This machine has been equipped with an EPA certified engine.
Additional information can be found in the engine manufacturers notes.
WARNING
Diesel engine exhaust and some of its
constituents are known totheState
of California to cause cancer, birth
defects, and other reproductive harm.
Caution
This engine is an EPA engine.
Adjusting the engine speed will interfere
with EPA certivication and emissions.
Only authorized personnel can make
adjustments to this engine.
Please contact you nearest engine or
Wacker Dealer for more information.
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FOREWORD
Foreword
For yourownsafetyandprotection 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.
Defective machine parts are to be replaced as soon as possible.
All rights, especially the right for copying and distribution are reserved.
Copyright 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 of reproduction, distribution or saving on data carriers of any type ormethod not authorizedby Wacker
represents an infringement of valid copyrights and will be prosecuted.
We expressly reserve the right to technical modifications- even without express due notice - which aim at improving our machines or their safety standards.
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TABLE OF CONTENTS
FOREWORD3
SAFETY INSTRUCTIONS6
General instructions6
Operation6
Safety checks7
Maintenance7
Transport7
Maintenance checks7
TECHNICAL DATA8
DESCRIPTION10
Field of application10
Dimensions10
Max. admissible inclination10
Description of function11
TRANSPORT TO WORK SITE, RECOMMENDATIONS ON COMPACTION12
Transport to work site12
Recommendations on compaction12
OPERATION13
Starting13
Forward and reverse motion13
Switching off14
Compaction without extension plates14
Emergency start by hand14
Mechanical oil pressure control15
Starting with external battery etc.15
Forward speed too low19
Reverse speed too low19
No reverse motion19
Loss of hydraulic oil19
Battery-charge warning lamp does not go off19
Engine does not start19
ELECTRIC WIRING DIAGRAM20
EC - CONFORMITY-CERTIFICATE21
5
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS FOR THE USE OF VIBRATORY
PLATES WITH COMBUSTION ENGINES
General instructions
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.Vibratory plates may only be used for compaction jobs. Both the manufacturer’s operating instructions
and these safety instructions have to be observed.
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.
4.It is possible that this vibratory plate exceeds the admissible sound level of 89 dB (A). According to the
rules for the prevention of accidents regarding emission of noise, the employees have to wear ear protection if the sound level reaches 89 dB (A) or more.
Operation
1.When starting a 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.
☛ATTENTION! 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
2.The functioning of operating levers or elements is not to be influenced or rendered ineffective.
3.During operation the operator may not leave the control elements.
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.
5.Stop engine before filling fuel tank. When refilling fuel tank, do not allow fuel to come into contact with
the hot parts of the engine or spill onto the ground.
6.Do not smoke or handle open fire near this machine.
7.The tank lid must fit tightly. Shut off fuel cock, if available when stopping the engine. For long distance
transports of machine operated by fuel or fuel - mixtures, the fuel tank has to be drained completely.
the engine starts running.
☛ATTENTION! Leaky fuel tanks may cause explosions and must therefore be replaced immediately.
8.Do not operate the machine in areas where explosions may occur.
9.Make sure that sufficient fresh air is available when operating vibratory plates with combustion engines
in enclosed areas, tunnels, adits and deep trenches.
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.
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.
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SAFETY INSTRUCTIONS
12.Make sure the soil or subsoil to be compacted has a high enough load carrying capacity.
13.Use appropriate protective clothing while working or while carrying out maintenance work.
14.When traveling backwards the operator has to guide the vibration plate laterally by its guide handle so
thathewillnotbesqueezedbetweenthehandleandapossibleobstacle.Specialcareisrequiredwhenwork
ing on uneven ground or when compacting coarse material. Make sure of a firm stand when operating
the machine under such conditons.
15.Vibratory plates are to be guided such that hand injuries caused by solid objects are avoided.
16.Vibratory plates have to be guided such that their stability is guaranteed.
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 checks
1.Vibratory plates may only be operated with all safety devices installed.
2.Before starting operation, the operator has to check that all control and safety devices function properly.
