Weber mt CR 7 CCD Manual

CR 7 CCD
Lombardini 15 LD 440
0106-englisch
OPERATING AND
MAINTENANCE
INSTRUCTIONS
Weber Maschinentechnik GmbH
P. O. Box 21 53, D-57329 Bad Laasphe-Rückershausen
Phone ++27 54 / 398-0
Telefax (++ 27 54) 3 98-101 (Switchboard) &
3 98-102 (Spare Parts)

2CR7CCD

3
CR7CCD
Preface
These operating and maintenance instructions describe the safe operation of the CR7 CCD soil compactor. Please read
this operation manual and familiarize yourself with all details of your soil compactor before operating the machine for the
first time. Carefully follow all instructions and always carry out the described operations in the indicated order.
Please refer to the following page for the General Safety Instructions.
We reserve the right to modifiy our equipment without prior notice.
In chapter 1, the soil compactor is briefly described to provide you with a good overview on the location of the individual
assembly groups and their functions. Chapter 2 describes how to put the soil compactor into and out of operation and how
to work with the machine.
In chapter 3, you will find a survey on and a description of the required service work. Chapter 4 contains instructions for
trouble shooting by the operator. Chapter 5 describes how to preserve the soil compactor for an extended storage, e.g.
during the winter season.
We placed a great emphasis on a user-friendly lay-out with clear pictorial and textual information. In the text, you will find
figures in brackets which point out to illustrations, whereby the first figure indicates the figure number and the second one
- separated by a dash - indicates the item number on the corresponding illustration.
Example 1: (2/1) means figure 2, item 1
Example 2: (2/3,6) means figure 2, item 3 and item 6
Important information for the operator and service personnel is highlighted by pictograms.
Indicates important information and hints which must be followed by the operator and service personnel.
Indicates working and operating methods requiring in addition the observance of all applicable environment
protection and waste disposal regulations.
Indicates working and operating methods which must be precisely followed in order to prevent the soil
compactor from being damaged or deteriorated.
Indicates working and operating methods which must be precisely followed in order to avert direct danger to
persons.
For further information, please contact your authorized WEBER distributor or one of the addresses on the last page.

4CR7CCD
General Safety Instructions
General
All safety notes (see also explanations of the pictogram meanings in the preface) must be read and observed (any lack of
clarity must be dispelled before the soil compactor is put into operation), because otherwise the use of the machine may
* constitute a risk to life and limb of the user
* impair the machine and other valuable property.
In addition to these operating instructions and the mandatory accident prevention regulations in the country of use and on
the operating site, the generally accepted technical standards for safe and professional work must be also observed.
Designated Use
Soil compactors are only allowed to be operated in accordance with their designated use, whereby the operating and
maintenance instructions, the generally accepted safety and traffic rules and the regulations of the individual countries of use
must be followed.
The soil compactor has been exclusively designed for the compaction of
- sand
- gravel
- crushed aggregates
- semi-cohesive mixed material
- concrete block pavement.
Any other use of the soil compactor is considered contrary to its designated use. The company operating the soil compactor
bears the sole responsibility for any misuse of the machine.
Driving Permission
Only trustworthy persons, who are aged at least 18 years, are allowed to handle soil compactors. They must be properly trained
in the operation and maintenance of the soil compactor by the employer or his authorized representative.
Protective Equipment
When operating the soil compactor described in this operation and maintenance manual, the noise level at the operator's ear
may exceed 90 dB(A). The German noise protection regulations (VBG 121) require the operator to wear personal ear
protectors in case of noise levels of 90 dB(A) and more.
Additionally, a safety helmet and safety shoes belong to the protective equipment.
EC Machinery Directive, prEN500-1, EN292

