Wacker Neuson DPU4545Hec User manual

Operator’s manual

Vibratory plate

DPU

4545, 5545, 6555

05.2015

5100009744en / 02

Manufacturer

Wacker Neuson Produktion GmbH & Co. KG

Preußenstraße 41

80809 München

www.wackerneuson.com

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

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

Translation of the original operator's manual in German

5100009744IVZ.fm 3

1 Foreword ....................................................................................................................6

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

2.1 Use of the manual.......................................................................................................... 7

2.2 Storing the manual......................................................................................................... 7

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

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

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

2.6 Symbol explanation........................................................................................................ 9

2.7 Wacker Neuson representative.................................................................................... 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............................................................................................... 14

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

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

3.6.1 Working area................................................................................................... 15

3.6.2 Service............................................................................................................ 15

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

3.6.4 Handling and use............................................................................................ 16

3.7 Specific safety instructions - vibratory plates............................................................... 16

3.7.1 External influences.......................................................................................... 16

3.7.2 Operational safety........................................................................................... 17

3.7.3 Safety distances.............................................................................................. 18

3.8 General safety instructions - combustion engines ....................................................... 18

3.9 General safety instructions - fuel, lubricants or coolants.............................................. 19

3.10 General safety instructions - Starter batteries.............................................................. 19

3.11 Maintenance................................................................................................................. 20

3.12 Personal Protection Equipment.................................................................................... 21

3.13 Safety equipment......................................................................................................... 22

3.14 Behavior in dangerous situations................................................................................. 23

4 Safety and information labels ................................................................................24

5 Construction and function .....................................................................................26

5.1 Items supplied.............................................................................................................. 26

5.2 Application.................................................................................................................... 26

5.3 Brief description ........................................................................................................... 26

5.4 Versions....................................................................................................................... 28

Inhalt

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6 Components and operator controls ......................................................................29

6.1 Components................................................................................................................. 29

6.2 Operating elements...................................................................................................... 30

7 Transport .................................................................................................................32

7.1 Loading and transport................................................................................................... 33

8 Use and operation ...................................................................................................35

8.1 Before starting.............................................................................................................. 35

8.1.1 Checks before starting..................................................................................... 35

8.1.2 Adjust centre pole............................................................................................ 36

8.2 Notes on operation....................................................................................................... 36

8.3 Starting......................................................................................................................... 37

8.3.1 Starting the machine (manual start) ................................................................ 38

8.3.2 Cold starting the machine (manual start)......................................................... 40

8.3.3 Starting the machine (electric starter).............................................................. 41

8.4 Operation...................................................................................................................... 43

8.4.1 Choose travel direction.................................................................................... 43

8.4.2 Compatec - Read compaction display............................................................. 43

8.5 Turning off .................................................................................................................... 43

8.5.1 Turning off the machine (manual start)............................................................ 44

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

9 Maintenance ............................................................................................................45

9.1 Maintenance table........................................................................................................ 46

9.2 Maintenance work ........................................................................................................ 47

10 Troubleshooting ......................................................................................................55

10.1 Fault table..................................................................................................................... 55

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

11 Disposal ...................................................................................................................58

11.1 Disposal of batteries..................................................................................................... 58

12 Accessories .............................................................................................................59

13 Technical data .........................................................................................................60

13.1 Combustion engine....................................................................................................... 64

14 Technical data .........................................................................................................66

14.1 Combustion engine....................................................................................................... 72

15 Technical data .........................................................................................................74

15.1 Combustion engine....................................................................................................... 82

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16 Emission control systems information and warranty .........................................84

EC Declaration of Conformity ................................................................................85

EC Declaration of Conformity ................................................................................87

EC Declaration of Conformity ................................................................................89

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

1Foreword

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1Foreword

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

tion and maintenance of your Wacker Neuson machine. In the interest of your

own safety and to prevent accidents, you should carefully read through the safety

information, familiarize yourself with it and observe it at all times.

This operator's manual is not a manual for extensive maintenance and repair

work. Such work should be carried out by Wacker Neuson service or authorized

specialists.

The safety of the operator was one of the most important aspects taken into con-

sideration when this machine was designed. Nevertheless, improper use or in-

correct maintenance can pose a risk. Please operate and maintain your Wacker

Neuson machine in accordance with the instructions in this operator's manual.

Your reward will be troublefree operation and a high degree of availability.

Defective machine parts must be replaced immediately!

Please contact your Wacker Neuson representative if you have any questions

concerning operation or maintenance.

No part of this publication may be reproduced in any form or by any means, elec-

tronic or mechanical, including photocopying, without the expressed written per-

mission of Wacker Neuson.

Any type of reproduction, distribution or storage on data media of any type and

form not authorized by Wacker Neuson represents an infringement of copyright

and will be prosecuted.

We expressly reserve the right to make technical modifications – even without

special notice – which aim at further improving our machines or their safety stan-

dards.

2 Introduction

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2Introduction

2.1 Use of the manual

This manual is considered as part of the machine and must be kept in a safe

place throughout the entire lifecycle. This manual must be handed over to every

subsequent owner or user of the machine.

2.2 Storing the manual

This manual is part of the machine and must be stored in the immediate vicinity

of the machine and be available to staff at all times.

In the case of loss or if a second copy of this manual is required, there are two

options for obtaining a replacement:

 Download from the Internet - www.wackerneuson.com

 Contact your Wacker Neuson representative.

