Wacker Neuson DPU 4045H User manual

www.wackergroup.com
Operator´s Manual
Vibratory plate
DPU 4045H
0109984en 003
04.2008

T00940GB.fm 1
Important information
This machine has been provided with an EPA-certified engine.
Additional information can be found in the engine
manufacturer‘s notes.
Engine exhaust, some of its constitvents, and certain vehicle
components contain or emit chemicals known to the State of
California to cause cancer and birth defects or other reproduc-
tive harm.
WARNING
Caution
This engine is an EPA engine.
Adjusting the engine speed will interfere with EPA certification and
the emissions.
Only authorized personnel can make adjustments to this engine.
Please contact you nearest engine dealer or your Wacker Dealer for more
information.

T00940GB.fm 2

Vorwort.fm 3
Foreword
1. Foreword
For your own safety and protection from bodily injuries, carefully read,
understand and follow the safety instructions in this manual.
Please operate and maintain your Wacker machine in accordance with
the instructions in this manual. Your Wacker machine will reward your
attention by giving trouble-free operation and a high degree of
availability.
Replace faulty or defective components Immediately.
All rights, especially the right for copying and distribution are reserved
Copyright 2008by Wacker Construction Equipment AG
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express permission in writing from Wacker Construction Equipment AG.
Any type or manner of reproduction, distribution or storage on data
carriers or storage mediums not authorized by Wacker represents an
infringement of valid copyrights and will be prosecuted. We expressly
reserve the right to make technical modifications - even without due
notice - which aim at improving our machines or increasing their safety
standards.

Table Of Contents
4
1. Foreword 3
2. Safety instruction 6
2.1 General instructions ..............................................................................6
2.2 Operation ...............................................................................................6
2.3 Safety checks ........................................................................................8
2.4 Maintenance ..........................................................................................9
2.5 Transport ...............................................................................................9
2.6 Maintenance checks ............................................................................10
3. Technical Data 11
4. Description 13
4.1 Applications .........................................................................................13
4.2 Dimensions ..........................................................................................13
4.3 Max. admissible inclination ..................................................................13
4.4 Description of function .........................................................................14
5. Transport to work site /Recommendations on compaction 16
5.1 Transport to work site ..........................................................................16
5.2 Recommendations on compaction ......................................................17
6. Operation 18
6.1 Starting ................................................................................................18
6.2 Mechanical oil pressure control ...........................................................20
6.3 Forward and reverse motion ...............................................................21
6.4 Switching off ........................................................................................21
6.5 Compaction without extension plates ..................................................21
6.6 Additional notes on starting at very low temperatures! ........................22

Table Of Contents
5
7. Maintenance 23
7.1 Maintenance schedule ........................................................................23
7.2 Engine oil .............................................................................................24
7.3 Hydraulic control ..................................................................................25
7.4 Exciter .................................................................................................26
7.5 Exciter V-belt .......................................................................................27
8. Faults 28
8.1 Forward speed too low ........................................................................28
8.2 Reverse speed too low ........................................................................28
8.3 No reverse motion ...............................................................................28
8.4 Loss of hydraulic oil .............................................................................28
8.5 Engine does not start ..........................................................................29
9. Lables 30
EC - Conformity Certificate 31
DIN EN ISO 9001 Certificate 33

Safety instruction
SV00053GB.fm 6
2. Safety instruction
for the use of vibratory plates with combustion engines
2.1 General instructions
2.1.1 Vibratory plates may only be operated by persons who
∗are at least 18 years of age
∗are physically and mentally fit for this job
∗have been instructed in guiding vibratory plates and proved their ability
for the job to the employer
∗may be expected to carry out the job they are charged with carefully.
The persons must be assigned the job of guiding vibratory plates by
the employer.
2.1.2 Vibratory plates may only be used for compaction jobs. Both the
manufacturer’s operating instructions and these safety instructions
have to be observed.
2.1.3 The persons charged with the operation of vibratory plates have to be
made familiar with the necessary safety measures relating to the
machine. In case of extraordinary uses the employer shall give the
necessary additional instructions.
2.1.4 It is possible that these vibratory plates exceed the admissible
assessment sound level of 89 dB (A). Employees must wear personal
ear protection if the sound level reaches 89 dB (A) or more.
2.2 Operation
2.2.1 When starting the diesel engine with a starter crank make sure you
have assumed a proper position with respect to the engine and that
your hands are placed properly on the crank.
Only use the original engine manufacturer’s safety starting crank.
To avoid a possible return kick, turn safety starting crank through with
full force until the engine starts running.
2.2.2 The function of operation levers or elements is not to be influenced or
rendered ineffective.

