Weber Maschinentechnik GmbH CR 4 Manual

OPERATING AND
MAINTENANCE
INSTRUCTIONS
Weber Maschinentechnik GmbH
P. O. Box 21 53, D-57329 Bad Laasphe-Rückershausen
Phone ++27 54 / 398-0
Telefax (++ 27 54) 3 98-101 (Switchboard) & 3 98-102 (Spare
Parts)
CR 4
Hatz 1 B 30
Honda GX 270
0506-englisch

2CR4

3
CR4
Preface
These operating and maintenance instructions describe the safe operation of the CR 4 soil compactor. Please read this
operation manual and familiarize yourself with all details of your soil compactor before operating the machine for the first
time. Carefully follow all instructions and always carry out the described operations in the indicated order.
Please refer to the following page for the General Safety Instructions.
We reserve the right to modifiy our equipment without prior notice.
In chapter 1, the soil compactor is briefly described to provide you with a good overview on the location of the individual
assembly groups and their functions. Chapter 2 describes how to put the soil compactor into and out of operation and how
to work with the machine.
In chapter 3, you will find a survey on and a description of the required service work. Chapter 4 contains instructions for
trouble shooting by the operator. Chapter 5 describes how to preserve the soil compactor for an extended storage, e.g.
during the winter season.
We placed a great emphasis on a user-friendly lay-out with clear pictorial and textual information. In the text, you will find
figures in brackets which point out to illustrations, whereby the first figure indicates the figure number and the second one
- separated by a dash - indicates the item number on the corresponding illustration.
Example 1: (2/1) means figure 2, item 1
Example 2: (2/3,6) means figure 2, item 3 and item 6
Important information for the operator and service personnel is highlighted by pictograms.
Indicates important information and hints which must be followed by the operator and service personnel.
Indicates working and operating methods requiring in addition the observance of all applicable environment
protection and waste disposal regulations.
Indicates working and operating methods which must be precisely followed in order to prevent the soil
compactor from being damaged or deteriorated.
Indicates working and operating methods which must be precisely followed in order to avert direct danger to
persons.
For further information, please contact your authorized WEBER distributor or one of the addresses on the last page.

4CR4
General Safety Instructions
General
All safety notes (see also explanations of the pictogram meanings in the preface) must be read and observed
(any lack of clarity must be dispelled before the soil compactor is put into operation), because otherwise the
use of the machine may
* constitute a risk to life and limb of the user
* impair the machine and other valuable property.
In addition to these operating instructions and the mandatory accident prevention regulations in the country of
use and on the operating site, the generally accepted technical standards for safe and professional work
must be also observed.
Designated Use
Soil compactors are only allowed to be operated in accordance with their designated use, whereby the operating
and maintenance instructions, the generally accepted safety and traffic rules and the regulations of the individual
countries of use must be followed.
The soil compactor has been exclusively designed for the compaction of
- sand
- gravel
- crushed stone
- semi-cohesive mixed aggregates
- concrete block pavement.
Any other use of the soil compactor is considered contrary to its designated use. The owner of the soil compactor
bears the sole responsibility for any misuse of the machine.
Driving Permission
Only trustworthy persons, who are aged at least 18 years, are allowed to handle soil compactors. They must be
properly trained in the operation and maintenance of the soil compactor by the owner or his authorized
representative.
Protective Equipment
When operating the soil compactor described in this operation and maintenance manual, the noise level at the
operator's ear may exceed 90 dB(A). The German noise protection regulations (VBG 121) require the operator
to wear personal ear protectors in case of noise levels of 90 dB(A) and more.
Additionally, a safety helmet and safety shoes belong to the protective equipment.
EC Machinery Directive, prEN500-1, EN292

