevent a battery explosion: (Fig. 40)

• Maintain the electrolyte at the recommended level. Check level frequently. Add distilled water to batteries only before starting up, neverwhen shutting down.With electrolyte at the proper level, less space is available for gases toaccumulate in the battery.

• Use a flashlight to check the electrolyte level.Never use a flame. (Fig. 41)

• Do not short across the battery terminals.The spark could ignite the gases.

Battery acid will burn skin, eat holes in clothing,and may cause blindness if splashed into eyes. Ifyou spill acid on yourself flush skin immediatelywith lots of water. Apply baking soda to help neu-tralize the acid. If acids gets in your eyes, flushimmediately with large amounts of water andseek proper medical treatment immediately.

When servicing batteries, remember that alead-acid storage battery generates (when chargingor discharging) hydrogen and oxygen – a veryexplosive mixture.A spark of flame could ignitethese gases.


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38

HYDRAULIC SYSTEMS

NOTE: Hydraulic Systems have “special features”.Some of the features affecting your safety are listedbelow.

Pressure can be maintained in hydraulic and aircircuits long after the engine has been shut down.This pressure can cause hydraulic fluid or itemssuch as pipe plugs to “shoot out” at high speed ifpressure is not released correctly. Release systempressure before attempting to make adjustmentsor repairs.

Consult the manufacturer’s instructions for correctprocedure.

Before disconnecting hydraulic fluid lines, be sureyou:• Shut off engine.

• Always release any air pressure (supercharge) on the hydraulic reservoir.

• Move pedals and control levers repeatedly through their operating ranges to relieve all pressures.

Pressurized hydraulic fluid can penetrate theskin and cause serious injury. Therefore, be sureall connections are tight and that lines, pipes, andhoses are in good condition before starting theengine.

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


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39

HYDRAULIC SYSTEMS (CONT’D)

If you are struck by escaping hydraulic fluidunder pressure, serious injury can occur ifproper medical treatment is not administeredimmediately.

During operation, hydraulic fluid and air in anunvented hydraulic tank becomes heatedand will tend to expand.This will raise thepressure inside an unvented hydraulic tank. Ifthe filler cap is removed rapidly, the pressure inthe tank can force the oil out of the tank veryrapidly. The hydraulic fluid may be veryhot and may cause severe burns. Alwaysrelieve tank pressure before removing the capcompletely. Consult the manufacturer’sinstructions for the correct procedure.

When adding fluid to any system, be sure touse the fluid recommended by the manufacturer.Certain fluids, when mixed, may destroy sealscausing loss of control and possible personalinjury.

Keep hydraulic relief valve settings set tothe manufacturer’s recommendations. Excessivepressures could result in structural orhydraulic failures. Low pressure could result inloss of control. Either condition could causepersonal injury or death.

Be sure the engine is stopped and machine isproperly locked out and controls tagged, beforeworking on a machine. Only run engine when it isessential, as in the case of pressure adjustments,lubrication, or tests. Follow the manufacturer’srecommendations when making adjustments.Never resume operation until satisfactoryadjustments have been made. The operatormust follow the mechanic’s instructions whenadjustments are being made or machine isbeing serviced.


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40

TIRE INSPECTION

Recommended air pressure must be maintainedin every tire. Daily checks assure that inflation iscorrect. If your periodic check discloses a tire thatis continuously losing air, a leak is indicated andmust be repaired. (FIG. 43)

During your pressure checks, also inspect for:

• Objects wedged between or embedded in tires.

• Missing valve caps and wheel lugs.

• Cuts, tears, and breaks that may need repair.

• Abnormal or uneven wear.

• Damaged or poor fitting rim or rim flanges.

• Projecting body hardware, loose fender bolts,spring clips – anything that could contact a tire.

Do not burn or weld on wheels or rims.


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41

PNEUMATIC TIRES

Changing tires or adding air can be a hazardousbusiness. Special tools and procedures arerequired for changing off-highway tires.

Explosion and separation of a tire and/or rim partscan cause serious injury or death. (FIG. 44) Alwaysfollow the manufacturer’s recommendations orsee your tire supplier.


TIRE PRESSURE

Check tire pressure before starting operation.An air pressure rise during operation is normaland should NOT be reduced. Overloads or over-speeds may produce increased tire pressures dueto heat. Never bleed tires. Reduce your load – orspeed – or stop until tires cool.

ADD AIR

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

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ROPS (Roll-Over Protective Structures)

Periodically inspect ROPS for cracks and loose mountinghardware.

