Wacker Neuson RT560 User manual

Brand: Wacker Neuson

Model: RT560

Type: User manual

This manual is also suitable for

OPERATOR’S MANUAL

Roller

RT560

RT820

0114369

A0698

0114369

RT560 / RT820

This manual provides information and procedures to safely operate and maintain this WACKER model. For your

own safety and protection from injury, carefully read, understand and observe the safety instructions described

in this manual. THE INFORMATION CONTAINED IN THIS MANUAL WAS BASED ON MACHINES IN PRODUCTION

AT THE TIME OF PUBLICATION. WACKER CORPORATION RESERVES THE RIGHT TO CHANGE ANY PORTION

OF THIS INFORMATION WITHOUT NOTICE.

This manual is divided into the sections listed below:

Operation

Infra-Red Control

Maintenance

Item Number:

0007642, 0007643, 0007644, 0007645, 0007652, 0008047

CALIFORNIA

Proposition 65 Warning

1014SD4

Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and

other reproductive harm.

RT560 / RT820

Serial Number

My machine’s numbers are:

RevisionItem Number

Model number

Rev. Serial Number

MENOMONEE FALLS, WI USA 53051

hpkWlbs

dB(A) Manuf. Yr.

Model

MADE

IN USA

Item Number

88223

RT560

0007642

101

00010101

Nameplate

A nameplate listing the Model Number, Item Number, Revision, and Serial Number is attached to each unit. Please

record the information found on this plate so it will be available should the nameplate become lost or damaged. When

ordering parts or requesting service information, you will always be asked to specify the model, item number,

revision number, and serial number of the unit.

1021SD96

RT560 / RT820

iii

PATENT PENDING

111545

This machine may be covered by one or more of the following patents:

111891

OF THESE U.S. PATENTS:

4643611; 4555238; 5564375; 5586630; 4419048

WACKER MACHINES PROTECTED BY ONE OR MORE

RT560 / RT820

Keep this manual or a copy of it with the machine. If you lose this manual or need an

additional copy, please contact WACKER Corporation. This machine is built with user

safety in mind, however, it can present hazards if improperly operated and serviced.

Follow operating instructions carefully! If you have questions about operating or

servicing this equipment, please contact WACKER Corporation.

1-1

RT560/RT820

Operation

1.1 Safety Notes ............................................................................................... 1-2

1.2 Operating Safety......................................................................................... 1-3

1.3 Operator Safety while using Internal Combustion Engines.......................... 1-3

1.4 Service Safety............................................................................................. 1-4

1.5 Sound Level Values .................................................................................... 1-4

1.6 Engine Specifications.................................................................................. 1-5

1.7 Roller Specifications ................................................................................... 1-5

1.8 Lubrication Specifications ........................................................................... 1-5

1.9 Controls & Service Locations ...................................................................... 1-6

1.10 Application .................................................................................................. 1-8

1.11 Remote Control Features............................................................................ 1-8

1.12 Before Starting............................................................................................ 1-8

1.13 Starting ....................................................................................................... 1-9

1.14 Cold Weather Starting................................................................................. 1-9

1.15 Shutting Machine Off .................................................................................. 1-9

1.16 Emergency Stop ....................................................................................... 1-10

1.17 Travel Speed ............................................................................................ 1-10

1.18 Vibration.................................................................................................... 1-10

1.19 Direction & Steering Control...................................................................... 1-11

1.20 Engine Speed ........................................................................................... 1-11

1.21 Jump Starting............................................................................................ 1-11

1.22 Safety Back-Up Bar .................................................................................. 1-12

1.23 Operation on Slopes ................................................................................. 1-12

1.24 Roll-overs ................................................................................................. 1-12

1.25 Engine Oil Pressure Light ......................................................................... 1-13

1.26 Charging System Light.............................................................................. 1-13

1.27 Hour Meter................................................................................................ 1-13

1.28 Articulated Joint Locking Bar..................................................................... 1-13

1.29 Setting Control Channels .......................................................................... 1-14

Table of Contents

1 OPERATION

RT 560/820

1-2

1.1 Safety Notes

This manual contains NOTES, CAUTIONS, and WARNINGS which must be followed to prevent the possibility of

improper service, damage to the equipment, or personal injury.