5
CR4
Table of Contents
Preface ........................................................................................................................................................... 3
General Safety Instructions .......................................................................................................................... 4
1. Technical Description ................................................................................................................................... 6
1.1 Illustration ........................................................................................................................................................ 6
1.2 Machine Description ........................................................................................................................................ 7
1.3. Specifications CR 4 Hatz ................................................................................................................................. 8
1.3. Specifications CR 4 Honda .............................................................................................................................. 9
2 Operation ...................................................................................................................................................... 11
2.1 Safety Precautions for the Operation .............................................................................................................. 11
2.2 Transport ........................................................................................................................................................12
2.2.1 Loading by Crane ...........................................................................................................................................12
2.3 Commissioning ...............................................................................................................................................12
2.4 Pre-Start Work ................................................................................................................................................13
2.4.1. Checking the Fuel Level, Hatz Engine ............................................................................................................13
2.4.1.1 Checking the Fuel Level, Honda Engine .........................................................................................................14
2.4.2 Checking the Engine Oil Level ........................................................................................................................15
2.4.2.1 Hatz Engine ....................................................................................................................................................15
2.4.2.2 Honda Engine .................................................................................................................................................15
2.4.3 Fitting the Damper Plate .................................................................................................................................16
2.4.4 Fastening the Undercarriage ..........................................................................................................................17
2.5 Starting ...........................................................................................................................................................18
2.5.1 Starting, Hatz Engine ......................................................................................................................................18
2.5.2 Starting, Honda Engine ...................................................................................................................................19
2.6 Compaction Work ........................................................................................................................................... 20
2.7 Putting the Soil Compactor Out of Operation ..................................................................................................20
2.7.1 Stopping, Hatz Engine ....................................................................................................................................21
2.7.1.1 Stopping, Honda Engine .................................................................................................................................21
3 Maintenance .................................................................................................................................................22
3.1 Safety Precautions for Maintenance Work .....................................................................................................22
3.2 Maintenance Survey .......................................................................................................................................23
3.2.1 Maintenance ...................................................................................................................................................23
3.3 Description of the Maintenance Work .............................................................................................................24
3.3.1 Changing the Engine Oil, Hatz Engine............................................................................................................24
3.3.1.1 Cleaning the Engine Oil Filter, Hatz Engine ....................................................................................................25
3.3.1.2 Changing/Adding Engine Oil, Honda Engine ..................................................................................................26
3.3.2 Cleaning/Replacing the Air Filter Cartridge .....................................................................................................27
3.3.2.1 Hatz Engine ....................................................................................................................................................27
3.3.2.2 Honda Engine .................................................................................................................................................28
3.3.3 Replacing the Fuel Filter .................................................................................................................................29
3.3.3.1 Hatz Engine ....................................................................................................................................................29
3.3.4 Checking the Condition and Tension of the Vibrator V-Belt .............................................................................30
3.3.5 Replacing the V-Belt .......................................................................................................................................30
3.3.6 Changing the Vibrator Oil ............................................................................................................................... 31
3.3.7 Hydraulic Control ............................................................................................................................................31
3.4 Consumables and Quantities .........................................................................................................................32
4 Malfunctions During Operation ...................................................................................................................33
4.1 General ..........................................................................................................................................................33
4.2 Trouble Shooting ............................................................................................................................................34
5 Preserving the Machine ............................................................................................................................... 35
5.1 Preservation Measures ..................................................................................................................................35
5.2 Removing Machine Preservatives ..................................................................................................................35
6 Weber Maschinentechnik GmbH .................................................................................................................36

6CR4
1. Technical Description
Figure 1 Overall View CR 4
1.1 Illustration
1
2
3
6
7
8
9
10
12
5
11 4
1 Engine
2 Drive lever
3 Handle
4 Lifting lug
5 Reversible starter
6 Base plate
7 Protection frame
8 Engine bracket
9 Vibrator
10 V-belt guard
11 Spring bar
12 Speed adjusting lever
13 Vulkollan plate (not shown)

