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DPU 4545H

Wacker Neuson DPU 4545H User manual

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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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5100009744IVZ.fm
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
5100009744IVZ.fm 5
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.
All rights reserved, especially reproduction and distribution rights.
Copyright 2015 Wacker Neuson Produktion GmbH & Co. KG
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
100_0000_0013.fm 7
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
100_0000_0013.fm 9
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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100_0000_0013.fm
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
100_0000_0013.fm 11
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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100_0202_si_0006.fm
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
100_0202_si_0006.fm 13
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.
3 Security
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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.
3 Security
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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!
3 Security
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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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