Wacker Neuson RT560 User manual

www.wackergroup.com

Roller

RT /...

OPERATOR’S MANUAL

0154651en 003

1203

0154651EN

RT /... Table of Contents

wc_bo0154651002enTOC.fm 1

1. Foreword 3

2. Safety Information 4

2.1 Laws Pertaining to Spark Arresters ...................................................... 4

2.2 Operating Safety .................................................................................. 5

2.3 Operator Safety while using Internal Combustion Engines .................. 7

2.4 Service Safety ...................................................................................... 8

2.5 Label Locations .................................................................................... 9

2.6 Warning and Informational Labels ...................................................... 11

3. Technical Data 15

3.1 Engine ................................................................................................ 15

3.2 Roller .................................................................................................. 16

3.3 Lubrication .......................................................................................... 16

3.4 Sound and Vibration Measurements .................................................. 17

4. Operation 18

4.1 Operation and Service Locations ....................................................... 18

4.2 CombiControl Transmitter .................................................................. 20

4.3 Control Features ................................................................................. 23

4.4 Application .......................................................................................... 24

4.5 Before Starting ................................................................................... 24

4.6 Starting ............................................................................................... 24

4.7 Operation ............................................................................................ 26

4.8 Cold Weather Starting ........................................................................ 27

4.9 Engine Speed ..................................................................................... 27

4.10 Stopping ............................................................................................. 27

4.11 Position of Operator ........................................................................... 28

4.12 IR Receiving Eye Module ................................................................... 29

4.13 Range Limits ...................................................................................... 29

4.14 Operating Characteristics ................................................................... 30

4.15 Ni-cad Batteries .................................................................................. 30

4.16 Charging Transmitter Batteries .......................................................... 31

4.17 Replacing the Battery Pack ................................................................ 32

4.18 Jump Starting ..................................................................................... 32

4.19 Safety Back-up Bar ............................................................................ 33

4.20 Operation on Slopes ........................................................................... 34

4.21 Roll-overs ........................................................................................... 34

4.22 Engine Oil Pressure Light ................................................................... 35

4.23 Charging System Light ....................................................................... 35

Table of Contents RT /...

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4.24 Hourmeter ...........................................................................................35

4.25 Articulated Joint Locking Bar ...............................................................36

4.26 Setting Control Channels ....................................................................36

4.27 Decoder Module ..................................................................................37

5. Maintenance 38

5.1 Engine Fuel Delivery System Maintenance .........................................38

5.2 New Machines .....................................................................................38

5.3 Periodic Maintenance Schedule ..........................................................39

5.4 Air Cleaner ..........................................................................................40

5.5 Engine Oil System ...............................................................................41

5.6 Engine Oil ............................................................................................41

5.7 Valve Clearances ................................................................................42

5.8 Fuel Filter ............................................................................................43

5.9 Priming the Fuel System .....................................................................43

5.10 Articulated Joint & Steering Cylinder ...................................................44

5.11 Drive Gearcase ...................................................................................44

5.12 Exciter Lubrication ...............................................................................45

5.13 Cleaning Engine Cooling Fins .............................................................46

5.14 Scrapers ..............................................................................................47

5.15 Shockmounts .......................................................................................47

5.16 Cleaning CombiControl Transmitter ....................................................48

5.17 Hydraulic Oil Requirements .................................................................49

5.18 Hydraulic Fluid Level ...........................................................................49

5.19 Changing Hydraulic Oil & Filter ...........................................................50

5.20 Transporting Machine ..........................................................................51

5.21 Lifting Machine ....................................................................................51

5.22 Changing Drums .................................................................................52

5.23 Battery .................................................................................................53

5.24 Jobsite Storage ...................................................................................53

5.25 Storage ................................................................................................54

5.26 Hydraulic Schematic ............................................................................55

5.27 Hydraulic Diagram ...............................................................................57

5.28 Electrical Schematic (Main) .................................................................59

5.29 Electrical Diagram (Main) ....................................................................61

5.30 Electrical Schematic (Engine) .............................................................63

5.31 Electrical Diagram (Engine) .................................................................65

5.32 Troubleshooting ...................................................................................67

Foreword

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CALIFORNIA

Proposition 65 Warning:

Engine exhaust, some of its constituents, and certain vehicle

components contain or emit chemicals known to the State of California

to cause cancer and birth defects or other reproductive harm.

1. Foreword

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.

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.

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.

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

No part of this publication may be reproduced in any form or by any

means, electronic or mechanical, including photocopying, without

express written permission from Wacker Corporation.