7
CR4
1.2 Machine Description
The CR 4 soil compactors are machines of the walk-behind type used for compaction work in road construction and
landscape applications.
Propulsion
The CR4 is driven by a Hatz Diesel engine or a Honda gasoline engine.
Important!
Please refer to paragraph 1.3 (Specifications) for performance details of the engine and the whole
machine.
Function
The engine (1/1) drives the vibrator via a V-belt. The vibrator is screwed down to the base plate (1/6) and sets it
vibrating. The vibrating base plate performs the vibration work and travelling motion.
Accessories
A damper plate (2.4.3) and an undercarriage (2.4.4) are available as optional extras.
Operation
The soil compactor is started by means of a reversible starter (1/5).
The machine is steered with the handle (1/3) holding the lever (1/12) for the engine speed adjustment and the drive
lever (1/2) for the selection of the direction of travel and of the infinitely variable speed. The spring bar (1/11) allows
to lock the handle in vertical position during working breaks and when the machine is transported.

8CR4
1.3 Specifications CR 4 Hatz
CR 4 CR 4/65
Weight
Operating weight CECE in kg 248 260
Dimensions
Overall length (in mm) 1400 1400
Overall width (in mm) 500 650
Height with handle folded down (in mm)
1050 1050
Base plate contact length (in mm) 400 400
Propulsion
Engine manufacturer Hatz Hatz
Type 1 B 30 1 B 30
Max. output according to DIN 70020(in kW (HP)) 5.6/7.6 at 3600 5.6/7.6 at 3600
Type of combustion 4-stroke Diesel 4-stroke Diesel
Operating speed 3000 3000
Driving speed (depending on soil conditions, in
m/min) 22 22
Gradeability (depending on soil conditions, in %) 30 30
Depth compaction (in cm) 40 40
Performance (in m²/h) 660 858
Vibration
System Two-shaft vibrator Two-shaft vibrator
Mode of driving Mechanical Mechanical
Frequency (in Hz) 68 68
Centrifugal force (in kN) 38 38

9
CR4
1.3 Specifications CR 4 Honda
CR 4 HD CR 4 HD / 65
Weight
Operating weight CECE in kg 231 243
Dimensions
Overall length (in mm) 1400 1400
Overall width (in mm) 500 650
Height with handle folded down (in mm)
1050 1050
Base plate contact length (in mm) 400 400
Propulsion
Engine manufacturer Honda Honda
Type GX 270 GX 270
Max. output according to DIN 70020(in kW (HP)) 6.6/9.0 at 3600 6.6/9.0 at 3600
Type of combustion 4-stroke gasoline 4-stroke gasoline
Operating speed 3000 3000
Driving speed (depending on soil conditions, in
m/min) 22 22
Gradeability (depending on soil conditions, in %) 30 30
Depth compaction (in cm) 40 40
Performance in (m2/h) 660 858
Vibration
System Two-shaft vibrator Two-shaft vibrator
Mode of driving Mechanical Mechanical
Frequency (in Hz) 68 68
Centrifugal force (in kN) 38 38

10 CR4
3
4
12
Weber Maschinentechnik GmbH
Typ Masch.-Nr.
Betriebsgewicht Baujahr
Postfach 2153
57329 Bad Laasphe-Rückershausen
1 MACHINE NO. 3 TYPE
.................................................... ...................................................
2 YEAR OF CONSTRUCTION 4 ENGINE/SERIAL NO.
.................................................... ....................................................
CR 4 CR 4 HD
Noise and Vibration Data*
Sound pressure level LPA
(at the operator's place, according to
2000/14/EG, in dB(A))
101 99
Sound power level LWA
(according to I2000/14/EG, in dB(A)) 108 108
Hand/arm vibration(weighted root mean square
acceleration, at the handle, determined
according to 2002/44/EG, Part 1, in m/s² )
5 - 10 5 - 10
*The indicated noise and vibration data were determined with the engine at nominal speed and the vibration
system turned on, 2000/14/EG. During operation, these data may vary according to the specific conditions
prevailing on the job site.

