en Backpack Vibrator BV 35A-P BV 50A-P OPERATOR S MANUAL

Transcription

1 en Backpack Vibrator BV 35A-P BV 50A-P OPERATOR S MANUAL E N

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3 BV Table of Contents 1. Foreword 5 2. Safety Information Laws Pertaining to Spark Arresters Operating Safety Operator Safety while using Internal Combustion Engines Service Safety Label Locations Warning and Informational Labels Operation Application Recommended Fuel Starting the Engine (BV 35A-P) Stopping the Engine (BV 35A-P) Starting the Engine (BV 50A) Stopping the Engine (BV 50A) Operating the Machine When Vibration Is Complete Maintenance Periodic Maintenance Schedule Engine Oil Air Cleaner Spark Plug Head and Shaft Disassembly Storage Troubleshooting wc_bo en_003toc.fm 3

4 BV Table of Contents 5. Technical Data Engine Power Unit Sound and Vibration Data wc_bo en_003toc.fm 4

5 WARNING CALIFORNIA Proposition 65 Warning: Foreword Engine exhaust, some of its constituents, and certain vehicle components, contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. 1 Foreword This manual provides information and procedures to safely operate and maintain this Wacker Neuson model. For your own safety and protection from injury, carefully read, understand and observe the safety instructions described in this manual. Keep this manual or a copy of it with the machine. If you lose this manual or need an additional copy, please contact Wacker Neuson Corporation. This machine is built with user safety in mind; however, it can present hazards if improperly operated and serviced. Follow operating instructions carefully! If you have questions about operating or servicing this equipment, please contact Wacker Neuson Corporation. The information contained in this manual was based on machines in production at the time of publication. Wacker Neuson Corporation reserves the right to change any portion of this information without notice. All rights, especially copying and distribution rights, are reserved. Copyright 2008 by Wacker Neuson Corporation. 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 Neuson Corporation. Any type of reproduction or distribution not authorized by Wacker Neuson 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. wc_tx000001gb.fm 5

6 Safety Information 2. Safety Information BV This manual contains DANGER, WARNING, CAUTION, NOTICE 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 DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE: Used without the safety alert symbol, NOTICE indicates a situation which, if not avoided, could result in property damage. Note: Contains additional information important to a procedure. 2.1 Laws Pertaining to Spark Arresters Notice: State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust. Spark arresters are qualified and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator. wc_si000230gb.fm 6

7 BV 2.2 Operating Safety Safety Information WARNING Familiarity and proper training are required for the safe operation of the machine. Machines 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 location and proper use of all controls. Inexperienced operators should receive instruction from someone familiar with the machine before being allowed to operate it NEVER allow anyone to operate this equipment without proper training. People operating this equipment must be familiar with the risks and hazards associated with it 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 NEVER use accessories or attachments that are not recommended by Wacker. Damage to equipment and injury to the user may result NEVER leave the machine running unattended NEVER operate this machine in applications for which it is not intended ALWAYS wear protective clothing appropriate to the job site when operating the machine ALWAYS remain aware of moving parts and keep hands, feet, and loose clothing away from the moving parts of the machine ALWAYS read, understand, and follow procedures in the Operator s Manual before attempting to operate the machine ALWAYS store the machine properly when it is not being used. The machine should be stored in a clean, dry location out of the reach of children ALWAYS close fuel valve on engines equipped with one when machine is not being operated ALWAYS operate machine with all safety devices and guards in place and in working order. DO NOT modify or defeat safety devices. DO NOT operate machine if any safety devices or guards are missing or inoperative ALWAYS be sure operator is familiar with proper safety precautions and operation techniques before using machine. wc_si000230gb.fm 7

8 Safety Information 2.3 Operator Safety while using Internal Combustion Engines BV DANGER Internal combustion engines present special hazards during operation and fueling. Read and follow the warning instructions in the engine Owner s Manual and the safety guidelines below. Failure to follow the warnings and safety standards could result in severe injury or death DO NOT run the 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 DO NOT smoke while operating the machine DO NOT smoke when refueling the engine DO NOT refuel a hot or running engine DO NOT refuel the engine near an open flame DO NOT spill fuel when refueling the engine DO NOT run the engine near open flames ALWAYS refill the fuel tank in a well-ventilated area ALWAYS replace the fuel tank cap after refueling ALWAYS check the fuel lines and the fuel tank for leaks and cracks before starting the engine. Do not run the machine if fuel leaks are present or the fuel lines are loose. wc_si000230gb.fm 8

