Wacker Neuson DPU 4045 Operator'S Manual Download Page 1

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Operator's manual

Vibratory plate

DPU

4045, 4545, 5545,

6555

Model

DPU

Document

5100009744

Issue

01.2019

Version

Language

Summary of Contents for DPU 4045

Page 1: ...Operator s manual Vibratory plate DPU 4045 4545 5545 6555 Model DPU Document 5100009744 Issue 01 2019 Version 09 Language en ...

Page 2: ...he statutory provisions in particular the protection of copyright will lead to civil and criminal prosecution Wacker Neuson Produktion GmbH Co KG is constantly working on the improvement of its products as part of the technical further development Therefore we reserve the right to make changes to the illustrations and descriptions in this documentation without incurring any obligation to make chan...

Page 3: ...RNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm WARNING Cancer and Reproductive Harm www P65Warnings ca gov WARNING Batteries battery posts terminals and related accessories contain lead and lead compounds and other chemicals known to the State of California to cause cancer and birth defects or ...

Page 4: ...1 CALIFORNIA Proposition 65 Warning 4 100_0000_0024 fm ...

Page 5: ...ombustion engines 14 4 9 General safety instructions fuel lubricants and coolants 14 4 10 General safety instructions starter batteries 14 4 11 Maintenance 15 4 12 Personal Protective Equipment 15 4 13 Safety devices 16 4 14 Behavior in dangerous situations 16 5 Safety and information labels 17 6 Setup and function 19 6 1 Standard package 19 6 2 Application areas 19 6 3 Short description 19 6 4 Ve...

Page 6: ...hnical data 44 14 1 DPU4045 44 14 2 Combustion engine 45 15 Technical data 46 15 1 DPU4545 46 15 2 Combustion engine 48 16 Technical data 49 16 1 DPU5545 49 16 2 Combustion engine 52 17 Technical data 53 17 1 DPU6555 53 17 2 Combustion engine 57 EC Declaration of Conformity 58 DIN EN ISO 9001 certificate 31 ...

Page 7: ...al is not a manual for extensive maintenance or repair work Such work should be carried out by Wacker Neuson service or by technically trained personnel The Wacker Neuson machine should be operated and maintained in accordance with this operator s manual An improper operation or improper maintenance can pose dangers Therefore the operator s manual should be constantly available at the location of ...

Page 8: ...ght to change this information The manufacturer shall immediately include any modifications or additions in this manual 3 5 Target group Individuals working with this machine must be regularly trained on the dangers of handling the machine This manual is intended for the following people Operating personnel These individuals have been trained on the machine and informed about the possible dangers ...

Page 9: ...e Deployment of untrained personnel Using non approved spare parts and accessories Improper handling Structural modifications of any kind Failure to observe the General Terms and Conditions GT Cs 3 9 Product 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 inqu...

Page 10: ... result in risks to the operator and or third parties as well as damage to the machine In the case of unauthorized structural changes the liability and warranty of the manufacturer are no longer applicable The following cases are considered structural changes Opening the machine and the permanent removal of components Installing spare parts that do not originate from Wacker Neuson or are not compa...

Page 11: ...inimum age of 18 to operate this machine Be instructed in the independent operation of the machine Be authorized to operate machines and systems independently according to the standards of safety engineering 4 5 Residual risks Residual dangers in particular are hazards when dealing with machines that despite a safe design cannot be eliminated These residual dangers are not obvious and may be the s...

Page 12: ... values of vibration measurement refer to the Technical Data section Wear suitable clothing Keep loose clothing gloves jewelry and long hair away from moving rotating machine parts Danger of being pulled Ensure that no other individuals are in the danger zone 4 6 4 Handling and use Handle machines with care Do not operate machines with defective components or operator s controls Immediately replac...

Page 13: ...These can cause misfires as well as engine damage Fire hazard When operating the machine on sloped surfaces always approach slopes from below and always stay above the machine on a slope The machine could slip or tip over Do not exceed max allowable slanting position of the machine possible failure of the engine lubrication see chapter Technical Data Only Wacker Neuson use starter batteries These ...

