Wacker Neuson 0610049, Operator'S Manual

Page 1: ...www wackergroup com Operator s Manual Vibratory plate DPU 6055 0109986en 005 04 2008 ...

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Page 3: ...ain 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...

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Page 5: ... the right for copying and distribution are reserved Copyright 2008 by 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...

Page 6: ...n 15 5 1 Transport to work site 15 5 2 Recommendations on compaction 17 6 Operation 18 6 1 Starting 18 6 2 Mechanical oil pressure control 19 6 3 Electric start 21 6 4 Starting the engine with the safety starting crank 23 6 5 Starting in cold weather 26 6 6 Starting with external battery etc 28 6 7 Forward and reverse motion 29 6 8 Compaction without extension plates 29 6 9 Stopping the engine 30 ...

Page 7: ...speed too low 43 8 2 Reverse speed too low 43 8 3 No reverse motion 43 8 4 Loss of hydraulic oil 43 8 5 The charge control lamp will not extinguish 44 8 6 Engine does not start 44 9 Electricwirning Diagramm 45 10 Lables 46 EC Conformity Certificate 47 DIN EN ISO 9001 Certificate 49 ...

Page 8: ... 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 This machine generates noise that exceeds the country specific permissible noise levels individual rating level It may therefore be neces...

Page 9: ...may occur 2 2 10 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 11 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 ejec...

Page 10: ...or 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 2 4 Maintenance 2 4 1 Only use original spare parts Modifications to this machine ...

Page 11: ...ifting 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 transp...

Page 12: ...0 Power transmission From drive engine directly to exciter unit via automatic centrifugal and V belts Exciter Vibrations min 1 Hz ca 4150 69 Centrifugal force kN 60 Oil Fuchs Titan Unic 10W40 MC SAE 10W40 Oil quantity l 0 75 Drive motor Air colled single cylinder 4 stroke diesel engine with electric starter Piston displacement cm3 667 Rated power kW 9 3 at rpm min 1 2650 Operating rpm s min 1 2880...

Page 13: ... Special Wacker battery for vibro plates 12 V 55 Ah Alternator Rotary current generator with electronic regulator and rectifier Charging rate max A 26 Charging voltage V 14 Starter Starter motor D C V 12 Hydraulic control Oil Fuchs Renolin MR 520 Oil quantity l 0 4 Special lubricating grase L PA 97 dB A The weighted effec tive acceleration value determined according to EN ISO 5349 m s2 4 9 DPU 605...

Page 14: ...trenches as well as surface compaction In addition it is possible to vibrate paving stones an concrete blocks by using extension plates up to 86 cm accessories Extremely cohesive as well as frozen soils are not suitable for compaction An authorised specialist must give permission for the ground in question to be compacted 4 2 Max admissible inclination ...

Page 15: ...riable 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 3 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...

Page 16: ...r 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 b...

Page 17: ...ight position Requirements When transporting the vibrating plate compactor use only suitable hoisting gear with a minimum load bearing capacity see Technical data Always turn off the motor during transportation Note We recommend that the fuel tank be emptied and the carburetor run dry prior to transporting it Fuel could run out e g if the machine is tilted Vertically set guide handle head and lock...

Page 18: ...he central lifting point is located exactly above the centre of gravity of the machine The central lifting point can be displaced rearwards 18 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 ...

Page 19: ... 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 25o must not be exceeded A tilt in excess of this angle could l...

Page 20: ...al data through the filler neck 21 as needed The machine must be level and the engine stopped before proceeding with the oil level check Fuel When pouring diesel fuel into the fuel nozzle 20 maintain absolute cleanliness Impurities in the fuel can cause breakdowns in the injection system and premature clogging of the fuel filter Only refuel the machine when it s engine is stopped Never refuel the ...

Page 21: ...ng first filling of the fuel tank or if the tank has run dry in the case of an automatic engine stop due to an inefficient engine oil supply after freeing the engine when in presence of extremely low temperatures 1 Fill up fuel tank 2 Check engine oil level 3 To activate depress hand lever d for approx 5 seconds 4 Check to see that the engine does not leak 5 Start engine d ...

Page 22: ...ust fumes Exhaust fumes contain toxic carbon monoxide that can lead to unconsciousness or death Always switch off the engine during maintenance work Before starting the engine always make sure that nobody is in the danger area of the vibratory plate and also check to see if all the safety devices are installed Never use starter sprays to start the engine ...

Page 23: ...o load position 1 2 3 4 2 Leave decompression lever 2 in the position e 3 Put the ignition key into ignition switch 25 and turn it clockwise into operating position the charge control lamp 27 lights up and the buzzer will be heard Press in and hold the starter 26 until the engine has started f ...

Page 24: ...ped Stop the engine immediately in case of eventual irregularities then locate the fault and repair it The machine will start vibrating as soon as the engine starts revving up Note Do not activate automatic decompression lever while the engine is running 5 Bring the engine up to maximum rpm s and then check the air filter s service indicator also see chapter on Maintenance clean the dry type air f...