Notes:

Notes appear in italics and contain additional

information important to a procedure.

CAUTION: Cautions provide information important to prevent

errors which could damage machine or components.

WACKER equipment is designed with user safety in mind. When

properly maintained and used by trained operators in the applications

for which it was intended, this machine will provide many years of

safe, reliable service.

Should questions arise during the operation or service of this equip-

ment please contact your area WACKER Customer Support Center. A

complete listing of Support Centers appears on the front and rear

covers of this manual.

WARNING

Warnings warn of conditions or practices which

could lead to personal injury or death!

OPERATION 1

RT 560/820

1-3

1.2 Operating Safety

Familiarity and proper training are required for the safe operation of mechanical equipment! Equipment operated

improperly or by untrained personnel can be dangerous! Read the operating instructions and familiarize yourself

with the location and proper use of all controls. Inexperienced operators should receive instruction from someone

familiar with the equipment before being allowed to operate the machine.

Check that all safety devices and guards are in

place before starting machine! DO NOT operate

machine if any safety devices or guards are missing

or inoperative.

Disengage and stow locking bar for the articulated

joint before operating machine. The machine can-

not be steered when the locking bar is engaged.

Check that all controls are functioning properly

immediately after start-up! DO NOT operate ma-

chine unless all controls operate correctly.

Remain aware of changing positions and move-

ment of other equipment and personnel on the

jobsite.

Remain in visual contact with machine at all times

while operating controls.

WARNING

DO NOT run engine indoors or in an area with poor

ventilation unless exhaust hoses are used.

DO NOT fill fuel tank near an open flame, while

smoking or while engine is running.

DO NOT fill tank in an enclosed area with poor

ventilation.

1.3 Operator Safety while using Internal Combustion Engines

Internal combustion engines present special hazards during operation and fueling! Failure to follow the safety

guidelines described below could result in severe injury or death.

Remain aware of changing surface conditions and

use extra care when operating over uneven ground,

on hills, or over soft or coarse material. The ma-

chine could shift or slide unexpectedly.

Use caution when operating near the edges of pits,

trenches or platforms. Check to be sure ground

surface is stable enough to support the weight of

the machine and there is no danger of the roller

sliding, falling or tipping.

Position yourself safely when operating machine in

reverse or on hills. Leave enough space between

yourself and the machine so you will not be placed

in a hazardous position should the machine slide or

tip.

DO NOT touch or lean against hot exhaust pipes

or engine cylinder.

DO NOT operate with the fuel tank cap loose or

missing.

Keep area around hot exhaust pipes free of debris

to reduce the chance of an accidental fire.

1 OPERATION

RT 560/820

1-4

1.4 Service Safety

Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly

over a long period of time, periodic maintenance and occasional repairs are necessary.

Replace all guards and safety devices immediately

after servicing.

Turn engine off before performing maintenance or

making repairs.

Secure the articulated joint using the locking bar

before lifting or jacking machine up. Machine halves

could swing together unexpectedly and cause a

serious injury if this is not done.

DO NOT open hydraulic lines or loosen hydraulic

connections while engine is running! Hydraulic fluid

under pressure can penetrate the skin, cause burns,

blind or create other potentially dangerous haz-

ards. Set all controls in neutral and turn engine off

before loosening hydraulic lines.

WARNING

1.5 Sound Level Values

According to Appendix 1, paragraph 1.7.4.f of the EG-Machine Regulation, the requested noise levels are:

- The sound pressure level at the operator's location while operating machine using remote control from a distance

of 3 ft. (1 m) and 10 ft. (3 m):

= 82 dB(A) - at a distance of 10 ft. (3m)

= 86 dB(A) - at a distance of 3 ft. (1 m)

- The sound power level: L

= 109.7 dB(A)

These noise values were obtained at the operator's location according to ISO 3744 for the sound power level (L

) and

ISO 6081 for the sound pressure level (L

Noise levels were measured while running the machine at full speed, on crushed gravel, with vibration on.