Page 14: ...th soap and water Do not eat or drink while working with fuel lubricants and coolants Contaminated hydraulic oil or fuel from dirt or water can lead to premature wear or failure of the machine Dispose of spilled fuel lubricants and coolants according to the applicable provisions for environmental protection If fuel lubricants and coolants escape from the machine do not operate the machine any long...

Page 15: ... vicinity e g workshop 4 12 Personal Protective Equipment NOTICE To prevent personal injury when handling this machine personal protective equipment must be worn when working on or around this machine Pictogram Significance Description Wear safety shoes Safety shoes provide protection from bruises falling objects and slipping Wear protective gloves Protective gloves provide protection from abrasio...

Page 16: ... equipment on hand Make sure that all employees are familiar with accident reporting first aid and rescue facilities Keep access routes clear for emergency vehicles Make sure that employees receive first aid training Measures in the case of an emergency Immediately take the machine out of operation Remove injured and other people from the danger zone Initiate first aid measures Alert rescuers Keep...

Page 17: ...bels and signs immediately Item Label Description 1 Use personal protection equipment in order to avoid injuries and health hazards Ear protection Read operator s manual 2 Falling machines can cause serious injury Only lift machine at the central lifting point with certified lifting gear and tackle safety load hook Do not lift the machine on the central lifting point with an excavator bucket Do no...

Page 18: ... crushed or cut off from rotating engine parts Do not touch the support of the starting crank 7 US Machines Warning 8 Machines with electric starter Start Stop 9 Tie down 10 US Machines Warning against hot surface 11 US Machines Warning From chemicals that cause cancer birth defects or other reproductive damage Item Label Description 0220000 0219261 WARNING WARNUNG ADVERTENCIA ADVERTISSEMENT 02191...

Page 19: ...s preserved despite the high compaction performance The drive motor works according to the diesel principle is electrically started via a gear and pinion starter draws the combustion air through a dry type air cleaner and is air cooled To facilitate the starting process when very cold the drive motor has a decompression automation system This causes the compression to be very low when starting to ...

Page 20: ...tective frame is recommended 6 4 Versions This operator s manual covers the following models NOTICE Compatec compaction display only supports soil compaction and does not replace the professional measuring of soil density by an expert Versions Description H Hatz Y Yanmar e Electric starter h Operating hour meter ap Extension plates c Compatec compaction display s Narrow protective cage zf Addition...

Page 21: ...d spindle Central lifting point The central lifting point is used to lift the machine This is found in the center of gravity of the machine Item Designation Item Designation 1 Drive motor 7 Protective frame 2 Upper mass 8 Operating hour meter optional 3 Base plate 9 Extension plates 4 Center pole 10 Compatec compaction display optional 5 Central lifting point 11 Control lamp operation 6 Fuel tank ...

Page 22: ...drive motor can be varied remotely operated on the gas regulating lever Decompression lever The decompression lever may only be actuated to start the machine Jump start pin The jump start pin facilitates connecting the jumper cable when jump starting Handle center pole lock The handle center pole lock is used to release the center pole so that it can be returned to working position Threaded spindl...

Page 23: ...le and tested lifting gear and tackle safety load hooks of sufficient lifting capacity Only lift the machine from the central lifting point Reliably secure the machine to the lifting gear Do not lift the machine on the central lifting point with a forklift or excavator bucket Do not lift the machine at the control handle Evacuate danger zone while lifting do not stop under suspended loads WARNING ...

Page 24: ... into or onto a stable means of transport 3 After loading the machine lash down the machine to prevent it from rolling off slipping or tipping over Attach tie down lugs to the designated lashing points NOTICE Appoint a specialist flagman for a safe lifting operation Item Designation Item Designation 1 Central lifting point 2 Tie down lugs Item Designation 1 Belt 2 2 1 ...

Page 25: ...e 9 2 Notes about operation WARNING Improper handling may result in injury or serious material damage Please read and follow all safety instructions in this operator s manual NOTICE Perform control procedures according to the Maintenance chapter If necessary top off missing fuel lubricants and coolants see chapterTechnical Data Item Designation Item Designation 1 Center pole 2 Threaded spindle WAR...