Page 25: ... to start 3 Put the ignition key into ignition switch 25 and turn it clockwise into operating position the charge control lamp 27 lights up and the buzzer will be heard 4 Check to see that the safety starting crank is in good shape and clean Broken handle pipes worn cranking bolts etc must be replaced Lightly grease the gliding area located between the safety starting crank and the guide bush prot...

Page 26: ... the safety start crank out of the protective hood once the engine has started The friction non positive connection between engine and safety starting crank must be guaranteed by a firm grip on the handle pipe and rapid turning of the crank and must not be interrupted under any circumstances during the starting operation The connection between the crank web g and the crank claw will be released if...

Page 27: ... off immediately after the engine has started running and the acoustic alarm has stopped Stop the engine immediately in case of eventual irregularities then locate the fault and repair it The machine will start vibrating as soon as the engine starts revving up Note Do not activate automatic decompression lever while the engine is running 6 Bring the engine up to maximum rpm s and then check the ai...

Page 28: ...3 F 1 Push the throttle lever 8 to the full throttle position 2 Turn decompression lever to any position in front of starting position f 3 Crank the engine counter clockwise with the safety start crank 24 as long as necessary until cranking becomes easier 10 to 20 crank turns 4 Press pin d in for approx 5 seconds f ...

Page 29: ...ver 6 Fill the housing to the upper edge with low viscosity oil Replace cover and press down with force Exactly two successive fillings are required 7 Turn the decompression lever all the way to f 8 Then start the engine immediately with the electric starter or by using the safety start crank ...

Page 30: ...rting with an external battery 1 Connect the red jumper cable with the help of a clamp to the positive pole 1 of the discharged battery 2 Connect the other clamp of the red jumper cable to the plus pole 2 of the external donor battery 3 Connect the black jumper cablewith the help of a clamp to the negative pole 3 of the external battery 4 Connect the other clamp of the black jumper cable to a grou...

Page 31: ...n at standstill or in reverse direction The forward and reverse speeds can be varied by selecting intermediate positions of the shift lever 6 or the machine can be employed for particularly intensive compaction at standstill 6 8 Compaction without extension plates If the vibration plates is used without extension plates screw set of protective screws 8 pes into the threaded boreholes situated in t...

Page 32: ...ession 2 as this inevitably results in damage to the valve drive and decompression mechanism 1 Move the throttle control lever 8 to the stop 2 Turn the ignition key to the stop position and then pull it out once the engine has stopped The control lamp will extinguish and the acoustic alarm will turn off ...

Page 33: ...engine Check oil level if nec top up oil Centre pole height setting transport lock Regrease weekly Fuel tank Check water separator V belt Check V belt if nec replace monthly Protective frame Check attachment screws for tight fit Central lifting point Tow bar head Check oil level top up if necessary Exciter Oil change every 250 h or latest every 6 months Drive engine Oil change change oil filter Ke...

Page 34: ...zle Pay attention to the max level mark on the dip stick 7 2 2 Replacing oil and oil filter Note The work area should be covered with a waterproof sheet to protect the floor protection of the environment 1 Let engine warm up 2 Take off the front cover plate 3 Remove the oil hose from the support spanner opening 19 and then hang the hose into an appropriate container Danger of scalding by hot oil C...

Page 35: ...ter 7 Check and if necessary replace O ring k 8 Moisten thread and O ring of the screwed sealing plug with a lubricant 9 Fasten the oil hose to the support 10 Fill up with engine oil until the max marking of the dip stick is reached 11 Check the oil level again after a short engine test run and top up if necessary 12 Be sure to check that the screwed sealing plug does not leak 13 Fasten the front ...

Page 36: ... seconds The filter system must be cleaned if the bellows contracts and covers the green ring m Check the bellows often per day when working in extremely dusty conditions Note The air cleaner must be cleaned every day if conditions are adverse dry and dusty Do not clean with compressed air 7 3 2 Air filter maintenance 1 Loosen wing thumb screw o and carefully remove with cover p One turn of the co...

Page 37: ...ating it with a lamp Do not reuse the filter element if you have determine any kind of damages in the area of the filtering paper s or as the case may be in the area of the sealing lip t 5 Replace the filter element if the maintenance plan requires it 6 Follow the disassembly procedure in reverse order to refit the filter Caution Operating the engine without air cleaner can cause rapid engine wear...

Page 38: ...Water separator inspection Turn hex screw v 2 3 turns to detach Collect the emerging drops in a transparent container First water and then fuel drops will emerge as water is specifically heavier than diesel fuel A clear separating line will make this easily recognizable Turn the hex screw v back in once only clear fuel emerges v x w ...

