Wacker Neuson BPU 2540 User manual

www.wackergroup.com
Operator's manual
Vibrating plate
BPU ...
0210447en 002
04.2008

Contents
3
1. Foreword 5
2. Safety information 7
2.1 General instructions ..............................................................................7
2.2 Operation ...............................................................................................7
2.3 Safety checks ........................................................................................9
2.4 Maintenance ........................................................................................10
2.5 Transport .............................................................................................11
2.6 Maintenance checks ............................................................................11
3. Technical data 12
4. Description 14
4.1 Field of application ..............................................................................14
4.2 Max. permissible tilt .............................................................................14
4.3 Functional description .........................................................................15
5. Transport to the worksite 17
6. Recommendations for compacting 18
7. Operation 19
7.1 Start preparation ..................................................................................19
7.2 Starting the engine ..............................................................................19
7.3 Operating in the forward and reverse direction ...................................20
7.4 Turn off the engine ..............................................................................20
8. Maintenance 21
8.1 Maintenance schedule ........................................................................21
8.2 Checking engine oil level .....................................................................21
8.3 Changing the engine oil .......................................................................23
8.4 Cleaning the air filter / replacing the air filter inserts ...........................24
8.5 Checking / cleaning / replacing the spark plug ....................................25
8.6 Checking exciter V-belt .......................................................................26
8.7 Changing exciter V-belt .......................................................................26
8.8 Checking / filling hydraulic oil level ......................................................26
8.9 Checking exciter oil level .....................................................................27
8.10 Changing exciter oil .............................................................................27
9. Malfunction 28
9.1 Forward travel speed too low ..............................................................28
9.2 Reverse travel speed too low ..............................................................28
9.3 No forward movement .........................................................................28
9.4 Loss of hydraulic oil .............................................................................28

Contents
4
9.5 Engine will not start .............................................................................29
EC Declaration of Conformity 31
DIN EN ISO 9001 Certificate 33

Foreword
5
1. Foreword
For your own safety and protection from bodily injuries, carefully read,
understand and follow the safety information in this manual.
Please operate and maintain your Wacker machine in accordance with
the instructions in this operator's manual. Your Wacker machine will
reward you with troublefree operation and a high degree of availability.
Defective components must be replaced immediately.
All rights, especially the right for copying and distribution, are reserved
Copyright 2008by 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 any
type or method not authorized by Wacker represents an infringement of
valid copyrights and will be prosecuted. We expressly reserve the right
to make technical modifications - even without special notice - which aim
at further improving our machines or their safety standards.

T00940en.fm 6
Important note
This machine is equipped with an EPA-certified motor.
Relevant details can be found in the instructions of the motor
manufacturer.
The motor's exhaust fumes contain chemicals which the State
of California knows may cause cancer, congenital defects or
other reproductive anomalies.
WARNING
Caution
This is an EPA motor.
Regulating the motor speed influences the EPA certification and emission.
The motor may only be set by a skilled technician.
For more detailed information, please contact your nearest motor or
Wacker representative.

Safety information
SV00069en.fm 7
2. Safety information
For vibrating plates with combustion engine drive
2.1 General instructions
2.1.1 Vibrating plates may only be operated by persons who
∗are at least 18 years of age,
∗are physically and mentally fit for this job,
∗have been instructed in operating vibrating plates and have 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 operating vibrating plates by
the employer.
2.1.2 Vibrating plates are to be applied only for compacting work. Both the
manufacturer's operator's manual and this safety information must be
observed.
2.1.3 The persons charged with the operation of vibrating plates must 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.
2.1.4 It is possible that these vibrating plates exceed the admissible sound
level of 89 dB (A). If the sound level reaches 89 dB (A) or more, the
employees must wear ear protection.
2.2 Operation
2.2.1 The engine is started using a recoil starter. The decompression
automatic allows an easy and kickback-free start-up procedure.
2.2.2 The function of operation levers or elements must not be influenced or
rendered ineffective.

Safety information
SV00069en.fm 8
2.2.3 The operator must not leave the operator's area during the operation
of the machine.
2.2.4 Before going on breaks, the operator must switch off the motor of the
machine. The machine must be set down so it cannot tip over.
2.2.5 The tank may only be filled when the motor is switched off and the fuel
must not make contact with hot parts or fall on the ground.
2.2.6 Open flames and smoking are strictly prohibited in the immediate
vicinity of this machine.
2.2.7 The tank lid must be tightly secured. When the motor is switched off,
the fuel tap - if there is one - must be closed. When transported over
long distances, the tank of gasoline or mixed gasoline driven engines
must be completely emptied.
Leaking fuel tanks can lead to explosions and therefore must be
replaced immediately.
2.2.8 Do not operate this machine in areas where explosions may occur.
2.2.9 While operating vibrating plates with a combustion motor in closed
rooms, tunnels, drifts or deep trenches make sure that there is a
sufficient intake of fresh air.
2.2.10 While operating vibrating plates, keep hands, feet and clothing away
from moving parts. Protective shoes must be worn.
2.2.11 While working on cracked, cavity, acclivity or escarpment edges and
on trench edges and steps, operate the vibrating plates so that they
cannot tip over or fall down.
2.2.12 A sufficient load-bearing capacity of the surface or foundation to be
compacted must be ensured.

