Wacker Neuson BS 50-4s, BS 50-4As Repair Manual
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Wacker Neuson BS 50-4s, BS 50-4As Repair Manual

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Repair Manual
Vibratory Rammer
EN
1015
5100018465
01
5
1
0
0
0
1
8
4
6
5

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Summary of Contents for Wacker Neuson BS 50-4s, BS 50-4As

  • Page 1 Repair Manual Vibratory Rammer 1015 5100018465...
  • Page 2 Copyright notice © Copyright 2015 by Wacker Neuson Production Americas LLC All rights, including copying and distribution rights, are reserved. 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 Production Americas LLC.

  • Page 3: Foreword

    Foreword SAVE THESE INSTRUCTIONS—This manual contains important instructions for the machine models below. These instructions have been written expressly by Wacker Neuson Production Americas LLC and must be followed during installation, operation, and maintenance of the machines. Machine Item Number...
  • Page 4 Americas LLC will be referred to as Wacker Neuson. ■ Keep a copy of the Operator’s Manual with the machine at all times. ■ For spare parts information, please see your Wacker Neuson Dealer, or visit the Wacker Neuson website at http://www.wackerneuson.com/.
  • Page 5 ■ Serious injury hazards to the operator and persons in the work area ■ Permanent damage to the machine which will not be covered under warranty Contact your Wacker Neuson dealer immediately if you have questions about approved or unapproved parts, attachments, or modifications.
  • Page 6 Foreword Rammer wc_tx004061gb_FM10.fm...

  • Page 7: Table Of Contents

    Rammer Table of Contents Foreword Safety Information Signal Words Used in this Manual ............. 11 Machine Description and Intended Use ..........12 Safety Guidelines for Operating the Machine ........13 Safety Guidelines for Lifting the Machine ........... 14 Service Safety ..................15 Operator Safety while Using Internal Combustion Engines ....
  • Page 8 Table of Contents Rammer Removing the Ramming Shoe—BS60 and BS70 .......52 Installing the Ramming Shoe—BS60 and BS70 .........54 Removing the Lifting Cable ..............56 4.10 Installing the Lifting Cable ..............57 4.11 Removing the Oil Tank—BS 50-2i ............58 4.12 Installing the Oil Tank—BS 50-2i ............60 4.13 Removing the Fuel Tank ..............62 4.14...
  • Page 9 Rammer Table of Contents 4.47 Testing the Float Switch ..............163 4.48 Replacing the Float Switch ............... 166 Technical Data BS 50-4s ................... 172 BS 50-4As ..................173 BS 60-4s ................... 174 BS 60-4As ..................175 BS 70-4As ..................176 Sound Measurements ..............
  • Page 10 Table of Contents Rammer wc_br5100018465_FM10TOC.fm...

  • Page 11: Safety Information

    Rammer Safety Information Safety Information Signal Words Used 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 12: Machine Description And Intended Use

    Rammer 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 13: Safety Guidelines For Operating The Machine

    To ensure safe operation of the machine: ■ Do not operate the machine if any safety devices or guards are missing or inoperative. ■ Do not modify or defeat the safety devices. ■ Only use accessories or attachments that are approved by Wacker Neuson. wc_si000836gb_FM10.fm...

  • Page 14: Safety Guidelines For Lifting The Machine

    Safety Information Rammer Safe When operating this rammer: operating ■ Remain aware of the rammer’s moving parts. Keep hands, feet, and loose practices clothing away from the rammer’s moving parts. ■ When working near the edges of pits, slopes, trenches, and platforms, always operate the rammer in such a way that there is no possibility of it tipping over or falling in.

  • Page 15: Service Safety

    Machine When servicing or maintaining the machine: modifications ■ Use only accessories/attachments that are approved by Wacker Neuson. When servicing or maintaining the machine: ■ Do not defeat safety devices. ■ Do not modify the machine without the express written approval of Wacker Neuson.
  • Page 16 Safety Information Rammer ■ Replace worn or damaged components. Replacing parts and ■ Replace all missing and hard-to-read labels. labels ■ When replacing electrical components, use components that are identical in rating and performance to the original components. ■ 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 17: Operator Safety While Using Internal Combustion Engines

    Rammer 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 18: Operation

    Before using an oxygenated fuel, confirm the fuel’s contents. Some states and provinces require this information to be posted on the fuel pump. The following is the Wacker Neuson approved percentage of oxygenates: ETHANOL - (ethyl or grain alcohol) 10% by volume. You may use gasoline containing up to 10% ethanol by volume (commonly referred to as E10).

