Wacker Neuson BPU 2440 series, BPU 2950 series, BPU 2650R, BPU 2440A, BPU 2950R Repair Manual
...
www.wackergroup.com
Vibroplate
BPU 2440
BPU 2950
REPAIR MANUAL
0078232 004
0603 en
0078232
BPU 2440/2950 Repair Foreword
wc_tx000260gb.fm i
Operating / Parts Inf o r ma t i on
You must be familiar with the operation of this machine before you
attempt to trou bl es h oot or ma ke a ny re pa irs t o it. Ba sic op er atin g an d
maintenance procedures are described in the operator’s / parts
manual supplied with the machine. The operator’s / parts manual
should be kept with the machine. Use it to order replacement parts
when needed. If this manual becomes lost, please contact Wacker
Corporation to order a replacement.
Damage caused by misuse or neg lect of the unit should be brough t to
the attention of the operator, to prevent similar occurrences from
happening in the future.
This manual provides information and procedures to safe ly repair and
maintain this Wacker model. For your own safety and protection from
injury, carefully read, understand and observe the safety instructions
described in this manual. TH E INFORM ATION CONTAINED IN THIS
MANUAL WAS BASED ON MACHINES IN PRODUCTION AT THE
TIME OF PUBLICATION. WACKER CORPORATION RESERVES
THE RIGHT TO CHANGE ANY PORTION OF THIS INFORMATION
WITHOUT NOTICE.
This manual covers machines with Item Number:
5603, 5904, 6222, 6346, 6412, 6993, 7150, 7867, 7872, 7962
Foreword BPU 2440/2950 Repair
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CALIFORNIA
Proposition 65 Warning:
Engine exhaust, some of its constituents, and certain vehicle
components contain or em it chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
All rights, especially copying and distribution ri ghts, are reserved.
Copyright 2003 by Wacker Corporation.
No part of this pu blication may be rep roduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.
Any type of reproduction or distribution not authorized by Wacker
Corporation 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 their safety standards.
WARNING
Typ Table of Contents
wc_br0078232_002enTOC.fm 1
1. Safety Information 3
1.1 Operating Safety .................................................................................. 4
1.2 Operator Safety while using Internal Combustion Engines .................. 5
1.3 Service Safety ...................................................................................... 5
1.4 Labels ................................................................................................... 7
2. Technical Data 9
2.1 Engine .................................................................................................. 9
2.2 Plate ..................................................................................................... 9
2.3 Lubrication .......................................................................................... 10
2.4 Dimensions ......................................................................................... 10
3. General Information 11
3.1 Application .......................................................................................... 11
3.2 Tools ................................................................................................... 11
3.3 Ordering Parts ................................. .... ............................................... 11
3.4 Reference Numbers ( ) ....................................................................... 12
3.5 Weight Block ......................................................................................12
3.6 Lifting and Transporting the Machine .................................................12
3.7 Storage ............................................................................................... 13
3.8 Theory of Operation ...........................................................................14
3.9 Directional and Speed Control ........................................................... 16
3.10 Engine Speed and Machine Performance ..........................................18
3.11 Operating on Slopes ........................................................................... 18
3.12 To Start ............................................................................................... 19
3.13 To Stop ............................................ .... ..... .......................................... 19
4. Maintenance 20
4.1 General Maintenance ......................................................................... 20
4.2 Maintenance Schedule .................................................................... 21
4.3 Air Filter .............................................................................................. 22
4.4 Spark Plug .......................................................................................... 23
4.5 Cleaning Sediment Cup ..................................................................... 24
4.6 Adjusting Idle Speed ..........................................................................25
Table of Contents Typ
wc_br0078232_002enTOC.fm 2
4.7 Carburetor Adjustment ........................................................................25
4.8 Drive Belt .............................................................................................26
4.9 Exciter Oil ............................................................................................27
4.10 Control Circuit Oil ................................................................................27
4.11 Bleeding the Control Circuit .................................................................28
4.12 Re-installing Piston in Control Assembly .............................................29
5. Repair Procedures 30
5.1 General Repair ....................................................................................30
5.2 Checking Exciter Operation .................................................................31
5.3 Exciter Exploded View Illustration .......................................................32
5.4 Exciter Parts List .................................................................................33
5.5 Removing Exciter ................................................................................34
5.6 Installing Exciter ........................................ ..... .... .................................35
5.7 Exciter Assembly Cross Section .........................................................36
5.8 Exciter Cross Section List of Components ..........................................37
5.9 Servicing Exciter ..................................................................................38
5.10 Disassembling the Exciter ...................................................................38
5.11 Re-assembling the Exciter ..................................................................40
5.12 Servicing the Clutch ............................................................................44
5.13 Replacing the Engine ................................ ..... .....................................45
5.14 Engine Replacement—Honda .............................................................46
5.15 Engine Replacement—Robin ..............................................................47
6. Troubleshooting 48
BPU 2440/2950 Repair Safety Information
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1. Safety Information
This manual contains DANGER, WARNING, CAUTION, and NOTE
callouts which must be followed to reduce the po ssibility of personal
injury, damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid pos sible injury or death.