Page 26: ...ing mechanism in order to avoid damage to the machine and compaction material See chapter Accessories 9 3 Commissioning 9 3 1 Commissioning the machine manual start 1 Put the throttle lever in the full throttle position 2 Pull the decompression lever up NOTICE If the maximum permissible slanting position is exceeded this results in a failure of the engine lubrication and therefore inevitably cause...

Page 27: ...fter the decompression automation system locks into place give starting crank revolutions are required until the engine can be re compressed and strike NOTICE Once the engine starts the decompression lever disengages the maximum possible speed must be reached the engine starts and the vibration starts The friction connection between the engine and starting crank must be ensured through the anti tw...

Page 28: ...Fill motor oil in the metering device up to the upper rim 5 Seat the cover and forcibly press it in 6 Pull the decompression lever up until the detent 7 Then start the engine immediately See the chapter Commissioning the machine manual start NOTICE For temperatures below 5 C generally freely turn the engine Item Designation Item Designation 1 Decompression lever 3 Metering device 2 Lever for the o...

Page 29: ...ling position 3 Turn the ignition key switch to l 4 Pull out the starter rope slowly up to the compression resistor 5 Press and release the decompression lever 6 Quickly and strongly pull the starter rope on the starter handle while pulling the rope as far as possible 7 Allow the machine to warm up by idling for a few minutes Item Designation Item Designation 1 Throttle lever 3 Ignition lock 2 Dec...

Page 30: ...intended purpose the operator should stand behind the machine Guide and steer machine using the control handle 9 4 1 Select the travel direction 1 Put the throttle lever in the full throttle position 2 Select travel direction and speed with the control handle Item Designation Item Designation 1 Display unit 2 LEDs light progress bar NOTICE If all LEDs light up the system is fault free The LEDs wil...

Page 31: ...TICE To protect the machine the display unit warns the operator of over compaction by quickly flashing all LEDs The brightness of the LED automatically adjusts to the light conditions of the working area NOTICE It is possible to detect missing spots non compactable material if the spot is longer than one meter In the case of abrupt change from high to low compacted soil or vice versa there is a sl...

Page 32: ...lock to the left and pull out The charge control lamp will go out and the acoustic signal will be silent Item Designation Item Designation 1 Throttle lever 3 Charge control lamp 2 Ignition lock NOTICE The Compatec compaction display automatically switches itself off once the ignition switch key is pulled out The display unit has no sleep function Continuous operation without engine operation leads...

Page 33: ...witched off and the machine decommissioned WARNING Risk of fire and explosion from fuel and fuel vapors Fuel and fuel vapors may ignite or catch fire and cause serious burns Do not smoke Do not refuel near open flames Switch off the engine and allow to cool before refueling WARNING Warning of hot surfaces The muffler and engine can become extremely hot which can lead to severe skin burns if touche...

Page 34: ...ater trap Check the intake area of the combustion air Check air cleaner service indicator Cleaning replacing the air cleaner cartridge 500 hours Check the tapped clearance 25 h 250 h Check the exciter oil level Replace the exciter oil 250 h 1 2 year Check hydraulic oil level Check hydraulic hose lines 125 hours Check replace the V belt Check the rubber buffer 125 hours Check the to ensure the scre...

Page 35: ...ary top off the fuel with a clean filling container Fuel type See chapter Technical Data 6 Tightly seal the tank cap CAUTION Health risk from fuel lubricants and coolants Do not inhale fuel lubricants coolants or vapors Avoid contact of skin or eyes with fuel lubricants and coolants WARNING Risk of fire and explosion from fuel and fuel vapors Do not smoke Do not refuel near open flames Switch off ...

Page 36: ...minate detected damage Check and replace V belt and belt stabilizer Machines with Hatz engine Item Designation Item Designation 1 Plate cover 2 Hexagonal bolt NOTICE Since water is specifically heavier than diesel fuel the water will exit first and then the fuel This can be seen by a clear separating line WARNING Risk of fire and explosion when using flammable cleaning agents Do not clean the mach...