Page 39: ...y dirt into the fuel line Always replace fuel filter Pay attention to the flow direction look for the arrows Allow fuel to flow After a short test run make sure that fuel filter and line do not leak 7 4 3 Screwed connections control Make sure all accessible screwed connections are correctly tightened and in good shape Do not retighten cylinder head screws The adjusting screws for the speed governo...

Page 40: ...he battery cover Check to see that the gas venting hose does not have any kinks Protect hands end eyes against the acid Note Only replace defective batteries with original Wacker batteries Standard batteries are not suitable for the high vibration loads 4 When changing the battery Removal First disconnect negativ then positive terminal of battery Assembly First connect positive then negative termi...

Page 41: ...4 Close filler bore 7 6 2 Venting hydraulic control 1 Remove apron 4 by undoing the screws 3 2 Move centre pole into vertical position move shift lever 2 right into the reverse position open filler bore 3 Loosen connecting screw 5 4 Slowly push the shift lever into forward motion direction until hydraulic oil emerges bubblefree at the connection screw 5 Tighten connecting screw mount apron 6 If ne...

Page 42: ...sition vibration plate horizontally 2 Open filler bore 40 3 The oil level must reach the start of the thread of the filler bore 40 4 If necessary pour in oil see Technical Data through filler bore 40 use funnel 0 75 l 5 Close filler bore 40 torque setting 100 Nm Oil ...

Page 43: ...oisting gear and lifting tackle of sufficient lifting capacity Place the machine in a stable position 3 Tilt vibration plate and keep it tilted until the oil has run out 4 Place vibration plate in horizontal position Note Avoid spilling oil Remove any spilled oil immediately 5 Pour in oil see Technical Data through the filler bore 40 6 Close filler bore 40 torque setting 100 Nm 7 Mount extension p...

Page 44: ...placed 7 8 1 Changing the exciter V belt 1 Remove belt guard 41 2 Undo screw 42 3 Remove button 43 belleville spring 44 seal 45 and front segment of the V belt pulley 10 4 Change exciter V belt 12 5 Assemble the components in reverse order make sure that the coloured marking on the pin coincides with the marking on the V belt pulley 10 Do not oil or grease clutch components will damage the graphit...

Page 45: ...emedy To little hydraulic oil in the centre pole head Top up hydraulic oil Air in hydraulic control Bleed system Cause Remedy Too much hydraulic oil in centre pole head Correct oil level in accordance with mark Cause Remedy Mechanical fault Contact Wacker service dept Cause Remedy Leaks hydraulic hose defective Contact Wacker service dept ...

Page 46: ...use Remedy Dynamo defective Contact Wacker service dept Control unit defective Replace control unit on rear of the dynamo Cause Remedy Ignition lock defective Change defective parts Starter defective Start knop defective Battery flat Charge battery Lack of lubricating oil Fill up with oil and actuate valve lever at oil filter housing once ...

Page 47: ...wirning Diagramm 1 Bush plug 2 Button switch 3 Wire harnes 4 Control lamp Battery 5 Central plug 6 Socket head cap screw DIN912 M8x16 7 Piezoelectric buzzer 8 Mass line 9 Battery 10 Positive pol strop 11 Starter 12 Nose cap 13 Fixing fuse 14 Cable yarn ...

Page 48: ...gine operation 2 Notice Starting procedure 3 Notice Diesel 4 Notice Lifting point 5 Ear protection decal 6 Sound power level 7 Maintenance decal 8 Warning notice Do not run without protective devices Read operator s manual in detail 9 Notice Maintenance 10 Start Stop 11 Type 13 Wacker Logo ...

Page 49: ... been evaluated in conformity with Directive 2000 14 EC and has been manufactured in accordance with the following directives 2000 14 EG 2004 108 EG 98 37 EG EN 500 1 EN 500 4 0610053 0610049 0610175 9 3 kW Conformity assessment procedure At the following notified body Measured sound power level Guaranteed sound power level Annex VIII VDE Prüf und Zertifizierungsinstitut Zertifizierungsstelle Meri...

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Page 51: ... the following scope Machine manufacture Construction machines This Q System complies with the requirements of DIN EN ISO 9001 2000 and the requirements of the German and international Road Traffic Act This Certificate is valid until 2009 06 05 VDE Testing and Certification Institute Certification Date 2003 05 30 63069 Offenbach Merianstraße 28 Telefon 49 0 69 83 06 0 Telefax 49 0 69 83 06 555 E M...

Page 52: ... 0 Fax 49 0 89 3 54 02 390 Wacker Corporation P O Box 9007 Menomonee Falls WI 53052 9007 Tel 1 1 262 255 0500 Fax 1 1 262 255 0550 Tel 800 770 0957 Wacker Asia Pacific Operations Skyline Tower Suite 2303 23 F 39 Wang Kwong Road Kowloon Bay Hong Kong Tel 852 2406 6032 Fax 852 2406 6021 ...

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