Wacker Neuson DPU 4545H User manual

Operator’s manual

Vibratory plate

DPU

4545, 5545, 6555

09.2014

5100017354en / 01

Manufacturer

Wacker Neuson Produktion GmbH & Co. KG

Preussenstrasse 41

80809 Munich

www.wackerneuson.com

Tel.: +49-(0)89-354 02-0

Fax: +49-(0)89-354 02-390

Original operator's manual

5100009744IVZ.fm 3

1Preface .......................................................................................................................6

2 Introduction ...............................................................................................................7

2.1 Using the manual ........................................................................................................... 7

2.2 Storage place for the manual......................................................................................... 7

2.3 Accident prevention regulations..................................................................................... 7

2.4 Further information......................................................................................................... 7

2.5 Target group................................................................................................................... 8

2.6 Explanation of symbols .................................................................................................. 9

2.7 Wacker Neuson Contact partner.................................................................................. 10

2.8 Limitation of liability...................................................................................................... 10

2.9 Identification of the machine ........................................................................................ 11

3 Security ....................................................................................................................12

3.1 Policy............................................................................................................................ 12

3.2 Responsibility of the operator....................................................................................... 13

3.3 Obligations of the operator........................................................................................... 13

3.4 Personnel qualifications ............................................................................................... 13

3.5 General hazards........................................................................................................... 14

3.6 General safety information........................................................................................... 14

3.6.1 Working area................................................................................................... 14

3.6.2 Service ............................................................................................................ 14

3.6.3 Personal safety ............................................................................................... 15

3.6.4 Handling and use ............................................................................................ 15

3.7 Specific safety instructions - vibratory plates ............................................................... 15

3.7.1 External influences.......................................................................................... 15

3.7.2 Operational safety........................................................................................... 16

3.7.3 Safety distances.............................................................................................. 17

3.8 General safety instructions - combustion engines ....................................................... 17

3.9 General safety instructions - fuel, lubricants or coolants.............................................. 18

3.10 General safety instructions - batteries.......................................................................... 18

3.11 Maintenance................................................................................................................. 19

3.12 Personal Protection Equipment.................................................................................... 20

3.13 Safety equipment ......................................................................................................... 21

3.14 Behavior in dangerous situations................................................................................. 22

4 Safety and information labels ................................................................................23

5 Items supplied .........................................................................................................25

6 Construction and function .....................................................................................26

6.1 Application.................................................................................................................... 26

6.2 Brief description ........................................................................................................... 26

6.3 Versions ....................................................................................................................... 27

Inhalt

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7 Components and operator controls ...................................................................... 28

7.1 Components ................................................................................................................. 28

7.2 Operating elements ...................................................................................................... 29

8 Transport ................................................................................................................. 31

8.1 Loading and transport................................................................................................... 32

9 Use and operation ................................................................................................... 34

9.1 Before starting .............................................................................................................. 34

9.1.1 Checks before starting..................................................................................... 34

9.1.2 Adjust centre pole............................................................................................ 35

9.2 Notes on operation ....................................................................................................... 35

9.3 Starting ......................................................................................................................... 36

9.3.1 Starting the machine (manual start) ................................................................ 37

9.3.2 Cold starting the machine (manual start)......................................................... 39

9.3.3 Starting the machine (electric starter).............................................................. 40

9.4 Operation...................................................................................................................... 42

9.4.1 Choose travel direction.................................................................................... 42

9.4.2 Compatec - Read compaction display............................................................. 42

9.5 Turning off .................................................................................................................... 43

9.5.1 Turning off the machine (manual start)............................................................ 43

9.5.2 Turning off the machine (electric starter)......................................................... 44

10 Maintenance ............................................................................................................ 45

10.1 Maintenance table ........................................................................................................ 46

10.2 Maintenance work ........................................................................................................ 47

11 Troubleshooting ......................................................................................................55

11.1 Fault table..................................................................................................................... 55

11.2 Performing jump start with donor battery...................................................................... 56

12 Disposal ................................................................................................................... 58

12.1 Disposal of batteries ..................................................................................................... 58

