en Vibroplate BPU 2440 BPU 2950 REPAIR MANUAL

Transcription

1 en Vibroplate BPU 2440 BPU 2950 REPAIR MANUAL

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3 BPU 2440/2950 Repair Foreword This manual covers machines with Item Number: 5603, 5904, 6222, 6346, 6412, 6993, 7150, 7867, 7872, 7962 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. wc_tx000260gb.fm i

4 Foreword BPU 2440/2950 Repair WARNING CALIFORNIA Proposition 65 Warning: 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. All rights, especially copying and distribution rights, are reserved. Copyright 2003 by Wacker 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 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. wc_tx000260gb.fm ii

5 Typ Table of Contents 1. Safety Information Operating Safety Operator Safety while using Internal Combustion Engines Service Safety Labels Technical Data Engine Plate Lubrication Dimensions General Information Application Tools Ordering Parts Reference Numbers ( ) Weight Block Lifting and Transporting the Machine Storage Theory of Operation Directional and Speed Control Engine Speed and Machine Performance Operating on Slopes To Start To Stop Maintenance General Maintenance Maintenance Schedule Air Filter Spark Plug Cleaning Sediment Cup Adjusting Idle Speed wc_br _002entoc.fm 1

6 Table of Contents 4.7 Carburetor Adjustment Drive Belt Exciter Oil Control Circuit Oil Bleeding the Control Circuit Re-installing Piston in Control Assembly...29 Typ 5. Repair Procedures General Repair Checking Exciter Operation Exciter Exploded View Illustration Exciter Parts List Removing Exciter Installing Exciter Exciter Assembly Cross Section Exciter Cross Section List of Components Servicing Exciter Disassembling the Exciter Re-assembling the Exciter Servicing the Clutch Replacing the Engine Engine Replacement Honda Engine Replacement Robin Troubleshooting 48 wc_br _002entoc.fm 2

7 BPU 2440/2950 Repair 1. Safety Information 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 DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION 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. wc_si000099gb.fm 3

8 Safety Information 1.1 Operating Safety BPU 2440/2950 Repair 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 location and proper use of all controls. Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate the machine ALWAYS wear protective clothing appropriate to the job site when operating equipment ALWAYS remain aware of moving parts and keep hands, feet, and loose clothing away from moving parts of equipment ALWAYS read, understand, and follow procedures in Operator's Manual before attempting to operate equipment 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 ALWAYS check that all controls are functioning properly immediately after start-up! DO NOT operate machine unless all controls operate correctly ALWAYS operate machine with all safety devices and guards in place and in working order ALWAYS remain aware of changing positions and movement of other equipment and personnel on the jobsite 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 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 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 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 machine running unattended NEVER start a defective unit in need of service or repair. WARNING wc_si000099gb.fm 4

9 BPU 2440/2950 Repair Safety Information 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 DANGER safety guidelines could result in severe injury or death 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 DO NOT smoke while operating machine DO NOT smoke when refueling engine DO NOT refuel hot or running engine DO NOT refuel engine near open flame DO NOT spill fuel when refueling engine DO NOT run engine near open flames ALWAYS refill fuel tank in well-ventilated area ALWAYS replace fuel tank cap after refueling 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 ALWAYS keep area around hot exhaust pipes free of debris to reduce the chance of an accidental fire. 1.3 Service Safety WARNING 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 DO NOT stand under the machine while it is being hoisted or moved DO NOT get onto the machine while it is being hoisted or moved DO NOT use the machine as a ladder. Use safe ladders and platforms designed for this purpose DO NOT modify the equipment without express written approval of the manufacturer DO NOT attempt to clean or service machine while it is running. Rotating parts can cause severe injury. wc_si000099gb.fm 5

10 Safety Information BPU 2440/2950 Repair 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 engine is flooded or the smell of gasoline is present. A stray spark could ignite 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 area around muffler free of debris such as leaves, paper, cartons, etc. A hot muffler could ignite them, starting a fire ALWAYS replace worn or damaged components with spare parts designed and recommended by Wacker 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 ALWAYS check and tighten all external fasteners at regular intervals ALWAYS switch off the power supply at the battery disconnect before adjusting or maintaining the electrical equipment ALWAYS turn engine off before performing maintenance or making repairs ALWAYS keep hands, feet and loose clothing away from moving parts 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 Before you start the machine, ensure that all tools have been removed from the machine and that replacement parts and adjusters are firmly tightened. wc_si000099gb.fm 6

11 BPU 2440/2950 Repair 1.4 Labels Safety Information 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 machine. Shut off engine before refueling. WARNING! Hot surface. CAUTION! Read and understand 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. 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! Do not operate without safety guards. Read and understand instruction book. CAUTION! Lifting point wc_gr wc_si000099gb.fm 7