Any type of reproduction or distribution not authorized by Wacker

Corporation represents an infringement of valid copyrights and will be

prosecuted. We expressly reserve the right to make technical

modifications, even without due notice, which aim at improving our

machines or their safety standards.

WARNING

Safety Information RT /...

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2. Safety Information

This manual contains DANGER, WARNING, CAUTION, and NOTE

callouts which must be followed to reduce the possibility of personal

injury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this

symbol to avoid possible injury or death.

DANGER indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury.

CAUTION: Used without the safety alert symbol, CAUTION indicates

a potentially hazardous situation which, if not avoided, may result in

property damage.

Note: Contains additional information important to a procedure.

2.1 Laws Pertaining to Spark Arresters

Notice: State Health Safety Codes and Public Resources Codes

specify that in certain locations spark arresters be used on internal

combustion engines that use hydrocarbon fuels. A spark arrester is a

device designed to prevent accidental discharge of sparks or flames

from the engine exhaust. Spark arresters are qualified and rated by

the United States Forest Service for this purpose.

In order to comply with local laws regarding spark arresters, consult

the engine distributor or the local Health and Safety Administrator.

DANGER

WARNING

CAUTION

RT /... Safety Information

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2.2 Operating Safety

Familiarity and proper training are required for the safe operation of

equipment! Equipment operated improperly or by untrained personnel

can be dangerous! Read the operating instructions contained in both

this manual and the engine manual and familiarize yourself with the

location and proper use of all controls. Inexperienced operators should

receive instruction from someone familiar with the equipment before

being allowed to operate the machine.

2.2.1 ALWAYS operate machine with all safety devices and guards in place

and in working order. DO NOT modify or defeat safety devices. DO

NOT operate machine if any safety devices or guards are missing or

inoperative.

2.2.2 ALWAYS disengage and stow locking bar for the articulated joint

before operating machine. The machine cannot be steered when the

locking bar is engaged.

2.2.3 ALWAYS check that all controls are functioning properly immediately

after start-up! DO NOT operate machine unless all controls operate

correctly.

2.2.4 ALWAYS remain aware of changing positions and movement of other

equipment and personnel on the job site.

2.2.5 ALWAYS remain in visual contact with machine at all times while

operating controls.

2.2.6 ALWAYS remain aware of changing surface conditions and use extra

care when operating over uneven ground, on hills, or over soft or

coarse material. The machine could shift or slide unexpectedly.

2.2.7 ALWAYS use caution when operating near the edges of pits, trenches

or platforms. Check to be sure that ground surface is stable enough to

support the weight of the machine and that there is no danger of the

roller sliding, falling or tipping.

2.2.8 ALWAYS position yourself safely when operating machine in reverse

or on hills. Leave enough space between yourself and the machine so

you will not be placed in a hazardous position should the machine slide

or tip.

2.2.9 ALWAYS use the neck strap for the SmartControl™ Transmitter

(control box) provided by WACKER. This neck strap is designed to

break away so that the operator will not be injured should the machine

slide, tip, or fall.

2.2.10 ALWAYS wear protective clothing appropriate to the job site when

operating equipment.

2.2.11 ALWAYS remain aware of moving parts and keep hands, feet, and

loose clothing away from moving parts of equipment.

WARNING

Safety Information RT /...

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2.2.12 ALWAYS read, understand, and follow procedures in Operator’s

Manual before attempting to operate equipment.

2.2.13 ALWAYS store equipment properly when it is not being used.

Equipment should be stored in a clean, dry location out of the reach of

children.

2.2.14 NEVER allow anyone to operate this equipment without proper

training. People operating this equipment must be familiar with the

risks and hazards associated with it.

2.2.15 NEVER touch the engine or muffler while the engine is on or

immediately after it has been turned off. These areas get hot and may

cause burns.

2.2.16 NEVER use accessories or attachments that are not recommended by

Wacker. Damage to equipment and injury to the user may result.

2.2.17 NEVER leave machine running unattended.

2.2.18 NEVER start a defective unit in need of service or repair.

2.2.19 NEVER operate with fuel cap loose or missing.

RT /... Safety Information

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2.3 Operator Safety while using Internal Combustion Engines

Internal combustion engines present special hazards during operation

and fueling! Read and follow warning instructions in engine owner’s

manual and safety guidelines below. Failure to follow warnings and

safety guidelines could result in severe injury or death.