9 BV 2.4 Service Safety Safety Information WARNING A poorly maintained machine can become a safety hazard! In order for the machine to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary DO NOT attempt to clean or service the machine while it is running. Rotating parts can cause severe injury 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 DO NOT test for spark on gasoline-powered engines if the engine is flooded or the smell of gasoline is present. A stray spark could ignite the fumes 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 ALWAYS keep the area around the muffler free of debris such as leaves, paper, cartons, etc. A hot muffler could ignite the debris and start a fire ALWAYS replace worn or damaged components with spare parts designed and recommended by Wacker Neuson Corporation ALWAYS disconnect the spark plug on machines equipped with gasoline engines, before servicing, to avoid accidental start-up ALWAYS keep the machine clean and labels legible. Replace all missing and hard-to-read labels. Labels provide important operating instructions and warn of dangers and hazards. wc_si000230gb.fm 9

10 Safety Information 2.5 Label Locations BV wc_gr wc_si000230gb.fm 10

11 BV 2.6 Warning and Informational Labels Safety Information Wacker Neuson machines use international pictorial labels where needed. These labels are described below: Label Meaning DANGER! Engines emit carbon monoxide; operate only in well-ventilated area. Read the Operator s Manual. No sparks, flames, or burning objects near the machine. Shut off the engine before refueling. WARNING! Hot surface! WARNING! Always wear hearing and eye protection when operating this machine. A nameplate listing the model number, item number, revision number, 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 always be asked to specify the model number, item number, revision number, and serial number of the unit. wc_si000230gb.fm 11

12 Operation 3. Operation BV 3.1 Application This machine is intended for on-site vibration of concrete for foundations, walls, columns, slab work, etc. The self-contained design allows free movement about the jobsite without the restrictions of an electrical cord. 3.2 Recommended Fuel The engine requires regular grade unleaded gasoline. Use only fresh, clean gasoline. Gasoline containing water or dirt will damage fuel system. Consult engine owner s manual for complete fuel specifications. 3.3 Starting the Engine (BV 35A-P) See Graphic: wc_gr If engine is cold, move the choke lever (a) to the CLOSED position (a1). If engine is hot, set the choke to the OPEN position (a2) Press the priming bulb (b) repeatedly until fuel can be seen in the clear plastic fuel return tube (c) Turn the engine switch to the ON position (d1) Pull the starter grip (e) lightly until you feel resistance, then pull briskly. Return the starter grip gently Gradually open the choke as the engine warms up (a2) Open the throttle fully to operate equipment. (See Operating the Machine for more information.) wc_tx000776gb.fm 12

13 BV Operation d2 d1 wc_gr Stopping the Engine (BV 35A-P) See Graphic: wc_gr Reduce engine RPM to idle by moving throttle completely to right Turn engine switch to OFF (d2). wc_tx000776gb.fm 13

14 Operation 3.5 Starting the Engine (BV 50A) BV See Graphic: wc_gr and wc_gr If engine is cold, move the choke lever (a) to the CLOSED position (a1). If engine is hot, set the choke to the OPEN position (a2) Move the fuel valve lever (b) to the ON position Turn the engine switch (d) (on right shoulder) to the ON position Pull the starter grip (e) lightly until you feel resistance, then pull briskly. Return the starter grip gently Gradually open the choke as the engine warms up (a2) Open the throttle fully to operate equipment. (See Operating the Machine for more information.) a a2 a1 b e wc_gr Stopping the Engine (BV 50A) Reduce engine RPM to idle by moving throttle completely to right Turn engine switch to OFF (d2). wc_tx000776gb.fm 14

