Wacker Neuson DPU Series Operator's Manual
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Wacker Neuson DPU Series Operator's Manual

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Operator's manual
Vibratory plate
Test machine
DPU
DPU
5100008833
May 2015
01
en

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Summary of Contents for Wacker Neuson DPU Series

  • Page 1 Operator’s manual Vibratory plate Test machine Model Document 5100008833 Issue May 2015 Version Language...
  • Page 2 Manufacturer Wacker Neuson Produktion GmbH & Co. KG Preussenstrasse 41 80809 Munich www.wackerneuson.com Tel.: +49-(0)89-354 02-0 Fax: +49-(0)89-354 02-390 Translation of the original operator’s manual in German 100_0000_0001.fm...

  • Page 3: Table Of Contents

    Storage location of the manual ....................6 Accident prevention regulations....................6 More information.......................... 6 Target group ..........................6 Explanation of symbols........................ 6 Wacker Neuson Contact person....................7 Disclaimer ............................ 7 Product identification of the machine................... 7 Security ..........................8 Policy ............................8 Areas of responsibility of the operator ..................
  • Page 4 Table of contents Maintenance schedule – daily maintenance jobs ..............44 Maintenance schedule – regular intervals ................. 44 Maintenance jobs........................45 Troubleshooting ........................52 10.1 Troubleshooting table – machine....................52 10.2 Troubleshooting table – receiving units ..................53 10.3 Troubleshooting chart – remote control ..................54 10.4 Troubleshooting table –...

  • Page 5: Preface

    This operator's manual contains information and procedures for the safe operation and safe maintenance of your Wacker Neuson machine. For your own safety and to protect against injuries, you must read the safety instructions carefully; familiarize yourself with them and observe them at all times.

  • Page 6: Introduction

    The information contained in this manual is based on machines manufactured up to the time of printing. Wacker Neuson reserves the right to change this information. The manufacturer shall immediately include any changes or additions in this manual.

  • Page 7: Wacker Neuson Contact Person

    NOTE Supplementary information Wacker Neuson Contact person Depending on the country, the Wacker Neuson contact person is a Wacker Neuson service, a Wacker Neuson affiliate, or a Wacker Neuson dealer. On the Internet at www.wackerneuson.com. The manufacturer's address can be found at the beginning of this manual.

  • Page 8: Security

    The following cases are considered structural changes: Opening the machine and the permanent removal of components.  Installing spare parts that do not originate from Wacker Neuson or are not comparable in the design  system and quality of the original parts.

  • Page 9: User Responsibilities

    3 Security User responsibilities Knowing and implementing the applicable health and safety regulations.  In a risk assessment, risks resulting from on-site working conditions will be determined.  Create operating instructions for the operation of this machine.  Periodically check whether the user instructions correspond to the current state of regulations. ...

  • Page 10: Specific Safety Instructions - Vibratory Plates

    Do not exceed max. allowable slanting position of the machine – possible failure of the engine  lubrication, see chapter Technical Data. Only Wacker Neuson use starter batteries. These are vibration proof and therefore suitable for the  high vibration exposure.

  • Page 11: General Safety Instructions - Fuel, Lubricants And Coolants

    Changing revolutions per minute (RPM) influence the EPA certification and the emissions. Settings for this engine may only be changed by a professional. For more information, contact the manufacturer or your Wacker Neuson contact person. 3.10 General safety instructions – fuel, lubricants and coolants The following instructions must be complied with: Always wear safety glasses and protective gloves when handling fuel, lubricants and coolants.

  • Page 12: Personal Protection Equipment

    Technical Data section. When wearing ear protection, remain alert because your ability to hear noises such as screams or signal tones is restricted. Wacker Neuson recommends always wearing ear protection. 3.14 Safety equipment Safety devices protect the user of the machine from potential hazards. These include barriers (guards) or other technical measures.

  • Page 13: Behavior In Dangerous Situations

    3 Security Item Description Item Description Protective hood Emergency shutdown switch Automatic central position of control handle NOTE Always tighten loose screw connections using the specified torque setting. Protective hood The covers protect the operator from hot engine parts and noise. Emergency shutdown switch The emergency shutdown switch is used solely to deactivate the machine in the case of danger.