12 Safety Information Label Meaning BPU 2440/2950 Repair WARNING! To prevent hearing loss, wear hearing protection when operating this machine. wc_gr 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 always be asked to specify the model, item number, revision number, and serial number of the unit. wc_si000099gb.fm 8

13 BPU 2950/2440 Repair 2. Technical Data 2.1 Engine Technical Data Model BPU 2440A 5904 BPU 2440A 7150 BPU 2440A 7867 BPU 2950R 5603 BPU 2950R BPU 2950A 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 Idle Speed rpm Clutch Engagement rpm N/A Cylinder Compression psi N/A N/A 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) 2.2 Plate Model BPU 2440A 5904 BPU 2440A 7150 BPU 2440A 7867 BPU 2950R 5603 BPU 2950R BPU 2950A 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 wc_td000102gb.fm 9

14 Technical Data 2.3 Lubrication BPU 2950/2440 Repair Engine Exciter Model (S/N) Oil Grade Quantity ml (ounces) Oil Grade Quantity ml (ounces) BPU 2440A (5904) BPU 2440A (7150) BPU 2440A (7867) BPU 2650R (5603) BPU 2950R (6222, 6346) BPU 2950A (6412) 10W (20) 10W (20) 10W (20) 10W (26) 10W (24) 10W (37) SAE 15W (25) 2.4 Dimensions C E A B D wc_gr 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) * Guide handle in working position wc_td000102gb.fm 10

15 BPU 2440/2950 Repair 3. General Information General Information 3.1 Application Due to its low width of only 400 or 500 mm and its infinitely 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, compaction of marginal strips, repairs on blacktop surfaces as well as for all compaction 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 tool selection. The use of any special tools is recommended only for those operations 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 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. wc_tx000264gb.fm 11

16 General Information 3.4 Reference Numbers ( ) BPU 2440/2950 Repair Repair procedures contain reference numbers enclosed in parentheses ( ). These numbers refer to the item numbers shown on the assembly drawings and other detailed drawings. They are included to aid the mechanic in identifying parts and assembling components. 3.5 Weight Block See Graphic: wc_gr The weight block symbol gives an approximate weight measurement to aid the mechanic when lifting / hoisting larger components. 250 kg (550 lbs.) wc_gr Lifting and Transporting the Machine See Graphic: wc_gr a b wc_gr Lift the machine only by the lifting eye (a). Do not lift the machine by the control handle. When lifting, use an appropriate crane or hoist with minimum load-bearing capacity of 200 kg (440 lbs.). When transporting the machine, secure it using the tie-down brackets (b). wc_tx000264gb.fm 12

17 BPU 2440/2950 Repair General Information 3.7 Storage CAUTION Never lift or transport the machine with its engine running. CAUTION 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 Completely drain the fuel tank. Run the engine until carburetor is dry Thoroughly clean exterior of plate and engine. Visually inspect the unit for signs of damage, loose hardware, and worn shockmounts. Make any necessary repair Change engine oil and exciter oil Clean area around spark plug and remove plug. Pour 1 ounce (30 ml) of SAE 10W30 engine oil into engine cylinder through plug opening. Crank engine slowly three or four times to distribute oil. Replace the spark plug Store unit indoors in a clean dry area. If unit is to be stored outside, wrap it with a quality tarpaulin. wc_tx000264gb.fm 13

18 General Information 3.8 Theory of Operation BPU 2440/2950 Repair See Graphic: wc_gr and wc_gr The vibration required for compaction is produced by the exciter (a) which is firmly joined to the lower 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 central vibrator with aligned vibrations. Such a principle permits the direction of vibration to be changed 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 lower (j) masses are connected to each other by four 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. wc_tx000264gb.fm 14

