Wacker Neuson BS 50 Repair Manual
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Wacker Neuson BS 50 Repair Manual

Vibratory rammer
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Repair Manual
Rammer
BS 50 / BS 60 / BS 70
BS 500 / BS 600 / BS 700
BS 65 / BS 650
DS 70 / DS 720
0114549en
010
0510
0
1
1
4
5
4
9
E
N

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Summary of Contents for Wacker Neuson BS 50

  • Page 1 Repair Manual Rammer BS 50 / BS 60 / BS 70 BS 500 / BS 600 / BS 700 BS 65 / BS 650 DS 70 / DS 720 0114549en 0510...
  • Page 2 This publication may be photocopied by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permission from Wacker Neuson Corporation. Any type of reproduction or distribution not authorized by Wacker Neuson Corporation represents an infringement of valid copyrights. Violators will be prosecuted. Trademarks All trademarks referenced in this manual are the property of their respective owners.
  • Page 3 Use the separate Parts Book supplied with the machine to order replacement parts. If you are missing any of these documents, please contact Wacker Neuson Corporation to order a replacement or visit www.wackerneuson.com. When ordering parts or requesting service information, be prepared to provide the machine model number, item number, revision number, and serial number.
  • Page 4 Foreword Expectations This manual provides information and procedures to safely operate and main- tain the above Wacker Neuson model(s). For your own safety and to reduce the information in risk of injury, carefully read, understand, and observe all instructions described this manual in this manual.

  • Page 5: Table Of Contents

    Recommended Special Tools ............17 Recommended Repair Tools .............. 18 Maintenance Schedules Periodic Maintenance Schedule (BS 50/60/70-2, BS 65) ....19 Periodic Maintenance Schedule (BS 500/600/700/650) ..... 20 Periodic Maintenance Schedule (BS 50/60/70-2i) ......21 Periodic Maintenance Schedule (BS 500/600/700-oi) ......22 Periodic Maintenance Schedule (DS 70) ...........
  • Page 6 Inspecting the Spring System ..............98 Protective Pipe ..................99 Ramming System Lubrication (BS 500/600/700/650, DS 720) ..100 Ramming System Lubrication (BS 50/60/70, BS 65, DS 70) ....102 Crankcase Crank Gear and Connecting Rod ............104 Crank Gear, Connecting Rod, and Adjuster Assembly (BS 650/65 only) 106 Clutch Drum ..................110...
  • Page 7 Engine Does Not Accelerate or Runs Poorly ........125 Engine Overheats ................126 Rammer Does Not Tamp ..............126 Rammer Jumps Erratically ............... 127 10 Technical Data 10.1 BS 50-2 .................... 128 10.2 BS 50-4 .................... 129 10.3 BS 500 ....................130 10.4 BS 500S ...................
  • Page 8 Table of Contents Rammmer Repair 10.16 DS 70 ....................144 10.17 DS 720 ....................146 wc_br0114549en_010TOC.fm...

  • Page 9: Safety Information

    Rammer Repair Safety Information Safety Information Signal Words Found in this Manual This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE signal words which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol.

  • Page 10: Machine Description And Intended Use

    Rammer Repair Machine Description and Intended Use This machine is a vibratory rammer. The Wacker Neuson Rammer consists of a gasoline or diesel engine, a clutch, a fuel tank, a spring- loaded ramming system, a ramming shoe, and a handle. The engine transmits power through the ramming system and ramming shoe, generating percussive impact force to compact soil.

  • Page 11: Operating Safety

    • Familiarize yourself with the location and proper use of all controls and safety devices. • Contact Wacker Neuson Corporation for additional training if necessary. When operating this machine: • Do not allow improperly trained people to operate the machine.
  • Page 12 Safety Information Rammer Repair 1.3.5 Never leave the machine running unattended. 1.3.6 Never tamper with or disable the function of operating controls. 1.3.7 Never use the choke to stop the engine. 1.3.8 Never operate the machine in areas where explosions may occur. 1.3.9 Read, understand, and follow procedures in the Operator’s Manual before attempting to operate the machine.

  • Page 13: Operator Safety While Using Internal Combustion Engines

    Rammer Repair Safety Information Operator Safety while using Internal Combustion Engines WARNING Internal combustion engines present special hazards during operation and fueling. Failure to follow the warnings and safety standards could result in severe injury or death. Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below.

  • Page 14: Service Safety

    • Only trained personnel shall troubleshoot or repair problems occurring with the machine. • Contact Wacker Neuson Corporation for additional training if necessary. When servicing or maintaining this machine: • Do not allow improperly trained people to service or maintain the machine.
  • Page 15 1.5.11 ALWAYS clean debris from engine cooling fins. 1.5.12 When replacement parts are required for this machine, use only Wacker Neuson replacement parts or those parts equivalent to the original in all types of specifications, such as physical dimensions, type, strength, and material.
  • Page 16 Safety Information Rammer Repair DO NOT remove bottom spring cover without first reading disassembly procedures or receiving instruction from someone familiar with its safe removal! The spring cover is under heavy spring pressure and could cause a serious injury if the proper disassembly procedures are not followed.

  • Page 17: Tools

    Rammer Repair Tools Tools Recommended Special Tools See Graphic: wc_gr001305rm P/N 0081423 Spring box tool P/N 0117972 Clutch puller P/N 0153566 Clutch puller (DS 70 only) P/N 0116816 Impact bushing puller 0081423 0153566 0117972 0116816 wc_gr001305rm wc_tx001544gb.fm...

  • Page 18: Recommended Repair Tools

    Tools Rammer Repair Recommended Repair Tools Hex key or socket: 4 mm, 5 mm, 6 mm, 8 mm Ratchet wrench Extension Sockets: 10 mm, 13 mm, 17 mm, 19 mm (3/4”), 24 mm, 27 mm (1-1/16”), 32 mm, 38 mm (1-1/2”) Open-end wrench: 13 mm Screwdriver Needle-nose pliers...

  • Page 19: Maintenance Schedules

    Rammer Repair Maintenance Schedules Maintenance Schedules Periodic Maintenance Schedule (BS 50/60/70-2, BS 65) The table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and equipment.