Because this machine is operated using remote control the operator is not exposed to vibration.

Keep hands, feet and loose clothing away from

moving parts.

Replace all missing and hard-to-read decals. See

Parts Manual.

Check and tighten all external fasteners at regular

intervals.

Make sure slings, chains, hooks, ramps, jacks and

other types of lifting devices are attached securely

and have enough weight-bearing capacity to lift or

hold the machine safely. Always remain aware of

the position of other people around you when

lifting the machine.

DO NOT modify the equipment without expressed

written approval from WACKER Corporation.

OPERATION 1

RT 560/820

1-5

Engine Type Two cylinder, 4-cycle,

air cooled, diesel engine

Engine Make Lombardini

Engine Model 12LD475-2

Power @ 3000 rpm

Hp (kW) 20 (15)

Operating Speed rpm 2600 ± 100

Alternator V / Amp 12 / 16.5 @ 2600 rpm

Battery type 12V - Sealed - 800 cold starting amps

Air Cleaner type Dry pleated paper element

Valve Clearance - intake/exhaust in.(mm) 0.006–0.008 (0.15–0.20)

Fuel type No. 2 Diesel

Fuel Consumption gal.(l)/hr. 1.1 (4.2)

Fuel Tank Capacity gal. (l) 5.6 (21)

1.6 Engine Specifications

Type Quantity

Engine Crankcase CD rated - see Section 3.5 2.5 qt. (2.5 litres)

Hydraulic System *SAE 10W30 - Hydraulic Fluid 10.5 gal. (40 litres)

Exciter SAE 10W30 32 oz. (950 ml)

Drum Drive Gearcase SAE 10W30 8 oz. (240 ml)

Articulated Joint Shell Alvania No. 2 As required

Steering Cylinder Shell Alvania No. 2 As required

1.7 Roller Specifications

RT 560 RT 820

Overall Dimensions (l x w x h) in. 80 x 22 x 48 80 x 32 x 48

(mm) (2030 x 560 x 1220) 2030 x 820 x 1220

Operating Weight lb.(kg) 2830 (1283 ) 2960 (1345)

Area Capacity ft

) / hr. 7500 (690) 10900 (1016)

Inside Turning Radius in. (m) 63 (1.6) 58 (1.5)

Low Speed ft. (m)/min. 68 (21)

High Speed ft. (m)/min. 136 (41)

Vibration Frequency vpm (Hz) 2400 (40)

Gradeability with vibration % 50

Gradeability without vibration % 55

1.8 Lubrication Specifications

* See Section 3.16 “Hydraulic Oil Requirements”.

1 OPERATION

RT 560/820

1-6

1.9 Controls & Service Locations

234

10111314 12

1021SD84

1021SD85

OPERATION 1

RT 560/820

1-7

1 Oil Dipstick Access Door

2 Steering Cylinder Grease Fittings

3 Lifting Eye

4 Power On Indicator Light

5 Steering Cylinder Access Panel

6 Safety Back-up Bar

7 Fuel Tank Drain Plug

8 Tie Down Lugs

9 Drive Case Fill Plug

10 Drive Case Drain Plug

11 Oil Level Plug

12 Shockmount

13 Articulated Joint Grease Fitting

14 Drum Pusher Holes

15 Engine Oil Drain Plug

16 Filter Indicator for Air Cleaner

17 Engine Hood Latch

18 Oil & Fuel Filter Access Door

19 Scraper Bar

20 Articulated Joint Locking Bar

21 Battery

22 Fuel Tank Vent

23 Fuel Cap

24 Engine Throttle Control

25 Engine Oil Pressure Warning Light

26 Hour Meter

27 Charging System Warning Light

28 Hydraulic Tank Vent

29 Hydraulic Tank Return Line Filter

30 Hydraulic Oil Level Sight Gauge

31 Control Box Storage Area

32 Key Switch

33 Padlock Ring

34 Glow Plug Button

35 Cable-operated Control Box

36 Hydraulic Tank Drain Plug

Optional Infra-red Control

37 Receiving Eye

38 Infra-red Remote Control Transmitter

Optional Accessories

39 Adjustable Scraper Bars

1021SD96

1 OPERATION

RT 560/820

1-8

1.10 Application

This machine is designed for compaction of sub-bases and backfill for foundations, roads, parking lots, etc. A selection