19 BPU 2440/2950 Repair General Information d e l f i b h j g a k wc_gr c wc_gr wc_tx000264gb.fm 15

20 General Information 3.9 Directional and Speed Control BPU 2440/2950 Repair See Graphic: wc_gr The control lever (a) operates a hydraulically actuated piston which connects to the sleeve gear inside the exciter. As the piston moves in and out, the sleeve gear rotates, changing the position of the eccentric weights (c) inside the exciter. It is the position of the weights inside the exciter that determines the direction of travel. 1. Neutral: With the machine running and no control pressure applied, the eccentric weights spin in phase and apply force in either the upward or downward direction; each weight cancels any directional force produced by the other. Due to the direction of rotation, the natural tendency of the exciter is to shift into reverse. To prevent this from happening, spring tension (c) in the handle is used to apply a constant pressure on the control circuit. The value of the spring is such that it balances the exciter assembly in its neutral position. In neutral the machine will vibrate but will not travel forward or reverse. 2. Forward: When the control lever is moved forward, hydraulic pressure pushes against the actuating piston inside the exciter. As the piston moves in, the pin riding inside the helix of the sleeve gear rotates the gear which in turn rotates the rear weights away from the neutral position. The weights now rotate out of phase with each other. While the forces of one set of weights lift the plate the forces from the other set propel it forward. The farther the weights are shifted, the faster the travel speed. 3. Reverse: When the control handle is released, the sleeve gear, piston, and weights will automatically slip back into their neutral position. If the control handle is pulled back past neutral, they continue to slip until the piston reaches the end of its stroke and the weights have shifted a full 90 in the opposite direction. In this position, the plate will travel in reverse. Speed: Top speed is achieved when the exciter weights are rotated a full 90 in relation to each other. This occurs when the control lever is shifted as far as possible in the forward or reverse direction. Intermediate speeds are possible by partially shifting the control lever, allowing the weights to assume a position somewhere between 0 and 90. wc_tx000264gb.fm 16

21 BPU 2440/2950 Repair General Information 1 a b c wc_gr wc_tx000264gb.fm 17

22 General Information 3.10 Engine Speed and Machine Performance BPU 2440/2950 Repair Even a small rise or fall in engine speed will affect the centrifugal force produced by the exciter. If the engine runs overspeed even slightly, the centrifugal force will increase significantly and overload the exciter bearings. If the engine runs underspeed, the centrifugal force will drop significantly, causing poor compaction and slow travel speeds. When checking engine speed, use a tachometer for accuracy. Operate the unit at the appropriate rpm. Refer to the Technical Data. Service engine at recommended intervals and adjust drive belts regularly to maintain maximum machine performance Operating on Slopes See graphic: wc_gr When compacting on a slope, only approach the slope from the top. The operator must never stand between the machine and direction of descent. Do not operate on a slope of more than 20. If this degree of slope is exceeded, a failure of the engine s splash-type lubrication system may result. wc_gr wc_tx000264gb.fm 18

23 BPU 2440/2950 Repair 3.12 To Start General Information See graphic: wc_gr Open fuel valve by moving lever to the right (a1). Note: If engine is cold, move choke lever to close position (b1). If engine is hot, set choke to open position (b2 ) Turn engine switch to ON (e1) Open throttle by moving it slightly to left (d1) Pull starter rope (c). Note: If the oil level in the engine is low, the engine will not start. If this happens, add oil to engine. Some engines are equipped with an oil alert light (f) that will come on while pulling the starter rope Open choke as engine warms (b2) Open throttle fully to operate To Stop See Graphic: wc_gr Reduce engine RPM to idle by moving throttle completely to right (d2) Turn engine switch to OFF (e2) Close fuel valve by moving lever to the left (a2). wc_tx000264gb.fm 19

24 Maintenance 4. Maintenance BPU 2440/2950 Repair 4.1 General Maintenance Periodic maintenance is essential to prolong the service life of the plate and engine. Use the Maintenance Schedule as a guide when servicing the equipment. Compaction equipment is designed and manufactured to perform heavy work under harsh operating conditions. Because of the heavy demands, the frequency of engine maintenance may exceed that recommended by the engine manufacturer. For detailed maintenance procedures of the engine, refer to the engine manufacturer s service manual. wc_tx000328gb.fm 20

25 BPU 2440/2950 Repair 4.2 Maintenance Schedule Maintenance Daily before starting Every 25 hrs. Every 100 hrs. Every 300 hrs. Check engine oil level. Visually inspect exciter base for leaks. Inspect/clean air filter. Re-oil foam element; replace as required. Check/tighten external hardware. Change engine oil. Inspect/adjust V-belt. Check/regap spark plug. Replace when nececessary. Clean engine cylinder cooling fins. Inspect shockmounts. Replace if cracked or split. Change exciter oil. Chang hydraulic oil in handle. Change fuel filter or strainer. Clean combustion chamber. Check/adjust breaker point ignitions. Clean/rinse fuel tank. Clean rewind starter. For new or reconditioned engines: Check/adjust belt tension. Change engine oil. After first 5 hours of operation. After first 10 hours of operation. wc_tx000328gb.fm 21