11
CR4
2 Operation
2.1 Safety Precautions for the Operation
Safety and protection devices
Before every shift, the operator must check the operativeness of all controls and safety elements as well as the proper
installation of all protection devices. The soil compactor is only allowed to be operated with all protection devices in
place. The control's functionality is not allowed to be impaired or annulled.
Before starting the soil compactor, the operator must take his personal noise protection measures.
The engine is only allowed to be started if it has been assured that the soil compactor cannot automatically start
moving.
Conduct in Case of Failures
If defective safety devices or other failures which might affect the safe operation of the soil compactor are ascertained,
the supervisor must be informed without delay. In case of malfunctions endangering the unit's operational safety, the
machine must be turned off immediately.
Conduct of the Machine Operator
During the machine's operation, the operator has to constantly supervise the operational safety of the soil compactor.
When running the machine, the operator is not allowed to leave the operating controls of the soil compactor. In addition,
he must always have a sufficient visibility on the soil compactor's zone of operation.The operator must be assisted by a
second person if, because of the operating conditions, the visibility on the zone of operation is restricted.
Stability
Soil compactors must be used and operated in a way ensuring their stability. The machine's stability is especially
endangered on slopes and brinks. Thus, keep clear of slopes and brinks.
Driving and Compacting
When working on slopes, the operator must always walk on the uphill side. Compaction work on slopes exceeding the
maximum gradeability of the soil compactor is prohibited. When working/travelling on slopes, always use extreme
precaution and work directly in uphill or downhill direction.
Moist and loose bases considerably reduce the grip of the soil compactor on slopes. Increased danger of
accident!
Passing unevennesses or kerbs is only allowed at reduced speed. In addition, the soil compactor must be operated in a
way excluding any risk of injury caused by the handle swinging towards the operator.
Exhaust Precautions
Never inhale exhaust gasses. They contain carbon monoxide, a colorless, oderless and extremely dangerous
gas which can cause unconsciousness or death. Never operate the engine inddors or in a poorly ventilated
area, such as tunnerl, cave, etc. Exercise extreme care when operating the engine near people or animals.
Keep the exhaust pipe free of foreign objects.

12 CR4
Caution!
For commissioning, only carry out the pre-start work described in paragraph 2.4.
Keep to the initial maintenance intervals (refer to paragraph 3.2.1).
- Put the soil compactor out of operation as described in
paragraph 2.7.
- Lock the handle (2/1) by means of the spring bar (2/2).
Danger!
Never use the handle (2/1) for lifting the machine by
crane. The machine may overturn!!
- Put the crane hook (2a/1) into the protection frame (2a/2).
Danger!
Only use a lifting tackle and a crane of a sufficient
bearing capacity.
Danger!
Do not enter the zone under the suspended load.
2.2 Transport
2.2.1 Loading by Crane
2.3 Commissioning
Figure 2
1
2
Figure 2 a
1
2
Short distances on the job site can be covered by the soil
compactor in accordance with paragraph 2.6.
For transporting the compactor over long distances, however,
the machine can be lifted on an appropriate transport vehicle
(truck, trailer) by means of a crane.

13
CR4
- Put the soil compactor out of operation as
described in paragraph 2.7.
- Clean the area around the filler neck.
- Undo the cap (4/1) to open the fuel tank (3/1).
Caution!
Fill the tank up with clean Diesel fuel only.
Refer to paragraph 3.4 for quantities and
specifications.
- Fill the tank up to the bottom edge of the filler neck
(4/2).
Danger!
Take care that fuel does not come in
contact with hot engine parts. Extinguish all
open flames and do not smoke while filling
the tank.
Environment Hazard!
Always wipe up any spilled fuel. Dispose of
fuel-soaked cloth in an environmentally-
friendly manner.
- Firmly close the fuel tank (3/1) with the filler cap (3/
2).
2.4 Pre-Start Work
2.4.1 Checking the Fuel Level, Hatz Engine
Figure 3 1
Figure 4
1
2
2
- Check to ensure that all safety devices are in place.
- Check the whole soil compactor for evident damage (visual check).
- Check all screwed connections for tight seat, retighten them if necessary.
- Check the fuel level, if necessary, add fuel (refer to paragraph 2.4.1).
- Check the engine oil level, if necessary add engine oil (refer to paragraph 2.4.2).
- If required, fit the damper plate (refer to paragraph 2.4.3)