2.3.1 DO NOT run machine indoors or in an enclosed area such as a deep

trench unless adequate ventilation, through such items as exhaust

fans or hoses, is provided. Exhaust gas from the engine contains

poisonous carbon monoxide gas; exposure to carbon monoxide can

cause loss of consciousness and may lead to death.

2.3.2 DO NOT smoke while operating machine.

2.3.3 DO NOT smoke when refueling engine.

2.3.4 DO NOT refuel hot or running engine.

2.3.5 DO NOT refuel engine near open flame.

2.3.6 DO NOT spill fuel when refueling engine.

2.3.7 DO NOT run engine near open flames.

2.3.8 ALWAYS refill fuel tank in well-ventilated area.

2.3.9 ALWAYS replace fuel tank cap after refueling.

2.3.10 ALWAYS check fuel lines and fuel tank for leaks and cracks before

starting engine. Do not run machine if fuel leaks are present or fuel

lines are loose.

2.3.11 ALWAYS keep area around hot exhaust pipes free of debris to reduce

the chance of an accidental fire.

2.3.12

DANGER

Safety Information RT /...

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2.4 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.

2.4.1 ALWAYS replace safety devices and guards after repairs and

maintenance.

2.4.2 ALWAYS turn engine off before performing maintenance or making

repairs.

2.4.3 ALWAYS secure the articulated joint using the locking bar before

lifting, jacking, and servicing the machine. Machine halves could swing

together unexpectedly and cause a serious injury.

2.4.4 ALWAYS replace missing and hard-to-read labels. See Parts Manual

for ordering information.

2.4.5 ALWAYS make sure slings, chains, hooks, ramps, jacks and other

types of lifting devices are attached securely and have enough weight-

bearing capacity to lift or hold the machine safely. Always remain

aware of the position of other people around you when lifting the

machine.

2.4.6 ALWAYS keep area around muffler free of debris such as leaves,

paper, cartons, etc. A hot muffler could ignite them, starting a fire.

2.4.7 ALWAYS replace worn or damaged components with spare parts

designed and recommended by Wacker.

2.4.8 ALWAYS keep machine clean and labels legible. Replace all missing

and hard-to-read labels. Labels provide important operating

instructions and warn of dangers and hazards.

2.4.9 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

hazards. Set all controls in neutral and turn engine off before loosening

hydraulic lines.

2.4.10 DO NOT attempt to clean or service machine while it is running.

Rotating parts can cause severe injury.

2.4.11 DO NOT use gasoline or other types of fuels or flammable solvents to

clean parts, especially in enclosed areas. Fumes from fuels and

solvents can become explosive.

2.4.12 DO NOT modify the equipment without express written approval of the

manufacturer.

WARNING

RT /... Safety Information

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2.5 Label Locations

Safety Information RT /...

wc_si000038gb.fm 10

RT /... Safety Information

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2.6 Warning 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

machine. Shut off engine before refueling.

WARNING!

Hot surface!

WARNING!

Hot surface!

WARNING!

To prevent hearing loss, wear hearing protec-

tion when operating this machine.

WARNING!

Pinch point.

Safety Information RT /...

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Hydraulic oil reservoir fill

CAUTION!

Use only clean, filtered diesel fuel.

WARNING!

Read and understand the supplied operator’s

manual before operating this machine. Failure

to do so increases the risk of injury to yourself

or others.

CAUTION!

Engine oil may enter the cylinders if machine

tips over, causing possible engine damage.

WARNING!

Machine may receive stray signals if operated

near solid objects.

CAUTION!

Use only breakaway neck strap provided by

Wacker to avoid possible operator injury.

Label Meaning

RT /... Safety Information

wc_si000038gb.fm 13

Operator’s manual must be stored on

machine. Replacement operator’s manual can

be ordered through your local Wacker distribu-

tor.

CAUTION!

Engine oil pressure is low! Stop the engine

and check the oil level.

CAUTION!

Low voltage! Stop the engine and check the

charging system.

Control with cable

Control with infrared

Charge infrared battery

Glow plug. Press to pre-heat intake manifold

before starting in cold weather.

Tie-down point

CAUTION!

Lifting point

Label Meaning

Safety Information RT /...

wc_si000038gb.fm 14

Torque battery hold-down nuts to 3.39 Nm (30

in.lbs.) max.

A nameplate listing the Model Number, Item

Number, Revision, 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, item number, revision

number, and serial number of the unit.

This machine may be covered by one or more

patents.

Guaranteed sound power level in dB(A).

