Wacker Neuson BPU 2440 series Repair Manual Download Page 28 | Manualshive

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Maintenance

BPU 2440/2950 Repair

wc_tx000328gb.fm

24

4.5

Cleaning Sediment Cup

See Graphic: wc_gr000029

4.5.1

Turn fuel valve off.

4.5.2

Remove sediment cup (a) and O-ring (b).

4.5.3

Wash both thoroughly in a nonflammable solvent. Dry and reinstall
them.

4.5.4

Turn fuel valve on and check for leaks.

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Summary of Contents for BPU 2440 series

Page 1: ...www wackergroup com Vibroplate BPU 2440 BPU 2950 REPAIR MANUAL 0078232 004 0603 en 0 0 7 8 2 3 2...

Page 2: ......

Page 3: ...lacement 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...

Page 4: ...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 permiss...

Page 5: ...1 3 1 Application 11 3 2 Tools 11 3 3 Ordering Parts 11 3 4 Reference Numbers 12 3 5 Weight Block 12 3 6 Lifting and Transporting the Machine 12 3 7 Storage 13 3 8 Theory of Operation 14 3 9 Direction...

Page 6: ...2 Checking Exciter Operation 31 5 3 Exciter Exploded View Illustration 32 5 4 Exciter Parts List 33 5 5 Removing Exciter 34 5 6 Installing Exciter 35 5 7 Exciter Assembly Cross Section 36 5 8 Exciter...

Page 7: ...avoid possible injury or death DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation which...

Page 8: ...ctioning properly immediately after start up DO NOT operate machine unless all controls operate correctly 1 1 6 ALWAYS operate machine with all safety devices and guards in place and in working order...

Page 9: ...ueling engine 1 2 7 DO NOT run engine near open flames 1 2 8 ALWAYS refill fuel tank in well ventilated area 1 2 9 ALWAYS replace fuel tank cap after refueling 1 2 10 ALWAYS check fuel lines and fuel...

Page 10: ...cker 1 3 11 ALWAYS keep machine clean and labels legible Replace all missing and hard to read labels Labels provide important operating instructions and warn of dangers and hazards 1 3 12 ALWAYS check...

Page 11: ...ore operating this machine Fail ure to do so increases the risk of injury to your self or others WARNING Do not operate without safety guards Read and understand instruction book CAUTION Lifting point...

Page 12: ...Number Item Number Revision and Serial Number is attached to each unit Please record the infor mation found on this plate so it will be avail able should the nameplate become lost or damaged When orde...

Page 13: ...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 Cha...

Page 14: ...es Oil Grade Quantity ml ounces BPU 2440A 5904 10W40 600 20 SAE 15W40 750 25 BPU 2440A 7150 10W30 600 20 BPU 2440A 7867 10W30 600 20 BPU 2650R 5603 10W030 770 26 BPU 2950R 6222 6346 10W030 710 24 BPU...

Page 15: ...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 satisf...

Page 16: ...s 3 5 Weight Block See Graphic wc_gr000843 The weight block symbol gives an approximate weight measurement to aid the mechanic when lifting hoisting larger components 3 6 Lifting and Transporting the...

Page 17: ...3 7 1 Completely drain the fuel tank Run the engine until carburetor is dry 3 7 2 Thoroughly clean exterior of plate and engine Visually inspect the unit for signs of damage loose hardware and worn s...

Page 18: ...rolled 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...

Page 19: ...BPU 2440 2950 Repair General Information wc_tx000264gb fm 15 l f d e k a j b i h g wc_gr001430 wc_gr000085 c...

Page 20: ...l 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...

Page 21: ...BPU 2440 2950 Repair General Information wc_tx000264gb fm 17 wc_gr001431 1 2 3 c 90 90 a b 0...

Page 22: ...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...

Page 23: ...slightly to left d1 3 12 4 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...

Page 24: ...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 f...

Page 25: ...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 hyd...

Page 26: ...or explosion could result 4 3 3 Saturate foam element with engine oil and squeeze out excess If dirt is severe or element is torn or distorted replace the element 4 3 4 Clean paper cartridge c by blo...

Page 27: ...e 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 4 4 1 Remove spark plug and insp...

Page 28: ...b fm 24 4 5 Cleaning Sediment Cup See Graphic wc_gr000029 4 5 1 Turn fuel valve off 4 5 2 Remove sediment cup a and O ring b 4 5 3 Wash both thoroughly in a nonflammable solvent Dry and reinstall them...

