WACKER Group DPU 25..H.. Operator's Manual

www.wackergroup.com

Operator´s Manual

Vibratory plate

DPU 25..H..

0109976en 002

10.2007

T00940GB.fm 3

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 4

Vorwort.fm 5

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 2007 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 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

6

1. Foreword 5

2. Safety instruction 8

2.1 General instructions ..............................................................................8

2.2 Operation ...............................................................................................8

2.3 Safety checks ......................................................................................10

2.4 Maintenance ........................................................................................10

2.5 Transport .............................................................................................11

2.6 Maintenance checks ............................................................................11

3. Technical Data 12

4. Description 14

4.1 Applications .........................................................................................14

4.2 Dimensions ..........................................................................................14

4.3 Max. admissible inclination ..................................................................15

4.4 Description of function .........................................................................15

5. Transport to work site /Recommendations on compaction 17

5.1 Transport to work site ..........................................................................17

5.2 Recommendations on compaction ......................................................18

6. Operating instructions 19

6.1 Diesel fuel ............................................................................................19

6.2 Dry-type air filter ..................................................................................19

6.3 Air cleaner – inspecting the service indicator ......................................20

6.4 Starting the engine ..............................................................................20

6.5 Switching off the engine ......................................................................21

6.6 Short-term operation interruption ........................................................21

6.7 End of compaction operation ...............................................................21

7. Maintenance 22

7.1 Maintenance schedule ........................................................................22

7.2 Engine oil .............................................................................................23

7.3 Hydraulic control ..................................................................................25

7.4 Exciter .................................................................................................26

7.5 Exciter V-belt .......................................................................................27

Table Of Contents

7

8. Malfunction 28

8.1 Reverse speed too low ........................................................................28

8.2 Forward speed too low ........................................................................28

8.3 No advance .........................................................................................28

8.4 Loss of hydraulic oil .............................................................................28

8.5 Engine does not start ..........................................................................29

8.6 No vibration, even though engine is running .......................................29

9. Lables 30

EC - Conformity Certificate 31

DIN EN ISO 9001 Certificate 33

Safety instruction

SV00069GB.fm 8

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 This machine generates noise that exceeds the country-specific

permissible noise levels (individual rating level). It may therefore be
necessary to wear ear protection

2.2 Operation

2.2.1 Only use original spare parts. Modifications to this machine, including

the adjustment of the maximum engine speed set by the manufacturer,
are subject to the express approval of Wacker. In case of
nonobservance all liabilities shall be refused.

2.2.2 The function of operation levers or elements is not to be influenced or

rendered ineffective.

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.

Safety instruction

SV00069GB.fm 9

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.

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.

Safety instruction

SV00069GB.fm 10

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.

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 80° C). 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.

Safety instruction

SV00069GB.fm 11

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.

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

TD00682GB.fm 12

3. Technical Data

DPU 2540H DPU 2550H DPU2560H DPU 2560H-TS

Item no.

0610035 0610036 0610037 0610038

Operating weight

kg:

160 166 171

Advance and reverse travel

m/min:

24 22 20 23

Compacted area

m

2

/h:

576 660 720 828

Kraftübertragung

From drive engine directly to exciter unit via centrifugal

clutch and V-belt

Exciter

Vibrations

min

-1

(Hz):

ca. 5400 (90)

Centrifugal force

kN:

25

Oil

Fuchs Titan Unic 10W40 MC (SAE 10W40)

Oil quantity l:

0,6

Drive motor Air-cooled single-cylinder 4-cycle diesel engine with recoil starter

Piston displacement

cm

3

:

232

Engine speed (rpm)

min

-1

:

2800

Rated power (*)

kW (PS):

3,1 (4,2)

Fuel

Diesel

Fuel consumption

l/h:

0,4

Tank capacity

l:

3,0

Oil

Fuchs Titan Unic 10W40 MC (SAE 10W40)

Oil quantity

l:

0,9

Hydraulic control

Hydraulic oil Fuchs Renolin MR 520

Oil quantity 0,4

Technical Data

TD00682GB.fm 13

(*) In accordance with the installed useful outlet power according to Directive 2000/14/
EG

Special lubricating
grase

LPA:

94 dB(A)

The weighted effec­tive acceleration
value, determined
according to
EN ISO 5349

m/s

2

:

is 8,8

DPU 2540H DPU 2550H DPU2560H DPU 2560H-TS

Description

T00978GB.fm 14

4. Description

4.1 Applications

This vibratory plate is optimally suited for all types of soil compaction
applications in confined areas thanks to it’s narrow design and the
infinitely variable change of direction; application examples are e.g.
compaction in cable trenches, marginal strip compaction during
asphalt pavement patchwork as well as all those compaction jobs for
which the use of larger machines is not convenient.