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or modera te injury.
CAUTION: Used without the safety alert symbol, CAUTION indicates
a potentially hazardous situation which, if not avoided, may result in
property damage.
Note:
Contains addi tional infor m ation important to a procedure.
DANGER
WARNING
CAUTION
Safety Information BPU 2440/2950 Repair
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1.1 Operating Safety
Familiarity and proper training are required for the safe operation of
equipment! Equipment operated improperly or by untrained personnel
can be dangerous! Read the operating instructions contained in both
this manual and the en gine manual and familiarize yourself with the
location and prope r use of all contr ols. Inexperie nced operators shou ld
receive instruction from someone familiar with the equipment before
being allowed to operate the machine.
1.1.1 ALWAYS wear protective clothing appropriate to the job site when
operating equi pment.
1.1.2 ALWAYS remain aware of moving parts and keep hands, feet, and
loose clothing away from movi ng parts of equipment.
1.1.3 ALWAYS read, understand, and follow procedures in Operator's
Manual before attempting to operate equipment.
1.1.4 ALWAYS store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the reach of
children.
1.1.5 ALWAYS check that all controls are functioning properly immediately
after start-up! DO NOT operate machine unless all controls operate
correctly.
1.1.6 ALWAYS operate ma chi ne w ith all safety devices and g ua rd s i n pla c e
and in working order.
1.1.7 ALWAYS remain aware of cha ng in g positi o ns and move me nt of oth er
equipment and personnel on the jobsite.
1.1.8 ALW AY S rem ain aw are of c h angi ng s urfa ce c ond it ions a nd us e ex tr a
care when operating over uneven ground, on hills, or over soft or
coarse material. The machine could shift or slide unexpe ctedly.
1.1.9 ALWAYS be sure that all other persons are at a safe distance from the
machine. Stop the machine if people step into the working area of the
machine.
1.1.10 NEVER allow improperly trained people to operate this equipment.
People operating this equipment must be familiar with the potential
risks and hazards associated with it.
1.1.11 NEVER touch the engine or muffler while the engine is on or
immediately after i t has been turned off. The se areas get hot and may
cause burns.
1.1.12 NEVER use accessories or attachm ents that are not recom mended by
Wacker. Damage to equipment and injury to the user m ay result.
1.1.13 NEVER leave machine running unattended.
1.1.14 NEVER start a defective unit in need of service or repair.
WARNING
BPU 2440/2950 Repair Safety Information
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1.2 Operator Safety while using Internal Combustion En gines
Internal combusti on en gines pr esent specia l haza rds du rin g opera tion
and fueling! Read and follow warning instructio ns in engine owner's
manual and safety guidelines below. Failure to follow warnings and
safety guidelines could result in severe injury or death.
1.2.1 DO NOT r un mach ine in door s or in an enclo sed area s uch as a d eep
trench unless adequate ventilation, through such items as exhaust
fans or hoses, is provided. Exhaust gas from the engine contains
poisonous carbon monoxide gas; exposure to carbon monoxide can
cause loss of consciousness and may lead to death.
1.2.2 DO NOT smoke while operating machine.
1.2.3 DO NOT smoke when refueling engine.
1.2.4 DO NOT refuel hot or running engine.
1.2.5 DO NOT refuel engine near open flame.
1.2.6 DO NOT spill fuel when refu eling engine.
1.2.7 DO NOT run engine near open flames.
1.2.8 ALWAYS refill fuel tank in well-venti lated area.
1.2.9 ALWAYS replace fuel tank cap after refueling.
1.2.10 ALWAYS check fuel lines and fuel tank for leaks and cracks before
starting engine. Do not run machine if fuel leaks are present or fuel
lines are loose.