13 Accessories ............................................................................................................. 59

14 Technical data ......................................................................................................... 60

14.1 Combustion engine....................................................................................................... 62

15 Technical data ......................................................................................................... 64

15.1 Combustion engine....................................................................................................... 68

16 Technical data ......................................................................................................... 70

16.1 Combustion engine....................................................................................................... 74

5100009744IVZ.fm 5

EC Declaration of Conformity ................................................................................77

EC Declaration of Conformity ................................................................................79

EC Declaration of Conformity ................................................................................81

DIN EN ISO 9001 Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1Preface

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1 Preface

This operator's manual contains information and procedures for the safe opera-

tion and safe maintenance of your Wacker Neuson machine. For your own safety

and to protect against injuries, you must thoroughly read the safety instructions,

familiarize yourself with them and observe them at all times.

This operator's manual is not a manual for extensive maintenance or repair work.

Such work should be carried out by the Wacker Neuson service or by certified

personnel.

When building this equipment, great value was placed on the safety of its oper-

ator. However, an improper operation or improper maintenance can pose haz-

ards. Please operate and maintain your Wacker Neuson machine in accordance

with the information in this operator's manual. It will reward your attention by pro-

viding you with a trouble-free operation and high availability.

Defective machine parts must be replaced immediately!

Please contact your Wacker Neuson contact partner for questions regarding the

operation or repair.

All rights are reserved, in particular the right of duplication and distribution.

This operator's manual - even in part - may only be reproduced, used, copied or

distributed with the expressed, prior written consent from Wacker Neuson.

Any type of reproduction, distribution or storage on data carriers in any form or

type that is not approved by Wacker Neuson represents a violation of the valid

copyright and will be prosecuted.

We reserve the express right to technical changes that are used to improve our

machines or increase the safety standard, even without special notice.

2 Introduction

100_0000_0013.fm 7

2Introduction

2.1 Using the manual

This manual must be regarded as part of the machine and must be kept safe

throughout its service life. This manual must be passed on to any subsequent

owner or user of this machine.

2.2 Storage place for the manual

This manual is a component of the machine and must be kept accessible to per-

sonnel in the immediate vicinity of the machine at all times.

In the event of loss or requirement for a second copy of this manual there are two

options to obtain replacement:

 Download from the internet - www.wackerneuson.com

 Get in touch with Wacker Neuson contact person.

2.3 Accident prevention regulations

In addition to the instructions and safety information in this manual, local accident

prevention regulations and national health and safety regulations apply.

2.4 Further information

This manual applies to various machine types from one product series. For this

reason, some figures may vary slightly in appearance from the purchased ma-

chine. In addition, variant-specific components may be described here that are

not included.

The information contained in this manual is based on machines manufactured up

to the date of printing. Wacker Neuson reserves the right to make unannounced

changes to this information.

It must be ensured that any changes or additions are introduced immediately in

this manual by the manufacturer.

2 Introduction

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2.5 Target group

Notice: Persons working with this machine must be regularly trained about the

dangers of dealing with the machine.

This operator's manual is directed at the following persons:

Operating personnel:

These people are trained on the machine and informed about possible hazards

of improper conduct.

Technically trained personnel:

These people have a professional education as well as additional knowledge and

experience. They are able to assess the tasks assigned to them and to recognise

potential hazards.

2 Introduction

100_0000_0013.fm 9

2.6 Explanation of symbols

This manual contains particularly emphasized safety instructions for the catego-

ries: DANGER, WARNING, CAUTION and NOTE.

Before all work using this machine the notes and safety instructions must be read

and understood. All instructions and safety information in this manual must be

passed on to the service, maintenance and transport personnel.

Note

Notice: Additional information.

DANGER

This combination of symbol and signal word indicates a hazardous situation that

will result in death or serious injury if not avoided.

WARNING

This combination of symbol and signal word indicates a hazardous situation that

may result in death or serious injury if not avoided.

CAUTION

This combination of symbol and signal word indicates a potentially hazardous

situation that may result in minor injuries or damage to the machine if not avoid-

ed.