of drum types, drum size, and two vibration modes ensures excellent compaction of cohesive-type soils, as well as

loose soils and gravel. The drums protrude past the machine frame, making it ideally suited for working along trench

walls, excavations, pipelines and backfill applications.

1.11 Remote Control Features

This machine is designed specifically for remote control

operation. This feature protects the operator by keeping

him or her a safe distance away from the machine, and

the work area, during operation. When used in excava-

tions, it allows the operator to stand safely above the

trench, rather than in it.

The machine can be operated using either the standard

cable operated control system (a), or through an optional

wireless infra-red remote control system (b).

A built-in override detects if both control systems

are on at the same time. The override will automati-

cally disable the infra-red control system, if it detects

that the cable-operated control system is on.

The cable-operated control system uses a power cord to

connect the control box to the machine. By adding the

optional wireless infra-red control system, operating range

can be extended to 65 ft. (20 m).

Each system provides operator control of the following

machine functions:

1 - Forward ................................. F

2 - Reverse .................................R

3 - Vibration-High ......................

4 - Vibration-Low........................

5 - Steering-Left .......................... L

6 - Steering-Right........................R

7 - High Speed Travel ................

8 - Low Speed Travel................

9 - Power On-Off....................... I / 0

10 - Engine Start..........................

11 - Emergency Stop ...................

1.12 Before Starting

Before starting machine check the following:

- Engine oil level

- Condition of air cleaner

- Fuel level

- Hydraulic fluid level

9 10

Note:

To prevent accidental engagement of the starter

motor while the engine is running, the machine is equipped

with an anti-restart device. This device makes the

engine start switch (10) inactive, after the engine has

started.

1009SD91

1006SD91

OPERATION 1

RT 560/820

1-9

1.13 Starting

1. Check that the vibration switch on the control box (f)

is centered in the “0” (off) position and that on-off

switch (g) is in the “0” (off) position.

2. Pull throttle control

in position by rotating handle clockwise, until tight.

3. Turn key switch

(e) on machine to the ON position. Set

on-off switch (g) on control box to the “I” (on) position.

Press in engine start button

(h) and hold it down until

engine starts. Leave the key switch and on-off switch

on while operating roller.

CAUTION: DO NOT crank the engine more than 15-

20 seconds at a time or starter motor may overheat.

Wait 30-45 seconds between start-up attempts so

starter motor can cool down.

To operate machine using infra-red remote control,

the on-off switch (g) on the cable-operated control

box must be set to the “0” (off) position, or cable control

box must be disconnected from machine.

See Unit 2, “INFRA-RED CONTROL”, for more

information on the infra-red operating system.

4. Allow engine to warm up for a few minutes before

operating machine.

The yellow indicator light on top of the machine will come

on when the key switch is first turned on and will begin

flashing when the on-off switch on the control box is

switched on. It will continue to flash while the machine is

running.

HOUR

1009SD91

1006SD92

1.14 Cold Weather Starting

The engine is equipped with a glow plug system to pre-

heat the intake manifold and improve cold weather starts.

The preheat button (d) is located next to the key switch

on the machine control panel. Hold button in for 10-20

seconds to pre-heat intake manifold.

Crank engine immediately after releasing button.

Do not hold pre-heat button in longer than 30 seconds or

glow plug system may be damaged.

1.15 Shutting Machine Off

Turn vibration off. Unlock throttle control and push it in to

return engine to idle. Set on-off switch (g) to the OFF

position to close fuel valve and stop engine. Turn key

switch (e) on machine off.