26 Maintenance 4.3 Air Filter BPU 2440/2950 Repair See graphic: wc_gr Take off cover (a) and remove foam element (b) Wash element with liquid detergent (c) and hot water. Rinse with clean water. Wrap in a clean towel and wring dry. CAUTION Do not use gasoline, paint thinner, or other low flash point solvent for cleaning air cleaner element. A fire or explosion could result Saturate foam element with engine oil and squeeze out excess. If dirt is severe, or element is torn or distorted, replace the element Clean paper cartridge (c) by blowing compressed air through the filter from the inside or by tapping element on a hard surface. Use only light air pressure to avoid tearing element. Replace paper cartridges as necessary Re-install elements and cover Never operate machine with damaged air cleaner or missing air filters. CAUTION a c b a b c BPU 2950R BPU 2950A/2440A wc_gr wc_tx000328gb.fm 22

27 BPU 2440/2950 Repair 4.4 Spark Plug Maintenance See Graphic: wc_gr WARNING Clean or replace spark plug as needed to ensure proper operation. Refer to the engine Owner 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 the Technical Data for the recommended spark plug type and the electrode gap setting Remove spark plug and inspect it Replace plug if the insulator is cracked or chipped Clean spark plug electrodes with a wire brush Set the electrode gap (a) Tighten spark plug securely. CAUTION: A loose spark plug can become very hot and may cause engine damage. wc_tx000328gb.fm 23

28 Maintenance 4.5 Cleaning Sediment Cup BPU 2440/2950 Repair See Graphic: wc_gr Turn fuel valve off Remove sediment cup (a) and O-ring (b) Wash both thoroughly in a nonflammable solvent. Dry and reinstall them Turn fuel valve on and check for leaks. wc_tx000328gb.fm 24

29 BPU 2440/2950 Repair 4.6 Adjusting Idle Speed Maintenance See Graphic: wc_gr Adjust engine to the no load or idle speed per the Technical Data Start the engine and allow it to warm up to normal operating temperature Turn the throttle stop screw (a) in to increase speed, out to decrease speed. Make sure the throttle lever is touching the stop screw before measuring rpm. a wc_gr Carburetor Adjustment See Graphic: wc_gr The pilot screw (a) is fitted with a limiter cap to prevent excessive enrichment of the air-fuel mixture in order to comply with emission regulations. The mixture is set at the factory and no adjustment should be necessary. Do not attempt to remove the limiter cap. The limiter cap cannot be removed without breaking the pilot screw. a wc_gr wc_tx000328gb.fm 25

30 Maintenance 4.8 Drive Belt BPU 2440/2950 Repair See graphic: wc_gr00143 Recommended tools: Allen wrench 6 mm, Socket wrench 13 mm See Maintenance Schedule for service intervals. On new machines or after installing a new belt, check the belt tension after the first 5 hours of operation. Adjust belt for 1/4" 3/8" (5 10 mm) deflection when pressed midway between the belt pulleys (x). To tighten the belt, reduce the quantity of spacers (y) between the pulley halves (z); to loosen, add spacers Remove belt cover Remove the four hex nuts holding the pulley halves together Remove the outer pulley half and remove spacers as required to tighten the belt. Normally, removing one spacer is sufficient. When installing a new belt, remove or add spacers as required to obtain correct belt tension. Note: Place used spacers in equal quantities on either side of the pulley to maintain belt alignment. If spacers cannot be placed equally, place odd spacer to the outside of pulley Secure pulley halves together with hex nuts and recheck belt tension. Replace belt cover. x y z w wc_gr wc_tx000328gb.fm 26

31 BPU 2440/2950 Repair 4.9 Exciter Oil Maintenance See graphic: wc_gr The bearings in the exciter assembly are splash lubricated and rotate at a very high speed (up to 5400 rpm). It is important to maintain the exciter oil at the proper level and change it regularly to ensure maximum protection. To drain oil, remove drain plug and tip machine toward drain hole. Use a suction gun to draw oil out of the exciter case. When filling, position plate on a level surface and add oil through drain plug hole until oil is even with bottom edge of threads (a). Caution: DO NOT overfill exciter case. Excessive wear on engine and exciter bearings will result. a wc_gr Control Circuit Oil Check oil level in control handle once a week or every 25 hours. Remove plug from top of control handle. Add oil as required to maintain proper oil level. Oil level should be at OEL mark on outside of housing. If oil needs replenishing on a regular basis, it may be leaking past the seals on the pistons. Service the seals on the pistons. A low oil level may allow air to enter the control circuit. This condition is normally characterized by the plate s inability to travel in the forward direction. Should this occur, bleed the system. wc_tx000328gb.fm 27