2 Introduction

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2.7 Wacker Neuson Contact partner

The Wacker Neuson contact partner is, depending on the country, a Wacker

Neuson service, a Wacker Neuson subsidiary or a Wacker Neuson dealer.

Online at www.wackerneuson.com.

The manufacturer's address can be found at the beginning of this manual.

2.8 Limitation of liability

For the following violations, Wacker Neuson rejects any liability for personal in-

jury and material damage:

 Failure to follow this manual.

 Improper use.

 Use of untrained personnel.

 Use of non-approved spare parts and accessories.

 Improper handling.

 Structural modifications of any kind.

 Failure to comply with the "General Terms and Conditions" (GTC).

2 Introduction

100_0000_0013.fm 11

2.9 Identification of the machine

Data of the nameplate

The nameplate contains information that uniquely identifies this machine. This

information is required for ordering spare parts and when inquiring about techni-

cal issues.

 Enter information on the machine in the following table:

Pos. Designation Your information

1 Group and type

2 Year of manufacture

3 Machine no.

4 Version no.

5 Item no.

3 Security

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3 Security

Notice: Read and observe all notes and safety instructions in this manual. Fail-

ure to comply with these instructions may lead to electric shock, fire

and/or serious injury and may cause damage to the machine and/or to

other objects. Store the safety instructions and notes for future use.

3.1 Policy

State of the art

The machine is built according to the latest state of the art and the recognized

safety rules. However, improper use can present hazards to the life and limb of

the user, third persons or damage the machine and other equipment during use.

Intended use

The machine may only be used for the following purposes:

 Compacting soil.

 Compacting asphalt.

 Vibration of paving stones.

The machine may not be used for the following purposes:

 Compacting of strongly cohesive soils.

 Compacting frozen soil.

 Compacting hard, non-compressible surfaces.

 Compaction of unsound soils.

Intended use also includes the observance of all instructions and safety informa-

tion in this manual, as well as complying with the required service and mainte-

nance instructions.

Any other or additional use is considered improper. The manufacturer is not lia-

ble for any resulting damage. The risk is borne by the operator alone.

Structural changes

Structural modifications may not be made without the written permission of the

manufacturer. Unauthorized structural changes of this machine may lead to haz-

ards for users and/or third parties and damage to the machine.

The manufacturer is also not liable in the event of unauthorized structural chang-

es.

In particular, the following cases are considered structural changes:

 Opening the machine and the permanent removal of components.

 Installation of spare parts that do not originate from Wacker Neuson or are

not comparable in

the design system and quality of the original parts.

 Fitting of any kind of accessories not originating from Wacker Neuson.

3 Security

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3.2 Responsibility of the operator

The operator is the person who operates this machine for industrial or commer-

cial purposes or gives it to a third party for use / application and during operation

bears the legal product responsibility for the safety of personnel or third parties.

The operator must make the manual accessible to personnel at all times and en-

sure that the user has read and understood this manual.

3.3 Obligations of the operator

 To be familiar with and implement applicable health and safety regulations.

 To identify in a risk assessment hazards arising from working conditions on

the site.

 To create operator's manuals for the operation of this machine.

 To periodically check whether the operation instructions reflect the current

state of the regulations.

 To regulate and specify responsibilities for operation, troubleshooting, main-

tenance and cleaning.

 To train personnel at regular intervals and inform them about possible dan-

gers.

 To provide staff with the necessary protective equipment.

3.4 Personnel qualifications

This machine may only be installed and operated by trained personnel.

Misapplication or misuse by untrained personnel can endanger the health of the

user and/or third parties, including damage to or total failure of the machine.

In addition, the following requirements apply to the user:

 To be physically and mentally fit.

 Not to be under the influence of drugs, alcohol or medication.

 To be familiar with the safety instructions in this manual.

 To be familiar with the proper use of this machine.

 To be a minimum of 18 years of age to operate this machine.

 Has been instructed in the independent operation of the machine.

 Is entitled to operate equipment and systems independently, in accordance

with the standards of safety engineering.

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3.5 General hazards

Residual hazards are special hazards that cannot be eliminated when dealing

with machines despite the safety-compliant construction.