Safety information
SV00069en.fm 9
2.2.13 Wear suitable protective clothing during work and maintenance work.
2.2.14 When operating in the reverse direction, the operator must operate the
vibrating plate from the side in order to protect themselves from being
crushed between the end of the guide handle / machine and an
obstacle. Great care is necessary when working on uneven terrain and
compacting large materials. A safe distance must be kept here.
2.2.15 Vibrating plates are to be guided in such a way that hand injuries
caused by solid objects are avoided.
2.2.16 Vibrating plates must be so installed and operated that their vertical
stability is ensured.
2.2.17 Machines with integrated driving mechanisms must not be set down or
stored on the chassis. The driving mechanism is only intended for the
transport of this machine.
2.3 Safety checks
2.3.1 Vibrating plates may only be operated with all safety devices installed.
2.3.2 Before starting operation, the operator has to check that all control and
safety devices are functioning properly.
2.3.3 If defects on the safety devices or other defects impairing the
operational safety of machine are observed, the supervisor must be
informed immediately.
2.3.4 If there are defects jeopardizing operational safety, the machine has to
be switched off immediately.
2.3.5 All auxiliary materials, fuel, lubricants and coolants are to be stored in
marked containers according to the manufacturer's regulations.

Safety information
SV00069en.fm 10
2.4 Maintenance
2.4.1 Only use original spare parts. Alterations to this machine, incl.
adjustments of the maximum engine speed set by the manufacturer
may only be carried out with the express permission of WACKER. In
case of non-observance, all liability shall be refused.
2.4.2 Maintenance work may only be carried out when the drives are
stationary. If a spark plug connector is present, this should be
removed. This procedure may only be waived if the work cannot be
carried out when the motor is switched off.
2.4.3 While using vibrating plates with an electronic start, the battery must
be disconnected in each case before working on the electrical parts of
the machine.
2.4.4 Hydraulic lines must be depressurized before working on them. Great
care is required when disassembling hydraulic lines, as the oil can
reach temperatures of up to 80 °C. Protect the eyes from splashes.
2.4.5 As soon as maintenance and repair jobs have been completed, all
safety devices must be properly reinstalled.
2.4.6 In order to prevent malfunctions, the machine should be cleaned using
a water hose after each use. High pressure cleaners or chemical
agents must not be used.

Safety information
SV00069en.fm 11
2.5 Transport
2.5.1 For the loading and transportation of compacting machines with
hoisting gear, suitable sling chains must be secured at the relevant
fixing point.
2.5.2 Loading ramps must be able to bear the load and be in a stable
position. Make sure that no one can be endangered if the machine
slips away or tips over, or if parts suddenly move upward or downward.
2.5.3 When vibrating plates are being transported in vehicles, precautions
have to be taken to ensure that they do not slip or fall over.
2.6 Maintenance checks
2.6.1 According to the conditions and frequency of use, vibrating plates must
be checked for safe operation at least once a year by skilled
technicians, such as those employed by WACKER service stations,
and repaired if necessary.
Please observe the appropriate rules and regulations valid in your
country.

Technical data
TD00732en.fm 12
3. Technical data
BPU 2540 BPU 3050
Item no. 0008954 0008955
Length x Width X Height
mm: 733 x 400 x 1170 733 x 500 x 1170
Operating weight
kg: 144 160
Forward and reverse movement m/min: 21
Area capacity
m2/h: 504 630
Powertrain From the drive motor over the centrifugal clutch and
V-belt directly to the exciter
Exciter
Vibrations
rpm-1 (Hz): Approx. 5,400 (90)
Centrifugal force
kN: 25 30
Multi-range oil Fuchs Titan Unic 10W40 MC (SAE 10W40)
Oil quantity l: 0.6
Drive motor
Air-cooled, single-cylinder, four-stroke gasoline
engine with automatic shutdown if there is insufficient
oil
Engine displacement cm3:169 265
Engine speed
min-1:2,800
Rated power (*)
kW:2.7 4.8
Fuel Regular gasoline, lead-free (91 octane)
Fuel consumption
l/h: 0.8 1.1
Tank capacity l: 3.6 6.1
Spark plug Model: NGK BPR2HS

Technical data
TD00732en.fm 13
(*) corresponds to the installed effective power in accordance with
Directive 2000/14/EC.
Spark plug air gap mm: 0.6 - 0.7
Engine oil Fuchs Titan Unic 10W40 MC (SAE 10W40)
Oil quantity 0.6 1.0
Hydraulic control
Hydraulic oil Fuchs Renolin MR 520
Oil quantity 0.4
Sound pressure level at
operator's station LPA:89 dB(A) 93 dB(A)
The weighted effective
acceleration value, determined
according to EN ISO 5349 m/s2:1.9 2.8
BPU 2540 BPU 3050