Page 37: ... around the v belt pulley exciter and press over the v belt pulley engine 9 Push the v belt pulley engine inwards towards the machine 10 Screw the gasket bellville lock washers and mushroom shaped plate back on with the screw The torque setting is 49 Nm 11 Seat the belt guard and screw tight The torque setting is 25 Nm Item Designation Item Designation 1 Belt guard 2 Screw NOTICE Do not oil or gre...

Page 38: ...lley 7 Screw on nuts and tighten alternately while constantly rotating the V belt pulley 8 Assemble the belt guard Replace the exciter oil and check the oil level 1 Tip the machine to the side of the filler boring and support it 2 Place an appropriate collecting container below the filler boring 3 Remove dirt accumulation within the range of the filler boring DANGER Risk of scalding Use caution wh...

Page 39: ...d volume in the filler boring Use an appropriate and clean filling container 7 Place the machine level on the ground 8 Screw the screw plug with seal ring into the filler boring The torque setting is 100 Nm NOTICE Collect escaping or overflowing oil and dispose of with the waste oil in an environmentally friendly manner in accordance with the existing rules and regulations of the legislative body ...

Page 40: ...will not start Defective ignition lock Have the machine repaired Defective starter motor Discharge starter battery Charge starter battery Low oil level Top up oil and actuate valve hood on the oil filter housing The charge control lamp will not go out Defective alternator Have the machine repaired The acoustic signal will not stop sounding Defective voltage regulator Compaction display optional If...

Page 41: ...tarting process and contact your Wacker Neuson contact person 6 Run engine for a few minutes Disconnect the jumper cable 7 Disconnect clamping tongs of the black jumper cable from the grounding point of the machine 8 Disconnect the second clamping tongs of the black jumper cable from the donor battery 9 Disconnect the clamping tongs of the red jumper cable from the jump start pin and ensure that t...

Page 42: ...es may not be disposed of with normal household waste As an end user you may only dispose of used batteries via the manufacturer or specially equipped collection facilities statutory obligation to return the delivery is free Retailers and manufacturers are obliged to take back these batteries and properly recycle them or dispose of them as hazardous waste legal obligation Batteries obtained throug...

Page 43: ...against damage to the sett paving paving stone surface which is especially required for surface coated types of paving Machines with Hatz engine Starting crank DPU4545 and DPU5545 short tool shank of the starting crank DPU6555 long tool shank of the starting crank Starting crank holder A starting crank holder can be attached to store the starting crank on the machine CAUTION Accessories and spare ...

Page 44: ...859 764 859 859 Rated power kW 4 5 4 5 4 5 Nominal speed 1 min 3 000 3 000 3 000 Exciter oil volume l 0 75 0 75 0 75 Exciter oil type 75W 90 API GL 4 Hydraulic oil volume l 0 5 0 5 0 5 Type of hydraulic oil MR 520 Storage temperature range C 10 40 10 40 10 40 Operating temperature range C 10 40 10 40 10 40 Sound pressure level At location of operation LpA dB A 94 94 94 Standards EN 500 4 Sound pow...

Page 45: ...20 Max slanting position 20 Fuel type Diesel EN 590 Fuel consumption l h 1 4 Tank capacity l 3 3 Oil specification SAE 10W30 Max oil filling l 1 1 Max performance kW 4 5 Drill speed 1 min 3 000 Standards ISO 3046 IFN Air cleaner Dry type air cleaner Starter type Electric starter Battery voltage V Special Wacker Neuson starter battery for vibratory plates 12 V 45 Ah Battery capacity nominal value A...

Page 46: ...14 790 914 790 914 Rated power kW 6 4 6 4 6 4 Nominal speed 1 min 2 850 2 850 2 850 Exciter oil volume l 0 75 0 75 0 75 Exciter oil type 75W 90 API GL 4 Hydraulic oil volume l 0 5 0 5 0 5 Type of hydraulic oil MR 520 Storage temperature range C 15 40 15 40 15 40 Operating temperature range C 15 40 15 40 15 40 Sound pressure level At location of operation LpA dB A 94 94 94 Standards EN 500 4 Sound ...