  • Page 20: Periodic Maintenance Schedule (Bs 500/600/700/650)

    Maintenance Schedules Rammer Repair Periodic Maintenance Schedule (BS 500/600/700/650) The table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and equipment. Every Every Every Daily After...

  • Page 21: Periodic Maintenance Schedule (Bs 50/60/70-2I)

    Rammer Repair Maintenance Schedules Periodic Maintenance Schedule (BS 50/60/70-2i) The table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and equipment. After Every...

  • Page 22: Periodic Maintenance Schedule (Bs 500/600/700-Oi)

    Maintenance Schedules Rammer Repair Periodic Maintenance Schedule (BS 500/600/700-oi) The table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and equipment. After Every Every Every Daily...

  • Page 23: Periodic Maintenance Schedule (Ds 70)

    Rammer Repair Maintenance Schedules Periodic Maintenance Schedule (DS 70) After Every Every Daily Every 3 Every 5 first week month before months or months or starting 300 hours 500 hours hours 25 hours 100 hours Check fuel level. Check engine oil level. Check air filter indicator.

  • Page 24: Periodic Maintenance Schedule (Ds 720)

    Maintenance Schedules Rammer Repair Periodic Maintenance Schedule (DS 720) The table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and equipment. After Every Every Daily Every 3...

  • Page 25: Engine And Upper Machine Components

    Rammer Repair Engine and Upper Machine Components Engine and Upper Machine Components Removing the Silencing Cover See Graphic: wc_gr007457 Recommended Tools Ratchet Wrench Torque Wrench Hex Key or Hex Socket: 5 mm Loctite 243 (Blue) Remove the four socket head cap screws (b) that hold the silencing cover (a) to the guide handle (c).

  • Page 26: Replacing The Throttle Control (2010 And Later 2-Stroke Models)

    Engine and Upper Machine Components Rammer Repair Replacing the Throttle Control (2010 and later 2-stroke models) Requirements • Machine shut down and cool • Torque wrench Removal Perform the procedure below to remove the throttle control. 4.2.1 Remove the silencing cover. See topic Removing the Silencing Cover 4.2.2 Remove the carburetor guard...
  • Page 27 Rammer Repair Engine and Upper Machine Components Installation Perform the procedure below to install the throttle control. 4.2.1 Connect the throttle control to the machine with bolt . Adjust the nut on the throttle control lever so that the hardware lever moves freely but still holds its position while the rammer is operating.

  • Page 28: Replacing The Throttle Control (2010 4-Stroke Models)

    Engine and Upper Machine Components Rammer Repair Replacing the Throttle Control (2010 4-stroke models) Requirements • Machine shut down and cool • Torque wrench Removal Perform the procedure below to remove the throttle control. 4.3.1 Remove the silencing cover. See topic Removing the Silencing Cover 4.3.2 Disconnect the throttle cable at the swivel...
  • Page 29 Rammer Repair Engine and Upper Machine Components Continued from the previous page. 4.3.5 Remove the bolt and hardware 4.3.6 Remove the throttle lever from the machine. Result The removal procedure is now complete. Installation Perform the procedure below to install the throttle control. 4.3.1 Connect the throttle lever to the machine with bolt...
  • Page 30 Engine and Upper Machine Components Rammer Repair Continued from the previous page. 4.3.3 Support the throttle cable with new wire ties 4.3.4 Install the clamp 4.3.5 Connect the throttle cable at the swivel and the clamp 4.3.6 Reinstall the silencing cover. Result The replacement procedure is now complete.

  • Page 31: Throttle Control (Pre-2010 Models)

    Rammer Repair Engine and Upper Machine Components Throttle Control (pre-2010 models) See Graphic: wc_gr003876 4.4.1 Adjust the nut (a) on the throttle control lever (b) so that the lever moves freely but still holds its position while the rammer is operating. The recommended torque value is 2.9 Nm (2.1 ft.lbs.).

  • Page 32: Replacing The Stop Switch (2010 And Later 2-Stroke Models)

    Engine and Upper Machine Components Rammer Repair Replacing the Stop Switch (2010 and later 2-stroke models) Requirements • Machine shut down and cool • Torque wrench Removal Perform the procedure below to remove the stop switch. 4.5.1 Remove the silencing cover. See topic Replacing the Silencing Cover 4.5.2 Remove the throttle control.
  • Page 33 Rammer Repair Engine and Upper Machine Components Continued from the previous page. 4.5.6 Remove the screws that hold the throttle control bracket to the machine and pull the throttle control bracket (with stop switch) from the machine. 4.5.7 Pull the stop switch and wiring from the throttle control bracket.
  • Page 34 Engine and Upper Machine Components Rammer Repair Continued from the previous page. 4.5.2 Install the throttle control bracket and the stop switch with screws .Torque the screws to 10 Nm (7 ft.lbs.). 4.5.3 Reconnect the stop switch wiring to the engine. 4.5.4 Reinstall the clamp 4.5.5...

  • Page 35: Replacing The Stop Switch (2010 And Later 4-Stroke Models)

    Rammer Repair Engine and Upper Machine Components Replacing the Stop Switch (2010 and later 4-stroke models) Requirements • Machine shut down and cool • Torque wrench Removal Perform the procedure below to remove the stop switch. 4.6.1 Remove the silencing cover. See topic Replacing the Silencing Cover 4.6.2 Remove the throttle control.
  • Page 36 Engine and Upper Machine Components Rammer Repair Continued from the previous page. Installation Perform the procedure below to install the stop switch. 4.6.1 Slide the stop switch into the throttle control bracket and thread the wiring through the throttle control bracket. 4.6.2 Install the stop switch to the machine with screw .

  • Page 37: Replacing The Guide Handle (2010 And Later 2-Stroke Models)

    Rammer Repair Engine and Upper Machine Components Replacing the Guide Handle (2010 and later 2-stroke models) Requirements • Machine shut down and cool • Loctite® 243 Removal Perform the procedure below to remove the guide handle. 4.7.1 Remove the silencing cover. See topic Replacing the Silencing Cover 4.7.2 Remove the throttle control.
  • Page 38 Engine and Upper Machine Components Rammer Repair Continued from the previous page. 4.7.9 Remove the screws that hold the guide handle to the shock mounts and remove the guide handle from the machine. Result The removal procedure is now complete. Installation Perform the procedure below to install the guide handle.
  • Page 39 Rammer Repair Engine and Upper Machine Components Continued from the previous page. 4.7.4 Thread the upper fuel line through the hole in the guide handle and connect it to the fuel tank. 4.7.5 Install the fuel tank with screws . Torque the screws to 9 Nm (6 ft.lbs.).