32 Maintenance 4.11 Bleeding the Control Circuit BPU 2440/2950 Repair See graphic: wc_gr Recommended Tools: Allen wrench 6 mm Socket or box wrench 7 mm, 22 mm Bleed control circuit whenever handle or exciter have been opened for service Turn off engine before servicing Lock handle in its vertical upright position Remove belt guard to expose exciter pulley (a) Secure the control lever in the reverse position using a C-clamp to prevent the spring and piston inside from popping out when control assembly is removed. Remove control assembly from handle tube Fill handle tube with oil Remove bleeder screw (c) from cover flange on exciter Slowly rotate exciter pulley counterclockwise (same direction as normal operation) two full turns. Oil will flow out of bleeder hole during this procedure as the piston in the exciter extends and retracts inside flange cover Rotate exciter pulley to a position where oil is observed flowing from the hole and insert the bleed screw while holding the pulley in this position. This prevents air from being drawn back into the flange cover. Tighten the bleeder screw Top off oil in handle tube Make sure O-ring is in place between control assembly and tube flange and re-install control lever assembly. Coat bolts with Loctite 242 or equivalent and torque to 7 ft.lbs. (10 Nm) Remove fill plug from control lever assembly and fill with oil to OEL mark (b). Do not overfill Wait 30 seconds for oil to fill area under piston, then remove C-clamp and re-install fill plug Start plate and check directional control. wc_tx000328gb.fm 28

33 BPU 2440/2950 Repair Maintenance b "OEL" d 4 45 c 90 e a wc_gr Ref. Description Ref. Description 1. Fill Plug 4. O-Ring 2. Spring 5. Seal 3. Piston 6. O-Ring 4.12 Re-installing Piston in Control Assembly See graphic: wc_gr If it is ever necessary to re-install the piston into the control assembly, carry out the following procedure Place the control lever in a position approximately 45 to the assembly body. Insert the piston assembly until the first groove in the piston catches on the pinion (d) Move the lever to a position 90 to the assembly body. The pinion should pull the piston into the assembly body as the lever is rotated. When the lever reaches the 90 position, the end of the piston must be flush with the opening in the assembly body (e). If it is not, repeat the procedure, repositioning the piston as needed. wc_tx000328gb.fm 29

34 Repair Procedures 5. Repair Procedures BPU 2440/2950 Repair 5.1 General Repair The repair procedures specify using sealants and screw and nut adhesives to seal metal surfaces and secure fasteners in place. These products must be used where indicated. Although Loctite is referred to throughout this manual, an equivalent sealant such as Hernon or Omnifit may be used. When using sealants, always follow the application instructions on the container. Refer to the thread locking and sealant chart located in this manual. Most thread locking sealants break down at temperatures above 350 F (177 C). If a bolt or nut resists separation, apply heat to it using a small propane torch. When doing so, check to make sure no other portion of the unit will be damaged from the use of the torch. Correct torque values are listed whenever possible. Follow these specifications when replacing or tightening screws and nuts. This is especially important at sealed surfaces where screws must be tightened evenly to ensure airtight seals thus preventing leaks. The step-by-step procedures listed here provide complete descriptions for the removal and replacement of all serviceable parts. However, items such as bearings and shafts, assembled with press fits, should be inspected for wear and damage while still in place. Removing or installing such items often requires tools or presses to do the task properly. When installing bearings into housing, apply pressure only to the outer race of the bearing. If pressing a bearing onto a shaft, pressure should be applied only to the inner race. Apply pressure evenly around the bearing. Avoid using a hammer to pound bearings in place. If using heat to fit a bearing onto a race, use a hot plate or hot oil bath where the temperature can be controlled. Never heat a bearing using a propane torch. Excessive heat, over 350 F (150 C), can affect the hardness characteristics and tolerance values of the bearing. wc_tx000329gb.fm 30

35 BPU 2440/2950 Repair Repair Procedures 5.2 Checking Exciter Operation Before servicing the exciter, check for other possible problems that could affect machine operation, such as: engine speed, control circuit operation, drive belt tightness, and clutch performance. If the engine is running underspeed, the exciter VPM will be reduced, the plate will handle sluggishly and perform poorly, and travel speeds will be greatly reduced. Check engine speed with a tachometer. See Technical Data for correct engine speed. If engine cannot be brought up to speed, either the engine is at fault or exciter bearings are binding. Check general condition of engine, engine compression, and no-load operating speed To check bearings, run the machine with clutch engaged for several minutes to warm exciter. Bearings may appear to turn freely when cold but start to bind as they heat up. Stop engine and rotate the exciter by hand. Pinching hazard. Keep hands, feet, hair, and loose clothing away from moving parts Remove belt guard cover and check operation of drive belt, clutch, and exciter pulley. Use a vibration tachometer and check exciter VPM with engine running at full throttle ( rpm). CAUTION Air trapped in the control circuit will affect the plate s ability to maintain neutral position, or shift into forward. Make sure the system has been properly bled, seals in handle are in good condition, and oil is at correct level. See Bleeding the Control Circuit If control system checks out but machine s directional control still does not operate correctly, the exciter s actuating assembly is faulty or the exciter timing is set incorrectly. wc_tx000329gb.fm 31