Page 47: ...ce mm 790 914 790 914 790 914 790 914 914 Rated power kW 6 4 6 4 6 4 6 4 6 4 Nominal speed 1 min 2 850 2 850 2 850 2 850 2 850 Exciter oil volume l 0 75 0 75 0 75 0 75 0 75 Exciter oil type 75W 90 API GL 4 Hydraulic oil volume l 0 5 0 5 0 5 0 5 0 5 Type of hydraulic oil MR 520 Storage temperature range C 15 40 15 40 15 40 15 40 15 40 Operating temperature range C 15 40 15 40 15 40 15 40 15 40 Soun...

Page 48: ...Fuel type Diesel EN 590 Fuel consumption l h 1 6 1 6 1 6 Tank capacity l 5 0 5 0 5 0 Oil specification SAE 10W40 SAE 10W40 SAE 10W40 Max oil filling l 1 1 1 1 1 1 Max performance kW 7 0 7 0 7 0 Drill speed 1 min 3 600 3 600 3 600 Standards ISO 3046 IFN Air cleaner Dry type air cleaner Dry type air cleaner Dry type air cleaner Starter type Manual crank start Electric starter Electric starter Batter...

Page 49: ...e mm 790 914 790 914 790 914 790 914 Rated power kW 6 4 6 4 6 4 6 4 Nominal speed 1 min 2 850 2 850 2 850 2 850 Exciter oil volume l 0 75 0 75 0 75 0 75 Exciter oil type 75W 90 API GL 4 Hydraulic oil volume l 0 5 0 5 0 5 0 5 Type of hydraulic oil MR 520 Storage temperature range C 15 40 15 40 15 40 15 40 Operating temperature range C 15 40 15 40 15 40 15 40 Sound pressure level At location of oper...

Page 50: ... 790 914 Rated power kW 6 4 6 4 6 4 Nominal speed 1 min 2 850 2 850 2 850 Exciter oil volume l 0 75 0 75 0 75 Exciter oil type 75W 90 API GL 4 Hydraulic oil volume l 0 5 0 5 0 5 Type of hydraulic oil MR 520 Storage temperature range C 15 40 15 40 15 40 Operating temperature range C 15 40 15 40 15 40 Sound pressure level At location of operation LpA dB A 94 94 94 Standards EN 500 4 Sound power leve...

Page 51: ...ower kW 6 4 6 4 Nominal speed 1 min 2 850 2 850 Exciter oil volume l 0 75 0 75 Exciter oil type 75W 90 API GL 4 Hydraulic oil volume l 0 5 0 5 Type of hydraulic oil MR 520 Storage temperature range C 15 40 15 40 Operating temperature range C 15 40 15 40 Sound pressure level At location of operation LpA dB A 94 94 Standards EN 500 4 Sound power level Lwa measured guaranteed dB A 107 108 107 108 Sta...

Page 52: ...type Diesel EN 590 Fuel consumption l h 1 6 1 6 1 6 Tank capacity l 5 0 5 0 5 0 Oil specification SAE 10W40 SAE 10W40 SAE 10W40 Max oil filling l 1 1 1 1 1 1 Max performance kW 7 0 7 0 7 0 Drill speed max output 1 min 3 600 3 600 3 600 Standards ISO 3046 IFN Air cleaner Dry type air cleaner Dry type air cleaner Dry type air cleaner Starter type Manual crank start Electric starter Electric starter ...

Page 53: ... mm 861 1 005 861 1 005 861 1 005 861 1 005 Rated power kW 9 6 9 6 9 6 9 6 Nominal speed 1 min 2 800 2 800 2 800 2 800 Exciter oil volume l 0 75 0 75 0 75 0 75 Exciter oil type 75W 90 API GL 4 Hydraulic oil volume l 0 5 0 5 0 5 0 5 Type of hydraulic oil MR 520 Storage temperature range C 15 40 15 40 15 40 15 40 Operating temperature range C 15 40 15 40 15 40 15 40 Sound pressure level At location ...