  • Page 40: Replacing The Guide Handle (2010 And Later 4-Stroke Models)

    Engine and Upper Machine Components Rammer Repair Replacing the Guide Handle (2010 and later 4-stroke models) Requirements • Machine shut down and cool • Torque wrench • Loctite® 243 Removal Perform the procedure below to remove the guide handle. 4.8.1 Remove the silencing cover.
  • Page 41 Rammer Repair Engine and Upper Machine Components Continued from the previous page. 4.8.8 Remove the screws that hold the fuel tank to the guide handle. 4.8.9 Disconnect the upper fuel line from the tank. Thread the fuel line through the hole in the guide handle , then reconnect it to the fuel tank.
  • Page 42 Engine and Upper Machine Components Rammer Repair Installation Perform the procedure below to install the guide handle. 4.8.1 Install the guide handle to the shock mounts. Use Loctite® 243 on the screws and torque the screws to 24 Nm (18 ft.lbs.). 4.8.2 Feed the hoses through the clips 4.8.3...
  • Page 43 Rammer Repair Engine and Upper Machine Components Continued from the previous page. 4.8.5 Install the throttle stop and the throttle control bracket with screw Torque the screw to 9 Nm (6 ft.lbs.). 4.8.6 Install the fuel valve with screws . Torque the screws to 3 Nm (2 ft.lbs.).

  • Page 44: Replacing The Guide Handle (Pre-2010 Models)

    Engine and Upper Machine Components Rammer Repair Replacing the Guide Handle (pre-2010 models) See Graphic: wc_gr003704 Recommended Tools Ratchet Wrench Socket: 10 mm Screwdriver Pliers Loctite 243 (Blue) 4.9.1 Close the fuel valve. 4.9.2 Disconnect the fuel line. 4.9.3 Loosen the throttle cable holder. 4.9.4 Disconnect the throttle cable from the throttle cam lever.

  • Page 45: 4.10 Shock Mounts

    Rammer Repair Engine and Upper Machine Components 4.10 Shock Mounts See Graphic: wc_gr003705 Recommended Tools Ratchet Wrench Torque Wrench Loctite 243 (blue) 4.10.1 Remove the silencing cover, the air cleaner, and the guide handle. 4.10.2 Inspect the shock mounts (a) and make sure that they are securely mounted to the crankcase.

  • Page 46: Tillotson Carburetor (Bs 500/600/700/650 Only)

    Engine and Upper Machine Components Rammer Repair 4.11 Tillotson Carburetor (BS 500/600/700/650 only) See Graphic: wc_gr001308rm Recommended Tools Ratchet Wrench Torque Wrench Hex Key or Hex Socket: 4 mm, 6 mm Screwdriver Loctite 243 (blue) The Tillotson carburetor uses a fixed low and high speed fuel jet. The only adjustment is to set the engine idle speed.
  • Page 47 4.11.4 Close the fuel valve and disconnect the fuel line from the carburetor. See the section Fuel Lines for removal of fuel and vent lines for models BS 50/60/70/65. 4.11.5 Loosen the air duct clamps and remove the air duct.

  • Page 48: Fuel Lines (Bs 50/60/70-2, Bs 65)

    Engine and Upper Machine Components Rammer Repair 4.12 Fuel Lines (BS 50/60/70-2, BS 65) See Graphic: wc_gr001493 ALWAYS follow the instructions when disconnecting the fuel lines. Failure to do so may result in fuel leaking from the fuel system. CAUTION To disconnect the fuel lines: 4.12.1 Shut off the engine by moving the throttle through the detent to the off...

  • Page 49: Fuel Tank (Bs Models)

    Rammer Repair Engine and Upper Machine Components 4.13 Fuel Tank (BS Models) See Graphic: wc_gr001312rm 4.13.1 Remove the silencing cover. 4.13.2 Close the fuel valve (a). 4.13.3 Disconnect the fuel line (b) from the fuel tank. Disconnect the vent line (c) where used.

  • Page 50: Fuel Tank (Ds Models)

    Engine and Upper Machine Components Rammer Repair 4.14 Fuel Tank (DS Models) See Graphic: wc_gr001313rm 4.14.1 Remove the silencing cover. 4.14.2 Disconnect the fuel supply line (f) and fuel return line (c) from the fuel tank and drain the fuel into a suitable container. Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid which drains off.
  • Page 51 Rammer Repair Engine and Upper Machine Components wc_gr001313rm wc_tx001546gb.fm...

  • Page 52: 4.15 Fuel Tank Cap

    Engine and Upper Machine Components Rammer Repair 4.15 Fuel Tank Cap See Graphic: wc_gr004562 To disassemble and clean the fuel tank cap: 4.15.1 Grasp the fuel tank cap (a) in one hand and the baffle (b) in the other. 4.15.2 Pull and twist the baffle left and right to separate it from the fuel tank cap.
  • Page 53 Rammer Repair Engine and Upper Machine Components wc_gr004562 wc_tx001546gb.fm...

  • Page 54: Muffler (Pre-2009 Bs Models)

    Engine and Upper Machine Components Rammer Repair 4.16 Muffler (pre-2009 BS Models) See Graphic: wc_gr001314rm Recommended Tools Ratchet wrench Torque wrench Hex key: 5 mm Hex key or hex socket: 6 mm Socket: 19 mm (3/4”) Loctite 243 (blue) Carbon deposits can form in the muffler (d) and in the cylinder exhaust port.

  • Page 55: 4.17 Engine Cooling Fins

    Rammer Repair Engine and Upper Machine Components 35 Nm 18 Nm (25 ft.lbs.) (13 ft.lbs.) 18 Nm (13 ft.lbs.) 23 Nm 23 Nm (17 ft.lbs.) (17 ft.lbs.) wc_gr001314rm 4.17 Engine Cooling Fins Recommended Tools Screwdriver Compressed air The Wacker WM 80 engine is air cooled, so dirt accumulation between the cylinder ribs may cause the engine to overheat.

