instruction manual - Express Tools Ltd
Contents
1. The centrifugal clutch 9 interrupts the power transmission to the exciter 5 at low engine turning speed thus allowing for a perfect idling speed of the drive engine 1 The turning speed of the engine 1 can be infinitely adjusted by way of the throttle lever 6 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 he drive engine 1 works according to the 4 stroke principle is started by way of a recoil starter sucks in com bustion air over a dry air filter 12 and is air cooled To facilitate the starting procedure the drive engine 1 has an decompression mechanism 7 8 12 6 T00845GB 1 0 TRANSPORT TO WORK SITE RECOMMENDATIONS ON COMPACTION 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 ATTENTION The engine must be2. MAINTENANCE Air filter service A dirty air filter will restrict air flow to the carburettor To prevent carburettor malfunction service the air filter regularly Service more fregently when operating the engine in extremely dusty areas Warning Never use gasoline or low flash point solvents for cleaning the air cleaner element A fire or ex plosion could result Caution Never run the engine without the air cleaner Rapid engine wear will result 1 Remove the wing nut and the air filter cover Remove the elements and separate them Carefully check both elements for holes or tears and replace if damaged 2 Foam element Wash the element in a solution of household detergent and warm water then rinse thor oughly or wash in nonflammable or high flash point solvent Allow the element to dry thoroughly Soak the element in clean engine oil and squeeze out the excess oil The engine will smoke during initial start up if too much oil is left in the foam 3 Paper element Tap the element lightly serveral times on a hard surface to remove excess dirt or blow com pressed air through the filter from the inside out Never try to brush the dirt off brushing will force dirt into the fibers Replace the paper element if it is excessively dirt T00848GB 20 Reverse speed too low Cause Remedy Forward speed too low Cause Remedy No advance Cause Remedy Loss of hydraulic oil Cause Remedy Engine does not
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4. Visually inspect the spark plug Discard it if the insulator is cracked or chipped Clean the spark plug with a wire brush if it is to be reused Measure the plug gap with a feeler gauge The gap should be 0 7 0 8 mm 0 039 0 043 in Correct as nec essary by bending the side electrode Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross threading After the spark plug is seated tighten with a spark plug wrench to compress the washer Note If installing a new spark plug tighten 1 2 turn after the spark plug seats to compress the wash er If reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats to compress the washer Caution The spark plug must be securely tightened An improperly tightened spark plug can become very hot and may damage the engine Carburettor adjustment Start the engine and allow it to warm up to normal operting temperature With the engine idling turn the pilot screw in or out to the setting that produces the highest idle rom The correct setting will usually be approximately 2 1 4 turns from the fully closed position Caution Do not tighten the pilot screw against its seat as this will damage the pilot screw or seat After the pilot screw is correctly adjusted turn the throttle stop screw to obtain the standard idle speed Standard idle speed 1 400 150 rpm 1 Pilot screw 2 Throttle stop screw T00848GB 1 9
5. between the handle anda 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 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 devic es 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 ac cording 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 no
6. start Cause Remedy T00849GB Too little hydraulic oil in the centre pole head Air in hydraulic control Top up hydraulic oil Bleed system Too much oil in centre pole head Correct oil level in accordance with mark Mechanical fault Contact Wacker service dept Leaks hydraulic hose defective Change defective parts Note Bleed system after every dismantling operation Fuel tank empty Fuel shut off valve closed Air filter dirty Stop button defective Recoil starter defective Oil alert system has stopped engine Fuel up Open Clean Repair Repair Fill up with engine oil 21 FAULTS 22 HA WACCER EC CONFORMITY CERTIFICATE Wacker Construction Equipment AG PreuBenstraBe 41 80809 Munchen hereby certify that the construction equipment specified hereunder 1 Category Vibratory plate 2 Type BPU 2540A 3 Equipment item number 0008758 4 absolute installed power 4 0 kw has been evaluated in conformity with Directive 2000 14 EC Conformity At the following notified Measured Guaranteed assessment body sound power level sound power level procedure Annex VIII VDE Pruf und 102 dB A 108 dB A Zertifizierungsinstitut Zertifizierungsstelle MerianstraBe 28 63069 Offenbach Main and has been manufactured in accordance with the following directives 2000 14 EG EMV Richtlinie 89 336 EG 98 37 EG
7. 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 14 o ES 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 values 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 20 must not be exceeded ATTENTION If this gradient were exceeded this would result in a failure of the engine lubrication sys tem splash lubrication and thus inevitably lead to a breakdown of important engine components T00846GB 11 OPERATION Engine check before starting 1 Oil level check Insert dipstic