15 BV 3.7 Operating the Machine Operation See graphic wc_gr The Wacker backpack vibrator features a unique pendulous design. This design causes the vibrator to rattle and possibly feel off-center in rotation. This is normal; the vibrator is not broken or damaged. Setup and Controls: k d h j f g wc_gr To prepare the machine for operation: Make sure that the engine (f) has oil in it Rotate the engine so that the quick-disconnect coupler (g) points toward either the left side or right side of the backpack depending upon the operator s preference Turn the quick-disconnect coupler clockwise and insert the vibrator. Once the vibrator is inserted, turn the quick-disconnect coupler counter-clockwise to lock the vibrator in position Lift the shoulder harness (h) and place it over the operator s shoulders. Wrap the support belt (j) around the operator s waist and secure it with the hook-and-loop fasteners. The belt should fit snugly but should not cut or bind Test the throttle lever (k) and cable to ensure freedom of movement. wc_tx000776gb.fm 15

16 Operation To operate the machine: Turn the engine switch (d) to the ON position. BV Start the engine and allow it to warm up for approximately 5 7 minutes Bring the engine up to full throttle (approximately 9000 rpm for the BV 35A-P and 6000 rpm for the BV 50A-P) Activate the vibrator action by striking the side of the vibrator head against a solid object NOTE: Avoid slamming the nose of the vibrator head against solid objects. Head-on impacts may damage the machine Begin vibrating by placing the vibrator head into the concrete NOTE: Do not submerge the head and shaft above the coupler assembly. Operating tips: NEVER turn the vibrator off while it is submerged in the concrete During use, insert the head quickly into the mix and then pull it out slowly. Rapid removal is the main cause of poor concrete consolidation. For best results, submerge head completely and try to establish a symmetrical pattern for inserting and removing the head When moving around the jobsite, do not drag the vibrator head and shaft on the ground Avoid touching forms and rebars when inserting the vibrator head into the mix. This can transmit vibration to other areas of the mix which may already be setting When the vibrator is out of the concrete for extended periods of time, allow the engine to return to idle speed or simply turn the machine off. 3.8 When Vibration Is Complete When you are finished using the vibrator: Bring the engine RPM down to idle speed Lift the vibrator head out of the concrete Shut off the engine by turning the engine switch to the OFF position Disconnect the vibrator shaft from the engine Rinse the vibrator head and shaft thoroughly with clean water. Do not allow concrete to harden on these components See Maintenance chapter for extended storage procedures. wc_tx000776gb.fm 16

17 BV 4. Maintenance Maintenance 4.1 Periodic Maintenance Schedule The chart below lists basic machine and engine maintenance. Refer to your engine operator s manual for additional information on engine maintenance. Daily before starting After first 10 hrs. After first 25 hrs. Every 50 hrs. Every 100 hrs. Every 300 hrs. Check fuel level. Check engine oil level. Inspect air filter. Replace as needed. Change engine oil. Clean air cleaner. Check engine cooling fins (if equipped). Check and clean spark plug. Check fuel filter. Clean fuel tank. Clean spark arrester (if equipped). Check and adjust valve clearance. wc_tx000777gb.fm 17

18 Maintenance 4.2 Engine Oil BV See Graphic: wc_gr Drain oil while the engine is still warm Turn the engine 90 so the fuel tank is facing downward. Check that the fuel tank cap (a) is tightened Remove the oil fill plug (b) and drain the oil into a container by tipping the engine forward the oil filler neck (c). Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid which drains off. Dispose of this liquid in accordance with environmental protection legislation Fill the engine crankcase with recommended oil up to the level of the plug opening (d). See Technical Data for oil quantity and type Install the oil filler plug (b). wc_tx000777gb.fm 18

19 BV 4.3 Air Cleaner Maintenance See Graphic: wc_gr or wc_gr WARNING The engine is equipped with a foam element air cleaner. Service the air cleaner frequently to prevent carburetor malfunction. NOTICE: NEVER run engine without the air cleaner. Severe engine damage will occur. NEVER use gasoline or other types of low flash point solvents for cleaning the air cleaner. A fire or explosion could result. To service the air cleaner (GX35 engine): Press the latch tab (a) on top of the air cleaner cover (b) and remove the air cleaner cover. Remove the foam element (c) and inspect it for holes or tears. Replace the element if damaged Wash the element in a solution of mild detergent and warm water. Rinse thoroughly in clean water. Allow the element to dry thoroughly. Soak the element in clean engine oil and squeeze out excess oil. The engine will smoke when started if too much oil is left in the foam Using a moist rag, wipe dirt from the air cleaner body and cover. Be careful to prevent dirt from entering the carburetor Re-install the filter element and air cleaner cover. a b a c wc_gr wc_tx000777gb.fm 19