1.2.11 ALWAYS keep area a roun d hot exhaus t pipes free of de bris to red uce
the chance of an accidental fire.
1.3 Service Safety
Poorly maintained equipment can become a safety hazard! In order
for the equipment to operate safely and prop erly over a long period of
time, periodic maintenance and occasional repairs are necessary.
1.3.1 DO NOT stand under the machine while it is being hoisted or moved.
1.3.2 DO NOT get onto the machine while it is being hoisted or moved.
1.3.3 DO NOT use the machine as a ladder . Use safe ladders and platforms
designed for this purpose.
1.3.4 DO NOT modify the equipmen t without expre ss written approva l of the
manufacturer.
1.3.5 DO NOT attempt to clean or service machine while it is running.
Rotating parts can cause severe injury.
DANGER
WARNING
Safety Information BPU 2440/2950 Repair
wc_si000099gb.fm 6
1.3.6 DO NOT crank a flooded engine with the spark plug removed on
gasoline-powered eng ines. Fuel trapped in the cylinder will squirt o ut
the spark plug opening.
1.3.7 DO NOT test for spark on gasoline-powered engines, if engine is
flooded or the smell of gasoline is present. A stray spark could ignite
fumes.
1.3.8 DO NOT use gasoline or oth er type s of fu el s or flam ma bl e so lvents to
clean parts, especially in enclosed areas. Fumes from fuels and
solvents can become explosive.
1.3.9 ALWAYS keep area around muffler free of debris such as leaves,
paper, cartons, etc. A hot muffler could ignite them, starting a fire.
1.3.10 ALWAYS replace worn or damaged components with spare parts
designed and recommende d by Wacke r.
1.3.11 ALWAYS keep machine clean and labels legible. Replace all missing
and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
1.3.12 ALWAYS check and tighten all external fasteners at regular intervals.
1.3.13 ALWAYS switch off the power supply at the batte ry di sco nne ct befo re
adjusting or maintaining the electrical equipment.
1.3.14 ALWAYS turn engine off before performing maintenance or making
repairs.
1.3.15 ALWAYS keep hands, feet and loose clothing away fro m moving parts.
1.3.16 ALWAYS make sure slings, chains, hooks, ramps, jacks and other
types of lifting devices are attached securely and have enough weightbearing capacity to lift or hold the machine safely. Always remain
aware of the position of other people around you when lifting the
machine.
1.3.17 Before you start the machi ne, ensure that all tools have b een removed
from the machine and th at re place ment parts and adju sters are fir mly
tightened.
BPU 2440/2950 Repair Safety Information
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1.4 Labels
Label Meaning
DANGER!
Engines emit carbon monoxide; operate only
in well ventilated area. Read the op era tor's
manual.
No sparks, flames or burning obje cts near
machine. Shut off engine before refueling.
WARNING!
Hot surface.
CAUTION!
Read and underst and the supplied operator's
manuals before operating this machine. Failure to do so increases the risk of injury to yourself or others.
WARNING!
Do not operate without safety guards. Read
and understand instruction book.
CAUTION!
Lifting point
DO NOT OPERATE WITHOUT SAFETY
GUARDS. READ AND UNDERSTAND
INSTRUCTION BOOK.
NICHT OHNE SCHUTZVORRICHTUNG
BETREIBEN. BEDIENUNGSANWEISUNG
GENAU DURCHLESEN.
NO OPPRE SIN LOS DISPOSITIVOS
DE SEGURIDAD. LEA Y ENTIENDA
PRIMERO LAS INSTRUCCIONES.
NE PAS OPERER SANS DEFLECTEUR
PROTECTIF. LIRE ET COMPRENDRE
LES INSTRUCTIONS DE SERVICE.
WARNING
1007190
wc_gr001474
Safety Information BPU 2440/2950 Repair
wc_si000099gb.fm 8
WARNING!
To prevent hearing loss, wear hearing protection when operating this machine.