These residual hazards are not obvious and can be a source of possible injury

or health hazards.

If unforeseen residual risks arise, the machine is to be switched off immediately

and the responsible manager informed. This manager will take further decisions

and will do everything necessary to eliminate the arising hazard.

If required, the machine manufacturer must be informed.

3.6 General safety information

The safety instructions in this chapter include the "General safety instructions",

which should be set out in the manual in accordance with the applicable stand-

ards. It may contain information not relevant for this machine.

3.6.1 Working area

 Before starting work be familiar with the working environment, e.g. the bear-

ing capacity of the soil or obstacles in the environment.

 Secure the working area from the public transport area.

 Keep working area tidy. Cluttered or poorly lit areas may lead to accidents.

 Working with this machine in a potentially explosive environment is prohibit-

ed.

 Keep children and other people away when operating this machine. Distrac-

tions may lead to loss of control of the machine.

 Always secure the machine against tipping, rolling, sliding and crashing. Risk

of

injury!

3.6.2 Service

 Only allow the machine to be repaired or maintained by qualified technically

trained pe

rsonnel.

 Use only original spare parts and accessories. The operational safety of the

machine is thus maintained.

3 Security

100_0202_si_0006.fm 15

3.6.3 Personal safety

 Working under the influence of drugs, alcohol or medication can lead to seri-

ous injury.

 For all work appropriate protective equipment should be worn. Appropriate

pe

rsonal protective equipment reduces the risk of injury considerably.

 Remove tools before the machine is put into operation. Tools on a rotating

machine pa

rt can be ejected and cause serious injury.

 Always ensure stability.

 After prolonged working with this machine, vibration-induced long-term dam-

age cannot be ruled out completely. For exact values for vibration measure-

ment, see chapter Technical data.

 Wear appropriate clothing. Keep baggy or loose clothing, gloves, jewelry and

lo

ng hair away from moving/rotating machinery. Danger of being pulled in!

3.6.4 Handling and use

 Do not use machines with defective switches. Have the defective switches re-

placed immediately. Machines with defective switches carry a high risk of in-

jury.

 Store unused machines out of the reach of children. Machines may only be

op

erated by authorized personnel.

 Treat machines with care. Have defective parts immediately replaced before

this

machine is put into operation. Defective machines carry a high risk of ac-

cidents.

 Use the machine, accessories, tools etc. in accordance with these instruc-

tions.

3.7 Specific safety instructions - vibratory plates

3.7.1 External influences

The vibratory plate must not be operated in the event of the following external

influences:

 Heavy rain on inclined surfaces. Slipping hazard!

 Oil field environments - methane leaks from the soil. Explosion hazard!

 In dry, flammable vegetation. Fire hazard!

 In potentially explosive environments. Explosion hazard!

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3.7.2 Operational safety

 During operation of the machine ensure that no gas, water or electric lines or

pipes are damaged.

 The machine must not be used in tunnels or within closed areas in operation.

 Pay the utmost attention near drops or slopes. Falling hazard!

 The intended operator's position is behind the center pole, do not leave while

the unit is operational.

 Do not allow the machine to run unattended. Risk of injury!

 Demarcate work area spaciously and keep unauthorized persons away. Risk

of injury!

 Operators this machine must ensure that persons who are present in the

work area comply with a minimum distance of 2 meters from the operational

machine.

 Do not use start help sprays. They can cause misfires and engine damage.

Fire hazard!

 When operating the machine on sloping surfaces, always approach gradients

from the bottom and always stand above the machine on a slope. The ma-

chine could slip or tip over.

 Do not exceed the maximum permissible tilt of the machine - possible loss of

engine lubrication, see ChapterTechnical data.

 Only use Wacker Neuson batteries. They are vibration resistant and there-

fore suitable for high vibration loads.

3 Security

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3.7.3 Safety distances

Compaction work close to buildings can cause damage. For this reason, all po-

tential impacts and vibrations have to be tested on surrounding buildings in ad-

vance.

The relevant rules and regulations for the measurement, assessment and control

of vibration emissions must be observed.