Safety instruction
SV00053GB.fm 7
2.2.3 During operation the operator may not leave the control elements.
2.2.4 The operator has to stop the engine of the vibratory plate before going
on breaks. The machine has to be placed such that it cannot turn over.
2.2.5 Stop engine before filling fuel tank. When refilling fuel tank, do not
allow fuel to come into contact with the hot part of the engine or spill
onto the ground.
2.2.6 Do not smoke or handle open fire near this machine.
2.2.7 The tank lid must fit tightly. Shut fuel cock if available when stopping
the engine. For long distance transports of machines operated by fuel
or fuel - mixtures, the fuel tank has to be drained completely.
Leaky fuel tanks may cause explosions and must therefore be
replaced immediatelly.
2.2.8 Do not operate this machine in areas where explosions may occur.
2.2.9 Make sure that sufficient fresh air is available when operating vibratory
plates equipped with combustion engines in enclosed areas, tunnels,
galleries and deep trenches.
2.2.10 During operation keep your hands, feet and clothes away from the
moving parts of the vibraton plate. Wear safety shoes, and eye
protection glasses in case of trench operation where falling sand
stones maybe ejected.
2.2.11 When working near the edges of breaks, pits, slopes, trenches and
platforms, vibratory plates are to be operated such that there is no
danger of their turning over or dropping in.
2.2.12 Make sure the soil or subsoil to be compacted has a high enough load
carrying capacity.
2.2.13 Use appropriate protective clothing while working or while carrying out
maintenance work.

Safety instruction
SV00053GB.fm 8
2.2.14 When traveling backwards the operator has to guide the vibration plate
laterally by its guide handle so that he will not be squeezed between
the handle and a possible obstacle. Special care is required when work
ing on uneven ground or when compacting coarse material. Make sure
of a firm stand when operating the machine under such conditons.
2.2.15 Vibratory plates are to be guided such that hand injuries caused by
solid objects are avoided.
2.2.16 Vibratory plates have to be guided such that their stability is
guaranteed.
2.2.17 Machines with integrated transport trolley may not be parked or stored
on the trolley. This device has only been designed to transport the
machine.
2.3 Safety checks
2.3.1 Vibratory plates may only be operated with all safety devices installed.
2.3.2 Before starting operation, the operator has to check that all control and
safety devices function properly.
2.3.3 If defects in the safety equipment or other defects are detected which
impair the safe operation of the internal vibrator, the supervisor is to be
notified without delay.
2.3.4 The machine must to be switched off immediately in case of defects
jeopardizing the operational safety of the equipment.
2.3.5 Process materials and operating fuels must be stowed away in
receptacles or containers marked according to the respective
manufacturers specifications.

Safety instruction
SV00053GB.fm 9
2.4 Maintenance
2.4.1 Only use original spare parts. Modifications to this machine including
the adjustment of the maximum speed set by the manufacturer are
subject to the express approval of WACKER. In case of
nonobservance all liabilities shall be refused.
2.4.2 All drive units have to be switched off before carrying out maintenance
jobs. Deviations from this are only allowed if the maintenance or jobs
require a running engine.
2.4.3 When working on vibratory plates equipped with electric starter,
disconnect battery before carrying out maintenance or repair jobs on
the electric parts of the machine.
2.4.4 Remove pressure from hydraulic lines before working on them.
Caution: take care when removing hydraulic lines, for the oil may be
very hot (up. over 80oC). Precautions are to be taken to prevent oil
from splashing into the operator’s eyes.
2.4.5 All safety devices must be reinstalled properly immediately after
maintenance and repair jobs have been completed.
2.4.6 Do not hose down the machine with water after each use to avoid
possible malfunctions. Do not use high pressure washers nor chemical
products.
2.5 Transport
2.5.1 During transport, loading and unloading of vibration plates by means
of lifting devices, appropriate slinging means or hooks have to be used
on the lifting points provided for this purpose on the vibratory plate.
2.5.2 The load-carrying capacity of the loading ramps has to be sufficient
and the ramps have to be secure such that they cannot turn over. Make
sure that no one be endangered by machines turning over by slipping
or by moving machine parts.
2.5.3 When being transported on vehicles, precautions have to be taken that
vibration plates do not slip or turn over.

Safety instruction
SV00053GB.fm 10
2.6 Maintenance checks
2.6.1 According to the conditions and frequency of use, vibratory plates have
to be checked for safe operation at least once a year by skilled
technicians, such as those found at WACKER-service depots and
have to be repaired if necessary.
Please also observe the corresponding rules and regulations valid in your
country.

Technical Data
TD00691GB.fm 11
3. Technical Data
DPU 4045H
Item no. 0610051
Operating weight
without extension plates 440 (mm) kg:
kg: 367
390
Forward/reverse speed m/min: 0 to 20
Surface compaction performance m2/h: to 732
Power transmission From drive engine directly to exciter unit via
automatic centrifugal and V-belts
Exciter
Vibrations min-1 (Hz): 4140 (69)
Centrifugal force kN: 40
Multigrade oil Fuchs Titan Unic 10W40 MC (SAE 10W40)
Drive motor Air-colled single-cylinder 4 stroke diesel engine
Piston displacement cm3:413
Engine speed min-1:2800/220
Rated power (*) kW:
5,8
Fuel Diesel
Fuel consumption l/h: 1,5
Tank capacity l: 5,0
Oil Fuchs Titan Unic 10W40 MC (SAE 10W40)
Hydraulic control
Hydraulic oil Fuchs Renolin MR 520
Special lubricating grase LPA:92 dB(A)