3.Immediately notify your supervisor or superintendent if you have determined defects in the safety devices or other defects which could endanger the safe operation of the machine or which could endanger
the environment.
4.In case of defects jeopardizing the operational safety of the vibration plate, the machine has to be
stopped immediately.
5.Process materials and operating fuels must be stowed away in receptacles or containers marked according to the respective manufacturers specifications.
Maintenance
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.All drive units have to be switched off before carrying out maintenance jobs. Deviationsfrom this are only
allowed if the maintenance or jobs require a running engine.
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.
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.
5.As soon as maintenance and repair jobs have been completed all safety devices have to be reinstalled
properly.
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.
Transport
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.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.
3.When being transported on vehicles, precautions have to be taken that vibration plates do not slip or turn
over.
Maintenance checks
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.
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TECHNICAL DATA
DPU 5045HDPU 5045H - 750 wide
Item no.0007862 ...0007936 ...
Forward/reverse speedm/min:0 to 22
Surface compaction performancem2/h:to 900
Operating weight
without extension plates (440 mm) kg:387
with extension plates(600 mm)kg:410
with extension plates(750 mm)kg:426
Power transmissionFrom drive engine directly to exciter unit via
with electric starter
Piston displacementcm3:413
Engine speedmin-1:2900/210
Nominal output (*)kW (PS):6,1 (8,3)
OilFuchs Titan Unic 10W40 MC (SAE 10W40)
FuelDiesel
Fuel consumptionl/h:1,6
Tank capacityl:5,0
Electrical system
BatterySpecial Wacker-battery for vibro plates
12 V - 55 Ah
AlternatorRotary current generator with
electronic regulator and rectifier
Charging rate max.A:26
Charging voltageV:14
StarterStarter motor
D.C. V:12
Hydraulic control
Hydraulic oilFuchs Renolin MR 520
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TECHNICAL DATA
(*) In accordance with the installed useful outlet power according to Directive 2000/14/EG.
The sound pressure level at the operator‘s working place, determined according to the EN ISO 11204 standard,
is equal to LpA= 90 dB(A)
The weighted effective acceleration value, determined according to EN 1033 is 6 m/s2.
The sound and vibration measurements were carried out and obtained with the machine working on crushed
gravel at nominal engine speed.
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DESCRIPTION
Field of application
The application range of these machines reaches from the trench and surface compaction, even with semicohesive soils, to the vibration of interlocking paving stones and sett pavements.
Dimensions
Max. admissible inclination
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DESCRIPTION
Description of function
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 (Fig. 1), at standstill (Fig. 2) and in reverse motion (Fig. 3) is possible.
This process is hydraulically controlled with the operating control handle (6) on the centre pole head (7).
ForwardsStandstillReverse
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).
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).
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.
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.
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.
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.
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TRANSPORT TO WORK SITE, RECOMMENDATIONS ON COMPACTION
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!
- 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.
Recommendations on compaction
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 .
Recommendation: In each case determine the max. compaction depth with compaction tests and soil sam-
ples.
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 25omust not be exceeded.
☛ATTENTION!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 !
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OPERATION
Starting
Conditions:
Oil:Check oil level on oil dipstick (21), if necessary top up with Fuchs Titan Unic 10W40 MC using the
filler nozzle (19).
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.
Air filter:Clean air filter dry, dusty conditions.
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.
2. In extreme cold also activate the automatic decompression (2).
3. Turn ignition switch key (22) to operating position; then push in starter button and hold until engine is running.
☛ATTENTION!Wait until the engine stops before repeating the starting procedure.
4. Turn throttle control lever (8) into idling position, allow engine to warm up for 7 minutes at idling speed.
Note: Do not activate automatic decompression lever while the engine is running.
Forward and reverse motion
The engine speed can be infinitely varied on the throttle control lever (8).
The direction of travel is determinet with the shift lever (6).
Depending on the position of the shift lever (6), the vibration plate compacts in forward direction, 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.