Note:

The engine cannot be shut down using the throttle

control alone.The throttle lever only returns the engine to

idle.

1 OPERATION

RT 560/820

1-10

1009SD91

1.16 Emergency Stop

Press emergency stop button (a) at any time during

operation to stop machine. The emergency stop but-

ton disconnects the vibration and travel switches on

the control box. Pressing the stop button does not

shut off the engine.

Before resetting stop button, make sure vibration and

travel switches have been returned to their off posi-

tion and no one is near machine. To reset button, turn

it in direction of arrows.

1.18 Vibration

Two vibration modes are available - high and low. Low

amplitude vibration ( ) is typically used for shallow

lifts where only a thin layer of ground needs to be

compacted, or in areas where heavy compaction could

damage structures, such as over pipes or along the

side of foundations. High amplitude vibration ( ) can

be used in most other applications, and is preferred for

cohesive-type soils with heavy clay content.

Vibration operates only with the machine in the

low speed travel mode.

Vibration is controlled by a three-position switch (e)

located next to the travel switch on the control box. To

start vibration, first set machine to low speed travel

( ), then set vibration switch to either high amplitude

( ) or low amplitude ( ) vibration.

Position switch in the center "0" position to stop vibra-

tion.

Because the exciter weights must reverse direction

when switching between vibration modes, there is a

ten second delay built into the vibration circuit. This

allows time for the weights to come to a complete stop

before changing direction.

CAUTION: DO NOT run vibration over hard surfaces

like concrete or compacted asphalt, drum bearings

can be damaged.

1.17 Travel Speed

Travel speed is controlled by a two-position switch (b)

located on the left side of the control box.

There are two travel speeds available: high speed travel

( ) for movement around the jobsite, and low speed

travel ( ) for compaction.

High speed travel operates only in forward.

When operating in high speed the vibration function

becomes inoperative. Although vibration will automati-

cally stop when switching to high speed, it is recom-

mended that the vibration switch (e) be set to the "0" (off)

position. This will prevent vibration from coming on

unexpectedly when switching back to low speed.

OPERATION 1

RT 560/820

1-11

1.20 Engine Speed

During operation run engine at full throttle (2600 rpm).

This ensures maximum exciter speed and will produce

the best compaction.

1.19 Direction & Steering Control

Two switches on the control box control the motion of the

machine. One controls steering

other direction (d) - forward/reverse. To operate, press

switch with thumb in direction desired. Switches return to

their neutral positions when released.

1.21 Jump Starting

(Protecting Electrical System)

Before jump starting a dead battery make certain that the

battery is good and is only "discharged".

Jump starting a shorted or defective battery will cause the

voltage regulator to supply higher than normal voltage.

This can severely damage the digital electronics that

control machine operation. If there is any doubt as to the

battery's condition, a replacement battery should be

used or an attempt should be made to charge the battery

before starting the machine.

CAUTION: Never disconnect the battery (f) with the

machine running or attempt to run the machine without a

battery. Damage to the the electrical system will occur.

WARNING

Always follow safe procedures when jump starting.

Batteries can emit explosive hydrogen gas. Keep all

sparks and and flames away from the battery. Do

not short circuit battery posts. Do not touch frame or

negative terminal when working on positive termi-

nal.

Follow procedure below when jump starting:

1. Stop the engine on the vehicle with the good battery.

2. Connect one end of positive jumper cable to positive

(+) terminal on good battery and other end to positive

(+) terminal on "discharged" battery.

3. Connect negative jumper cable from negative (-)

terminal on good battery to an unpainted portion of the

machine frame away from the "discharged" battery.

4. Start engine on vehicle with good battery. Allow

discharged battery to charge for a few minutes before

cranking engine.

5. Reverse procedure in steps 3 and 2 to remove jumper

cables. Remove negative cable first.