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CR7CCD
Table of Contents
Preface ....................................................................................................................................................................3
General Safety Instructions ...................................................................................................................................4
1. Technical Description ............................................................................................................................................6
1.1 Illustration ...............................................................................................................................................................6
1.2 Machine Description .............................................................................................................................................. 7
1.2.1 Description of the COMPATROL ...........................................................................................................................8
1.2.2 Principles of Operation ..........................................................................................................................................8
1.3 Specifications ....................................................................................................................................................... 10
2 Operation .............................................................................................................................................................. 12
2.1 Safety Precautions for the Operation ................................................................................................................. 12
2.2 Transport ............................................................................................................................................................... 13
2.2.1 Loading by Crane ................................................................................................................................................. 13
2.3 Commissioning .................................................................................................................................................... 13
2.4 Pre-Start Work ...................................................................................................................................................... 14
2.4.1 Checking the Fuel Level ...................................................................................................................................... 14
2.4.2 Checking the Engine Oil Level ............................................................................................................................ 15
2.4.3 Fitting the Damper Plate ...................................................................................................................................... 16
2.4.4 Fitting/Detaching the Extension Plates .............................................................................................................. 16
2.5 Starting .................................................................................................................................................................. 17
2.6 Compaction Work ................................................................................................................................................. 19
2.7 Putting the Soil Compactor out of Operation ..................................................................................................... 20
2.7.1 Stopping ................................................................................................................................................................ 20
3 Maintenance ......................................................................................................................................................... 21
3.1 Safety Precautions for Maintenance Work ......................................................................................................... 21
3.2 Maintenance Survey ............................................................................................................................................. 22
3.2.1 Maintenance ......................................................................................................................................................... 22
3.3 Description of the Maintenance Work ................................................................................................................ 23
3.3.1 Changing the Engine Oil ...................................................................................................................................... 23
3.3.1.1 Cleaning the Engine Oil Filter ............................................................................................................................. 24
3.3.2 Cleaning/Replacing the Air Filter Cartridge ........................................................................................................ 25
3.3.3 Replacing the Fuel Filter ...................................................................................................................................... 26
3.3.4 Checking the Condition and Tension of the Vibrator V-Belt ............................................................................. 27
3.3.5 Replacing the V-Belt ............................................................................................................................................. 27
3.3.6 Changing the Vibrator Oil .................................................................................................................................... 28
3.3.7 Hydraulic Control ................................................................................................................................................. 29
3.4 Consumables and Quantities .............................................................................................................................. 30
4 Malfunctions During Operation ........................................................................................................................... 31
4.1 General .................................................................................................................................................................. 31
4.2 Trouble Shooting .................................................................................................................................................. 32
4.3 Repair and Replacement Work ............................................................................................................................ 33
4.3.1 Replacing the Battery........................................................................................................................................... 33
4.3.2 Replacing the Fuse .............................................................................................................................................. 33
5 Preserving the Machine ....................................................................................................................................... 34
5.1 Preservation Measures ........................................................................................................................................ 34
5.2 Removing Machine Preservatives ...................................................................................................................... 34
6 Addresses, Weber Maschinentechnik GmbH ..................................................................................................... 35
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6CR7CCD
1
2
34
6
7
8
9
14
10
12
1 Technical Description
1.1 Illustration
Figure 1 Overall View CR 7 CCD
1 Engine
2 Drive lever
3 Handle
4 Lifting lug
5 Ignition lock (not shown)
6 Base plate
7 Protective frame
8 Engine bracket
9 Vibrator
10 V-belt guard
11 Spring bar (not shown)
12 Engine speed adjusting lever
13 Vulkollan plate (not shown)
14 Extension plates
15 COMPATROL Compaction Control System
(not shown)


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CR7CCD
1.2 Machine Description
The CR 7 CCD soil compactors are machines of the walk-behind type used for compaction work in road construction
and landscape applications.
Propulsion
The CR 7 soil compactor is driven by a Lombardini Diesel engine.
Important!
Please refer to paragraph 1.3 (Specifications) for the performance details of the engine and the whole
machine.
Function
The engine (1/1) drives the vibrator via a V-belt. The vibrator is screwed down to the base plate (1/6) and sets it
vibrating. The vibrating base plate performs the vibration work and travelling motion.
Accessories
A damper plate (2.4.3),extension plates (2.4.4) and Compaction Control System Compatrol (1.2.1) are available
as optional extras.
Operation
The soil compactor is started by means of an electric starter (1/5).
The soil compactor is steered by means of the handle (1/3) holding the engine speed adjusting lever (1/12) and the
drive lever (1/2) to control the direction of travel and the infinitely variable driving speed. The spring bar (1/11) allows
to fix the handle in vertical position during work breaks and transports.

The COMPATROL compaction control system enables, during compaction work, to measure the degree of soil compaction
achieved and to optically indicate it by means of light-emitting diodes.