Replace all missing, deteriorated or worn rubber parts.

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

NEVER alter the ROPS in any way without the writtenapproval of the manufacturer.

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

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

Periodically inspect seat belts for wear, tear, deteriorationor excessive dirt. Replace them if necessary.

AIR CONDITIONERS

NEVER attempt to weld on or near air conditioners.Poisonous gas may be formed when refrigerant gas isexposed to a flame or excessive heat.

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


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PARKING AND TRANSPORTING

ALWAYS select a level area to park in and, ifpossible, one where children are unlikely to bepresent.ALWAYS chock the front AND rear ofthe roller … even if leaving the machine unattendedfor short periods.

ALWAYS use EXTRA care when towing a roller …when maneuvering in tight places, when backing(visibility is reduced, and jackknifing must beavoided), and when operating on grades. NEVERoperate a towed roller on steep grades or sideslopes, as the possibility of tipping or loss of controlis greater when towing a roller.

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

When necessary to disconnect and park a towedroller,ALWAYS select a location which is leveland, if possible, one where children are unlikelyto be present. BEFORE disconnecting, ALWAYSchock the front AND rear of the roll, and blockunder the tongue.

Extreme care should be exercised when loadingor unloading a walk-behind roller. It is generallybest to stand behind and to one side rather thandirectly behind a machine being propelled up ordown a ramp.

If the roller is designed to hang from the tailgateof a vehicle when being transported, ALWAYS becertain the hook brackets meet the rollermanufacturer’s specifications.

Special precautions must also be exercised whenloading or unloading, transporting or servicing atowed roller. Consult your manufacturer’smanual for specific details.

SPECIAL OPERATING AND MAINTENANCE PRECAUTIONS

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FOR TOWED ROLLERS

Most general safety precautions covered earlier inthis manual are also applicable to towed rolleroperation. Many other SPECIAL precautions must,however, be taken. Study your manufacturer’smanual(s) relative to special considerations whentowing. If you have questions or concerns, consultthe manufacturer or your dealer.

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

ALWAYS block under the tongue of the towedroller BEFORE attempting to connect it to thetowing vehicles or machine. NEVER attempt tolift heavy tongues or move towed rollers by hand.NEVER get any part of your body under the tonguewhen hitching or unhitching.

ALWAYS make sure the hitch pin is of the propersize, and securely locked in place before towing.(FIG. 48) If safety chains are provided, make surethey are properly and securely connected … atBOTH ends. Cross the chains under the tonguewhen connecting to the towing vehicle. If electricalor hydraulic connections are required, make surethe connections are properly and securely made.


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FOR LANDFILL COMPACTORS

General

Operators of landfill compactors should carefullyhandle fill materials that could be picked up andthrown by the wheels, become lodged in themachine, or that are highly flammable.

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

Travel with the blade as low as possible.

Maintain good operator visibility – keep all meshand windows free of accumulated materials thatreduce visibility.

When parking the machine,ALWAYS lower the blade.

FIRE PROTECTION

Maintain fire extinguishers and fire protectivesystems in good working order. ALWAYS rechargeextinguishers, or replace with a fully charged unitimmediately after use.

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


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FOR WALK-BEHIND ROLLERS

Start-Up

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

ALWAYS follow the manufacturer’s instructionsfor starting the engine.All controls MUST be inthe correct position BEFORE attempting to startthe engine ( for example, the shift lever must bein neutral).

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

OPERATION

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

NEVER ride on a walk-behind roller unless it isdesigned to accommodate riders and anappropriate seat is provided.

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

NEVER operate a walk-behind roller in unshoredtrenches or near steep, unsupported banks.Thevibrations could cause a cave-in.

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


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Do you understand this AEM SAFETY MANUAL ANDITEMS SUCH AS …

• Your safety program?• Your machine manufacturer’s manual(s)?• Proper clothing and personal safety equipment?• Your machine’s controls, warning signs and devices,

and safety equipment?• How to properly inspect, mount, and start your

machine?• How to check your machine for proper operation?• Your work area and any special hazards that may exist?

• Proper operating procedures?• Proper parking, shutdown, and dismounting

procedures?• Proper maintenance procedures?• Proper loading and unloading procedures for

transporting?• Under what conditions you should not operate

your machine?

If you do not understand any of these items, consultwith your supervisor BEFORE operating your machine!