4.2 Dimensions

Description

T00978GB.fm 15

4.3 Max. admissible inclination

4.4 Description of function

4.4.1 The vibration required for compaction is produced by the exciter (5)

which is firmly joinded to the lower mass (4). This exciter (5) 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 (13). 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 (7) on the centre pole head (8).

Description

T00978GB.fm 16

4.4.2 The drive engine (1) is anchored to the upper mass (3) and drives the

exciter (5). The torque is transmitted by means of a friction connection
through the centrifugal clutch (9) and the exciter V-belt (10).

4.4.3 The centrifugal clutch (9) interrupts flow of power to the exciter (5) at

low engine speeds and thus permits perfect idling of the drive engine
(1). The speed of the drive engine (1) can be infinitely varied by way of
the throttle lever (6).

4.4.4 The upper (3) and lower (4) masses are connected to each other by 4

vibration-damping shock mounts (11). This damping system prevents
the very high frequencies from being transmitted to the upper mass (3).
As a result the functionability of the drive engine (1) is retained in spite
of the high compaction performance.

4.4.5 The drive engine (1) works according to the diesel principle, is

equipped with a recoil starter, draws in combustion air through a dry
type air cleaner (12) and is air-cooled.

Forwards

Reverse

On the spot

Transport to work site /Recom-

T00979GB.fm17

5. Transport to work site /Recommendations on

compaction

5.1 Transport to work site

Conditions:

∗ To transport the vibration plate, use only suitable lifting equipment with

a minimum load-bearing capacity of 200 kg.

∗ Only attach suitable tackle at the central lifting point (15) provided.
∗ Always tie down the vibratory plate by the protective frame (14) and

latch the center pole in place during transport of the vibratory plate on
the loading area of a transport vehicle.

The engine must be stopped when using the integrated transport
device. Lubrication of the engine is not guaranteed if the engine is
running when the plate is in transport position.This could lead to
serious engine damages.

Furthermore the danger exists that oil will spill out of the crankcase
breather.

Note: Also observe the regulations in the chapter “Safety instructions“.

Transport to work site /Recommendations on compaction

T00979GB.fm18

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 (see chapter

“safety instructions“).

∗ The max. gradient of 20o must not be exceeded.

If this gradient were exceeded, this would result in a failure of the
engine lubrication system and thus inevitably lead to a breakdown of
important engine components.

Wrong! Right!

Operating instructions

T00980GB.fm 19

6. Operating instructions

6.1 Diesel fuel

Only use pure diesel fuel.Close fuel tank immediately. It is important to
maintain absolute cleanliness to avoid otherwise inevitable trouble
with the fuel injection system, and to avert a premature clogging up of
the fuel filter. Do not open the fuel line nor the fuel pump or any other
point of the fuel system to avoid danger of dirt contamination, not
even for bleeding of air. The fuel pump will bleed automatically. This
applies even should the fuel tank have run dry by mistake. In such a
case simply refill fuel tank.

6.2 Dry-type air filter

A loss of engine power with a simultaneous belching of smoke
indicates a plugged-up air filter. Remove filter cartridge and clean by
light tapping to dislodge dust from the paper element.

Clean filter housing! Use a clean rag, do not clean with compressed
air. While cleaning avoid by all means introducing dirt into the engine
intake port.

Operating instructions

T00980GB.fm 20

6.3 Air cleaner – inspecting the service indicator

Set the engine to full rpms for a short period of time. If the bellows is
drawn together during this time and the green field „1“ is covered, then
the air cleaner system is due for maintenance. Check the rubber
bellows repeatedly per day when working in dusty environments.

6.4 Starting the engine

∗ Only start with the engine starting procedure once a sufficiently stable

position is assured.

∗ Move throttle lever to start position.
∗ Slowly pull out starter rope until the engine’s compression resistance

can be felt.

∗ At this point let starter rope slowly return into starter housing.
∗ Now start the engine. Pull out the rope (evenly, not by jerks as is usual

with gasoline engines) and turn the engine with ever increasing speed.
Use complete length of starter rope.