36 Repair Procedures 5.3 Exciter Exploded View Illustration BPU 2440/2950 Repair wc_gr wc_tx000329gb.fm 32

37 BPU 2440/2950 Repair 5.4 Exciter Parts List Repair Procedures See graphic: wc_gr Ref. Description Ref. Description 1. Exciter housing 18. Idler gear 2. Screw M10x Idler shaft 3. Screw M10x Eccentric weight 4. Bearing (inner & outer race) 21. Washer 5. Bleed screw M4x5 22. Screw M10x35 6. Flanged cover 23. Retaining ring 7. Flanged cover 24. Wear ring 8. Washer 25. Retaining ring 9. Screw M6x Sleeve gear bearing 10. Pulley 27. Sleeve gear 11. Tolerance ring 28. Vent plug 12. Screw M6x Drive shaft 13. Holder 30. Guide pin 14. Flanged cover 31. Screw M10x Shaft seal 32. Piston assembly 16. Key 33. Piston seal 17. Retaining ring wc_tx000329gb.fm 33

38 Repair Procedures 5.5 Removing Exciter BPU 2440/2950 Repair See graphic: wc_gr Recommended Tools: Socket wrench 19 mm Allen wrench 6 mm, 8 mm Open-end wrench 17 mm, 19 mm Locking pliers 3-jaw puller Rubber mallet High-strength thread locking adhesive Gasket eliminator Turn machine s engine off Remove belt guard and remove drive belt Using a 3-jaw puller (a), remove pulley (b) from exciter drive shaft Clamp the control line hose with locking pliers or C-clamp to prevent leaking. Then, disconnect the line from the front exciter flange cover Using a 19 mm socket, remove the four hex nuts (c) that secure the tubular frame (d) to the plate. Remove the frame from the plate Using an appropriate lift or crane, lift the complete upper mass from the baseplate to expose the exciter assembly Mark the exciter housing referencing the right hand front side (e) Remove the eight socket head screws (f) securing exciter and lift the exciter from the plate. d c b a e f wc_gr wc_tx000329gb.fm 34

39 BPU 2440/2950 Repair 5.6 Installing Exciter Repair Procedures See graphic: wc_gr Scrape off old gasket material and thoroughly clean mounting surfaces on exciter and baseplate Once thoroughly clean and completely dry, coat mounting baseplate (a) with Loctite 515 gasket eliminator or equivalent Position exciter assembly so that exciter drive pulley faces front right corner (b) of plate Coat threads of mounting bolts (c) with Loctite 242 or equivalent, insert them and torque to 36 ft.lbs. (49 Nm) Inspect shockmounts (d). Replace any that appear worn or damaged. Coat threads of shockmount with Loctite 242 or equivalent, insert, and torque to 63 ft.lbs. (86 Nm) Position upper mass onto lower mass and secure with nuts. Torque nuts to 63 ft.lbs. (86 Nm) Install new tolerance ring (e) and carefully tap on exciter drive pulley (f) until it is flush against shaft shoulder Connect control hose and bleed the system Install drive belt. Adjust belt tension and check alignment of pulleys. Replace belt guard cover Fill exciter (g) with oil. f c e b g d a wc_gr wc_tx000329gb.fm 35

40 Repair Procedures 5.7 Exciter Assembly Cross Section BPU 2440/2950 Repair a wc_gr wc_tx000329gb.fm 36

41 BPU 2440/2950 Repair Repair Procedures 5.8 Exciter Cross Section List of Components See Graphic: wc_gr Ref. Description Ref. Description 1. Flange cover 14. Piston assembly 2. Idler shaft 15. Piston seal 3. Holder 16. Eccentric weight bolt (2) 4. Shaft seal 17. Flanged cover bolt (2) 5. Drive shaft 18. Roller bearing 6. Vent plug 19. Retaining ring 7. Retaining ring 20. Idler gear 8. Wear ring 21. Eccentric weight 9. Flanged cover 22. Shaft key 10. Retaining ring 23. Piston head 11. Guide pin 24. Retaining Ring 12. Sleeve gear 25. Bearing (2) 12a. Sleeve gear bearing 26. Washer 13. Flange cover 27. Screw wc_tx000329gb.fm 37