20 Maintenance To service the air cleaner (GXH50 engine): BV Pemove the air cleaner cover (a). Remove the foam element (b) and inspect it for holes or tears. Replace the element if damaged Wash the element in a solution of mild detergent and warm water. Rinse thoroughly in clean water. Allow the element to dry thoroughly. Soak the element in clean engine oil and squeeze out excess oil. The engine will smoke when started if too much oil is left in the foam Using a moist rag, wipe dirt from the air cleaner body (c) and cover. Be careful to prevent dirt from entering the carburetor Re-install the filter element and air cleaner cover. a c b wc_gr wc_tx000777gb.fm 20

21 BV 4.4 Spark Plug Maintenance See Graphic: wc_gr WARNING Clean or replace the spark plug as needed to ensure proper operation. Refer to your engine operator s manual. The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Do not touch the muffler while it is hot. Note: Refer to section Technical Data for the recommended spark plug type and the electrode gap setting Remove the spark plug and inspect it Replace the spark plug if the insulator is cracked or chipped Clean the spark plug electrodes with a wire brush Set the electrode gap (a) Tighten the spark plug securely. NOTICE: A loose spark plug can become very hot and may cause engine damage. wc_tx000777gb.fm 21

22 Maintenance 4.5 Head and Shaft Disassembly BV See graphic: wc_gr a c b j f e h g r q k m v t l n o p d s u w x wc_gr Disassembling the flexible casing and core: Place the vibrator head assembly (a) in a vise equipped with a set of V jaws Unscrew the casing assembly (b) from the vibrator head assembly using a 32mm wrench or pipe wrench. Note: Threads on the casing assembly are left-hand and require uniform heat to remove Pull the casing assembly away from the head and core assembly (c) Unscrew the core assembly from the head assembly using a 12mm wrench or adjustable wrench. Note: Use an additional wrench or pliers to hold the shaft joint (d) while unscrewing the core assembly. wc_tx000777gb.fm 22

23 BV Lubricating the core assembly: Maintenance A light coat of grease (i.e. Dubois TPG, Wacker Neuson part number ) should be applied to the entire length of the core assembly. Apply grease to the core assembly at least twice a year Disassembling the casing drive assembly: Remove retaining ring (e) using retaining ring pliers Remove the drive joint spacer (f) and drive joint assembly (g, h, j). NOTICE: To avoid damaging drive joint (g), be careful when removing the drive joint assembly Unscrew drive joint (g) from drive joint (j) using a 3/8" wrench for the hex and a 1/4" square rachet (or metric equivalents) Remove the bearing (h) from drive joint (g) Disassembling the vibrator head assembly: Place the vibrator head assembly in a vise equipped with a set of V jaws Unscrew the hose connector (k) from the bearing case (l) using a 38mm wrench or a large pipe wrench. Note: Threads on the casing assembly are left-hand and require uniform heat to remove Remove the flex joint (m) from the drive joint (u) Unscrew the bearing case from the body (n) using a 41mm wrench or a large pipe wrench Unscrew the nose (o) from the body using a 1-1/4" wrench or a large pipe wrench. Note: Threads on the casing assembly are left-hand and require uniform heat to remove Disassembling the hose connector assembly: Remove the top snap ring (p) using snap-ring pliers Remove the shaft joint (d) from the hose connector (k) Remove the bottom snap ring (q) Unscrew the drive joint (r) from the shaft joint using a 1/4" square rachet (or metric equivalent). Hold the shaft joint with a 12mm wrench or pliers. Note: Threads are right-hand. wc_tx000777gb.fm 23

24 Maintenance See graphic: wc_gr BV a c b j f e h g r q k m v t l n o p d s u w x wc_gr Disassembling the eccentric assembly: Place the bearing case (l) in a standard vise with the male threads positioned upward Using a hammer, gently tap the upper portion of the eccentric weight (t). Note: Place your hand on the underside of the bearing case to catch the eccentric weight as it comes apart from the bearing case Unscrew the drive joint (u) from the eccentric weight using a 1/4" square ratchet (or metric equivalent) Remove the bearing (v), spacer (w), and oil seal (x) from the eccentric Reassembling the head and shaft: Perform steps through in the reverse order. wc_tx000777gb.fm 24

