Wacker Neuson BPU 2440 series Betriebsanleitung

www.wackergroup.com

Vibroplate

BPU 2440

BPU 2950

REPAIR MANUAL

0078232 004

0603 en

0078232

BPU 2440/2950 Repair Foreword

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Operating / Parts Information

You must be familiar with the operation of this machine before you

attempt to troubleshoot or make any repairs to it. Basic operating and

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 neglect of the unit should be brought to

the attention of the operator, to prevent similar occurrences from

happening in the future.

This manual provides information and procedures to safely 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. THE INFORMATION 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 oremit chemicals known to the State of California

to cause cancer and birth defects or other reproductive harm.

All rights, especially copying and distribution rights, are reserved.

No part of this publication may be reproduced 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 possibility 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 possible 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 moderate 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 additional information 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 engine manual and familiarize yourself with the

locationand proper use ofall controls.Inexperienced operators should

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 equipment.

1.1.2 ALWAYS remain aware of moving parts and keep hands, feet, and

loose clothing away from moving 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 machine with all safety devices and guards in place

and in working order.

1.1.7 ALWAYS remain aware of changing positions and movement of other

equipment and personnel on the jobsite.

1.1.8 ALWAYS remain aware of changing surface conditions and use extra

care when operating over uneven ground, on hills, or over soft or

coarse material. The machine could shift or slide unexpectedly.

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 it has been turned off. These areas get hot and may

cause burns.

1.1.12 NEVER use accessories or attachments thatare not recommendedby

Wacker. Damage to equipment and injury to the user may 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 Engines

Internal combustion engines present special hazards during operation

and fueling! Read and follow warning instructions 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 run machine indoors or in an enclosed area such as a deep

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 refueling engine.

1.2.7 DO NOT run engine near open flames.

1.2.8 ALWAYS refill fuel tank in well-ventilated 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 around hot exhaust pipes free of debris to reduce

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 properly 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 equipment without express written approval 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

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1.3.6 DO NOT crank a flooded engine with the spark plug removed on

gasoline-powered engines. Fuel trapped in the cylinder will squirt out

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 other types of fuels or flammable solvents 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 recommended by Wacker.

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 battery disconnect before

adjusting or maintaining the electrical equipment.

1.3.14 ALWAYS turn engine off before performing maintenance or making

repairs.

1.3.15 ALWAYSkeep hands, feet and loose clothing away from 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 weight-

bearing 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 machine, ensure that all tools have been removed

from the machine and that replacement parts and adjusters are firmly

tightened.

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