8. EN 500 1 EN 500 4 4 Dr Sick B ard of Directors File certificate carefully C0008007 GB 24 VDE Pr f und Zertifizierungsinstitut VDE VERBAND DER ELEKTROTECHNIK ELEKTRONIK INFORMATIONSTECHNIK e V CERTIFICATE Registration Number 6236 QM 06 97 This is to certify that the company WACCER Wacker Construction Equipment AG Wacker Werke GmbH amp Co KG with the locations Head Office Munich Preussenstr 41 80809 Miinchen Production plant Reichertshofen Karlsfeld logistics centre Sales regions with all branches all over Germany has implemented and maintains a Quality System for the following scope Machine manufacture Construction machines This Q System complies with the requirements of DIN EN ISO 9001 2000 This Certificate is valid until 05 06 2006 VDE Testing and Certification Institute Certification loc D 63069 Offenbach Main Merianstra e 28 Date 02 06 2003 The VDE Testing and Certification Institute is accredited by DARAccreditation Bodies i according to DIN EN 45012 and notified in the EU under ID No 0366 etc Wacker Construction Equipment AG PreuBenstraBe 41 80809 M nchen Tel 49 0 89 3 54 02 0 Fax 49 0 89 3 54 02 390 Wacker Corporation P O Box 9007 Menomonee Falls WI 53052 9007 Tel 1 1 262 255 0500 Fax 1 1 262 255 0550 Tel 800 770 0957 Wacker Asia Pacific Operations Skyline Tower Suite 2303 23 F 39 Wang Kwong
9. b 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 pro tection if the sound level reaches 89 dB A or more Operation 1 The engine is started by way of a recoil starter The automatic decompression system makes possible a simple and backstroke safe engine starting procedure 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 refil
10. hrough the oil filler tube 16 and then Remove the oil filler cap 16 Release the waist oil drain hose 2 and collect the draining oil in an appropriate container check the oil level ATTENTION Place machine in horizontal position before checking engine oil level Install the oil filter cap 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 T00848GB 17 MAINTENANCE Hydraulic control Check oil level 1 Move centre pole into vertical position 2 Push operating control handle 7 to forward travel position laa 3 Open filler bore 17 WA Y 4 The oil level must reach the upper edge Oil i of the gear add Fuchs Renolin MR 520 hydraulic fluid if required dl r 5 Close filler bore 17 Hydraulic control system is self bleeding Exciter 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 brand oil Fuchs Titan Unic 10W40 MC through filler bore use funnel 5 Close filler bore 19 a Changing the oil 1 Open fi
11. ine warms up gradually move the choke lever to the OPEN position Position the throttle lever for the desired engine speed Oil alert system The oil alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crank case Before the oil level in the crankcase drops below a safe limit the oil alert system will automatically shut down the engine the engine switch will remain in the l position Note If engine does not start check oil level Forward and reverse motion The engine speed can be infinitely varied with the throttle control lever 6 The direction of travel is determined with the operating control handle 7 Depending on the position of the control handle 7 the vibration plate compacts in forward direction on the spot or in reverse direction IBERRRRER Forwards On the spot Reverse T00847GB 14 OPERATION Stopping the engine To stop the engine in an emergency turn the engine switch to the O position Under normal conditions use the following procedure 1 Push the throttle lever forward all the way to the stop 2 Turn the ignition switch to the 0 position 3 Turn off the fuel shut off valve lever in arrow direction T00847GB 1 5 MAINTENANCE Maintenance schedule Check all external screw connections for tight fit approx 8 hours after first operation Parts Maintenance jobs Maintena
12. k in oil filler neck but without screwing in If oil level is low fill to the top of the oil filler neck with high grade Fuchs Titan Unic 10W40 MC oil ATTENTION Place machine in horizontal position before checking engine oil level 2 Dual air cleander gt Dual element type lt Check the air cleaner elements to be sure they are clean and in good condition Clean or replace the ele ments if necessary 3 Fuel Use any regular grade automotive gasoline unleaded gasoline is preferred with a pump octane rating of 86 or higher Never use an oil gasoline mixture or dirty gasoline Avoid getting dirt dust or water in the fuel tank Caution Gasoline substitutes are not recommended they may be harmful to the fuel system compo nents Starting the engine 1 Move the fuel shut off valve lever in arrow direction to the ON position 2 Move the choke lever to the CLOSE position Note If the engine is warm or the air temperature is high move the control lever away from the CHOKE postion as soon as the engine starts T00847GB 12 OPERATION 3 Pull the throttle lever 6 back slightly 4 Turn the engine switch to the l position 5 Pull the starter grip lightly until resistance is felt then pull briskly Caution Do not allow the starter grip to snap back against the engine Return it gently to prevent damage to the starter T00847GB 1 3 OPERATION Operation the engine As the eng
13. l at nominal engine speed TD00610GB 8 DESCRIPTION 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 Dimensions 1300 Max admissible inclination T00845GB 9 DESCRIPTION Description of function 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 direc tion 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 13 t y m Forwards On the spot Reverse 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
14. ling 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 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 SV00019GB 6 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 that he willnot be squeezed