A nameplate listing the Model Number, Item
Number, Revision, and Serial Number is
attached to each unit. Please record the information found on this plate so it will be available should the nameplate become lost or
damaged. When ordering parts or requesting
service information, you will alwa ys be asked
to specify the model, item number, revision
number, and serial number of the unit.
Label Meaning
wc_gr001475
BPU 2950/2440 Repair Technical Data
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2. Technical Data
2.1 Engine
2.2 Plate
Model
BPU
2440A
5904
BPU
2440A
7150
BPU
2440A
7867
BPU
2950R
5603
BPU
2950R
6222
6346
BPU
2950A
6412
6993
7872
7962
Engine
Engine Make Honda Honda Robin Robin Honda
Engine Model GX 140 GX 160 EY 27W W1-280 GX 240
Rated Power kW (Hp) 3.7 (5.0) 4.0 (5.5) 6 (8) 6 (8) 6 (8)
Operating Speed rpm 3600 3600 3550 3550 3550
Idle Speed rpm 1400 1400 1200 1200 1400
Clutch Engagement rpm 2100 2100 2100 2100 N/A
Cylinder Compression psi 85-121 85-121 N/A N/A 85-121
Valve Clearance
(cold)
intake
exhaust:
mm (in.)
0.15 (0.006)
0.20 (0.008)
0.15 (0.006)
0.20 (0.008)
0.10
(0.004)
0.10
(0.004)
0.10
(0.004)
0.10
(0.004)
0.15
(0.006)
0.20
(0.008)
Spark Plug Champion
RNYC
NGK
BPR6ES
Champion
L-86
Champion
L-86
Champion
RN9YC
Spark Plug Gap mm (in. ) 0.76 (0.030) 0.76 (0.030) 0.64
(0.025)
0.64
(0.025)
0.76
(0.030)
Air Cleaner type Pleated paper cartridge with oil wetted foam pre-cleaner
Fuel Tank Capacity liter (gal) 3.7 (1) 3.7 (1) 5.7 (1.5) 5.7 (1.5) 5.7 (1.5)
Model
BPU
2440A
5904
BPU
2440A
7150
BPU
2440A
7867
BPU
2950R
5603
BPU
2950R
6222
6346
BPU
2950A
6412
6993
7872
7962
Plate
Vibration Frequency VPM
(Hz)
5400
(90)
5400
(90)
5400
(90)
5400
(90)
5400
(90)
5400
(90)
Travel Speed m (ft.)/min 23 (75) 20 (65) 20 (65) 20 (65) 20 (65) 20 (65)
Power Take-Off kW (Hp) --- Centrifugal clutch & V-belt
Technical Data BPU 2950/2440 Repair
wc_td000102gb.fm 10
2.3 Lubrication
2.4 Dimensions
* Guide handle in working position
Engine Exciter
Model
(S/N)
Oil Grade
Quantity
ml (ounces)
Oil Grade
Quantity
ml (ounces)
BPU 2440A
(5904)
10W40 600 (20)
SAE 15W40 750 (25)
BPU 2440A
(7150)
10W30 600 (20)
BPU 2440A
(7867)
10W30 600 (20)
BPU 2650R
(5603)
10W030 770 (26)
BPU 2950R
(6222, 6346)
10W030 710 (24)
BPU 2950A
(6412)
10W40 1100 (37)
Dimension mm (in.) BPU 2950 BPU 2440
A 700 (27.5) 700 (27.5)
B 1380 (54) 1600 (63)
C 635 (26) 560 (22)
D 500 (19.5) 400 (15.5)
E* 1020 (40) 880 (35)
A
B
C
D
E
wc_gr001180
BPU 2440/2950 Repair General Information
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3. General Information
3.1 Application
Due to its low width of only 400 or 500 mm and its infinite ly variable
working speed setting, this vibratory plate is particularly suited for all
kinds of soil compaction in confined areas such as in cable trenches
40 cm wide or more, compact ion of marginal stri ps, repairs on blackt op
surfaces as well as for all com paction jobs where the use of large scale
equipment is not suitable. Do not use this machine for any other
purpose.
3.2 Tools
Since all possible problems encountered while repairing the
equipment cannot be anticipated, it is up to the mechanic to use
common sense and good judgment in t ool selection.