2.3 Accident prevention regulations

Local accident prevention regulations and national occupational safety provi-

sions apply in addition to the notes and safety information contained in this man-

ual.

2.4 Further information

This manual is valid for different machine types from a product range. As such,

some illustrations may differ from the appearance of your machine. Variant-de-

pendent components may also be described that are not included in the delivery.

The information contained in this manual is based on machines which have been

manufactured at the time of printing. Wacker Neuson reserves the right to amend

this information without notification.

It must be ensured that any potential amendments or supplements from the man-

ufacturer are included immediately in this manual.

2 Introduction

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100_0000_0013.fm

2.5 Target group

Note: Persons working with this machine must receive regular training about the

risks and hazards of this machine.

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

Operatives:

These persons are introduced to the machine and informed about potential haz-

ards arising from improper behavior.

Specialist staff:

These persons have specialist training, as well as additional knowledge and ex-

perience. They are able to assess the tasks entrusted to them and recognize po-

tential risks and hazards.

2 Introduction

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2.6 Symbol explanation

This manual contains prominent safety information relating to category types:

DANGER, WARNING, CAUTION and NOTE.

Before commencing any work on or with this machine, notes and safety informa-

tion must be read and understood. All notes and safety information contained in

this manual must also be shared with maintenance, repair, and transport staff.

Notes

Note: Further information.

DANGER

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

which, if ignored, will lead to death or serious injuries.

WARNING

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

which, if ignored, may lead to death or serious injuries.

CAUTION

This combination of symbol and signal word indicates a potentially hazardous

situation, which, if ignored, may lead to minor injuries and damage to the ma-

chine.

2 Introduction

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2.7 Wacker Neuson representative

Depending on your country, the Wacker Neuson representative is a Wacker

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

On the Internet at www.wackerneuson.com.

The address of the manufacturer is located at the beginning of this manual.

2.8 Limitation of liability

Wacker Neuson will refuse to accept liability for injuries to persons or for damage

to materials in the following cases:

 Failure to comply with this manual.

 Improper use.

 Use of untrained staff.

 Use of non-authorized spare parts and accessories.

 Improper handling.

 Any type of structural alteration.

 Non-compliance with with the General Terms and Conditions of Business

(T&C).

2 Introduction

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2.9 Identification of the machine

Nameplate data

The nameplate lists information that uniquely identifies this machine. This infor-

mation is needed to order spare parts and when requesting additional technical

information.

 Enter details on the machine in the following table:

Item Designation Your information

1 Group and type

2 Construction year

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.

3 Security

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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.

Spare parts or accessories from Wacker Neuson can be safely assembled or

mounted.

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.

The manual must be kept next to the machine or place of use.

The operator must hand over the manual to subsequent operators or owners of

the machine.

The country-specific regulations, standards, and guidelines on accident preven-

tion and environmental protection must be observed. The operator’s manual

must supplemented with additional instructions that take regulatory, national, or

generally applicable safety standards into consideration.

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.

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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.

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.

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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.

 Make working area to public transport safe.

 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 personnel.

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

machine is thus maintained.

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

personal protective equipment reduces the risk of injury considerably.

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

machine part 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

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

 Ensure that no other individuals are in the danger zone!

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3.6.4 Handling and use

 Handle machines with care. Do not operate machines with defective compo-

nents or operator’s controls. Immediately replace defective components or

operator’s controls. Machines with defective components or operator’s con-

trols carry a high risk of injury!

 The operator’s controls of the machine shall not be improperly locked, manip-

ulated, or changed.

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

operated by authorized personnel.

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

tions.

 After operation, store the cooled machine in a locked, clean, frost-protected

and dry location that is inaccessible to other people and children.

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!

3 Security

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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 Wacker Neuson use starter batteries. These are vibration proof and

therefore suitable for the high vibration exposure.

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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 measuring, evaluating, and reducing vibra-

tion emissions — especially the DIN 4150-3 — must be considered.

Wacker Neuson accepts no liability for any damage to buildings.

3.8 General safety instructions - combustion engines

The following instructions must be adhered to:

 Before starting work, check the engine to ensure there are no leaks and/or

cracks in the fuel lines, 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

damage.

 Make sure that the exhaust system of the engine is free of debris. Fire haz-

ard!

 Switch off before refueling the engine.

 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 surface and exhaust system can quickly become extremely hot.

Risk of burns!

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:

 Always wear safety glasses and protective gloves when handling fuel, lubri-

cants, and coolants. If hydraulic oil, fuel, oil, or coolant gets into your eyes,

see a doctor immediately.

 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 contact

partner.

3.10 General safety instructions - Starter batteries

The following instructions must be adhered to:

 When disconnecting the starter battery, always disconnect the negative ter-

minal first!

 When connecting the starter battery, always connect the positive terminal

first! Fasten battery terminal cover!

 Flames, sparks, and smoking are prohibited when handling starter batteries.

 Starter batteries contain corrosive acid. Wear acid-proof protective gloves

and safety glasses when handling starter batteries.

 Prevent incorrect connection of the starter battery or bridging of the terminals

with tools. Risk of short circuit!

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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

replaced.

 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.

Safety 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).

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Wacker Neuson DPU4545Hec User manual

Wacker Neuson DPU4545Hec User manual

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