8CR7CCD
1.2.1 Description of the COMPATROL
Compaction Control System
COMPATROL is a continuous compaction control system
for soil compactors of the walk-behind-type. The system can
be used on soils of the “V1” class (well compactable soils).
The COMPATROL compaction control system consists of
an acceleration sensor (2/2) fitted to the base plate (2/1) and
of the Compaction Control Display (CCD) (3/2) integrated in
the dashboard (3/1).
Light-emitting diodes (4/1) optically indicate the operating
modi described in the following.
When the soil compactor is dismantled, i.e. when the
base plate is detached from the engine bracket,
always make sure that the acceleration sensor (2/2)
is disconnected from the compaction control display
(3/1) in order to avoid damage to the COMPATROL
measuring system.
1.2.2 Principles of Operation
When the ignition is switched on (2.5), the COMPATROL
compaction control system makes an operational check. All
light-emitting diodes (4/1) will light up
When the engine has been started (2.5), the LEDs (5/1/2) will
light up until the correct frequency is reached. As soon as the
correct vibration frequency is reached, the red LED (5/2) will
be extinguished. If the red diode (5/2) does not go out, please
refer to chapter 4.2 “Trouble Shooting“.
Figure 3
Figure 4
Figure 5
Figure 2
1
1
2
1
1 2





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CR7CCD
When the operating frequency is achieved, the green LED (6/
1) and at least one of the yellow LEDs (6/2) will light up to
indicate that the COMPATROL system is ready for work.
During the compaction process, the compaction achieved is
continuously measured and optically indicated by the yellow
LEDs 1 to 7 (7/8/1). The maximum compaction is achieved
when the number of flashing diodes does not increase anymore.
When all LEDs (9/1) light up, compaction work must be
stopped immediately.
The maximum compaction is achieved.
Continued compaction will cause the material to re-
loosen.
Grounds which are too hard may cause damage to the
machine.
Figure 6
Figure 7
Figure 8
Figure 9
1
1
1
2
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10 CR7CCD
1.3 Specifications
Weight
Operating weight according to CECE in kg 480 504
Dimensions
Overall length (in mm) 1835 1835
Width with extension plates (in mm) 600 800
Height with handle folded down (in mm) 1135 1135
Base plate length (contact area in mm) 440 440
Propulsion
Engine manufacturer
Type
Maximum output according to DIN 70020 (in kW (HP))
Type of combustion
Operating speed
Driving speed (dependent on soil conditions (in m/min) 24 19
Gradeability (dependent on soil conditions, in %) 30 30
Depth compaction (in cm) 70 70
Performance (in m2/h) 864 912
Vibration
System
Mode of driving
Frequency (in Hz)
Centrifugal force (in kN)
CR 7 CCD
Lombardini
15LD440
8,1 (11,0)
65
60
4-stroke Diesel
3000
Two-shaft vibrator
Mechanical

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CR7CCD
12
Weber Maschinentechnik GmbH
Typ Masch.-Nr.
Betriebsgewicht Baujahr
Postfach 2153
57329 Bad Laasphe-Rückershausen
4
3
CR 7 CCD
Noise and Vibration Data*
Sound pressure level LPA
(at the operator's place, according to 2000/14/EG, in dB(A)) 98
Sound power level LWA
(according to 2000/14/EG, in dB(A)) 109
Hand/arm vibration (weighted root mean square acceleration,
at the handle, determined according to 2002/44/EG, Part 1,
in m/s² ) forward/reverse
5,2 *
3,7 **
3 TYPE
.........................................
4 ENGINE/SERIAL No.
.........................................
1 MACHINE NO.
.........................................
2 YEAR OF CONSTRUCTION
.........................................
* 600 mm
** 800 mm
MADE IN ITALY
*The indicated noise and vibration data were determined with the engine at nominal speed and the vibration
system turned on, 2000/14/EG. During operation, these data may vary according to the specific conditions
prevailing on the job site.

12 CR7CCD
2 Operation
2.1 Safety Precautions for the Operation
Safety and protection devices
Before every shift, the operator must check the operativeness of all controls and safety elements as well as the proper
installation of all protection devices. The soil compactor is only allowed to be operated with all protection devices in
place. The control's functionality is not allowed to be impaired or neutralized.
Before starting the soil compactor, the operator must take his personal noise protection measures. Before starting the
engine, check to ensure that the soil compactor cannot slip out of control.
Conduct in Case of Failures
If defective safety devices or other failures which might affect the safe operation of the soil compactor are ascertained,
the supervisor must be informed without delay. In case of malfunctions endangering the unit's operational safety, the
machine must be turned off immediately.
Conduct of the Machine Operator
During the machine's operation, the operator has to constantly supervise the operational safety of the soil compactor.
When running the machine, the operator is not allowed to leave the operating controls of the soil compactor. In addition,
he must always have a sufficient visibility on the soil compactor's zone of operation.The operator must be assisted by a
second person if, because of the operating conditions, the visibility on the zone of operation is restricted.
Stability
Soil compactors must be used and operated in a way ensuring their stability. The machine's stability is especially
endangered on slopes and brinks. Thus, keep clear of slopes and brinks.
Driving and Compacting
When working on slopes, the operator must always walk on the uphill side. Compaction work on slopes exceeding the
maximum gradeability of the soil compactor is prohibited. When working/travelling on slopes, always use extreme
precaution and work directly in uphill or downhill direction.
Moist and loose bases considerably reduce the grip of the soil compactor on slopes. Increased danger of
accident!
Passing unevennesses or kerbs is only allowed at reduced speed. In addition, the soil compactor must be operated in a
way excluding any risk of injury caused by the handle swinging towards the operator.
Exhaust Precautions
Never inhale exhaust gasses. They contain carbon monoxide, a colorless, oderless and extremely dangerous gas
which can cause unconsciousness or death. Never operate the engine inddors or in a poorly ventilated area, such
as tunnerl, cave, etc. Exercise extreme care when operating the engine near people or animals. Keep the exhaust
pipe free of foreign objects.