1021SD96

1 OPERATION

RT 560/820

1-12

1.23 Operation on Slopes

When operating on slopes or hills special care must be

taken to reduce the risk of personal injury or damage to

the equipment. Whenever possible, operate machine up

and down hills rather than from side to side to improve

stability and reduce the possibility of a rollover. The

machine is equipped with safety switches which will

interrupt the power to the fuel solenoids should the side–

to–side operating angle exceed 45°. Forward/backward

tilt is not limited by the safety switches. For safe operation

and for protection of the engine, continuous duty use

should be restricted to slopes of 14° (25% grade) or less.

WARNING

MAXIMUM RECOMMENDED SLOPE

14°

25%

NEVER operate machine on side slopes greater than

26° (50% grade). At slopes greater than this, the

machine may roll over, even on stable ground.

1009SD66

1.24 Roll-overs

Proper operation of the machine on slopes will prevent

roll-overs. Read and follow Safety instructions in Sec-

tions

1.2 Operating Safety

and

1.23 Operation on Slopes

If a machine rollover does occur care must be used to

prevent damage to the engine. In this position, oil from the

engine crankcase can flow into the combustion chamber,

which can severely damage the engine next time it is

started. If the machine has rolled on its side, immediate

steps should be taken to right the machine.

CAUTION: To prevent damage to the engine after a roll-

over, the machine must NOT be started, AND must be

serviced to remove any oil that may have been trapped

in the combustion chambers. Contact your local WACKER

dealer or Lombardini Engine dealer for

instructions or servicing.

1.22 Safety Back-Up Bar

A safety bar is mounted to the rear section of the machine

behind the control panel.

The safety bar operates in reverse only!

If the machine backs into an obstruction or for some

reason the operator becomes trapped behind it, the bar

will be pressed forward and stop the machine. The

machine will resume reverse travel when the bar is

released.

1006SD94

OPERATION 1

RT 560/820

1-13

1.25 Engine Oil Pressure Light

The oil pressure warning light (a) will come on when oil

pressure falls to 7 psi (50 kPa).

CAUTION: DO NOT continue to operate machine with

warning light on or engine damage may occur. Stop

engine and check oil level.

HOUR

1.26 Charging System Light

The engine is equipped with an alternator and voltage

regulator to maintain the battery charge. The charging

system warning light (b) indicates the condition of the

battery charging system. Although the machine will run

with the light on for a short period of time, continued

operation will drain the battery and eventually cause the

machine to lose all operating functions.

CAUTION: If operating machine in a narrow trench or

other confined area, drive machine into a safer area as

soon as possible to avoid stranding it in a hazardous or

inaccessible location.

1.28 Articulated Joint Locking Bar

A bar is provided to lock the articulated joint, and prevent

the two machine halves from swinging together.

When lifting or jacking up the machine, secure the

articulated joint with the bar as shown (d). Hold bar in

position using the cotter pin provided.

When operating the machine place the bar in the storage

clamp as shown (e).

1009SD34

1006SD95

1.27 Hour Meter

The hour meter (c) records the actual running time of the

engine. Use the hour meter when planning scheduled

maintenance.

1 OPERATION

RT 560/820

1-14

1007SD07

Decoder Module

Cable-operated Control Box

Infra-red Transmitter

1.29 Setting Control Channels

The remote control system can be tuned to 16 different

channels. This allows two or more machines to operate

in the same area without interference.

A channel selection switch (g) is included in the cable-

operated control box, infra-red transmitter, and the de-

coder module (f), which is located under the rear panel

at the back of the machine.

For operation of the remote control systems ALL switch-

es must be set to the SAME channel.

The channel comes preset from the factory to the last

digit of the serial number.

To set control channel:

Remove covers from control box and transmittter. Re-

move rear panel covering decoder module. Insert a small

screwdriver into the slot provided at the center of the

selection switch in each device. Rotate switch until arrow

is pointing at desired channel number.

Make note of the channel in use, and label the control

box, transmitter and machine to identify the correct

channel number.

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Wacker Neuson RT560 User manual

Brand: Wacker Neuson

Model: RT560

Type: User manual

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