TEST YOUR KNOWLEDGE

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

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

Practice all other usual and customary safe workingprecautions, and above all –

REMEMBERSAFETY IS UP TO YOU

YOU CAN PREVENT SERIOUSINJURY OR DEATH

A FINAL WORD TO THE USER

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NOTICE OF COPYRIGHT PROTECTIONAEM Safety Manuals are protected as a copyrighted work withownership duly registered with the Copyright Office,Washington,D.C.Any reproduction, translation, decompiling or other use of anAEM Safety Manual, or portion thereof, or the creation of deriv-

ative works based on an AEM Safety Manual,without the prior writ-ten approval of AEM, is expressly prohibited. Copyright infringe-ment can result in civil and criminal sanctions, damages and otherpenalties being imposed.

Copyright © 1978 AEM (Association of Equipment Manufacturers)Former Copyright © CIMA (Construction Industry Manufacturer Association)

Revised 6/02, 9/04

SAFETY ALERT SYMBOLThis Safety Alert Symbol meansATTENTION is involved!

The Safety Alert Symbol identifies important safetymessages on machines, safety signs, in manuals, orelsewhere.When you see this symbol, be alert tothe possibility of personal injury or death. Followthe instructions in the safety message.

Why is SAFETY important to YOU?

3 BIG REASONS:• Accidents KILL or DISABLE• Accidents COST• Accidents CAN BE AVOIDED

KE40246P1 6/9/05 3:14 PM Page 2

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

2004-CE-RD7H-Q.fm

William Lahner Greg OrzalVice President of Engineering Manager, Product Engineering

WACKER CORPORATIONDate / Datum / Fecha / Date

EC DECLARATION OF CONFORMITYCE-KONFORMITÄTSERKLÄRUNG

DECLARACIÓN DE CONFORMIDAD DE LA CE DÉCLARATION DE CONFORMITÉ C.E.

WACKER CORPORATION, N92 W15000 ANTHONY AVENUE, MENOMONEE FALLS, WISCONSIN USA

hereby certifies that the construction equipment specified hereunder / bescheinigt, daß das Baugerät / certifica que la máquina de construcción / atteste que le matériel :

1. Category / Art / Categoría / CatégorieVibrating Walk-Behind Rollers

Geführte Vibrationswalzen Rodillos Vibrantes con Conductor a Pie

Rouleaux Compacteurs Vibrants à Conducteur à Pied

2. Type / Typ / Tipo / Type RD 7H, RD 7H-ES, RD 7H-S

3. Item number of equipment / Artikelnummer / Número de referencia de la máquina / Numéro de référence du matériel :

0008042, 0009408, 0009487

4. Net installed power / Absolute installierte Leistung / Potencia instalada neta / Puissance installée nette :5,6 kW

Has been sound tested per Directive 2000/14/EC / In Übereinstimmung mit Richtlinie 2000/14/EG bewertet worden ist / Ha sido ensayado en conformidad con la norma 2000/14/CE / A été mis à l’épreuve conforme aux dispositions de la directive 2000/14/CEE :

and has been produced in accordance with the following standards:und in Übereinstimmung mit folgenden Richtlinien hergestellt worden ist:y ha sido fabricado en conformidad con las siguientes normas:et a été produit conforme aux dispositions des directives européennes ci-après :

2000/14/EC89/336/EEC98/37/EECEN 500-1EN 500-4

AUTHORIZED REPRESENTATIVE IN THE EUROPEAN UNIONBEVOLLMÄCHTIGTER VERTRETER FÜR DIE EUROPÄISCHE GEMEINSCHAFTREPRESENTANTE AUTORIZADO EN LA UNIÓN EUROPEAREPRÉSENTANT AGRÉÉ AUPRÈS DE L’UNION EUROPÉENNE

WACKER CONSTRUCTION EQUIPMENT AGPreußenstraße 4180809 München

Conformity Assessment Procedure / Konformitätsbewertungsverfahren / Procedimiento para ensayar conformidad / Procédé pour l’épreuve de conformité

Name and address of notified body / Bei folgender einbezogener Prüfstelle / Oficina matriculadora / Organisme agrée

Measured sound power level / Gemessener Schall-leistungspegel / Nivel de potencia acústica determinado / Niveau de puissance acoustique fixé

Guaranteed sound power level / Garantierter Schallleistungspegel / Nivel de potencia acústica garantizado / Niveau de puissance acoustique garanti

Annex VIII BSI, 389 Chiswick High Road, London W4 4AL

United Kingdom

107 dB(A)

108 dB(A)

26.01.04

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

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