14 CR4
2.4.1.1 Checking the Fuel Level, Honda Engine
- Put the soil compactor out of operation as described in
paragraph 2.7.
- Clean the area around the filler neck.
- Undo the cap (3a/1) to open the fuel tank (3a/2).
Caution!
Fill the tank up with clean regular gasoline only. Refer
to paragraph 3.4 for quantities and specifications.
- Fill the tank up to the bottom edge of the filler neck (4a/1).
Danger!
Take care that fuel does not come in contact with hot
engine parts. Extinguish all open flames and do not
smoke while filling the tank.
Environment Hazard!
Always wipe up any spilled fuel. Dispose of fuel-
soaked cloth in an environmentally-friendly manner.
- Firmly close the fuel tank with the filler cap (3a/1).
Figure 3 a
Figure 4 a
1
2
1

15
CR4
Caution!
The engine oil level must be checked with the soil
compactor standing horizontally on the ground.
- Pull out the oil filler screw with the oil dipstick (5/1), wipe it
off with a clean, non-fluffing cloth and insert it again.
Caution!
-Screw the oil dipstick (5/1) down.
-Undo the oil dipstick once again.
Caution!
The oil level must reach up to the top mark
(5/max).
- If required, add engine oil according to paragraph 3.3.1
(refer to paragraph 3.4 for quantities and specifications).
- Firmly screw the oil dipstick down.
Caution!
The engine oil level must be checked with the soil
compactor standing horizontally on the ground.
- Pull out the oil filler screw with the oil dipstick (5a/1), wipe it off
with a clean, non-fluffing cloth and insert it again.
Caution!
Do not screw down!!
- Pull the oil dipstick out once again.
Caution!
The oil level must reach up to the top mark
(5b/max).
- If required, add engine oil according to paragraph 3.3.1 (refer
to paragraph 3.4 for quantities and specifications).
- Firmly screw the oil dipstick down.
2.4.2 Checking the Engine Oil Level
2.4.2.1 Hatz Engine
Figure 5 max.
2.4.2.2 Honda Engine
max.
min.
1
Figure 5 a
Figure 5 b
1
1

16 CR4
2.4.3 Fitting the Damper Plate
- Put the soil compactor out of operation as described
in paragraph 2.7.
- Lift the soil compactor by means of a crane as
described in paragraph 2.2.1.
Caution!
Do not enter the zone under the suspended
load. - Risk of injury!
- Fasten the Vulkollan plate (6/1) with the holder (6/
2) and screw (6/3) at the base plate (6/4) as shown.
- Align the Vulkollan plate (6a/1) beneath the base
plate (6a/4) in the long holes located at the front of
the Vulkollan plate.
- Fasten the Vulkollan plate (6a/3) with the holder
(6a/1) and the screws (6a/2) at the font, beneath
the base plate (6a/4).
- Fasten the Vulkollan plate (6b/1) with the holder
(6b/2) and the screws (6b/3) at the back.
Figure 6
Figure 6a
Figure 6b
Important!
Check to ensure that the Vulkollan plate is correctly fitted
beneath the base plate. If not, realign the Vulkollan plate
as described above.
3
1
2
3
4
1
2
3
1
2
4