Page 29: ...out to decrease speed Make sure the throttle lever is touching the stop screw before measuring rpm 4 7 Carburetor Adjustment See Graphic wc_gr0001061 The pilot screw a is fitted with a limiter cap to...

Page 30: ...een the pulley halves z to loosen add spacers 4 8 1 Remove belt cover 4 8 2 Remove the four hex nuts holding the pulley halves together 4 8 3 Remove the outer pulley half and remove spacers as require...

Page 31: ...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 4 10 Control Circuit Oil Check oil level in control...

Page 32: ...er 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 cov...

Page 33: ...ton assembly until the first groove in the piston catches on the pinion d 4 12 2 Move the lever to a position 90 to the assembly body The pinion should pull the piston into the assembly body as the le...

Page 34: ...cations 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 st...

Page 35: ...gs 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 Pin...

Page 36: ...cedures BPU 2440 2950 Repair wc_tx000329gb fm 32 5 3 Exciter Exploded View Illustration wc_gr001436 10 11 12 13 14 15 4 7 2 2 3 1 4 5 6 7 8 9 16 17 4 22 21 20 19 18 4 4 33 32 31 21 20 30 29 28 27 26 2...

Page 37: ...ric 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 M6x20 26 Sleeve gea...

Page 38: ...from exciter drive shaft 5 5 4 Clamp the control line hose with locking pliers or C clamp to prevent leaking Then disconnect the line from the front exciter flange cover 5 5 5 Using a 19 mm socket re...

Page 39: ...ts c with Loctite 242 or equivalent insert them and torque to 36 ft lbs 49 Nm 5 6 5 Inspect shockmounts d Replace any that appear worn or damaged Coat threads of shockmount with Loctite 242 or equival...

Page 40: ...Repair Procedures BPU 2440 2950 Repair wc_tx000329gb fm 36 5 7 Exciter Assembly Cross Section 1 2 3 4 5 6 7 8 9 10 12a 12 13 11 14 15 27 23 26 25 24 16 5 2 17 18 19 20 21 22 wc_gr001442...

Page 41: ...r 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...

Page 42: ...ove all exciter weights 21 5 10 3 Remove snap rings 7 10 from drive shaft 5 10 4 Mark location of all flange covers 1 2 9 13 and remove covers from exciter Note Flange covers 9 13 on drive shaft are e...

Page 43: ...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 neces...

Page 44: ...the housing using a flange cover Installing drive shaft 5 11 4 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...

Page 45: ...b fm 41 Procedure continued on next page 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 cor rect distance in...

Page 46: ...r and piston slide freely 5 11 12 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...

Page 47: ...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 sh...

Page 48: ...y 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 cl...

Page 49: ...mounted directly to the engine On newer models the beltguard is mounted to a baseplate that is mounted to the upper mass Engine Removal 5 13 1 Remove the tubular frame from the plate 5 13 2 Remove dr...

Page 50: ...9 Nm on BPU 2950A models 5 14 2 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 bo...

Page 51: ...hown 5 15 2 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 5 15 3 On older models secure...

Page 52: ...eplace tolerance ring Remove exciter and adjust timing Check oil level in exciter and inspect exciter bearings Replace bearings if necessary Plate pulls to one side Shockmounts damaged Inspect and rep...

Page 53: ...before disassembly Temp range 54 to 149 C 65 to 300 F 29312 5 ml 26685 10 ml 73285 50 ml Loctite 290 Hernon 431 Omnifit 1710 230LL Green Medium to high strength for locking preassembled threads and f...

Page 54: ...n Primer 10 Omnifit VC Activator Aerosol Spray Fast curing primer for threadlocking retaining and sealing compounds Must be used with stainless steel hardware Recommended for use with gasket sealants...

Page 55: ...5 M4 26 2 9 36 4 1 43 4 9 9 32 7 3 M5 53 6 0 6 8 5 7 10 5 16 8 4 M6 7 10 10 14 13 17 10 5 M8 18 25 26 35 30 41 1 2 13 6 M10 36 49 51 69 61 83 11 16 17 8 M12 63 86 88 120 107 145 3 4 19 10 M14 99 135 1...

Page 56: ...3 5 42 4 7 11 32 9 9 64 No 10 32 3 6 45 5 1 60 6 8 3 8 5 32 1 4 6 8 1 9 12 12 16 7 16 3 32 5 16 13 18 19 26 24 33 1 2 13 1 4 3 8 23 31 33 45 43 58 9 16 5 16 7 16 37 50 52 71 69 94 5 8 16 3 8 1 2 57 7...

Page 57: ......

Page 58: ...0 Fax 49 0 89 354 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 Sunley Center Unit 912...

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