  • Page 56: Muffler (Ds Models)

    Engine and Upper Machine Components Rammer Repair 4.18 Muffler (DS Models) See Graphic: wc_gr001315rm Recommended Tools Ratchet wrench Torque wrench Hex key: 5 mm Hex key or hex socket: 6 mm Socket: 19 mm (3/4”) Loctite 243 (blue) Carbon deposits can form in the muffler (a) and in the cylinder exhaust port.
  • Page 57 Rammer Repair Engine and Upper Machine Components > w c _ g r 0 0 1 3 1 5 r m wc_tx001546gb.fm...

  • Page 58: Replacing The Carburetor (Wm 80 Engines)

    Engine and Upper Machine Components Rammer Repair 4.19 Replacing the Carburetor (WM 80 engines) Removal Removing Walbro Carburetor (auto-release choke models) 4.19.1 Stop the machine and allow it to cool. 4.19.2 Remove the carburetor guard 4.19.3 Loosen the hose clamp and remove the air duct 4.19.4 Disconnect the ignition wire from the spark plug.
  • Page 59 Rammer Repair Engine and Upper Machine Components Continued from the previous page. 4.19.7 Have a container ready, then remove the oil hose and drain it. 4.19.8 Make sure the throttle is in the OFF position. This position also closes the fuel valve. Then, remove the fuel hose and drain it.
  • Page 60 Engine and Upper Machine Components Rammer Repair Installation Perform the procedure below to install the carburetor 4.19.1 Assemble the adapter , lower gasket , flange and upper (k), gasket to the carburetor Note: The gaskets are not interchangeable. 4.19.2 Connect the oil hose , and the fuel hose , to the carburetor.
  • Page 61 Rammer Repair Engine and Upper Machine Components 4.19.4 Slide the throttle cable through the adapter and reconnect it to the clamp wc_gr007456 4.19.5 Install the air duct with the hose clamp. 4.19.6 Using Loctite® 243 on the screws, install the carburetor guard Result The installation procedure is now complete.

  • Page 62: Replacing The Wm 80 Engine (2010 And Later Models)

    Engine and Upper Machine Components Rammer Repair 4.20 Replacing the WM 80 Engine (2010 and later models) Requirements • Engine cool • Carburetor removed Removal Perform the procedure below to remove the engine. 4.20.1 Remove the carburetor. 4.20.2 Remove the muffler 4.20.3 Remove the bracket 4.20.4 Disconnect the wiring to the switches 4.20.5 Remove the screws that hold the engine and remove the engine...
  • Page 63 Rammer Repair Engine and Upper Machine Components Installation Perform the procedure below to install the engine. 4.20.1 Install the engine to the machine with three screws. Torque the screws to 28 Nm (20 ft.lbs.). 4.20.2 Reconnect the wiring to the switches. 4.20.3 Install the bracket 4.20.4 Install the muffler .

  • Page 64: Replacing The Wm 80 Engine (Pre-2010 Models)

    Engine and Upper Machine Components Rammer Repair 4.21 Replacing the WM 80 Engine (pre-2010 models) See Graphic:wc_gr002935 Removal: 4.21.1 Stop the machine and allow it to cool. 4.21.2 Remove the carburetor. See section Removing Carburetor. 4.21.3 Remove the muffler guard (a) (if equipped) and the muffler (b). 4.21.4 Disconnect the connector (c) from the stop switch.
  • Page 65 Rammer Repair Engine and Upper Machine Components wc_gr002935 wc_tx001546gb.fm...

  • Page 66: Replacing The Carburetor (Wm 100 Engines)

    Engine and Upper Machine Components Rammer Repair 4.22 Replacing the Carburetor (WM 100 Engines) Requirements • Machine shut down and cool • Loctite® 243 or equivalent • Torque wrench Removal Perform the procedure below to remove the engine. 4.22.1 Disconnect the spark plug. 4.22.2 Remove the side guard 4.22.3 Disconnect the throttle cable 4.22.4 Disconnect the air hose...
  • Page 67 Rammer Repair Engine and Upper Machine Components Continued from the previous page. 4.22.6 Disconnect the hose 4.22.7 Remove screw and disconnect the linkage. 4.22.8 Remove the carburetor Result The removal procedure is now complete. wc_tx001546gb.fm...
  • Page 68 Engine and Upper Machine Components Rammer Repair Installation Perform the procedure below to install the carburetor. 4.22.1 Install the carburetor , gaskets , and adapter 4.22.2 Reconnect the linkage with screw 4.22.3 Reconnect the hose 4.22.4 Reconnect the fuel hose and the compensation hose 4.22.5 Reconnect the air hose This procedure continues on the next page.
  • Page 69 Rammer Repair Engine and Upper Machine Components Continued from the previous page. 4.22.6 Reconnect the throttle cable 4.22.7 Install the side guard Result The replacement procedure is now complete. wc_tx001546gb.fm...

  • Page 70: Replacing The Wm 100 Engine

    Engine and Upper Machine Components Rammer Repair 4.23 Replacing the WM 100 Engine Requirements • Machine shut down and cool • Loctite® 243 or equivalent • Torque wrench • Two wire ties Removal Perform the procedure below to remove the engine. 4.23.1 Remove the carburetor.
  • Page 71 Rammer Repair Engine and Upper Machine Components Continued from the previous page. 4.23.6 Remove the heat shield 4.23.7 Disconnect the throttle cable at the swivel and the clamp 4.23.8 Remove the nuts that hold the engine and remove the engine from the machine.
  • Page 72 Engine and Upper Machine Components Rammer Repair Installation Perform the procedure below to install the engine. 4.23.1 Apply Loctite® 243 to the four engine studs 4.23.2 Slide the engine (with clutch installed) into the machine. 4.23.3 Loosely install the support bracket and heat shield with nut Install the other three nuts and torque them to 25 Nm (18 ft.lbs.).
  • Page 73 Rammer Repair Engine and Upper Machine Components Continued from the previous page. 4.23.5 Fit the lower guard to the support bracket. Then, using Loctite® 243 on the screws, install the lower guard to the engine. Torque the screws to 25 Nm (18 ft.lbs.). Torque the support bracket screw 25 Nm (18 ft.lbs.).