Wacker Neuson accepts no liability for any damage to buildings.

3.8 General safety instructions - combustion engines

The following instructions must be adhered to:

 Check the engine before starting work for leaks and cracks in the fuel line,

tank and fuel cap.

 Do not use a defective engine. Replace damaged parts immediately.

 The preset engine speed must not be adjusted. This could lead to engine

da

mage.

 Make sure that the exhaust muffler of the engine is free of debris. Fire hazard!

 Before refueling, switch off engine and allow to cool.

 Use the correct fuel type. Fuel must not be mixed with other liquids.

 For refueling, use clean filling aids. Do not spill fuel; wipe up any spilled fuel

immediately.

 Engine must not be started near spilled fuel. Explosion hazard!

 When operating in partially-enclosed spaces sufficient ventilation must be

provided. Do not breathe in exhaust fumes. Poisoning hazard!

 The engine block and exhaust muffler can become very hot after a short time.

Burning hazard!

Notice: This machine is equipped with an EPA-certified engine.

Adjusting the speed influences the EPA certification and emissions.

Adjustments to this engine may only be carried out by a professional.

For more information, contact the engine manufacturer or the Wacker

Neuson contact partner.

3 Security

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3.9 General safety instructions - fuel, lubricants or coolants

The following instructions must be adhered to:

 When handling fuels, lubricants or coolants, always wear safety glasses and

protective gloves. Seek medical attention if hydraulic oil, fuel, oil or coolant

gets into the eye.

 Avoid direct skin contact with fuel, lubricants or coolants. Rinse skin immedi-

ately with soap and water.

 Do not eat or drink while working with fuel, lubricants or coolants.

 Hydraulic oil or fuel contaminated by dirt or water can cause premature wear

or failure of the machine.

 Dispose of discharged or spilled supplies according to applicable regulations

for environmental protection.

 If fuel, lubricants or coolants emerge from the machine, cease operation of

the

machine and immediately have it repaired by the Wacker Neuson con

tact

partn

er.

3.10 General safety instructions - batteries

The following instructions must be adhered to:

 When disconnecting the battery, always disconnect the negative terminal

first!

 When connecting the battery, always disconnect the positive terminal first!

Secure the terminal cover!

 Fire, sparks and smoking are prohibited when handling batteries.

 Batteries contain corrosive acid. When handling batteries, wear acid-proof

prote

ctive gloves and glasses.

 Prevent incorrect connection of the battery or shorting of the terminals with

tools. Short circuit hazard!

3 Security

100_0202_si_0006.fm 19

3.11 Maintenance

The following instructions must be adhered to:

 This machine may not be maintained, repaired, adjusted or cleaned while

switched on.

 Observe maintenance intervals.

 After every maintenance or repair the safety devices on this machine must be

rep

laced.

 Observe the maintenance schedule. Work not listed must be taken on by the

service of

the Wacker Neuson contact partner.

 Always immediately replace worn or damaged machine parts. Only use spare

parts from Wacker Neuson.

 Keep the machine clean.

 Missing, damaged or illegible safety stickers must be replaced immediately.

Safet

y stickers contain important information for the protection of the user.

 Maintenance work must be carried out in a clean and dry environment (e.g.

a

workshop).

3 Security

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3.12 Personal Protection Equipment

Notice: To avoid personal injury as much as possible when using this machine,

personal protective equipment must be worn when working on or with

this machine.

Notice: This machine may exceed the country-specific permissible noise limit

(personal rating level). This is why ear protection must be worn. For ex-

act values for noise measurement, see chapter Technical data..

Work particularly cautiously and pay attention when wearing ear pro-

tection, as the ability to hear noises, such as screams or signal tones,

is restricted.

Wacker Neuson recommends always wearing ear protection.

Pictogram Significance Description

Use safety shoes! Safety shoes protect against

crushing, falling and slipping on

slippery surfaces.

Use protective gloves! Protective gloves protect

against abrasions, cuts, punc-

tures as well as hot surfaces.

Use ear protection! Ear protection protects against

permanent hearing damage.

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