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CR7CCD
- Put the soil compactor out of operation as described in
paragraph 2.7.
- Lock the handle (10/1) by means of the spring bar (10/2).
Danger!
Never use the handle (10/1) for lifting the machine by
crane. The machine may overturn!!
-
Danger!
Only use a lifting tackle and a crane of a sufficient
bearing capacity.
Danger!
Do not enter the zone under the suspended load.
2.2 Transport
Figure 10
Figure 11
1
2
1
2
Short distances on the job site can be covered by the soil
compactor in accordance with paragraph 2.6.
For long distances, however, the compactor can be lifted on
an appropriate transport vehicle (truck, trailer) by means of a
crane.
2.2.1 Loading by Crane
2.3 Commissioning
Caution!
For commissioning, only carry out the pre-start work described in paragraph 2.4.
Keep to the initial maintenance intervals (refer to paragraph 3.2.1).
Connect the crane hook (11/1) to the folding lifting eye (11/2).

14 CR7CCD
- Put the soil compactor out of operation as described in
paragraph 2.7.
- Loosen the tank cover (12/1).
-Push the tank cover(13/1) aside.
- Clean the area around the filler neck.
- Open the cap (14/2) of the fuel tank (14/1).
Caution!
Fill the tank up with clean Diesel fuel only. Refer to
paragraph 3.4 for quantities and specifications.
- Replenish to the lower edge of the filler neck (14/3).
Danger!
Take care that fuel does not come in contact with
hot engine parts. Extinguish all open flames and do
not smoke while filling the tank.
Environment Hazard!
Always wipe up any spilled fuel. Dispose of fuel-
soaked cloth in an environmentally-friendly manner.
- Firmly close the fuel tank (13/2) with the tank cap (13/3).
- Firmly tighten the tank cover (15/1).
Figure 13
Figure 12
2.4 Pre-Start Work
- Check to ensure that all safety devices are in place.
- Check the whole soil compactor for evident damage (visual check).
- Check all screwed connections for tight seat, retighten them if necessary.
- Check the fuel level, if necessary, add fuel (refer to paragraph 2.4.1).
- Check the engine oil level, if necessary add engine oil (refer to paragraph 2.4.2).
- If required, fit the damper plate (refer to paragraph 2.4.3).
. If required, fit the extension plates (refer to paragraph 2.4.4.).
2.4.1 Checking the Fuel Level
1
1
Figure 14
Figure 15
2
32
31
1

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CR7CCD
Caution!
The engine oil level must be checked with the soil
compactor standing horizontally on the ground.
- Pull out the oil dipstick (16/1), wipe it off with a clean, non-
fluffing cloth and insert it again.
Caution!
-Screw the oil dipstick (16/1) down.
-Undo the oil dipstick once again.
Caution!
The oil level must reach up to the top mark
(16/max).
- If required, add engine oil according to paragraph 3.3.1
(refer to paragraph 3.4 for quantities and specifications).
- Firmly screw the oil dipstick down.
Figure 16
1
max.
2.4.2 Checking the Engine Oil Level

16 CR7CCD
- Put the soil compactor out of operation as described in paragraph
2.7.
- Lift the soil compactor by means of a crane as described in
paragraph 2.2.1.
- Put the damper plate beneath the machine.
Caution!
Do not enter the zone under the suspended load. - Risk of
injury!
- Attach the Vulkollan plate (17/1), together with the holder (17/2),
the screws, lock washers and the nut (17/3), to the front of the
base plate (17/4) as shown.
- Attach the Vulkollan plate (18/1), together with the holder (18/3),
the screws, nuts and the lock washers (18/2) to the back of the
base plate.
Important!
Check to ensure that the Vulkollan plate is correctly fitted
beneath the base plate.
Danger!
Do not enter the zone under the suspended load!
Figure 17
Figure 18
2.4.4 Fitting/Detaching the Extension Plates
- Undo three each fastening screws (19/2) and remove the
extension plates.
- Put the extension plates (19/1) against both sides of the base
plate and fix them by means of three each fastening screws (19/
2).
Firmly tighten the screws!
1
3
4
2
3
1
2
Figure 19
2.4.3 Fitting the Damper Plate
2
1