  • Page 14: Safety And Information Labels

    4 Safety and information labels Safety and information labels WARNING Illegible symbols Over time, labels and signs on the machines can become dirty or otherwise unrecognizable. Keep all safety, warning, and operating instructions on the machine in a legible  condition.

  • Page 15: Safety And Information Labels On The Remote Control

    4 Safety and information labels Item Label Description  Label identifies the remote control in the bracket. Label identifies the connection of the charging cable for charging.  0216635 US Machines Warning. WARNING WARNUNG ADVERTENCIA 0219261 ADVERTISSEMENT 0219176 Closing the protective hood can lead to crushing wounds. When closing the protective hood, do not grab between the machine ...

  • Page 16: Design And Function

    5 Design and function Design and function Standard package The machine is delivered fully assembled and is ready for use out of the box. The standard package includes: Vibratory plate  Remote control (optional)  Operator’s manual  Manual for machine configuration (includes PIN data of the machine) ...
  • Page 17 5 Design and function In order for the machine to be able to execute the control commands, the remote control and machine must be set to the same transmission channel. Each machine has its own address for the transmission channel. Upon delivery, the transmitter unit is set to the address of the machine and will only work with this machine.

  • Page 18: Versions

    5 Design and function 5.3.4 Machine protection – installation (optional) The acceleration load of the upper mass is monitored via a machine protection sensor. When a threshold value corresponding to operation of the vibratory plate on an extremely hard surface (concrete, asphalt) is exceeded, a warning is given to the operator.

  • Page 19: Components And Operator's Controls

    6 Components and operator's controls Components and operator's controls Components Item Designation Item Designation Drive motor Central lifting point Upper mass Eyelet for padlock Base plate Receiving units Center pole Bracket for remote control and charging cable Fuel tank Nameplate Center pole The center pole can be adjusted to the optimum working height.
  • Page 20 6 Components and operator's controls Item Designation Item Designation Hood opener Vibratory rammer ON/OFF switch (red) Control handle Display and control lamps (diagnostic and Height adjustment mechanism of center pole configuration menu) Adjusting key (black) Footrest of center pole lock Start button Emergency shutdown switch Slow/fast rocker switch...
  • Page 21 6 Components and operator's controls Display and control lamps 1 2 3 4 5 6 Item Designation Item Designation Control lamp for operation Control lamp for oil pressure Control lamp for charging Control lamp for coolant temperature Control lamp for preheating Display Control lamp for air cleaner Control lamp for operation...
  • Page 22 6 Components and operator's controls Display The following information is displayed in sequence: Number of operating hours.  The transmission channel set on the machine.  Error statuses.  Diagnostic menu.  Configuration menu.  Diagnostic menu Diagnostics In the diagnostic menu on the display, the following information about the machine can be accessed: Overview of all detected errors (error memory).

  • Page 23: Components And Operator's Controls - Remote Control Unit

    6 Components and operator's controls Components and operator’s controls – remote control unit The remote control of the DPU 80r and DPU 100r may only be used for these machines. 11 10 9 Item Designation Item Designation Joystick (left, right) Engine start button Socket for charging cable ON/OFF switch...
  • Page 24 6 Components and operator's controls Operation Operation control lamp flashes green when the remote control is switched on.  The control lamp for operation flashes green when the remote control is switched on.  The control lamp for operation flashes red when the charge situation of the battery is low. ...

  • Page 25: Transport

    7 Transport Transport WARNING Improper handling can result in injury or serious material damage. Please read and follow all safety instructions in this operator’s manual.  DANGER Danger from falling. Falling machines can cause serious injury e.g. through crushing. Only use suitable and tested lifting gear and tackle (safety load hooks) of sufficient ...
  • Page 26 7 Transport Lift machine NOTE Establish a flagman for a secure lifting process. Item Designation Item Designation Central lifting point (attachment point) Tie-down lugs 1. Place the central lifting point in the vertical position. 2. To lift the motor, hang suitable tackle at the central lifting point. 3.

  • Page 27: Operation And Use

    Complete the following inspections: Check machine and components for damage. If there is any visible damage, do not use the machine  and immediately contact the Wacker Neuson service. Ensure that loose packing material has been removed from the machine. ...
  • Page 28 8 Operation and use 8.1.2 Set center pole Item Designation Item Designation Center pole Star knob The optimum working height of the center pole can be adjusted by turning the star knob. 8.1.3 Remote controlled machine Remove remote control from the bracket Image in progress Item Designation...