  • Page 74: Removing The Wm 90 Engine

    Engine and Upper Machine Components Rammer Repair 4.24 Removing the WM 90 Engine See Graphic: wc_gr001954, wc_gr003661, wc_gr001956, and wc_gr001957 4.24.1 Disconnect the spark plug cap (a) from the spark plug. 4.24.2 Disconnect the fuel line (b) from the carburetor and plug the line. 4.24.3 Disconnect the stop switch wire (c).
  • Page 75 Rammer Repair Engine and Upper Machine Components wc_gr003661 wc_gr001954 wc_tx001546gb.fm...

  • Page 76: Engine (Ds Models)

    Engine and Upper Machine Components Rammer Repair 4.25 Engine (DS Models) See Graphic: wc_gr001317rm Recommended Tools Ratchet wrench Torque wrench Socket: 19 mm (3/4”) Hex key: 5 mm Hex key or hex socket: 4 mm, 6 mm Screwdriver 4.25.1 Close the fuel valve. 4.25.2 Disconnect the fuel lines.
  • Page 77 Rammer Repair Engine and Upper Machine Components w c _ g r 0 0 1 3 1 7 r m wc_tx001546gb.fm...

  • Page 78: Clutch (2- And 4-Stroke Models)

    Engine and Upper Machine Components Rammer Repair 4.26 Clutch (2- and 4-stroke models) See Graphic: wc_gr007517 Recommended Tools Impact wrench Torque wrench Socket: 17 mm Needle-nose pliers Clutch puller P/N 0117972 Removal 4.26.1 Remove the engine from the rammer. 4.26.2 Check the condition of the clutch shoes (a) and replace them if necessary.
  • Page 79 Rammer Repair Engine and Upper Machine Components BS Models wc_tx001546gb.fm...

  • Page 80: Clutch (Ds 720 Only)

    Engine and Upper Machine Components Rammer Repair 4.27 Clutch (DS 720 only) See Graphic: wc_gr001319rm Recommended Tools Impact wrench Torque wrench Needle-nose pliers Clutch puller P/N 0153566 Removal 4.27.1 Remove the engine from the rammer. 4.27.2 Check the condition of the clutch shoes (a) and replace them if necessary.
  • Page 81 Rammer Repair Engine and Upper Machine Components DS 720 Models wc_gr001319rm wc_tx001546gb.fm...

  • Page 82: Clutch (Ds 70 Only)

    Engine and Upper Machine Components Rammer Repair 4.28 Clutch (DS 70 only) See Graphic: wc_gr002372rm Recommended Tools Impact wrench Torque wrench Needle-nose pliers Clutch puller P/N 0153566 Removal 4.28.1 Remove the engine from the rammer. 4.28.2 Check the condition of the clutch shoes (a) and replace them if necessary.
  • Page 83 Rammer Repair Engine and Upper Machine Components DS 70 Models wc_gr002372rm wc_tx001546gb.fm...

  • Page 84: Ramming System

    Ramming System Rammer Repair Ramming System Bellows Se Graphic: wc_gr001321rm Recommended Tools Ratchet wrench Torque wrench Hex key or hex socket: 8 mm Socket: 13 mm Punch Rubber mallet Screwdriver Loctite 243 The bellows provides a flexible joint between the ramming system and the upper machinery.
  • Page 85 Rammer Repair Ramming System wc_gr001321rm Installation 5.1.9 Oil the inner edges of the bellows. 5.1.10 Place the lower clamp (f) on the protective pipe (j). 5.1.11 Press the bellows (e) onto the protective pipe (j) with a strong downward push. 5.1.12 Partially tighten the clamp onto the bellows.
  • Page 86 Ramming System Rammer Repair 5.1.20 Fasten the guide cylinder to the crankcase. Apply Loctite 243 and torque the screws to 43 Nm (32 ft.lbs.). 5.1.21 Lay the rammer flat on the ground and align the protective pipe with the upper machinery. 5.1.22 Position the clamps so that the clamp screws (k) are in line with the sightglass (m).

  • Page 87: Replacing The Ramming Shoe

    Rammer Repair Ramming System Replacing the Ramming Shoe Requirements • Torque wrench • Lifting device capable of lifting the machine Removal Perform the procedure below to remove the shoe. 5.2.1 Support the machine with a lifting device capable of lifting the weight of the machine.
  • Page 88 Ramming System Rammer Repair Installation Follow the guidelines below when installing the shoes. 5.2.7 The plow bolts as well as hex bolts have different lengths. Use the longer of the bolts where needed. wc_gr007519 5.2.8 When reusing bolts, clean the threads thoroughly before use. 5.2.9 Be sure notches of plow bolts seat in grooves of shoe.
  • Page 89 Rammer Repair Ramming System Notes wc_tx001547gb.fm...

  • Page 90: Spring System Cover Removal And Installation

    Ramming System Rammer Repair Spring System Cover Removal and Installation See Graphic: wc_gr001324rm Recommended Tools Ratchet wrench Torque wrench Hex key or socket: 13 mm Hydraulic press or Two threaded rods and nuts: M8 x 120 mm or Spring box tool P/N 0081423 Loctite 243 The spring system cover is under heavy pressure.
  • Page 91 Rammer Repair Ramming System 5.3.14 Attach the ramming system to the upper machinery. Hydraulic Press Method wc_gr001324rm wc_tx001547gb.fm...
  • Page 92 Ramming System Rammer Repair See Graphic: wc_gr001325rm Threaded Rod Removal Method 5.3.15 Remove the ramming shoe per section Ramming Shoe. Separate the ramming system from the upper machinery per section Bellows. 5.3.16 Remove the two socket head cap screws that are opposite of each other on the spring system cover.
  • Page 93 Rammer Repair Ramming System Threaded Rod Method wc_gr001325rm wc_tx001547gb.fm...
  • Page 94 Ramming System Rammer Repair See Graphic: wc_gr001326 Spring Box Tool Removal Method 5.3.1 Remove the ramming shoe per section Ramming Shoe. Separate the ramming system from the upper machinery per section Bellows. 5.3.2 Align three holes in the spring box tool (a) with three socket head cap screws in the spring system cover.
  • Page 95 Rammer Repair Ramming System Spring Box Tool Method Screw Position Machine Schraube position La posicion del tornillo La position de vis BS45Y, BS52Y, ES45Y, ES52Y BS60Y, GVR151Y BS62Y, BS65y, BS600, BS650, BS700, BS60-2i, BS70-2i, BS65V, BS60-4, DS72Y, DS720, DS70 BS92Y, BS105Y BS500, BS50-2I, BS50-4 wc_gr001326 wc_tx001547gb.fm...