Technical Data
TD00691GB.fm 12
(*) In accordance with the installed useful outlet power according to Directive 2000/14/
EG.
The weighted effec-tive
acceleration value, determined
according to EN ISO 5349 m/s2:4,4
DPU 4045H

Description
T00986GB.fm 13
4. Description
4.1 Applications
The application range of these machines reaches from the trench and
surface compaction, even with semi-cohesive soils, to the vibration of
interlocking paving stones and sett pavements.
4.2 Dimensions
4.3 Max. admissible inclination

Description
T00986GB.fm 14
4.4 Description of function
4.4.1 The vibration required for compaction is produced by the exciter (13)
which is firmly joined to the lower mass (5). This exciter (13) is
designed as a central vibrator with aligned vibrations. Such a principle
permits the direction of vibration to be changed by turning the eccentric
weights (15). In this way an infinitely variable transition between
vibration in forward motion , at standstill and in reverse motion is
possible. This process is hydraulically controlled with the operating
control handle (6) on the centre pole head (7).
4.4.2 The drive engine (1) anchored to the upper mass (4) drives the exciter
(13). The torque is transmitted by means of a friction connection
through the centrifugal clutch (11) and the exciter V-belt (12).
Forwards Standstill Reverse

Description
T00986GB.fm 15
4.4.3 The centrifugal clutch (11) interrupts flow of power to the exciter (13)
at low engine speed and thus permits perfect idling of the drive engine
(1).
4.4.4 The automatic V-belt pulley (10) combined with the centrifugal clutch
(11) ensures optimum tension of the exciter V-belt (12) during
operation and relief of the tension of the exciter V-belt (12) when the
machine is being relocated or transported.
4.4.5 Moreover, the automatic V-belt pulley (10) automatically adapts to the
V-belt flanks in line with the wear and thus makes the entire drive from
the engine (1) to the exciter (13) maintenance-free (see chapter
Exciter V-belt).
4.4.6 The speed of the drive engine (1) can be infinitely varied by remote
control on the throttle control lever (8). The upper (4) and lower (5)
masses are connected to each other by 4 vibration-damping rubber
metal shock mounts (14). This damping system prevents the very high
frequencies from being transmitted to the upper mass (4). As a result
the functionability of the drive engine (1) is retained in spite of the high
compaction performance. The drive engine (1) works on the diesel
principle; it is started electrically by a pinion starter (3), draws in the
combustion air through an air filter, dry (9) and is air-colled.
4.4.7 To facilitate the starting procedure (at very low temperatures, with
hand start) the drive engine (1) has an automatic decompression
mechanism (2). It ensures that compression is very low during the
cranking operation but steadily increases after a few revolutions when
it then switches over to full compression.

Transport to work site /Recommendations on compaction
T00987GB.fm 16
5. Transport to work site /Recommendations on compaction
5.1 Transport to work site
Conditions:
∗To transport the vibration plate, only use suitable lifting equipment with
a minimum load-bearing capacity of 500 kg.
∗Always switch off engine before transporting the machine!
∗Vertically set guide handle head and lock into place.
∗Only attach suitable tackle at the central lifting point (18a) provided.
The central lifting point is located exactly above the centre of gravity of
the machine. The central lifting point can be displaced rearwards
(18b), given an application in which the height of the machine is of
importance (torque wrench setting = 85 Nm).
∗During transport on the loading area of a vehicle, tie down the vibration
plate using the lugs (17).
Note: Also overve the regulations in safety instructions.

Transport to work site /Recom-
T00987GB.fm 17
5.2 Recommendations on compaction
5.2.1 Ground conditions
The max. compaction depth depends on several factors relating to the
ground condition, such as moisture, grain distribution etc,
it is therefore not possible to specify exact values.
Recommendation: In each case determine the max. compaction
depth with compaction tests and soil samples.
5.2.2 Compaction on slopes
The following points are to be observed when compacting on sloped
surfaces (slopes, embankments):
∗Only approach gradients from the bottom (a gradient which can be
easily overcome upwards, can also be compacted downwards without
any risk).
∗The operator must never stand in the direction of descent.
∗The max. gradient of 25omust not be exceeded.
A tilt in excess of this angle could lead to a stopping of the engine due
to the automatic low oil shut-off system. A restarting of the engine can
only take place after the valve lever at the oil filter housing has been
actuated once.
Right ! Wrong!

Operation
T00988GB.fm 18
6. Operation
6.1 Starting
6.1.1 Conditions:
Oil:
Check oil level with oil dipstick (21), if necessary top up with Fuchs
Titan Unic 10W40 MC through oil filler neck (19).
Fuel:
When pouring diesel fuel into the filler neck (20), maintain absolute
cleanliness. Impurities in the fuel can cause breakdowns in the
injection system and premature clogging of the fuel filter.
Air filter:
Clean air filter dry, dusty conditions.
6.1.2 Once these points have been observed, you can start the engine as
follows:
1. Turn the throttle control lever (8) clockwise into full load position.