Description
T01090en.fm 14
4. Description
4.1 Field of application
4.1.1 BPU 2540
Through the low width and continuous switchability especially suitable
for all surface compacting work in limited space conditions (e.g. in
cable trenches) or the compacting of edge trims when repairing
blacktops, as well as all compacting work where the use of a large
machine is not possible.
4.1.2 BPU 3050
The range of application reaches from trench and surface compacting,
including semi-cohesive ground, to pressing interlocking paving
stones into place.
4.2 Max. permissible tilt

Description
T01090en.fm 15
4.3 Functional description
The vibration required for compaction is generated by the exciter (5)
that is permanently attached to the base plate (4). The exciter is
designed as a central vibrator with directional vibrations. This principle
allows you to change the direction of vibration by simply turning the
eccentric weights (13). This makes a gradual transition possible
between the vibration states: moving forward, moving in reverse and
in a stationary position. This procedure is hydraulically controlled with
the control handle (7) on the guide handle head (8).
When hydraulic oil is lost the machine operates in the reverse direction
(danger of crushing).
The drive motor (1) attached to the upper mass (3) powers the exciter
(5). The torque is transferred non-positively by the centrifugal clutch (9)
and the exciter V-belt (10).
When the motor speed is low, the centrifugal clutch (9) interrupts the
power flow to the exciter (5) which allows the drive motor (1) to idle
properly. The speed of the drive motor can be continuously varied
using the throttle regulation lever (6).
Forward movement Stationary Reverse movement

Description
T01090en.fm 16
The upper mass (3) and the base plate (4) are connected to each other
via 4 vibration-damping rubber metal shockmounts (11). This damping
prevents very high frequencies from being transferred to the upper
mass (3). This maintains proper functioning of the drive motor (1)
despite a high compaction capacity.

Transport to the worksite
T01091en.fm 17
5. Transport to the worksite
Requirements:
∗When transporting the vibrating plate compactor, use only suitable
hoisting gear with a minimum load-bearing capacity of 200 kg.
∗Always turn off the motor during transportation!
∗Vertically set guide handle head and lock into place.
∗Fasten suitable lifting tackle to the central suspension (15) provided.
∗If you transport the vibrating plate compactor on the cargo area of a
vehicle, strap it down securely at the protective frame (14).
When using the integrated driving mechanism, you must turn off the
engine. If the engine is running, engine lubrication cannot be ensured
in the transport position. This can cause serious engine damage.
There is also a danger that oil may leak out of the engine crankcase
breather.
Note: Also observe the regulations in the chapter Safety
information.

Recommendations for compacting
T01091en.fm 18
6. Recommendations for compacting
6.0.1 Condition of the ground
The maximum layer thickness depends on several factors such as the
condition of the ground/soil, the moisture, grading etc.
This is why it is not always possible to make precise
recommendations.
Recommendation: In certain cases, determine the maximum layer
thickness by conducting compacting tests and taking ground samples.
6.0.2 Compacting on a slope
The following points must be observed if you plan to compact inclined
surfaces (slopes, escarpments):
∗Start at the bottom of a slope (slopes that can also be easily managed
in an upward direction can be safely travelled in a downward direction).
∗The operator must never stand with their back facing the bottom.
∗Do not exceed maximum tilt of 20°.
Working on slopes that exceed this tilt will cause the engine lubrication
system to fail and thus inevitably damage parts of the engine.
Incorrect ! Correct !

Operation
T01092en.fm 19
7. Operation
7.1 Start preparation
Before you start the engine, check the following:
fFuel level – the tank should be at least half full.
fMotor oil level.
fAir filter.
fFuel lines for leaks.
fExternal screw connections for tightness.
7.2 Starting the engine
fOpen the fuel tap (a1).
fCold start: Close the choke (d2).
Warm start: Open the choke (d1).
Note: The engine is hand warm or hotter with warm start.
fSet the engine switch to "ON" (b2).
fPush the throttle lever to the left (c2).
fPull out the starter rope (e) until compression resistance can be felt and then
let it roll back in again.
fPull the starter rope with force, but not suddenly.
The engine starts.
fLet starter rope slowly roll back in.
fOpen the choke while the engine is warming up.
fOpen the throttle lever completely for operation (c1).
a1
a2 b2
b1 c1 c2 c3
d2
wc_gr000655
e
d1

Operation
T01092en.fm 20
7.3 Operating in the forward and reverse direction
fPress the control handle in the direction of travel.
Note: The forward and reverse speed can be continuously varied.
7.4 Turn off the engine
fPush the throttle lever to the right to idle operation (c3).
fSet the engine switch to "OFF" (b1).
fClose the fuel tap (a2).