  • Page 96: Spring System

    Ramming System Rammer Repair Spring System See Graphic: wc_gr001327rm, wc_gr001328rm Recommended Tools Impact wrench Socket: 32 mm or 24mm (BS 500 only) deep well Drift pin Torque wrench Rubber mallet Impact bushing puller P/N 0116816 Loctite 243 (blue) Disassembly 5.4.1 Remove the ramming shoe and separate the ramming system from the upper machinery.
  • Page 97 Rammer Repair Ramming System Assembly 5.4.10 Slide the ram (e) into the spring cylinder (h). 5.4.11 Reinstall the bushing (f) and the spring set (g). 5.4.12 Reinstall the piston guide (j). 5.4.13 Replace the locknut (k) and torque it to: BS 500 - 210 Nm (155 ft.lbs.) BS 600/700 - 250 Nm (184 ft.lbs.).

  • Page 98: Inspecting The Spring System

    Replace the cylinder if it is badly worn. Minimum spring free Maximum spring height (a) height difference (b) BS 500, BS 50 194 mm (7 21/32 in.) 5 mm (3/16 in.) BS 600, BS 60 BS 700, BS 70 217 mm (8 9/16 in.) 5 mm (3/16 in.)

  • Page 99: Protective Pipe

    Rammer Repair Ramming System Protective Pipe See Graphic: wc_gr001330rm Recommended Tools Ratchet Wrench Torque Wrench Extension Hex Socket: 6 mm Loctite 243 (Blue) If the protective pipe becomes loose or damaged, it must be replaced on the spring cylinder. 5.6.1 Remove the bellows following the procedures in section Bellows.

  • Page 100: Ramming System Lubrication (Bs 500/600/700/650, Ds 720)

    Ramming System Rammer Repair Ramming System Lubrication (BS 500/600/700/650, DS 720) See Graphic: wc_gr001331rm Recommended Tools Hex Key: 8 mm Ratchet Wrench Torque Wrench Extension Sockets: 19 mm (3/4”), 27 mm (1 1/16”) Teflon Tape Oil for lubrication is carried throughout the ramming system by the action of the rammer.
  • Page 101 Rammer Repair Ramming System 5.7.9 Reinstall the seal-ring and the fill plug. Torque the fill plug to 47 Nm (35 ft.lbs.). Note: An alternate method of changing the oil is to drain and fill the oil from the sightglass. wc_gr001331rm wc_tx001547gb.fm...

  • Page 102: Ramming System Lubrication (Bs 50/60/70, Bs 65, Ds 70)

    Ramming System Rammer Repair Ramming System Lubrication (BS 50/60/70, BS 65, DS 70) Background Lubricating oil is distributed throughout the ramming system by the action of the rammer. Holes drilled in the piston carry oil from the bottom of the rammer to the crankcase as the rammer operates. Oil in the ramming system must be maintained at the correct level to ensure the ramming system operates efficiently.
  • Page 103 Note: Dispose of used oil in accordance with local environmental regula- tions. 5.8.7 Remove the drain plug . (On BS 50 machines, remove the sightglass 5.8.8 Tilt the rammer backward until it is resting on the handle and drain the oil into a suitable container.

  • Page 104: Crankcase

    Crankcase Rammer Repair Crankcase Crank Gear and Connecting Rod See Graphic: wc_gr007520 Recommended Tools Hex key: 8 mm 2-Jaw bearing puller Large diameter retaining-ring pliers Hydraulic press Screwdriver Split puller Slide hammer Torque wrench Loctite® 243 (blue) Removal 6.1.1 Remove the four socket head cap screws that secure the ramming system to the crankcase.
  • Page 105 Rammer Repair Crankcase 6.1.14 The needle bearing (c) remains intact in the crankcase cover. Inspect the needle bearing for wear and, if damaged, remove it by using a slide hammer or similar pulling device. wc_gr007520 Assembly 6.1.15 If the needle bearing was removed, press a new bearing into the cover until the outer race is flush with the flange surface.

  • Page 106: Crank Gear, Connecting Rod, And Adjuster Assembly (Bs 650/65 Only)

    Crankcase Rammer Repair Crank Gear, Connecting Rod, and Adjuster Assembly (BS 650/65 only) See Graphic: wc_gr001334rm Recommended tools Hex key: 8 mm 2-Jaw bearing puller Large diameter retaining-ring pliers Hydraulic press Screwdrivers or pry bars Split puller Slide hammer Punch Torque wrench Loctite 243 (blue) Removal...
  • Page 107 Rammer Repair Crankcase 6.2.13 The crankgear needle bearing (19), oil seal (11), and ball bearing (10) remain intact in the bearing mount. • Examine the needle bearings for wear. • If damaged, replace the needle bearings by removing the large retain- ing ring (8) holding the ball bearing to the bearing mount and press out the needle bearings and seal.
  • Page 108 Crankcase Rammer Repair Assembly 6.2.16 If the needle bearing (17) was removed, apply Loctite 609 to a new needle bearing and press it into the bearing mount until the outer race is flush with the flange surface. 6.2.17 Press the ball bearing (27) into the connecting rod. 6.2.18 Press the connecting rod assembly (24) onto the eccentric drive shaft (23) and secure it in place with the small snap ring (25).
  • Page 109 Rammer Repair Crankcase Notes wc_tx001548gb.fm...

  • Page 110: Clutch Drum

    Crankcase Rammer Repair Clutch Drum See Graphic: wc_gr001335rm Recommended Tools Hex Key: 8 mm Large diameter retaining-ring pliers Hydraulic press Screwdriver Slide hammer Torque wrench Loctite 243 (blue) Shell Alvania RL2 Removal 6.3.1 Remove the four socket head cap screws that secure the ramming system to the crankcase.
  • Page 111 Rammer Repair Crankcase wc_gr001335rm Assembly 6.3.14 If the needle bearing was removed, press a new bearing into the cover until the outer race is flush with the flange surface. NOTICE: Keep the inside of the clutch drum absolutely free of any oil and grease.