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CR7CCD
Figure 20
1
1
2
3
4
5
6
7
2.5 Starting
Danger!
Before starting the machine, always ensure that nobody is in
the danger area of the soil compactor and that all protective
devices are properly in place.
When starting the soil compactor in closed premises, always
ensure a proper ventilation - danger of poisoning.
Caution!
Never use starting aid sprays!
- Put the engine speed adjusting lever (20/1) into the full speed
position.
- Put the ignition key (21/1) into the lock and turn it into position 1.
- Turn the ignition key (21/1) into position 2.
- Release the ignition key as soon as the engine starts.
Important!
The ignition key must automatically return into position 1 and
must remain in this position during operation. The alternator
charge pilot lamp (21/3) and the oil pressure pilot lamp (21/4)
must go out immediately after starting.
Caution!
The pilot lamp (21/2) lights up to indicate the engine's
operation.
As long as the ingition is switched on, the hourmeter
(21/7) records the working hours performed.
The symbols (21/5) and (21/6)are not assigned to a
function.
Figure 21
Figure 22
1

When the ignition is switched on, the COMPATROL compaction control
system makes an operational check. All light-emitting diodes (22/1) will light
up.

18 CR7CCD
When the engine has been started, the LEDs (23/1) will light
up until the correct frequency is reached. As soon as the
correct vibration frequency is reached, the red light-emitting
diode (23/2) will be extinguished. If the red LED (23/2) does not
go out, please refer to paragraph 4.2 “Trouble Shooting“.
Important!
In case of any irregularity, turn off the engine
immediately, localize and repair the malfunction.Let
the engine idle for some minutes.
In case of ambient temperatures of 5 degrees C below
zero or less, the starting procedure must be carried
out in accordance with the operation manual of the
engine manufacturer.
Caution!
If the ignition key does not automatically return into
position 1, put the machine out of operation - risk of
starter damage because of starter working during
machine operation.
Figure 23
2
1

19
CR7CCD
Figure 24
2.6 Compaction Work
- Put the soil compactor into operation (refer to paragraph
2.5).
As soon as the engine reaches its operating temperature:
- push the engine speed adjusting lever (20/1) into the full
speed position.
Caution!
Compaction work is only allowed at full engine speed,
otherwise the centrifugal clutch may slip and cause
increased wear.
Important!
As soon as the centrifugal clutch achieves the cutting-
in speed, the vibrator is automatically turned on.
When the operating frequency is reached, the green LED (24/
1) and at least one of the yellow LEDs (24/2) will light up to
indicate that the COMPATROL compaction control system is
ready for work.
During the compaction process, the compaction achieved is
continuously measured and optically indicated by the yellow
LEDs 1 – 7 (25/1). The maximum compaction is achieved when
the number of flashing diodes (25/26) does not increase anymore
When all LEDs (27/1) light up, compaction work must be
stopped immediately.
The maximum compaction is achieved.
Continued compaction will cause the material to re-
loosen.
Grounds which are too hard may cause damage to the
machine!
Danger!
If obstructions (such as walls or trenches) are
encountered, take care that persons do not get crushed
and that the machine does not slip out of control.
Warning!
During work breaks, even if they are short, the soil
compactor must be put out of operation (refer to 2.7).
- Steer the soil compactor with the handle (20/1) into the
desired direction.
Figure 25
Figure 26
Figure 27
1
1
2
1
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20 CR7CCD
2.7.1 Stopping


1
1
Figure 28
Figure29
- Push the speed adjusting lever (28/1) to the back and let the engine
idle for some minutes.
- Turn the ignition key (29/1) from position "1" back in-
to position "0".
- Take out the ignition key.
2.7 Putting the Soil Compactor Out of Operation
Before work breaks and at the end of every day’s shift, the
soil compactor must be parked on a stable base which
should be as horizontal as possible.
Warning!
If the soil compactor causes an obstruction when
being parked, precautionary measures must be
taken in order to make the machine visible. If the
machine is parked on traffic roads, the safety
precautions required by the traffic regulations must
be additionally observed.
Caution!
Never stop the engine while it is running at full
speed, but let the engine idle for some minutes.