  • Page 29: Notes On Operation

    8 Operation and use Check remote control Remote control and carrying strap are undamaged.  Remote control is free of dirt.  Notes on operation WARNING Danger of tipping There is a serious risk of injury from slipping or tipping over of the machine. Near edges, at least 2/3 of the machine must be on a load-bearing surface.

  • Page 30: Commissioning

    8 Operation and use Remote-controlled machinery – direction of movement The direction of movement of the machine is independent from the position of the operator. If the joystick of the remote control is pressed forward, the machine moves always forward. WARNING Mixing up the direction of movement of the machine poses a danger of crushing for others.

  • Page 31: Din En Iso 9001 Certificate

    8 Operation and use When the machine is activated, all control lamps light up for approx. 1 second.  The following are displayed in sequence: Auto-engaging status.  The transmission channel set on the machine (optional).  Possibly the most recent error. ...
  • Page 32 8 Operation and use 8.3.2 Commission machine (center pole) Item Designation Item Designation Start button Control lamp 1. The red control lamp on the center pole flashes briefly at intervals of 5 seconds to signal readiness to start. 2. Briefly press start button of the center pole – the motor will start automatically. NOTE The starting process can take up to 2 minutes.

  • Page 33: Operation

    8 Operation and use Start engine Item Designation Engine start button 1. Directly aim remote control towards a receiver unit. 2. Briefly press start button of the remote control – the motor will start automatically. When the receiving units flash yellow, the machine is ready. NOTE The starting process can take up to 2 minutes.
  • Page 34 8 Operation and use 8.4.1 Operate machines with center pole Item Designation Item Designation Vibratory rammer Forward Central position of control handle Reverse 1. Pull vibration switch 2. Select travel direction and speed with the control handle. Speed display by lighting of the slow/fast-rocker switch or flashing for intermediate positions. ...
  • Page 35 8 Operation and use 8.4.2 Operating a remote-controlled machine The following table shows how the machine moves when the respective joystick of the remote control is operated: No movement Forward Reverse Forward left turn Forward right turn Reverse left turn Reverse right turn Left stand rotation Right stand rotation...

  • Page 36: Decommissioning

    8 Operation and use 8.4.4 Reading Compatec – compaction display This display roughly indicates the progress of the compaction. NOTE To protect the machine, Compatec – compaction display warns the operator of over- compaction by quickly flashing all LEDs. NOTE The brightness of the LED automatically adjusts to the light conditions of the working area.
  • Page 37 8 Operation and use 2. Press the start button – the engine switches off. NOTE Compatec - compaction display automatically switches itself off once the machine is turned off. 8.5.2 Decommissioning the machine (remote control) Switch off remote control and engine Item Designation Item...
  • Page 38 8 Operation and use Item Designation Item Designation Control lamps ON/OFF switch (red) Display 1. Open rear protective hood. 2. Press the ON/OFF switch on the machine in order to deactivate it. If the operation and receiving unit control lamps turn off, the machine is deactivated. 3.
  • Page 39 8 Operation and use 8.5.4 Charge rechargeable battery (remote control) NOTE Charging the battery at temperatures below 0°C may not be possible. Charging rechargeable battery with charging cable NOTE After connecting the charging cable to the remote control, the rechargeable battery is loaded.
  • Page 40 8 Operation and use 8.5.5 Rechargeable battery charger with external charging device (optional) Only use external battery chargers from Wacker Neuson. Remove rechargeable battery from the remote control Item Designation Item Designation Rechargeable battery Clip 1. Press the clip and simultaneously pull the rechargeable battery to the right.

  • Page 41: Setting The Transmission Channel (Remote Control)

    8 Operation and use 1. Push rechargeable battery into the remote control until the clip snaps into place. Setting the transmission channel (remote control) The machine can only be operated if the transmission channel of the remote control corresponds to the transmission channel of the machine.

  • Page 42: Operation Of The Configuration Menu

    8 Operation and use Error message.  Item Designation Item Designation Consecutive number Error code Operating hours 1. In the diagnostics menu, select the error memory. 2. To select the stored error, repeatedly press the black setting button until the desired area appears. 3.