Operating instructions

T00980GB.fm 21

6.5 Switching off the engine

∗ Pull throttle lever back to STOP position.
∗ Press down stop button.

6.6 Short-term operation interruption

Set throttle control lever to idling position.

6.7 End of compaction operation

Stop engine.

Maintenance

T00981GB.fm 22

7. Maintenance

7.1 Maintenance schedule

Parts Maintenance jobs

Maintenance

interval

Engine oil

Check oil level.
Check combustion and cooling air area for dirt.

daily

Air filter

Inspect the air cleaner service indicator while the
engine is running.
Clean or replace the air cleaner insert if necessary.

Exciter Check for tightness.

Bowden cable Check to see smooth running.

Exciter Check attachment screws for tight fit.

monthly

Hydraulic control Check oil level, top up if necessary.

V-belt Check V-belt tension-retension, if need be.

Protective frame

Check fastening screws of protective frame and
central suspension for tight fit.

Engine oil

First oil change; check valve air gap, set to 0,10 mm
with cold engine.

after 25 hours

Exciter Check oil level-fill up, if need be. after 150 hours

Engine oil Replace.

after 250 hoursValve clearance

Check, set to 0,10 mm with cold engine.
Control screwed connections.

Exciter Oil change.

Drive engine

Tighten all accessible screw connections.
Fuel filter change.
Maintenance of dry air filter.

after 500 hours

Oil filter Clean. after 1000 hours

Drive engine Siphon off water from fuel tank. once a year

Maintenance

T00981GB.fm 23

7.2 Engine oil

7.2.1 Check oil level:

∗ The engine must be horizontally place when filling in oil or checking the

oil level.

∗ Check oil level with dip stick (16).
∗ If oil level is to low, top up with oil Fuchs Titan Unic 10W40 MC through

oil feed opening (16).

Engine oil capacity: 0,9 l.

7.2.2 Oil change:

Drain the oil while the engine is still warm to assure rapid and complete
draining.

1. Remove the oil filler cap (16).

2. Screw waste oil drain hose (2) onto oil change valve (20). Collect
the waste oil with an appropriate container and then dispose of oil.

3. Unscrew waste oil drain hose (2) and fasten to the corresponding
support.

Maintenance

T00981GB.fm 24

4. Pour the recommended oil through the oil filler tube (16) and then
check the oil level.

Place machine in horizontal position before checking engine oil level.

5. Use cap to close off oil change valve (20).

Take notice: Please pay attention to the corresponding environmental
laws when disposing of used engine oil. We recommend you carry the
oil in a container to a central collecting point for used oils. Do not pour
used engine oil into the garbage nor into the sewer system, waste
pipes or even on the ground.

Maintenance

T00981GB.fm 25

7.3 Hydraulic control

7.3.1 Check oil level:

1. Move centre pole into vertical position.

2. Push operating control handle (7) to forward ravel position.

3. Open filler bore (17).

4. The oil level must reach the upper edge Oil of the gear; add Fuchs
Renolin MR 520 hydraulic fluid if required.

5. Close filler bore (17).

Hydraulic control system is self-bleeding.

Oil

Maintenance

T00981GB.fm 26

7.4 Exciter

7.4.1 Check oil level:

1. Position vibration plate horizontally.

2. Open filler bore (19).

3. The oil level must reach the start of the thread (19) of the filler bore.

4. If necessary, pour in oil Fuchs Titan Unic 10W40 MC through filler
bore (use funnel).

5. Close filler bore (19). (Tightening torque 100 Nm)

Maintenance

T00981GB.fm 27

7.4.2 Changing the oil:

1. Open filler bore (19).

2. Tilt vibration plate and keep it tilted until the oil has run out.

3. Place vibration plate in horizontal position.

4. Pour in 0,6 l oil Fuchs Titan Unic 10W40 MC through the filler bore
(19).

5. Close filler bore (19). (Tightening torque 100 Nm)

Do not pour in too much oil!

7.5 Exciter V-belt

Remove belt guard. Remove the screws from the engine’s V-belt
pulley and then pull off the V-belt pulley half. Take out the necessary
number of discs (removal of one disc is usually enough). Place the
discs just removed on the outside of the V-belt pulley half. Turn in the
screws by hand and then alternately tighten while constantly turning
the engine’s V-belt pulley. Run the machine a few moments and then
retighten the screws if necessary.