  • Page 112: Oil Injection (If Equipped)

    Oil Injection (if equipped) Rammer Repair Oil Injection (if equipped) Testing the Float Switch (2010 and later models) Background The function of the float switch is to prevent the engine from running without oil in the oil tank. If the oil tank is low on oil, the float switch opens and kills the ignition.
  • Page 113 Rammer Repair Oil Injection (if equipped) 7.1.3 Check the continuity of the float switch by measuring across the connector. Does the float switch have continuity? Yes ____ No ____ The float switch is OK. The float switch has failed; replace it. 7.1.4 Reconnect the float switch.

  • Page 114: Replacing The Float Switch (2010 And Later Models)

    Oil Injection (if equipped) Rammer Repair Replacing the Float Switch (2010 and later models) Requirements • New float switch • 2-cycle engine oil Removal Perform the procedure below to remove the float switch. 7.2.1 Remove the silencing cover. See topic Removing the Silencing Cover.
  • Page 115 Rammer Repair Oil Injection (if equipped) Continued from the previous page. 7.2.6 Unscrew the float switch assembly from the oil tank. 7.2.7 Remove the float switch and wiring from the machine. Installation Perform the procedure below to install the float switch. 7.2.1 Screw the new float switch assembly into the oil tank.

  • Page 116: Float Switch Testing And Replacement (Pre-2010 Models)

    Oil Injection (if equipped) Rammer Repair Float Switch Testing and Replacement (pre-2010 models) See Graphic: wc_gr001526 NOTICE: Do not bypass the float switch except during testing; engine failure may occur. The function of the float switch is to prevent the engine from running without oil in the oil tank.
  • Page 117 Rammer Repair Oil Injection (if equipped) wc_gr001526 wc_tx001549gb.fm...

  • Page 118: Oil Line Check Valve

    Oil Injection (if equipped) Rammer Repair Oil Line Check Valve See Graphic: wc_gr001527 The the function of the oil line check valve (a) is to prevent raw fuel from backing up to the oil pump. It is important that the check valve be installed in the correct direction.
  • Page 119 Rammer Repair Oil Injection (if equipped) wc_gr001527 wc_tx001549gb.fm...

  • Page 120: Oil Pump / Cartridge Assembly

    Oil Injection (if equipped) Rammer Repair Testing/Replacing the Oil Pump Background Oil-injection Rammers can run up to 65 hours on one tank of oil. If the Rammer has been used for a long period of time, and it does not appear to have used any oil and the oil line check valve is operating correctly, remove and check the oil pump.
  • Page 121 Rammer Repair Oil Injection (if equipped) Continued from the previous page. 7.5.5 Separate the pump from the cartridge portion of the pump assembly. The cartridge may remain in the engine. 7.5.6 Inspect the gear for damage. If the gear is damaged, replace it. 7.5.7 Open the bleed screw until oil flows from the output nipple...
  • Page 122 Oil Injection (if equipped) Rammer Repair Continued from the previous page. 7.5.9 Remove the cartridge assembly Result The removal procedure is now complete. Installation Perform the procedure below to install the oil pump. 7.5.1 Slide the cartridge assembly into the crankcase. 7.5.2 Install the pump to the machine using three screws .

  • Page 123: Low Oil Shutdown (If Equipped)

    Rammer Repair Low Oil Shutdown (if equipped) Low Oil Shutdown (if equipped) Testing the Low Oil Unit See Graphic: wc_gr003673 The function of the low oil unit is to prevent the engine from running after startup if the engine is low on oil. To test the low oil unit: 8.1.1 Remove the lower engine guard (a).

  • Page 124: Troubleshooting

    Troubleshooting Rammer Repair Troubleshooting Engine Hard to Start Problem / Symptom Reason / Remedy The air filters are dirty. Clean or replace the filters. There is too much oil in the Drain the fuel from the tank and fill it with new mixed fuel.

  • Page 125: Engine Does Not Start

    Rammer Repair Troubleshooting Engine Does Not Start Problem / Symptom Reason / Remedy There is no fuel in the tank. Add fuel. The fuel valve is closed. Open the fuel valve. Clean or replace the spark plug. Set the electrode gap. The spark plug is fouled The fuel filter is plugged.

  • Page 126: Engine Overheats

    Troubleshooting Rammer Repair Engine Overheats Problem / Symptom Reason / Remedy There is not enough oil in the Drain the fuel from the tank and fill it with new mixed fuel. fuel mix The carburetor fuel mix is set Reset the carburetor adjustments. too lean The cooling fins/fan blades Clean the debris from the fins and the blades.

  • Page 127: Rammer Jumps Erratically

    Rammer Repair Troubleshooting Rammer Jumps Erratically Problem / Symptom Reason / Remedy There is oil or grease on the Inspect and clean the clutch. clutch. The spring(s) in the ramming Disassemble the spring cylinder. Inspect and replace system are broken or worn. any damaged components.

  • Page 128: Technical Data

    Three stage with cyclonic precleaner type Engine Lubrication With standard two-cycle oil use 50:1 ratio. oil grade With Wacker Neuson two-cycle or other oil meeting the NMMA TC-W3 specification, a ratio from 50:1 to 100:1 can be used. Fuel Tank Capacity 3.0 (3.2) l (qts.)

  • Page 129: Bs 50-4

    Rammer Repair Technical Data 10.2 BS 50-4 Item Number: BS 50-4s 0620071, 0620078 0620811 Rammer Engine Model WM90 type Engine Speed - operating 4200 ± 100 Engine Speed - idle 2000 ± 100 Clutch Engagement 2500 ± 100 Max. rated power @ kW(HP) 2.1 (2.8) @ 4200 rpm...
  • Page 130 Dual Element Engine Lubrication oil grade With standard two-cycle oil - use 50:1 ratio. With Wacker Neuson two-cycle or two-cycle oil per NMMA TC-W3, API TC, JASO FC or ISO EGD specifications - use 100:1 or 50:1 ratio. Ramming System...