Label Meaning

RT /... Technical Data

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3. Technical Data

3.1 Engine

Item Number Revision

9000 121 & higher

9001 123 & higher

9002 124 & higher

9003 121 & higher

Item No.

RT560

0009000

0009001

RT820

0009002

0009003

Engine

Engine Type 2 cylinder, 4 cycle,

air cooled, diesel engine

Engine Make Lombardini

Engine Model 12LD475-2

Rated Power

kW (Hp)

15.6 (20.9)

Alternator

Amp / V

12 / 16.5 @ 2600 rpm

Engine Speed - full load

rpm

2600 ± 100

Valve Clearance (cold)

intake / exhaust:

mm (in.)

0.20 (0.008)

Air Cleaner

type

Dry pleated paper elements

Battery

V / size

12V - Sealed - 800 cold starting amps

Fuel

type

No. 2 Diesel

Fuel Tank Capacity

l (gal.)

21 (5.6)

Fuel Consumption

l (gal.)/hr.

4.2 (1.1)

Technical Data RT /...

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3.2 Roller

3.3 Lubrication

Item No:

RT560

0009000

0009001

RT820

0009002

0009003

Roller

Overall Dimensions

mm

(in.)

2030 x 560 x 1220

(80 x 22 x 48)

2030 x 820 x 1220

(80 x 32 x 48)

Operating Weight

kg (lb.)

1346 (2976) 1408 (3106)

Area Capacity

m² (ft²) / hr.

690 (7500) 1016 (10900)

Inside Turning Radius

m (in.)

1.6 (53) 1.5 (58)

Low Speed

m (ft.)/min.

21 (68)

High Speed

m (ft.)/min.

136 (41)

Vibration Frequency

Hz (vpm)

40 (2400)

Gradeability with

Vibration

%

50

Gradeability without

Vibration

%

55

Item No:

RT560

0009000

0009001

RT820

0009002

0009003

Lubrication

Engine Crankcase

type

l (qt.)

SAE 10W30 Class CD rated

2.5 (2.5)

Hydraulic System

type

l (gal)

Premium grade, Anti-wear hydraulic fluid SAE 10W30

40 (10.5)

Exciter

type

ml (oz.)

SAE 10W30

950 (32)

Drum Drive Gearcase

type

ml (oz.)

SAE 10W30

370 (12.5)

Articulated Joint

type

qty.

Shell Alvania No. 2 Grease

As Required

Steering Cylinder

type

qty.

Shell Alvania No. 2 Grease

As Required

RT /... Technical Data

wc_td000038gb.fm 17

3.4 Sound and Vibration Measurements

According to Appendix 1, paragraph 1.7.4.f of the EG-Machine

Regulation, the requested noise levels are:

The sound pressure level at operator’s location (L

pA

) = 83 dB(A).

The guaranteed sound power level (L

WA

) = 109 dB(A).

These noise values were obtained at the operator’s location according

to ISO 3744 for the sound power level (L

WA

) and ISO 6081 for the

sound pressure level (L

pA

).

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.

Operation RT /...

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4. Operation

4.1 Operation and Service Locations

Ref. Description Ref. Description

1. Oil Dipstick Access Door 21. Battery

2. Steering Cylinder Grease Fittings 22. Fuel Tank Vent

3. Lifting Eye 23. Fuel Cap

4. Power On Indicator Light 24. Engine Throttle Control

5. Steering Cylinder Access Panel 25. Engine Oil Pressure Warning Light

6. Safety Back-up Bar 26. Hour Meter

7. Fuel Tank Drain Plug 27. Charging System Warning Light

8. Tie Down Lugs (shown with

scraper bars removed)

28. Hydraulic Tank Vent

9. Drive Case Fill Plug 29. Hydraulic Tank Return Line Filter

10. Drive Case Drain Plug 30. Hydraulic Oil Level Sight Gauge

11. Oil Level Plug 31. CombiControl Transmitter Storage

Area

12. Shockmount 32. Key Switch

13. Articulated Joint Grease Fitting 33. Padlock Ring

14. Drum Pusher Holes 34. Glow Plug Button

15. Engine Oil Drain Plug 35. CombiControl Transmitter

16. Filter Indicator for Air Cleaner 36. Hydraulic Tank Drain Plug

17. Engine Hood Latch 37. Receiving Eye

18. Oil & Fuel Filter Access Door 38. Control Cable

19. Scraper Bar 39. Adjustable Scraper Bars

20. Articulated Joint Locking Bar

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