Malfunction

T00982GB.fm 28

8. Malfunction

8.1 Reverse speed too low

8.2 Forward speed too low

8.3 No advance

8.4 Loss of hydraulic oil

Cause Remedy

To little hydraulic oil in the centre pole
head.

Top up hydraulic oil.

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.

Malfunction

T00982GB.fm 29

8.5 Engine does not start

8.6 No vibration, even though engine is running

Cause Remedy

Throttle lever in stop or idle position. Place throttle lever in start position.

No fuel at the injection pump.

Add fuel. Check complete fuel system.

Check feeder line to engine and fuel
filter.

Wrong valve tapped clearance.

Check valve clearance, set if
necessary.

Worn out valves.

Call in Wacker Service.Cylinder and/or piston ring wear.

Injection nozzle not operating.

Cause Remedy

Worn-out V-belt Replace V-belt

Worn-out clutch lining Replace clutch linings

Lables

SK00666GB.fm 30

9. Lables

1 Notice-Easy-change fuel filter inside tank

2 Maintenance-Notice

3 Notice-Starting

4 Notice-Lifting point

5 Warning notice

- Do not run without protective devices.

- Read operator’s manual in detail.

6 Sound power level

7 Ear protection decal

8 Start-Stop

9 Notice-Air cleaner service indicator

Inspect during engine operation

10 Flipping over warning notice

C0038007GB.fm

Bescheinigung bitte sorgfältig aufbewahren / File certificate carefully

EG - Konformitätserklärung

EC - Conformity Certificate

Wacker Construction Equipment AG, Preußenstraße 41, 80809 München

bescheinigt, daß das Baugerät:
hereby certify that the construction equipment specified hereunder:

1. Art / Category:

Vibrationsplatte / Vibratory plate

2. Typ / Type:

DPU 2540H / DPU 2550H / DPU 2560H / DPU 2560H-TS

3. Gerätetypnummer / Equipment item number:

0610035, 0610036, 0610037, 0610038

4. absolute installierte Leistung / Absolute installed power:

3,1 kW

in Übereinstimmung mit Richtlinie 2000/14/EG bewertet worden ist:
has been evaluated in conformity with Directive 2000/14/EC:

und in Übereinstimmung mit folgenden Richtlinien hergestellt worden ist:
and has been manufactured in accordance with the following directives:

* 2000/14/EG
* 98/37/EG
EN 500-1
EN 500-4

Konformitätsbewer­tungsverfahren
Conformity assessment
procedure

Bei folgender
einbezogener Prüfstelle
At the following notified
body

Gemessener
Schallleistungspegel
Measured sound
power level

Garantierter
Schallleistungspegel
Guaranteed sound
power level

Anhang VIII

Annex VIII

VDE Prüf- und
Zertifizierungsinstitut
Zertifizierungsstelle
Merianstraße 28
63069 Offenbach/Main

106 dB(A) 108 dB(A)

Dr. Stenzel

Leitung Forschung und Entwicklung

Research and Development Management

Prüf- und Zertifizierungsinstitut

VERBAND DER ELEKTROTECHNIK

ELEKTRONIK INFORMATIONSTECHNIK e.V.

C E R T I F I C A T E

Registration-Number: 6236/QM/06.97

This is to certify that the company

Wacker Construction Equipment AG

Wacker-Werke GmbH & Co. KG

at the following locations

Head Office Munich

Preußenstraße 41

80809 Munich

Production plant Reichertshofen

Karlsfeld logistics centre

Sales regions with all branches all over Germany

has implemented and maintains a

Qality Management System for 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: 2006-05-30

63069 Offenbach, Merianstraße 28
Telefon: [phone], Telefax: [phone]
E-Mail: [e-mail]

, http://www.vde-institut.com

The VDE Testing and Certification Institute is accredited by DAR Accreditation
Bodies according to DIN EN ISO 17020 and DIN EN ISO 45012 and notified in the EU
under ID.No. 0366.

TGA-ZM-09-92-00
KBA-ZM-A 00021-97

DIN EN ISO 9001 Certificate

Wacker Construction Equipment AG - Preußenstraße 41 - 80809 München - Tel.: [phone] - Fax: [phone]
Wacker Corporation - P.O. Box 9007 - Menomonee Falls, WI 53052-9007 - Tel.: [phone] - Fax: [phone] - Tel.: [phone]
Wacker Asia Pacific Operations-Skyline Tower, Suite 2303, 23/F, 39 Wang Kwong Road, Kowloon Bay, Hong Kong-Tel.: [phone]-Fax: [phone]