  • Page 43: Maintenance

    9 Maintenance Maintenance WARNING Improper handling can result in injury or serious material damage. Please read and follow all safety instructions in this operator’s manual.  WARNING Danger of poisoning by exhaust fumes. Exhaust fumes contain poisonous carbon monoxide, which can lead to loss of consciousness or death.

  • Page 44: Maintenance Schedule - Daily Maintenance Jobs

    Replace exciter oil. *  Check the V-belt of the fan – tighten *.  Replace the hydraulic oil filter with air cleaner.*  Check tapped clearance and adjust if necessary. * Have this work done by the service of Wacker Neuson. 100_0202_mt_0011.fm...

  • Page 45: Maintenance Jobs

     Replace the tooth belt pulley of the engine.*  Replace the hydraulic hose lines.* Have this work done by the service of Wacker Neuson. Maintenance jobs CAUTION Health hazard from fuel, lubricants and coolants Do not inhale vapors from fuel, lubricants and coolants.
  • Page 46 9 Maintenance 4. If necessary, remove and clean the dirty fuel filter. Reinsert fuel filter before topping up. 5. Add fuel to the limit mark – for fuel type, see Technical Data chapter. 6. Replace fuel cap and tighten. 7. Close rear protective hood. NOTE Dispose of impurities of the fuel filter in accordance with the applicable provisions for environmental protection.
  • Page 47 9 Maintenance NOTE The amount of oil between the upper and lower mark is between 0.6 l (DPU 80) and 1.0 l (DPU 100). Top up motor oil 1. Remove dirt accumulation in the area of the oil filler opening. 2.
  • Page 48 9 Maintenance NOTE Dispose of oil in accordance with the applicable provisions for environmental protection. Fill motor oil 1. Remove dirt accumulation in the area of the oil filler opening. 2. Remove cover of the oil filler opening. 3. If necessary, fill with oil until the upper mark of the oil-level dipstick is reached – for oil specification and amount of oil, see Technical Data chapter.
  • Page 49 If the machine is losing coolant, check the cooling system for leaks, and have the machine repaired by the service of the Wacker Neuson contact person. 1. If necessary, top up coolant to the upper edge of the filler opening – for coolant specification, see Technical Data chapter.
  • Page 50 9 Maintenance 9.4.7 Check exciter oil level and top up exciter oil Image in progress Item Designation Item Designation Screw plug with seal ring of the oil filler Level of exciter oil opening Screw plug with seal ring of the oil drain opening Check exciter oil level 1.
  • Page 51 Top up hydraulic oil NOTE If the machine is losing hydraulic oil, check the hydraulic line for leaks, and have the machine repaired by the service of the Wacker Neuson contact person. WARNING Hot hydraulic oil can cause injury by scalding.

  • Page 52: 10 Troubleshooting

    Compatec - compaction display Switch-on with the engine running. Have the machine repaired.* (optional): Sensor is defective. If all LEDs permanently flash after initialization, the sensor has not been successfully tested. Have this work done by the service of Wacker Neuson. 100_0202_ts_0010.fm...

  • Page 53: Troubleshooting Table - Receiving Units

     Reduce compaction performance through lower deflection of the joystick of the remote control. Switching from fast to slow  operation. Have this work done by the service of Wacker Neuson. 100_0202_ts_0010.fm...

  • Page 54: Troubleshooting Chart - Remote Control

    Remote control switches itself off – if no button on the remote control is pressed, the remote control will automatically switch off after 10 minutes. Have this work done by the service of Wacker Neuson. 100_0202_ts_0010.fm...

  • Page 55: Troubleshooting Table - Display

    Cooling system is leaking. Have the machine repaired.* Have this work done by the service of Wacker Neuson. Fault indications on the display The last error is briefly displayed after each activation of the machine. If the error is corrected, the error message should be acknowledged in the diagnostic menu because the error is no longer relevant for further operation.
  • Page 56 10 Troubleshooting Error code Display Possible causes Remedial measure Oil pressure Engine oil level is too low. 1. Deactivate machine. shutdown 2. Top up motor oil. Oil pressure switch or electrical Have the machine repaired.* connection is defective. Excess temperature Coolant level is too low.
  • Page 57 10 Troubleshooting Error code Display Possible causes Remedial measure Machine overloaded Machine is overloaded because the soil Deactivate the machine and cannot be compacted any further. then re-activate it. To prevent overload, observe the following rules: Avoid operation on non-compactable soil. ...