The use of any spe cial tools is r ecommended only f or those operat ions
where the use of conventional tools proves inadequate.
Before substituting another tool or procedure, you should be satisfied
that neither personal injury nor damage to the component will result.
3.3 Ordering Parts
Operating / Parts Inf o r ma t i on
You must be familiar with the operation of this machine before you
attempt to trou bl es h oot or ma ke a ny re pa irs t o it. Ba sic op er atin g an d
maintenance procedures are described in the operator’s / parts
manual supplied with the machine. The operator’s / parts manual
should be kept with the machine. Use it to order replacement parts
when needed. If this manual becomes lost, please contact Wacker
Corporation to order a replacement.
Damage caused by misuse or neg lect of the unit should be brough t to
the attention of the operator, to prevent similar occurrences from
happening in the future.
General Information BPU 2440/2950 Repair
wc_tx000264gb.fm 12
3.4 Reference Numbers ( )
Repair procedures contain reference numbers enclosed in
parentheses ( ). These numbers refer to the item numbers shown on
the assembly drawing s and other detaile d drawings. They are incl uded
to aid the mechanic in identifying parts and assembling components.
3.5 Weight Block
See Graphic: wc_gr000 84 3
The weight block symbol gives an approximate weight measurement
to aid the mechanic when lifting / hoisting larger components.
3.6 Lifting and Transporting the Machine
See Graphic: wc_gr000 98 6
Lift the machine only by the lifti ng eye (a). Do not lift the machine by
the control hand le. When liftin g, use a n approp riate cran e or hoi st with
minimum load-bearing capacity of 200 kg (440 lbs.).
When transporting the machine, secure it using the tie-down brackets
(b).
250 kg
(550 lbs.)
wc_gr000843
a
b
wc_gr000986
BPU 2440/2950 Repair General Information
wc_tx000264gb.fm 13
Never lift or trans port the machine with its engine running.
3.7 Storage
Job Site Storage
Never allow the machine to sit overnight in a ditch, trench, or other low
area that may fill with water during heavy rain.
Long-term Storage
Before storing the unit for a long period of time, be sure it is in good
condition. The following steps are recommended before storing.
3.7.1 Completely drain the fuel tank. Run the engine until carburetor is dry.
3.7.2 Thoroughly clean ext erior of plate and engine. Visuall y inspect the uni t
for signs of damage, loose hardware, and worn shockmounts. Make
any necessary repair.
3.7.3 Change engine oil and exciter oil.
3.7.4 Clean area around spar k pl u g an d re m ove pl ug. Pou r 1 o un c e (3 0 m l)
of SAE 10W30 engine oil into engine cylinder throug h plug opening.
Crank engine slowly three or four times to distribute oil. Replace the
spark plug.
3.7.5 Store unit indoors in a clean dry area. If unit is to be stored outside,
wrap it with a quality tarpaulin.
CAUTION
CAUTION
General Information BPU 2440/2950 Repair
wc_tx000264gb.fm 14
3.8 Theory of Operation
See Graphic: wc_gr000085 and wc_gr001430
The vibration required for compaction is produced by the exciter (a)
which is firmly joined to the l ower mass (b). The exciter contains two
shafts with eccentric weights attached to each shaft. The shafts are
connected by a sleeve gear and rotate in opposite directions. The
exciter is designed as a centr al vibrator with aligned vibrati ons. Such a
principle permits the direction of vi bration to be ch anged by rotating the
eccentric weights (c) in relation to one another. 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 (d) on the center pole head
(e).
The drive engine (f) is anchored to the upper mass and drives the
exciter. The torque is transmitted by means of a friction connection
through the centrifugal clutch (g) and the exciter V-belt (h).
The centrifugal clutch interrupts flow of power to the exciter at low
engine speeds and thus permits perfect idling of the drive engine. The
speed of the drive engine can be infinitely varied by way of the throttle
control lever (i).
The upper and l ower (j) masse s are con nected t o each ot her by f our
vibration-damping shock mounts (k). This damping system prevents
the very high frequencies from being transmitted to the upper mass. As
a result, the functionality of the drive engine is retained in spite of the
high compaction performance.
The drive engine works according to the 4-stroke principle, is started
by way of a recoil starter, draws in combustion air over a dry air filter,
(l) and is air-cooled.
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