17
CR4
2.4.4 Fastening the Undercarriage
- Put the soil compactor out of operation as described
in paragraph 2.7.
- Lock the handle (6c/2) by means of the locking
lever (6c/1).
- Fit the locking pin (6d/1) to the base plate (6d/2).
- Lift the soil compactor at the back by means of the
handle (6e/1).
- Push the undercarriage (6e/2) beneath the base
plate (6e/4) by means of the drawbar (6e/3).
- The locking pin (6f/1) must sit in the iron clip (6f/2)
of the undercarriage.
- Tow the soil compactor into the desired direction by
means of the handle (6e/3).
Warning!
Check to ensure that the locking pin (6f/1)
correctly engages in the iron clip ((6f/2). If the
locking pin is incorrectly fitted, the soil
compactor may disengage from the
undercarriage - Risk of injury because the
soil compactor may slip out of control!
Figure 6c
Figure 6d
Figure 6e
1
2
12
Figure 6f
3
1
2
4
1
2

18 CR4
2.5 Starting
2.5.1 Starting, Hatz Engine
Figure 7
Figure 8
1
2
1
Danger!
Before starting the machine, always ensure
that nobody is in the danger area of the soil
compactor and that all protective devices are
properly in place.
When starting the soil compactor in closed
premises, always ensure a proper ventilation
- danger of poisoning.
Caution!
Never use starting aid sprays!
- Put the speed adjusting lever (7/1) into the full speed position.
- Slowly pull the handle (8/1) of the reversible starter (8/2) until a
resistance is felt.
- Let the handle (8/1) recoil into its original position and then firmly pull
the cable with both hands to start the engine.
Important!
If the engine fails to start, repeat the starting procedure.
- As soon as the engine starts, let the starter cable return into its
housing (8/2).
- Let the engine idle for some minutes.
Important!
In case of ambient temperatures of 5 degrees C below zero or less, the starting procedure must be carried
out in accordance with the operation manual of the engine manufacturer.

19
CR4
- Turn the stop button (9/1) into the "START"
position.
- Push the fuel cock (10/1) into the "ON" position.
- Push the speed adjusting lever (7/2) approx. 1/3
to the left.
- In case of a cold engine and/or low ambient
temperatures, totally close the choke (10/2).
(Choke to the left).
- In case of a warm engine and/or high ambient
temperatures, open the choke (10/2) half to all
the way. (Choke to the right).
- Slowly pull the handle (11/1) of the reversible
starter (11/2) until a resistance is felt.
- Let the handle (11/1) recoil into its original
position and then firmly pull the cable with both
hands to start the engine.
Important!
If the engine should fail to start, repeat the
starting procedure.
- As soon as the engine starts, let the starter
cable recoil into its housing (11/2).
- Slowly bring the choke (10/2) into the fully open
position (choke to the right) and let the engine
idle to warm up.
Figure 9
Figure 10
2.5.2 Starting, Honda Engine
Figure 11
Stop
Start
1
2
1
1
2

20 CR4
2.6 Compaction Work
- Put the soil compactor into operation (refer to paragraph 2.5).
As soon as the engine reaches its operating temperature:
- push the speed adjusting lever (12/2) into the full speed position.
Caution!
Compaction work is only allowed at full engine speed, otherwise the
centrifugal clutch may slip and cause increased wear.
Important!
As soon as the centrifugal clutch achieves the cutting-in speed, the
vibrator is automatically turned on.
Danger!
If obstructions (such as walls or trenches) are encountered, take care
that persons do not get crushed and that the machine does not slip out
of control.
Warning!
During work breaks, even if they are short, the soil compactor must be
put out of operation (refer to 2.7).
- Steer the soil compactor with the handle (12/1) into the desired direction.
2.7 Putting the Soil Compactor Out of Operation
Before work breaks and at the end of every day’s shift, the soil compactor
must be parked on a stable base which should be as horizontal as possible.
Warning!
If the soil compactor causes an obstruction when being parked,
precautionary measures must be taken in order to make the machine
visible. If the machine is parked on traffic roads, the safety precautions
required by the traffic regulations must be additionally observed.
Caution!
Never stop the engine while it is running at full speed, but let the engine
idle for some minutes.
Figure 12
2
1