42 Repair Procedures 5.9 Servicing Exciter BPU 2440/2950 Repair Recommended Tools Allen wrench 5 mm, 8 mm Snap ring pliers external type Torque wrench 38 ft.lbs. (50 Nm) Screwdriver Rubber mallet Arbor press Wooden V-block Loctite sealants 242, 271, Disassembling the Exciter See graphics: wc_gr001443, wc_gr001444, wc_gr Refer to Cross Section Component List for item numbers ( ). Remove exciter as shown in section Removing Exciter Mark front corner of housing on side that exciter pulley attaches to Jam the gears to prevent them from turning and remove all exciter weights (21) Remove snap rings (7, 10) from drive shaft Mark location of all flange covers (1, 2, 9, 13) and remove covers from exciter. Note: Flange covers (9, 13) on drive shaft are equipped with threaded pusher holes (a) Remove drive shaft (2). Place exciter in an arbor press pulley side up. Press on pulley side of drive shaft (b) until the shaft is pushed completely through the side of the housing. The shaft will press out with sleeve gear (12), piston assembly (14), and inner bearing races intact. Note: During this step the roller bearing on the opposite end of shaft will be pressed out of exciter housing. Remove bearing as it becomes free of housing to prevent it from falling Use arbor press or 2-jaw puller to remove bearing races and sleeve gear bearing (12a). wc_tx000329gb.fm 38

43 BPU 2440/2950 Repair Repair Procedures Remove piston assembly (15) from drive shaft by placing on a wooden V-block (c). The block should have a hole drilled in it for the guide pin (11). Press guide pin (d) (DO NOT HAMMER) through shaft until piston (e) can be removed. Spin head (23) of piston assembly by hand and check condition of small bearings (25) inside. Head should rotate smoothly with no side play. If necessary, remove retaining ring holding head and replace bearings Press idler shaft from exciter Use an arbor press or puller to remove bearing race and idler gear (20). a wc_gr b d e f wc_gr c wc_gr wc_tx000329gb.fm 39

44 Repair Procedures 5.11 Re-assembling the Exciter BPU 2440/2950 Repair Refer to Cross Section Component List for item numbers ( ). See graphics: wc_gr and wc_gr When installing shafts, make sure drive shaft is installed on machined end of housing. Later housings are symmetrical and are machined at all four bearing locations. On these housings, the drive shaft may be installed on either side. Installing idler shaft Assemble retaining ring (19), key (22), gear (20), and bearing races onto shaft Press roller bearing into one side of exciter housing. Use a flange cover as a guide in positioning the bearing the correct distance into the housing Install the idler shaft. Complete the installation by pressing the remaining bearing into the opposite side of housing. Position the bearing into the housing using a flange cover. Installing drive shaft Using the wooden V-block to secure shaft, position the piston assembly (14) in shaft and press guide pin (11) through. Caution: Do not hammer on guide pin. Hammering may mushroom top of pin and cause it to bind in the sleeve gear. Note: When installing guide pin, make sure it extends an equal distance on each side of shaft so it will slide freely once sleeve gear is installed Press sleeve gear bearing (12a) on shaft and secure in place with retaining ring (10) Press bearing race on pulley side of shaft. Do not install bearing race on opposite side of shaft until shaft and sleeve gear are in place Insert drive shaft assembly through housing and slide sleeve gear (12) on shaft and over sleeve gear (12a). Note: Sleeve gear must be installed so that when the piston assembly is pulled out, the bolt holes in the shaft face the timing mark on the gear Press bearing into pulley side of exciter housing. Position it in the housing using a flanged cover. wc_tx000329gb.fm 40

45 BPU 2440/2950 Repair Repair Procedures b a d c wc_gr wc_gr Ref. Note a. Drive shaft side machined surface b. Pulley end of housing c. Piston end of housing d. Use flanged covers to position bearings the correct distance into exciter housing. Procedure continued on next page. wc_tx000329gb.fm 41