25 BV Maintenance notes: Maintenance Bearing (v) and oil seal (x) should be replaced after 200 hours of use. The bearing must be greased with Orelube G- 1/3 grease or equivalent Inspect the angled end of the eccentric weight (t) for wear. If visible wear is present, the eccentric weight should be replaced Inspect the nose (o) for wear. If visible wear is present, the nose should be replaced. wc_tx000777gb.fm 25

26 Maintenance 4.6 Storage BV If power unit is to be stored for more than 30 days: Change engine oil and follow procedures described in engine manual for engine storage Clean entire power unit and engine Cover entire machine and store in a clean, dry area. 4.7 Troubleshooting Problem / Symptom Vibrator does not develop full speed Vibrator stops shaking; continues to spin without resuming shaking action. Engine runs; vibrating action is erratic Reason / Remedy Deposits built up in engine. Clean or replace engine air filter. Throttle is defective or out of adjustment. Metal dust may have accumulated in contact points between eccentric and nose. Clean contact points. Head or flexshaft may be damaged. Check clutch wear. Vibrator rattles. Common with new machines. Rattle should disappear with regular use of vibrator. Eccentric feels on center inside head. Engine does not run, or engine runs erratically Common with new machines. Upon startup, tap the vibrator head lightly against the ground or a solid object to knock the eccentric off center. Check fuel level. Check spark plug. Clean air filter. Adjust carburetor. wc_tx000777gb.fm 26

27 BV Notes: Maintenance wc_tx000777gb.fm 27

28 Technical Data 5. Technical Data BV 5.1 Engine Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Part No. BV 35A-P Engine BV 50A-P Engine type Engine make 4-stroke, overhead valve, single cylinder Honda Engine model GX35 GXH50 Max. rated rated speed kw (Hp) rpm rpm Displacement cm³ (in³) 35.8 (2.2) 49 (3) Spark plug Electrode gap mm (in.) NGK CM5H or NGK CMR5H ( ) NGK CR5HSB or Denso U16FSR-UB ( ) Engine speed - idle rpm 3100 ± ± 200 Air cleaner type Foam Element Foam Element Engine lubrication oil grade SAE 10W-30, API SJ or SL SAE 10W-30, API SJ or SL Engine oil capacity ml (oz.) 100 (3.38) 250 (8.45) Fuel type Regular Unleaded Regular Unleaded Fuel tank capacity l (gal.) 0.7 (0.185) 0.8 (0.211) wc_td000232gb.fm 28

29 BV 5.2 Power Unit Technical Data Item Number: Power Unit BV 35A-P BV 50A-P Dimensions (l x w x h) mm (in) 635 x 483 x 584 (25 x 19 x 23) 584 x 483 x 584 (23 x 19 x 22) Weight kg (lbs.) 11.4 (25.1) 15.4 (34) Speed (no load) rpm Sound and Vibration Data The required sound specification, Paragraph f of 89/392/EEC Machinery Directive, is: the sound pressure level at operator s location (L pa ): BV 35A-P 94.5 db(a) BV 50A-P 91.1 db(a) the guaranteed sound power level (L WA ): BV 35A-P db(a) BV 50A-P db(a) These sound values were determined according to ISO 3744 for the sound power level (L WA ) and ISO 6081 for the sound pressure level (L pa ) at the operator s location. Products are tested for hand/arm vibration (HAV) level in accordance with ISO 5349 Part 1 and ISO 8662 Part 1. The weighted effective acceleration value, determined according to ISO 5349, is: BV 35A-P 9.1 m/s 2 (29.8 ft/s 2 ) BV 50A-P 9.0 m/s 2 (29.5 ft/s 2 ) The sound and vibration measurements were obtained with the unit operating at full throttle. Vibration values will vary depending on throttle position, operating conditions, and hand placement. wc_td000232gb.fm 29

30 Wacker Construction Equipment AG Preußenstraße 41 D München Tel.: +49-(0) Fax: (0) Wacker Neuson Corporation P.O. Box 9007 Menomonee Falls, WI Tel. : (262) Fax: (262) Tel. : (800) Wacker Asia Pacific Operations Skyline Tower, Suite 2303, 23/F 39 Wang Kwong Road, Kowloon Bay, Hong Kong Tel Fax: