Wacker Neuson BPU 3545A User manual

www.wackergroup.com
Operator´s Manual
VIBRATORY PLATE
BPU 3545A
0200301en - 12.2001
0008783 100

85716 Unterschleißheim Tel. [phone] Fax [phone]
86167 Augsburg Tel. [phone] Fax [phone]
93128 Regenstauf Tel. [phone] Fax [phone]
95326 Kulmbach Tel. [phone] Fax [phone]
85077 Manching Tel. [phone] Fax [phone]
90765 Fürth-Stadeln Tel. [phone] Fax [phone]
83064 Raubling Tel. [phone] Fax [phone]
94491 Hengersberg Tel. [phone] Fax [phone]
82538 Geretsried Tel. [phone] Fax [phone]
63477 Maintal Tel. [phone] Fax [phone]
67133 Maxdorf Tel. [phone] Fax [phone]
56218 Mülheim-Kärlich Tel. [phone] Fax [phone]
97080 Würzburg Tel. [phone] Fax [phone]
35435 Wettenberg Tel. [phone] Fax [phone]
66119 Saarbrücken Tel. [phone] Fax [phone]
55270 Mainz Tel. [phone] Fax [phone]
34233 Fuldatal Tel. [phone] Fax [phone]
40721 Hilden Tel. [phone] Fax [phone]
53842 Troisdorf Tel. [phone] Fax [phone]
45326 Essen Tel. [phone] Fax [phone]
57080 Siegen Tel. [phone] Fax [phone]
44319 Dortmund Tel. [phone] Fax [phone]
52351 Düren Tel. [phone] Fax [phone]
48291 Telgte Tel. [phone] Fax [phone]
33699 Bielefeld Tel. [phone] Fax [phone]
21109 Hamburg Tel. [phone] Fax [phone]
24145 Kiel Tel. [phone] Fax [phone]
28307 Bremen-Mahndorf Tel. [phone] Fax [phone]
26789 Leer-Bingum Tel. [phone] Fax [phone]
30165 Hannover Tel. [phone] Fax [phone]
38112 Braunschweig Tel. [phone] Fax [phone]
23617 Stockelsdorf Tel. [phone] Fax [phone]
71254 Ditzingen Tel. [phone] Fax [phone]
88353 Kißlegg-Zaisenhofen Tel. [phone] Fax [phone]
76327 Pfinztal Tel. [phone] Fax [phone]
89155 Erbach Tel. [phone] Fax [phone]
79112 Freiburg-Opfingen Tel. [phone] Fax [phone]
74172 Neckarsulm-Obereisesheim Tel. [phone] Fax [phone]
72336 Balingen-Frommern Tel. [phone] Fax [phone]
77694 Kehl-Goldscheuer Tel. [phone] Fax [phone]
13627 Berlin Tel. [phone] Fax [phone]
14974 Genshagen Tel. [phone] Fax [phone]
19061 Schwerin/Görries Tel. [phone] Fax [phone]
01097 Dresden Tel. [phone] Fax [phone]
04430 Bienitz/OT Dölzig Tel. [phone] Fax [phone]
99428 Nohra Tel. [phone] Fax [phone]
09247 Röhrsdorf Tel. [phone] Fax [phone]
39167 Irxleben Tel. [phone] Fax [phone]
17033 Neubrandenburg Tel. [phone] Fax [phone]
.

H00575GB 1
CONTENTS
Type Item no.
BPU 3545A 0008783 ...
This machine has been equipped with an EPA certified engine.
Additional information can be found in the engine manufacturers notes.

2

T00778GB 3
FOREWORD
Foreword
For your own safety and protection from bodily injuries, carefully read, understand and follow the safety instruc-
tions in this manual.
Please operate and maintain your Wacker machine in accordance with the instructions in this manual. Your
Wacker machine will reward your attention by giving trouble-free operation and a high degree of availability.
Defective machine parts are to be replaced as soon as possible.
All rights, especially the right for copying and distribution are reserved
Copyright by Wacker-Werke GmbH & Co. KG
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-Werke GmbH & Co. KG.
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 technical modifications- even without express due notice - which aim at im-
proving our machines or their safety standards.

0126424GBIVZ.GB.fm 4
TABLE OF CONTENTS
FOREWORD 3
SAFETY INSTRUCTIONS 6
General instructions 6
Operation 6
Safety checks 7
Maintenance 7
Transport 7
Maintenance checks 7
TECHNICAL DATA 8
DESCRIPTION 9
Field of application 9
Dimensions 9
Max. admissible inclination 9
Description of function 10
TRANSPORT TO WORK SITE / RECOMMENDATIONS ON COMPACTION 11
Transport to work site 11
Recommendations on compaction 11
OPERATION 12
Starting 12
Starting the engine 12
Handling 14
Forward and reverse motion 14
Stopping the engine 14
MAINTENANCE 15
Maintenance schedule 15
Engine oil 16
Air filter 16
Dual type air filter 16
Fuel tank 16
Spark plug 17
Carburettor 17
Service instructions 18
Hydraulic control 18
Mounting instruction 18
MOTOR 20
High altitude applications 20
FAULTS 21

0126424GBIVZ.GB.fm 5
TABLE OF CONTENTS
Forward speed too low 21
Reverse speed too low 21
No reverse motion 21
Loss of hydraulic oil 21
Engine does not start 21
ACCESSORIES 22
EC - CONFORMITY-CERTIFICATE 23

SV00019GB 6
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS FOR THE USE OF VIBRATORY
PLATES WITH COMBUSTION ENGINES
General instructions
1. Vibratory plates may only be operated by persons who
* are at least 18 years of age
* are physically and mentally fit for this job
* have been instructed in guiding vibratory plates and proved their ability for the job to the
employer
* may be expected to carry out the job they are charged with carefully.
The persons must be assigned the job of guiding vibratory plates by the employer.
2. Vibratory plates may only be used for compaction jobs. Both the manufacturer’s operating instructions
and these safety instructions have to be observed.
3. The persons charged with the operation of vibratory plates have to be made familiar with the necessary
safety measures relating to the machine. In case of extraordinary uses the employer shall give the
necessary additional instructions.
4. It is possible that this vibratory plate exceeds the admissible sound level of 89 dB (A). According to the
rules for the prevention of accidents regarding emission of noise, the employees have to wear ear pro-
tection if the sound level reaches 89 dB (A) or more.
Operation
1. The engine is started by way of a recoil starter. The automatic decompression system makes possible
a simple and backstroke-safe engine starting procedure.
2. The functioning of operating levers or elements is not to be influenced or rendered ineffective.
3. During operation the operator may not leave the control elements.
4. The operator has to stop the engine of the vibratory plate before going on breaks. The machine has to
be placed such that it cannot turn over.
5. Stop engine before filling fuel tank. When refilling fuel tank, do not allow fuel to come into contact with
the hot parts of the engine or spill onto the ground.
6. Do not smoke or handle open fire near this machine.
7. The tank lid must fit tightly. Shut off fuel cock, if available when stopping the engine. For long distance
transports of machine operated by fuel or fuel - mixtures, the fuel tank has to be drained completely.
☛ATTENTION! Leaky fuel tanks may cause explosions and must therefore be replaced immediately.
8. Do not operate the machine in areas where explosions may occur.
9. Make sure that sufficient fresh air is available when operating vibratory plates with combustion engines
in enclosed areas, tunnels, adits and deep trenches.
10. During operation keep your hands, feet and clothes away from the moving parts of the vibraton plate.
Wear safety shoes, and eye protection glasses in case of trench operation where falling sand stones
maybe ejected.
11. When working near the edges of breaks, pits, slopes, trenches and platforms, vibratory plates are to be
operated such that there is no danger of their turning over or dropping in.

SV00019GB 7
SAFETY INSTRUCTIONS
12. Make sure the soil or subsoil to be compacted has a high enough load carrying capacity.
13. Use appropriate protective clothing while working or while carrying out maintenance work.
14. When traveling backwards the operator has to guide the vibration plate laterally by its guide handle so
thathewillnotbesqueezedbetweenthehandleandapossibleobstacle.Specialcareisrequiredwhenwork
ing on uneven ground or when compacting coarse material. Make sure of a firm stand when operating
the machine under such conditons.
15. Vibratory plates are to be guided such that hand injuries caused by solid objects are avoided.
16. Vibratory plates have to be guided such that their stability is guaranteed.
17. Machines with integrated transport trolley may not be parked or stored on the trolley. This device has
only been designed to transport the machine.
Safety checks
1. Vibratory plates may only be operated with all safety devices installed.
2. Before starting operation, the operator has to check that all control and safety devices function properly.
3. Immediately notify your supervisor or superintendent if you have determined defects in the safety devic-
es or other defects which could endanger the safe operation of the machine or which could endanger
the environment.
4. In case of defects jeopardizing the operational safety of the vibration plate, the machine has to be
stopped immediately.
5. Process materials and operating fuels must be stowed away in receptacles or containers marked ac-
cording to the respective manufacturers specifications.
Maintenance
1. Only use original spare parts. Modifications to this machine, including the adjustment of the maximum
engine speed set by the manufacturer, are subject to the express approval of Wacker. In case of non-
observance all liabilities shall be refused.
2. All drive units have to be switched off before carrying out maintenance jobs. Deviations from this are only
allowed if the maintenance or jobs require a running engine.
3. When working on vibratory plates equipped with electric starter, disconnect battery before carrying out
maintenance or repair jobs on the electric parts of the machine.
4. Remove pressure from hydraulic lines before working on them. Caution: take care when removing hy-
draulic lines, for the oil may be very hot (up. over 80oC). Precautions are to be taken to prevent oil from
splashing into the operator’s eyes.
5. As soon as maintenance and repair jobs have been completed all safety devices have to be reinstalled
properly.
6. Do not hose down the machine with water after each use to avoid possible malfunctions. Do not use high
pressure washers nor chemical products.
Transport
1. During transport, loading and unloading of vibration plates by means of lifting devices, appropriate sling-
ing means or hooks have to be used on the lifting points provided for this purpose on the vibratory plate.
2. The load-carrying capacity of the loading ramps has to be sufficient and the ramps have to be secure
such that they cannot turn over. Make sure that no one be endangered by machines turning over by slip-
ping or by moving machine parts.
3. When being transported on vehicles, precautions have to be taken that vibration plates do not slip or turn
over.
Maintenance checks
According to the conditions and frequency of use, vibratory plates have to be checked for safe operation at
least once a year by skilled technicians, such as those found at Wacker-service depots and have to be repaired
if necessary.
Please also observe the corresponding rules and regulations valid in your country.

TD00575GB 8
TECHNICAL DATA
BPU 3545A
Item no. 0008783 ...
Operating weight
without extension plates (440) kg: 294
with extension plates narrow (500) kg: 308
with extension plates Serial (600) kg: 317
with extension plates wide (760) kg: 336
Power transmission From drive engine directly to exciter unit
via centrifugal clutch and gasoline engine
Exciter
Vibrations min-1 (Hz): 4150 (69)
Multigrade oil SAE 10W-40
Centrifugal force kN: 35
Drive motor Air-cooledsingle-cylinder 4-stroke gasoline
engine with recoil starter
Piston displacement cm3: 270
Rated power kW: 6,6
at rpm min-1: 3600
Operating rpm’s min-1: 2600
Oil SAE 10W-40
Fuel gasoline
Fuel consumption l/h: 1,6
Tank capacity l: 6,4
Electrical system Internal ignition cut-off switch
The required sound specifications, called-for by the EC-Machine Regulations per Appendix 1, Paragraph
1.7.4.f, are
- sound pressure level at the operator's location LpA = 88 dB(A)
The sound values were determined according to ISO 3744 for the sound power level (LwA) and, alternately,
ISO 6081 for the sound pressure level (LpA) at the operator's location.
The weighted effective acceleration value, determined according to ISO 8662, Part 1, is 6,4 m/s2.
The sound and vibration measurements were carried out and obtained with the machine working on crushed
gravel at nominal engine speed.

T00803GB 9
DESCRIPTION
Field of application
The application range of these machines reaches from the trench and surface compaction, even with semi-
cohesive soils, to the vibration of interlocking paving stones and sett pavements.
Dimensions
Max. admissible inclination

T00803GB 10
DESCRIPTION
Description of function
The vibration required for compaction is produced by the exciter (4) which is firmly joinded to the lower mass
(3). This exciter (4) is designed as a central vibrator with single-plane vibrations. Such a principle permits the
direction of vibration to be changed by turning the eccentric weights (12). In this way an infinitely variable tran-
sition between vibration in forward motion, on the spot and in reverse motion is possible. This process is hy-
draulically controlled with the operating control handle (6) on the centre pole head (7).
☛ATTENTION! If the machine looses its hydraulic oil it will start traveling backwards (danger of crushing).
The drive engine (1) is anchored to the upper mass (2) and drives the exciter (4). The torque is transmitted by
means of a friction connection through the centrifugal clutch (8) and the exciter V-belt (9).
The centrifugal clutch (8) interrupts flow of power to the exciter (4) at low engine speeds and thus permits per-
fect idling of the drive engine (1). The speed of the drive engine (1) can be infinitely varied by way of the throttle
control lever (5).
The upper (2) and lower (3) masses are connected to each other by 4 vibration-damping shock mounts (10).
This damping system prevents the very high frequencies from being transmitted to the upper mass (2). As a
result the funcionability of the drive engine (1) is retained in spite of the high compaction performance.
The drive engine (1), is started by way of a rewind starter.
Forwards On the spot Reverse

T00804GB 11
TRANSPORT TO WORK SITE / RECOMMENDATIONS ON COMPACTION
Transport to work site
Conditions:
- To transport the vibration plate, use only suitable lifting equipment with a minimum load-bearing capacity
of 400 kg.
- Always switch off engine before transporting the machine!
- Only attach suitable tackle at the central lifting point (13) provided.
- During transport on the loading area of a vehicle, tie down the vibraion plate using the lugs (14).
Note: Also oserve the regulations in the safety instructions.
Recommendations on compaction
Ground conditions
The max. compaction depth depends on several factors relating to the ground condition, such as moisture,
grain distribution etc.
It is therefore not possible to specify exact values.
Recommendation: In each case determine the max. compaction depth with compaction tests and soil sam-
ples.
Compaction on slopes
The following points are to be observed when compacting on sloped surfaces (slopes, embankments):
* Only approach gradients from the bottom (a gradient which can be easily overcome upwards, can also be
compacted downwards without any risk).
* The operator must never stand in the direction of descent (see chapter “Safety instructions“).
* The max. gradient of 20omust not be exceeded.
☛ATTENTION! If this gradient were exceeded, this would result in a failure of the engine lubrication sys-
tem and thus inevitably lead to a breakdown of important engine components.
Right ! Wrong !

T00805GB 12
OPERATION
Starting
Pre-starting check
1. Oil level check
Insert dipstick in oil filler neck, but without screwing in. If oil level is low, fill to the top of the oil filler neck with
high grade SAE 10 W 40 oil.
2. Dual-air cleander >Dual element type<
Check the air cleaner elements to be sure they are clean and in good condition. Clean or replace the ele-
ments if necessary.
3. Fuel
Use any regular grade automotive gasoline (unleaded gasoline is preferred) with a pump octane rating of
86 or higher.
Never use an oil/gasoline mixture or dirty gasoline: Avoid getting dirt, dust or water in the fuel tank.
Caution: Gasoline substitutes are not recommended, they may be harmful to the fuel system compo-
nents.
Starting the engine
a) Turn the fuel valve to the ON position.
b) Move the choke lever to the CLOSE position.
Note: If the engine is warm or the air temperature is high, move the control lever away from the CHOKE
postion as soon as the engine starts.
c) Move the throttle lever slightly to the left.
a) b) c)
☞With recoil starter:
d) Turn the engine switch to the ON position.
e) Pull the starter grip lightly until resistance is felt, then pull briskly.
Caution: Do not allow the starter grip to snap back against the engine.
Return it gently to prevent damage to the starter.

T00805GB 13

T00805GB 14
OPERATION
Handling
As the engine warms up, gradually move the choke lever to the OPEN position.
Position the throttle lever for the desired engine speed.
Oil alert system
The oil alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crank-
case. Before the oil level in the crankcase drops below a safe limit, the oil alert system will automatically shut
down the engine (the engine switch will remain in the ON position).
1 Engine switch
2 Note: If engine does not start
check oil level
Forward and reverse motion
The engine speed can be infinitely varied with the throttle control lever (5).
The direction of travel is determined with the operating control handle (6).
Depending on the position of the control handle (6), the vibration plate compacts in forward direction, on the
spot or in reverse direction.
Forwards On the spot Reverse
Stopping the engine
To stop the engine in an emergency, turn the engine switch to the OFF position. Under normal conditions, use
the following procedure:
a) Move the throttle lever fully to the right.
b) Turn the engine switch to the OFF position.
c) Turn the fuel valve to the OFF position.
a) b) c)

T00806GB 15
MAINTENANCE
Maintenance schedule
Check all external screw connections for tight fit approx. 8 hours after first operation.
Parts Maintenance jobs Maintenance interval
Air filter Check for external damage and tight fit. daily
Check filter cartridge, clean or replace if necessary.
Fuel tank Check tank lid for tight fit, replace if necessary.
Drive engine Check oil level, top up if necessary.
Exciter Check for tightness.
Drive engine First oil change. 20 hours
Centre pole Grease moveable locking device, and spindle or pole monthly
height adjustment.
Drive engine Clean spark plug, check spark plug gap 0,7 mm.
Centre pole head Check oil level, top up if necessary.
V-belt Check V-belt tension - retension, if need be.
Protective frame Check fastening screws of protective frame and
central suspension for tight fit.
Drive engine Oil change. 100 hours
Exhaust muffler Remove combustion residue from spark arrester.
Exciter Oil change.
Exciter Check oil level-fill up, if need be. 150 hours
Exciter Oil change. 250 hours
Drive engine Valve clearance - Check, set - 0,15 mm 300 hours
intake valve, 0,20 mm exhaust valve.

T00806GB 16
MAINTENANCE
Engine oil
Oil change
Drain the oil while the engine is still warm to assure rapid and complete draining.
1. Remove the oil filler cap and the drain plug to drain the oil.
2. Install the drain plug, and tighten it securely.
3. Refill with the recommended oil and check oil level.
4. Install the oil filter cap.
Engine oil capacity: 1,1 l (1,06 USqt., 1,78 lmp pt)
Air filter
Air filter service
A dirty air filter will restrict air flow to the carburettor. To prevent carburettor malfunction, service the air filter
regularly. Service more freqently when operating the engine in extremely dusty areas.
Warning: Never use gasoline or low flash point solvents for cleaning the air cleaner element. A fire or ex-
plosion could result.
Caution: Never run the engine without the air cleaner. Rapid engine wear will result.
Dual type air filter
1. Remove the wing nut and the air filter cover. Remove the elements and separate them. Carefully check both
elements for holes or tears and replace if damaged.
2. Foam element: Wash the element in a solution of household detergent and warm water, then rinse thor-
oughly, or wash in nonflammable or high flash point solvent. Allow the element to dry thoroughly. Soak
the element in clean engine oil, and squeeze out the excess oil. The engine will smoke during initial start-
up if too much oil is left in the foam.
3. Paper element: Tap the element lightly serveral times on a hard surface to remove excess dirt, or blow com-
pressed air through the filter from the inside out. Never try to brush the dirt off; brushing will force dirt into
the fibers.
Replace the paper element if it is excessively dirt.
Fuel tank
Fuel strainer cup cleaning
Turn the fuel valve to Off. Remove the sediment cup and O-ring, and wash them in nonflammable or high flash
point solvent. Dry them thoroughly, and reinstall securely. Turn the fuel valve on, and check for leaks.

T00806GB 17
MAINTENANCE
Spark plug
Spark plug service
Recommended spark plug: BP6ES-11, BPR6ES-11 (NGK), W20EP-U11, W20EPR-U11 (ND).
Caution: Never use a spark plug of incorrect heat range.
To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.
1. Remove the spark plug cap, and use a spark plug wrench to remove the plug.
Warning: If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler.
2. Visually inspect the spark plug. Discard it if the insulator is cracked or chipped. Clean the spark plug with a
wire brush if it is to be reused.
3. Measure the plug gap with a feeler gauge. The gap should be 0,7-0,8 mm (0.039-0.043 in). Correct as nec-
essary by bending the side electrode.
4. Check that the spark plug washer is in good condition, and thread the spark plug in by hand to prevent
cross-threading.
5. After the spark plug is seated, tighten with a spark plug wrench to compress the washer.
Note: If installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the wash-
er. If reinstalling a used spark plug, tighten 1/8-1/4 turn after the spark plug seats to compress
the washer.
Caution: The spark plug must be securely tightened. An improperly tightened spark plug can become
very hot and may damage the engine.
Carburettor
Carburettor adjustment
* Start the engine and allow it to warm up to normal operting temperature.
* With the engine idling, turn the pilot screw in or out to the setting that produces the highest idle rpm. The
correct setting will usually be approximately 2 1/4 turns from the fully closed position.
Caution: Do not tighten the pilot screw against its seat as this will damage the pilot screw or seat. After
the pilot screw is correctly adjusted, turn the throttle stop screw to obtain the standard idle
speed. Standard idle speed: 1 400 + 150 rpm.
1. Pilot screw 2. Throttle stop screw

T00806GB 18
MAINTENANCE
Service instructions
1. Adjusting the V-belt tension
Remove belt guard. Loosen nuts situated on the motor V-belt pulley and remove outer V-belt pulley half.
Remove necessary number of shims (the removal of one shim is usually suffecient). Install the removed
shims on the outside of the V-belt pulley. (If one shim is removed, install it on the outer half of the pulley, if
two, one on the outer and one on the inner V-belt pulley half, etc.). Thus V-belt alignment is maintained.
Install spring washer in a way such that the large collar comes to lie on the motor V-belt pulley. Loosen nuts
and under continual rotation of the engine V-belt pulley tighten nuts alternately. Allow engine to run for a
short while, if necessary retighten nuts.
2. Lubricating the exciter
On delivery of the machine, the exciter is filled with oil. Change oil after every 250 hours of operation, use
0,75 l SAE 10 W 40. For this purpose place the vibration plate on level ground. Remove drain plug situated
on the outside of the vibration plate. If necessary, remove the extension plate before draining the oil. This
will avoid unwanted spillages. Correct oil level = lower edge of threaded bore.
Hydraulic control
When checking the oil level in the motor and exciter, also check oil level in the centre pole head and top up if
necessary. Top up to mark when centre pole is placed in vertical position. If there is too much oil in the centre
pole head the reverse motion is hard to engage, if the quantity of oil is insufficient the advance speed is re-
duced. We use hydraulic oil Fuchs Renolin MR 520, suitable also for low temperatures, in the hydraulic sys-
tems as standard.
Mounting instruction
1. Exciter
When disassembling exciter components, always remove eccentric weights first. When assembling, the ec-
centric weights have to be installed last of all. When installing exciter shafts mind marking of toothed gears.
Assembly of exciter shaft is correct when all eccentric weights point down while piston is at half stroke. Dur-
ing assembly of eccentric weights on exciter shaft, keep shafts blocked to avoid pinching of fingers. Mind
lefthand thread when assembling V-belt pulley. Tightenallscrewswiththeprescribedtorque,mindqualities
of screws (see screw head).
2. Hydraulic control
Bleed hydraulic system after having topped up with oil, then check oil level again (total quantity required
approx. 0,4 liters).