46 Repair Procedures BPU 2440/2950 Repair Timing Exciter Weights Refer to Cross Section Component List for item numbers ( ). See graphics: wc_gr001448, wc_gr001449, and wc_gr CAUTION Align timing marks on gears with piston extended. View shafts from piston side and compare position of bolt holes in shafts and timing marks on gears with those shown. If bolt pattern does not match sleeve gear was installed incorrectly. Back gear off bearing and rotate it onehalf turn Install wear ring (17) After installation is complete, operate piston by hand and make sure both sleeve gear and piston slide freely Using Loctite 515 gasket eliminator or equivalent on flange, assemble it to housing. Coat M10 screws with Loctite 242 or equivalent and secure flange to housing. Torque screw to 7 ft.lbs. (10 Nm) Install retaining ring (7) on end of drive shaft Once assembled, exciter weights can cause exciter shafts to turn unexpectedly and with considerable force. Keep fingers and hands away from gears and weights when handling exciter assembly to prevent being pinched. Install exciter weights. Coat threads of M10x25 screws with Loctite 271 or equivalent and secure weights to drive shaft. Coat threads of M10x35 screws with Loctite 271 or equivalent and secure weights to idler shaft. Torque screws to 38 ft.lbs, (50 Nm) Re-install the exciter assembly to plate. wc_tx000329gb.fm 42

47 BPU 2440/2950 Repair Repair Procedures c b f g a wc_gr d wc_gr e wc_gr Ref. Note a. Bolt holes must face timing mark with piston extended. b. Piston c. Position of exciter weights, piston fully extended. View from piston side. d Timing marks e. Apply gasket eliminator to flange. f. Idler shaft g. Drive shaft wc_tx000329gb.fm 43

48 Repair Procedures 5.12 Servicing the Clutch BPU 2440/2950 Repair See graphic: wc_gr The engine clutch is keyed (a) to the engine drive shaft (b) and secured using a washer and hex screw. To replace clutch shoes or springs: Remove snap ring (c) that secures bearing (d) to hub (e) Pry behind clutch drum and rap center bolt with rubber mallet until the drum and bearing are free from hub. It is not necessary to remove clutch hub when replacing the clutch shoes or springs. Although clutch hub is keyed to shaft, it may bind tightly due to rust and corrosion, making it difficult to remove. When installing a new clutch, clean engine drive shaft and coat it with anti-seize lubricating compound before before installing the new clutch. Note: Model 2440A also includes spacer (f). b d f a c e wc_gr wc_tx000329gb.fm 44

49 BPU 2440/2950 Repair 5.13 Replacing the Engine Repair Procedures Wacker BPU series reversible vibroplates are powered by Robin or Honda engines in either 5.0, 5.5, or 8 hp models. Replacing the engine is similar for either type of engine; however, there are subtle differences. Older plates have a beltguard mounted directly to the engine. On newer models the beltguard is mounted to a baseplate that is mounted to the upper mass. Engine Removal Remove the tubular frame from the plate Remove drive belt, pulley, and clutch from engine drive shaft On older models, remove the four bolts securing the beltguard to the engine. On newer models, remove the four bolts securing the beltguard to the baseplate Remove engine mounting bolts and using an appropriate hoist or crane, lift the engine off the upper mass. wc_tx000329gb.fm 45

50 Repair Procedures 5.14 Engine Replacement Honda BPU 2440/2950 Repair See graphic: wc_gr Using an appropriate hoist or crane to lift engine, place the engine on the upper mass and secure the engine with the four mounting bolts (a). Torque the bolts to 18 ft.lbs. (25 Nm) on BPU 2440A models; 36 ft.lbs. (49 Nm) on BPU 2950A models On older models, secure the beltguard to the engine using the four mounting bolts. On newer models, secure the beltguard to the baseplate using the four M10x25 mounting bolts Coat engine drive shaft with anti-seize and re-install drive belt, pulley, and clutch onto drive shaft Re-install tubular frame to upper mass. BPU 2440A 3 1 a BPU 2950A 5 1 a 4 2 a 2 wc_gr Ref. Note 1. Baseplate 2. Upper Mass 3. Use Loctite 242 or equivalent on screw when installing. 4. Mounting bar 5. Lock nut wc_tx000329gb.fm 46

51 BPU 2440/2950 Repair 5.15 Engine Replacement Robin Repair Procedures See graphic: wc_gr The engine hardware is designed to provide clearance between the engine crankcase and the upper console. Any contact between the console and the engine may stress the engine block. There should be a small air gap between the engine and plate after hardware has been tightened Place the cupped washer and flat washer as shown Using an appropriate hoist or crane, place the engine on the upper mass and secure the engine with the four mounting bolts. Torque the bolts to 38 ft.lbs (50 Nm) On older models, secure the beltguard to the engine using the four mounting bolts. On newer models, secure the beltguard to the baseplate using the four M10x25 mounting bolts Coat engine drive shaft with anti-seize and re-install drive belt, pulley, and clutch onto drive shaft Re-install tubular frame to upper mass. BPU 2950R wc_gr Ref. Note 1. Torque nut to 38 ft.lbs (50 Nm). 2. Check for air gap after assembly. 3. Cupped washer 4. Flat washer wc_tx000329gb.fm 47