  • Page 131: Bs 500S

    (psi) Engine Lubrication oil grade With standard two-cycle oil - use 50:1 ratio. With Wacker Neuson two-cycle or two-cycle oil per NMMA TC-W3, API TC, JASO FC or ISO EGD specifications - 100:1 or 50:1 ratio. Ramming System Lubri- oil grade...

  • Page 132: Bs 50-2I

    Three stage with cyclonic precleaner type Engine Lubrication With standard two-cycle oil use 50:1 ratio. oil grade With Wacker Neuson two-cycle or other oil meeting the NMMA TC-W3 specification, a ratio from 50:1 to 100:1 can be used. Fuel Tank Capacity 3.0 (3.2) l (qts.)

  • Page 133: Bs 500-Oi

    Rammer Repair Technical Data 10.6 BS 500-oi Item Number: BS 500-oi 0009165, 0009343 Rammer Engine Model type WM80 Engine Speed - full 4400 ± 100 Engine Speed - idle 1800 ± 100 Clutch Engagement 2800 ± 100 Spark Plug type Champion RL95YC Electrode Gap mm (in.)

  • Page 134: Bs 60/70-2

    Three stage with cyclonic precleaner type Engine Lubrication With standard two-cycle oil use 50:1 ratio. oil grade With Wacker Neuson two-cycle or other oil meeting the NMMA TC-W3 specification, a ratio from 50:1 to 100:1 can be used. Fuel Tank Capacity 3.0 (3.2) l (qts.)

  • Page 135: Bs 60-4

    Rammer Repair Technical Data 10.8 BS 60-4 Item Number: BS 60-4s 0620072 BS 60-4 0620074 0009340 BS 60-4s 0620483 0620000 0620073 0620563 0620051 Rev 202 and 0620109 higher 0620073 0620110 Rev 201 and lower Rammer Engine Model type WM90 WM100 Engine Speed - operating 4200 ±...

  • Page 136: Bs 600/700

    Dual Element Engine Lubrication oil grade With standard two-cycle oil - use 50:1 ratio. With Wacker Neuson two-cycle or two-cycle oil per NMMA TC-W3, API TC, JASO FC or ISO EGD specifications - 100:1 or 50:1 ratio. Ramming System oil grade...

  • Page 137: Bs 600S

    (psi) Engine Lubrication oil grade With standard two-cycle oil - use 50:1 ratio. With Wacker Neuson two-cycle or two-cycle oil per NMMA TC-W3, API TC, JASO FC or ISO EGD specifications - 100:1 or 50:1 ratio. Ramming System oil grade...

  • Page 138: 10.11 Bs 60/70-2I

    Three stage with cyclonic precleaner type Engine Lubrication With standard two-cycle oil use 50:1 ratio. oil grade With Wacker Neuson two-cycle or other oil meeting the NMMA TC-W3 specification, a ratio from 50:1 to 100:1 can be used. Fuel Tank Capacity 3.0 (3.2) l (qts.)

  • Page 139: 10.12 Bs 600/700-Oi

    Cylinder Head 8.0–9.7 (120–140) bar/cm Compression (cold) (psi) Engine Lubrication oil grade Wacker Neuson two-cycle or two-cycle oil per NMMA TC- W3, API TC, JASO FC or ISO EGD specifications. Ramming System oil grade SAE 10W30 Lubrication Ramming System ml (oz.)

  • Page 140: 10.13 Bs 600/700 High Altitude

    Dual Element Engine Lubrication oil grade With standard two-cycle oil - use 50:1 ratio. With Wacker Neuson two-cycle or two-cycle oil per NMMA TC-W3, API TC, JASO FC or ISO EGD specifications - 100:1 or 50:1 ratio. Ramming System oil grade...

  • Page 141: Bs 65-V

    Three stage with cyclonic precleaner type Engine Lubrication With standard two-cycle oil use 50:1 ratio. oil grade With Wacker Neuson two-cycle or other oil meet- ing the NMMA TC-W3 specification, a ratio from 50:1 to 100:1 can be used. Fuel Tank Capacity 3.0 (3.2) l (qts.)

  • Page 142: Bs 650

    Dual Element Engine Lubrication oil grade With standard two-cycle oil - use 50:1 ratio. With Wacker Neuson two-cycle or two-cycle oil per NMMA TC-W3, API TC, JASO FC or ISO EGD specifications - 100:1 or 50:1 ratio. Ramming System oil grade...
  • Page 143 Rammer Repair Technical Data Notes wc_td000112gb.fm...
  • Page 144 Technical Data Rammer Repair 10.16 DS 70 Item Number: DS 70 DS 70 DS 70 0009342 0620049 0620052 0009402 0620050 0620053 0009403 0620054 Rammer Operating weight 83 (183) kg (lbs.) strokes/min. Percussion rate Single stroke work J/mkp Stroke of ramming shoe (up) to 71 (2.78) mm (in.) Ramming system lubrication...
  • Page 145 Rammer Repair Technical Data Item Number: DS 70 DS 70 DS 70 0009342 0620049 0620052 0009402 0620050 0620053 0009403 0620054 Engine Engine Type single cylinder, air cooled, 4-stroke diesel engine Engine Make Yanmar Engine Model L48EE- L48V4LF9T L48EE- DWK3 9EWSA DWK3 Max.

  • Page 146: Ds 720

    Technical Data Rammer Repair 10.17 DS 720 Item Number: DS 720 DS 720 0008200 0008200 DS 720 Rev. 115 and lower Rev. 116 and higher 0009309 0008203 0008203 Rev. 114 and lower Rev. 115 and higher Rammer Operating weight kg (lbs.) 75 (165) strokes/ Percussion rate...
  • Page 147 Rammer Repair Technical Data Item Number: DS 720 DS 720 0008200 0008200 DS 720 Rev. 115 and lower Rev. 116 and higher 0009309 0008203 0008203 Rev. 114 and lower Rev. 115 and higher Engine Engine Type single cylinder, air cooled, 4-stroke diesel engine Engine Make Yanmar Engine Model...
  • Page 148 Fax: +49 - (0)89-3 54 02-390 Wacker Neuson Corporation · N92W15000 Anthony Ave. · Menomonee Falls, WI 53051 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 ·Tel. : (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
  • Page 149 Click below to find more Mipaper at www.lcis.com.tw Mipaper at www.lcis.com.tw...

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