15. ller 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 brand oil Fuchs Titan Unic 10W40 MC through the filler bore 19 5 Close filler bore 19 ATTENTION Do not pour in too much oil 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 T00848GB 18 MAINTENANCE Fuel strainer cup cleaning Turn the fuel valve to Off Remove the sediment cup and O ring and wash them in nonflammable or high flash point solvent Dry them thoroughly and reinstall securely Turn the fuel valve on and check for leaks Spark plug Recommended spark plug BP6ES 11 BPR6ES 11 NGK W20EP U11 W20EPR U11 ND Caution Never use a spark plug of incorrect heat range To ensure proper engine operation the spark plug must be properly gapped and free of deposits 1 2 Remove the spark plug cap and use a spark plug wrench to remove the plug Warning If the engine has been running the muffler will be very hot Be careful not to touch the muffler
16. n observance all liabilities shall be refused 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 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 Remove pressure from hydraulic lines before working on them Caution take care when removing hy draulic 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 As soon as maintenance and repair jobs have been completed all safety devices have to be reinstalled properly 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 2 During transport loading and unloading of vibration plates by means of lifting devices appropriate sling ing means or hooks have to be used on the lifting points provided for this purpose on the vibratory plate 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 slip ping or by moving machine parts When being transported on vehicles precautions have to be taken that vibration plates do not slip or turn o
17. nce interval Air filter Check for external damage and tight fit Check filter cartridge clean or replace if necessary Fuel tank Check tank lid for tight fit replace if necessary Engine oil Check oil level top up if necessary Exciter Check for tightness Bowden cable Check to see smooth running First oil change after 20 hours Ignition system Clean spark plug check spark plug gap 0 7 mm monthly Exciter Check attachment screws for tight fit 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 Further oil changes after 100 hours Exhaust muffler Remove combustion residue from spark arrester Check oil level fill up if need be after 150 hours Oil change after 250 hours Check set 0 15 mm intake valve 0 20 mm exhaust after 300 hours valve T00848GB 16 MAINTENANCE Engine oil Check oil level 0 A 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 brand quality oil Fuchs Titan Unic 10W40 MC through oil feed opening 16 Engine oil capacity 0 6 1 Oil change Drain the oil while the engine is still warm to assure rapid and complete draining 1 2 Attach the waist oil drain hose 2 back again Pour the recommended oil t
18. ver 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 SV00019GB 7 TECHNICAL DATA ftom mer k Advance and reverse travel m min Power transmission From drive engine directly to exciter unit via centrifugal clutch and V belt Exciter Vibrations min Hz ca 5400 90 Centrifugal force kN 25 Oil Fuchs Titan Unic 10W40 MC SAE 10W40 Oil quantity I 0 6 Drive motor Air cooled single cylinder 4 cycle gasoline engine with recoil starter Piston displacement E 163 Engine speed rpm inv 2800 Rated power 3 1 4 2 Fuel Gasoline Fuel consumption 0 8 Tank capacity 3 7 Oil Fuchs Titan Unic 10W40 MC SAE 10W40 Oil quantity i 0 6 Hydraulic control Hydraulic oil Fuchs Renolin MR 520 Oil quantity E 0 4 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 Lon 89 dB A The weighted effective acceleration value determined according to EN 1033 is 10 m s The sound and vibration measurements were carried out and obtained with the machine working on crushed grave
19. www wackergroup com 0203079en 001 01 2005 Vibratory plate BPU 2540A Operator s Manual CONTENTS Type Item no BPU 2540A 0008758 This machine has been equipped with an EPA certified engine Additional information can be found in the engine manufacturers notes WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or 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 H00610GB 1 FOREWORD Foreword For your own safety and protection from bodily injuries carefully read understand and follow the safety instruc tions 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 an
20. y type or method not authorized by 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 im proving our machines or their safety standards T00778GB 3 TABLE OF CONTENTS FOREWORD 3 SAFETY INSTRUCTIONS 6 General instructions 6 Operation 6 Safety checks 7 Maintenance 7 Transport 7 Maintenance checks 7 TECHNICAL DATA 8 DESCRIPTION 9 Applications 9 Dimensions 9 Max admissible inclination 9 Description of function 10 TRANSPORT TO WORK SITE RECOMMENDATIONS ON COMPACTION 11 Transport to work site 11 Recommendations on compaction 11 OPERATION 12 Engine check before starting 12 Starting the engine 12 Operation the engine 14 Forward and reverse motion 14 Stopping the engine 15 MAINTENANCE 16 Maintenance schedule 16 Engine oil 17 Hydraulic control 18 Exciter 18 Exciter V belt 18 Fuel strainer cup cleaning 19 Spark plug 19 Carburettor adjustment 19 Air filter service 20 TABLE OF CONTENTS FAULTS 21 Reverse speed too low 21 Forward speed too low 21 No advance 21 Loss of hydraulic oil 21 Engine does not start 21 EC CONFORMITY CERTIFICATE 23 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 jo
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