  • Page 58: Perform Jump Start With Donor Starter Battery

    2. Have the machine repaired.* Have this work done by the service of Wacker Neuson. 10.5 Perform jump start with donor starter battery If the starter battery of the machine is discharged and the engine does not start, a jump-start with a donor battery is possible.
  • Page 59 Perform jump start 5. Start engine. If the engine does not start after more than two minutes, inform your Wacker Neuson contact person. 6. Run engine for a few minutes. Disconnect the jumper cable 7. Disconnect clamping tongs of the black jumper cable from the grounding point of the machine.

  • Page 60: 11 Disposal

    11 Disposal 11 Disposal 11.1 Disposal of batteries For customers in EU countries The unit contains one or more batteries or rechargeable batteries (hereinafter referred to as "the battery"). This battery is subject to the European Directive on (old) batteries (old) rechargeable batteries and the respective national laws.

  • Page 61: 12 Accessories

    Spare parts and accessories that do not originate from Wacker Neuson can increase the risk of injury and damage to the machine. If other spare parts and accessories are used, Wacker Neuson shall not be held liable.  A wide range of accessories is offered for the machine.

  • Page 62: 13 Technical Data

    13 Technical data 13 Technical data 13.1 Designation Unit DPU 80Le DPU100Le Item number 5100018444 5100018445 Centrifugal force Vibrations 56.4 59.6 3,380 3,580 Compaction performance Travel speed* m/min Reverse travel* m/min Gradeability Length (center pole in 2,223 2,223 working position) Width 670/770 870/970...
  • Page 63 13 Technical data Designation Unit DPU 80Le DPU100Le Sound pressure level dB(A) At location of operation L Standard EN 500-4 Sound power level L dB(A) measured guaranteed Standard EN 500-4, 2000/14/EG Vibration total value a < 2.5 < 2.5 Standard EN 500-4 Uncertainty of measurement of the vibration total value a...
  • Page 64 13 Technical data Designation Unit DPU 80rLe DPU 100rLe Maximum allowable hydraulic pressure Coolant volume Type of coolant SAE J1034: water (1:1) SAE J1034: water (1:1) Exciter oil quantity 1.35 1.35 Type of exciter oil SAE 75W90 SAE 75W90 Hydraulic oil volume 17.7 17.7 Type of hydraulic oil...

  • Page 65: Combustion Engine

    13 Technical data 13.2 Combustion engine DPU 100 Designation Unit DPU 80 Manufacturer Kohler Type of engine KDW 702 KDW 1003 Combustion process Four-cycle Four-cycle Cooling Water cooling Water cooling Cylinders Displacement cm³ 1,028 Maximum slanting position ° 25.0 25.0 Fuel type Diesel Diesel...

  • Page 66: Us Combustion Engine

    13 Technical data 13.3 US combustion engine DPU 100 US Designation Unit DPU 80 US Manufacturer Kohler Type of engine KDW 702 US KDW 1003 US Combustion process Four-cycle Four-cycle Cooling Water cooling Water cooling Cylinders Displacement cm³ 1,028 Maximum slanting position °...

  • Page 67: 14 Emission Control Systems Information And Warranty

    14 Emission control systems information and warranty 14 Emission control systems information and warranty The Emission Control Warranty and associated information is valid only for the U.S.A., its territories, and Canada. Emission control systems warranty statement See the engine owner’s manual for the applicable exhaust and evaporative emission warranty statement.

  • Page 68: Ec Declaration Of Conformity

    EC Declaration of conformity Manufacturer Wacker Neuson Produktion GmbH & Co. KG, Preussenstrasse 41, 80809 Munich Product Product DPU 80Le DPU 100Le Product type Vibratory plate Function of product Soil compaction Item number 5100018444 5100018445 Net installed power 11.0 kW 16.0 kW...

  • Page 69: Ec Declaration Of Conformity

    EC Declaration of conformity Manufacturer Wacker Neuson Produktion GmbH & Co. KG, Preussenstrasse 41, 80809 Munich Product Product DPU 80rLe DPU 100rLe Product type Vibratory plate Function of product Soil compaction Item number 5100016604 Net installed power 11.0 kW 16.0 kW...
  • Page 72  ...

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