ForwardsStandstillReverse
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OPERATION
Switching off
☛ATTENTION!Never switch off the engine with the automatic decompression (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. When the engine is at a standstill, turn the ignition key (22) to the Stop position and pull out, control lamp
goes off.
Compaction without extension plates
If the vibration plates is used without extension plates, screw set of protective screws (8pes) No. 0067519 into
the threaded boreholes situated in the lower mass, in order to avoid threads from being damaged.
Emergency start by hand
An automatic decompression (2) is provided to facilitate starting. It ensures that there is only a little compression pressure during the first few revolutions of the crankshaft. After several revolutions it automatically switches over to the full compression pressure.
1. Turn the throttle control lever (8) to the full load position.
2. Following the direction of long arrow, turn the decompression lever until the stop position. At this point automatic decompression lever engages with an audible click, and the engine is ready to start.
3. Insert crank (24) into the bushing.
4. After having engaged the automatic decompression system to the stop position, the engine will require five
full turns of the crank until the engine regains its compression and fires up. If for any reason less than five
turns are required for the starting procedure, turn the decompression lever back in the direction of the short
dashed arrow. Each audible „click“ of the mechanism is equivalent to one turn less with the crank.
5. Stand beside the engine (feet slightly apart), viewing in the forward direction.
6. Place one hand on the machine an crank with the other hand.
☛ATTENTION!Keep a firm hold of the crank while cranking in order to avoid the risk of sudden slip-
page.
7. Turn crank slowly at first until crank engages and then increase cranking speed.
8. As soon as the engine is running, remove crank (24).
9. Throttle control lever (8) in idling position; allow engine to warm up at idling speed for 2 - 3 minutes.
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OPERATION
Mechanical oil pressure control
It is necessary to reactivate the mechanical oil pressure control in the following cases:
- after the initial filling - 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 „1“ for approx. 5 seconds.
4. Hold down pin „1“ during approx. 5 seconds in the case of encapsulated engine versions.
5. Simultaneously actuate hand lever a few times in the case of engines equipped with fuel pumps.
6. Complete engine. Check to see that encapsulating elements seal correctly.
☛ATTENTION!Check oil level every 8 to 15 operating hours in spite of the mechanical oil pressure con-
trol.
Starting with external battery etc.
Observe the following connection sequence when using an external battery to start the engine:
1. Connect one end of jumper cable to positive terminal of auxiliary battery.
2. Connect the other end of jumper cable to positive terminal of the vibro plate battery.
3. Now connect jumper cable clamp to negative terminal of the auxiliary battery.
4. Connect other end of jumper cable to the upper mass of the vibratory plate, e.g. to the motor fixing screws.
The connection point should be as far away as possible from the battery of the vibratory plate.
5. Disconnect jumper cable in reserve order.
☛ATTENTION!Only 12 V batteries may be used. The use of e.g. a 24 V truck battery will lead to an
explosion of the vibro plate battery!
Additional notes on starting at very low temperatures!
☛ATTENTION!Never use starting sprays or similar - they are forbidden because they are dangerous.
Only use original Wacker crank.
☛ATTENTION!If cranking, is too slow, the engine can start running in the opposite direction of rotation.
In this case the air is drawn in through the exhaust and the exhaust gases excape through
the air filter.
Risk of fire! Switch off engine and start it again.
In case of a manual start: Free the engine by turning it approximately 10 to 20 times with the decompression
lever in a central position. Then the engine is decompressed, but not ready to start. This intermediate position
is used to turn the engine "free" when at very low temperatures. The turning resistance becomes appreciably
lower owing to the change in viscosity of the oil film. At the same time you will hear that the nozzle of the fuel
injection system is injecting cleanly (rattling).
At very low temperatures (below -5
Note: Do not use more than 2 doses as otherwise there is a risk of crank back-swing.
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C, use the starting oil dosing device (23).
15
MAINTENANCE
Maintenance schedule
ComponentMaintenance workMaintenance interval
External hardwareCheck for tightness.approx. 8 hours after
initial start-up
Drive engineFirst oil change and filter.25 hours after initial
Valve clearanceCold engine: Check valve clearance, and adjuststart-up
if necessary.