Page 54: ... 861 1 005 861 1 005 861 1 005 Rated power kW 9 6 9 6 9 6 9 6 Nominal speed 1 min 2 800 2 800 2 800 2 800 Exciter oil volume l 0 75 0 75 0 75 0 75 Exciter oil type 75W 90 API GL 4 Hydraulic oil volume l 0 5 0 5 0 5 0 5 Type of hydraulic oil MR 520 Storage temperature range C 15 40 15 40 15 40 15 40 Operating temperature range C 15 40 15 40 15 40 15 40 Sound pressure level At location of operation ...

Page 55: ...mm 861 1 005 861 1 005 861 1 005 861 1 005 1 005 Rated power kW 9 6 9 6 9 6 9 6 9 6 Nominal speed 1 min 2 800 2 800 2 800 2 800 2 800 Exciter oil volume l 0 75 0 75 0 75 0 75 0 75 Exciter oil type 75W 90 API GL 4 Hydraulic oil volume l 0 5 0 5 0 5 0 5 0 5 Type of hydraulic oil MR 520 Storage temperature range C 15 40 15 40 15 40 15 40 15 40 Operating temperature range C 15 40 15 40 15 40 15 40 15 ...

Page 56: ...ted power kW 9 6 9 6 Nominal speed 1 min 2 800 2 800 Exciter oil volume l 0 75 0 75 Exciter oil type 75W 90 API GL 4 Hydraulic oil volume l 0 5 0 5 Type of hydraulic oil MR 520 Storage temperature range C 15 40 15 40 Operating temperature range C 15 40 15 40 Sound pressure level At location of operation LpA dB A 97 97 Standards EN 500 4 Sound power level Lwa measured guaranteed dB A 108 109 108 10...

Page 57: ...tion l h 1 9 1 9 1 9 Tank capacity l 6 0 6 0 6 0 Oil specification SAE 10W40 SAE 10W40 SAE 10W40 Max oil filling l 1 9 1 9 1 9 Max performance kW 10 1 10 1 10 1 Drill speed 1 min 3 600 3 600 3 000 Standards ISO 3046 IFN Air cleaner Dry type air cleaner Dry type air cleaner Dry type air cleaner Starter type Electric starter Manual crank start Electric starter Battery voltage V Special Wacker Neuson...

Page 58: ... number Guaranteed sound power level 108 db A Conformity assessment procedure 2000 14 EC Annex VIII Notified body 5100009662 5100016954 5100022113 Net installed power 4 5 kW Measured sound power level 107 db A Reichertshofen 01 02 2019 Managing Director 5100009744en_09_DPU4045_CE Guidelines and standards We hereby declare that this product complies with the relevant provisions and requirements of ...

Page 59: ...sound power level 108 db A Conformity assessment procedure 2000 14 EC Annex VIII Notified body 5100009659 5100009661 5100015429 5100016951 5100016953 5100022112 Net installed power 6 4 kW Measured sound power level 107 db A Guidelines and standards We hereby declare that this product complies with the relevant provisions and requirements of the following directives and standards 2006 42 EC 2000 14...

Page 60: ...power level 108 db A Conformity assessment procedure 2000 14 EC Annex VIII Notified body 5100009652 5100009654 5100009655 5100009656 5100016947 5100016949 5100016950 Net installed power 6 4 kW Measured sound power level 107 db A Guidelines and standards We hereby declare that this product complies with the relevant provisions and requirements of the following directives and standards 2006 42 EC 20...

Page 61: ...procedure 2000 14 EC Annex VIII Notified body 5100009636 5100009638 5100009639 5100009651 5100015773 5100015774 5100015775 5100016940 5100016941 5100016943 5100016944 5100016945 5100021400 Net installed power 9 6 kW Measured sound power level 108 db A Guidelines and standards We hereby declare that this product complies with the relevant provisions and requirements of the following directives and ...

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