Inlet valve 0,1 mm - outlet valve 0,2 mm.
Air filterCheck dry type air filter - clean or replace filterdaily
cartridge if necessary (pay attention to the
maintenance indication).
Drive engineCheck oil level, if nec. top up oil.
Centre pole heightRegrease.weekly
setting, transport
lock
V-beltCheck V-belt, if. nec. replace.monthly
Protective frame,Check attachment screws for tight fit.
central lifting point
Tow-bar headCheck oil level, top up if necessary.
Drive engineOil change, change oil filter.every 250 h
Keep cooling fins free of dirt, clean dry.
Retighten all accessible screw connections.
ExciterOil change.
BatteryCheck acid level, if nec. top up with distilled water.
Valve clearanceCold engine: Check valve clearance, and adjust
if necessary.
Inlet valve 0,1 mm - outlet valve 0,2 mm.
Fuel filterChange filter.every 500 h
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Engine oil
Check oil level:
Check oil level on oil dipstick (21).
If the oil level is too low, top up with Fuchs Titan Unic
10W40 MC though the filler nozzle (19).
Changing the oil:
1. Let engine warm up.
2. Loosen oil drain screw.
3. Loosen fastening screws and place bracket over used oil
container.
4. Remove oil drain screw and pour oil into container.
5. Screw oil drain screw back in and refasten bracket.
6. Pour in 1,0 l of oil through the filler nozzle (19).
Battery
Check acid level:
1. Remove battery cover.
2. Check acid level, if necessary top up with distilled water.
3. Secure battery cover.
MAINTENANCE
☛ATTENTION! Do not close venting opening!
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 terminal of battery.
When using starting sprays etc., see chapter operation.
Hydraulic control
Check oil level:
1. Move centre pole into vertical position.
2. Open filler bore (26).
3. Oil level must be at mark, if necesary topup with hydraulic oil Fuchs Renolin MR 520.
4. Close filler bore (26).
Venting hydraulic control:
1. Remove apron (28) by undoing the screws (29).
2. Move centre pole into vertical position, move shift lever
(6) right into the reverse position, open filler bore (26).
3. Loosen connecting screw (27).
4. Slowly push the shift lever (6) into forward motion direction until hydraulic oil emerges bubblefree at the connection screw.
5. Tighten connecting screw (27), mount apron (28).
6. If necessary, top up with Fuchs Renolin MR 520, seal filler bore (26).
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MAINTENANCE
Exciter
Oil
Check oil level:
1. Position vibration plate horizontally.
2. Open filler bore (30).
3. The oil level must reach the start of the thread of the filler bore (30).
4. If necessary, pour in Fuchs Titan Unic 10W40 MC through filler bore (30) (use funnel 0,75 l).
5. Close filler bore (30).
Changing the oil:
1. Open filler bore (30).
2. Tilt vibration plate and keep it tilted until the oil has run out.
3. Place vibration plate in horizontal position.
4. Pour in 0,75 l Fuchs Titan Unic 10W40 MC through the filler bore (30).
5. Close filler bore (30).
☛ATTENTION! Do not pour in too much oil!
Exciter V-belt
It is not necessary to retighten the V-belt owing to the use of
the automatic centrifugal clutch.
Should the V-belt width fall below 15,5 mm the V-belt must be
replaced.
Changing the exciter V-belt:
1. Remove belt guard (31).
2. Undo screw (32).
3. Remove button (33), belleville spring (34), seal (35) 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 (36) coincides with the marking on
the V-belt pulley (10)
☛ATTENTION! Do not oil or grease clutch components (will
damage the graphite bushes).
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Forward speed too low
Reverse speed too low
No reverse motion
FAULTS
Cause:- To little hydraulic oil in the centre pole head.
- Air in hydraulic control.
Remedy: - Top up hydraulic oil.
- Bleed system.
Cause:- Too much oil in centre pole head.
Remedy: - Correct oil level in accordance with mark.
Cause:- Mechanical fault.
Remedy: - Contact Wacker service dept.