  • Page 19: Recommended Fuel-2 Stroke

    Before using an oxygenated fuel, confirm the fuel’s contents. Some states and provinces require this information to be posted on the fuel pump. The following is the Wacker Neuson approved percentage of oxygenates: ETHANOL - (ethyl or grain alcohol) 10% by volume. You may use gasoline containing up to 10% ethanol by volume (commonly referred to as E10).
  • Page 20 NOTICE: Use only the recommended gasoline/oil mixture to fuel this machine. Using gasoline alone will severely damage the engine. ■ Use only Wacker Neuson two-cycle or other fully synthetic oil meeting the Requirements NMMA TC-W3, JASO FD, or ISO-L-EGD specification.

  • Page 21: Starting, Operating, And Stopping The Machine-Wm 100

    Rammer Operation Starting, Operating, and Stopping the Machine—WM 100 ■ Rammer is in serviceable condition and has been properly maintained. Requirements ■ There is fuel in the tank. Starting the Perform the procedure below to start the machine. machine 1. Set the throttle to the idle position (c ).
  • Page 22 Operation Rammer Continued from the previous page. Operating the Perform the procedure below to operate the rammer. machine 1. Open the choke (a). 2. Set the throttle to the full position (c 3. Guide the rammer’s direction of travel. Allow the rammer to pull itself forward. Do not try to overpower the rammer.

  • Page 23: Starting, Operating, And Stopping The Machine-Honda

    Rammer Operation Starting, Operating, and Stopping the Machine—Honda ■ Rammer is in serviceable condition and has been properly maintained. Requirements ■ There is fuel in the tank. Starting the Perform the procedure below to start the machine. machine 1. Set the throttle to the idle position (c ).
  • Page 24 Operation Rammer Continued from the previous page. Operating the Perform the procedure below to operate the rammer. machine 1. Open the choke (a). 2. Set the throttle to the full position (c 3. Guide the rammer’s direction of travel. Allow the rammer to pull itself forward. Do not try to overpower the rammer.

  • Page 25: Starting, Operating, And Stopping The Machine

    Rammer Operation Starting, Operating, and Stopping the Machine ■ Rammer is in serviceable condition and has been properly maintained. Requirements ■ There is fuel in the tank. Starting the Perform the procedure below to start the machine. machine 1. Set the throttle to the idle position (c ).
  • Page 26 Operation Rammer Continued from the previous page. Operating the Perform the procedure below to operate the rammer. machine 1. Set the throttle to the full position (c ). The choke will open automatically. 2. Guide the rammer’s direction of travel. Allow the rammer to pull itself forward. Do not try to overpower the rammer.

  • Page 27: Low Oil Shut-Off Switch-Wm100

    Rammer Operation Low Oil Shut-Off Switch—WM100 Overview The low oil shutoff switch is designed to prevent engine damage caused by an insufficient amount of oil. When the engine is started, an illuminated indicator (a) notifies the operator of the status of the engine oil level. wc_gr011597 Condition Engine oil level status...

  • Page 28: Low Oil Shut-Off Switch-Honda

    Operation Rammer Low Oil Shut-Off Switch—Honda Overview The low oil shutoff switch is designed to prevent engine damage caused by an insufficient amount of oil. When starting the engine, an illuminated indicator (a) notifies the operator that the engine oil level is low. wc_gr011882 Condition Engine oil level status...

  • Page 29: Troubleshooting

    Rammer Troubleshooting Troubleshooting Diagnosing Starting Issues Tools required All procedures can be accomplished with the following tools: ■ Spark tester (part number 5000078836) ■ Multimeter ■ General hand tools (ratchet set, screwdrivers, etc.) Where to start To determine where to start: 1.

  • Page 30: Diagnosing Performance Issues

    Troubleshooting Rammer Engine runs, but carburetor floods See topics 1. Check carburetor for dirt. See engine repair manual — 2. Check the fuel flow Checking the Fuel Flow Diagnosing Performance Issues Background The two most common causes for performance problems are: Probable cause See Topic 1.

  • Page 31: Checking The Fuel Flow

    Rammer Troubleshooting Checking the Fuel Flow WARNING Fire hazard. Fuel is flammable and may ignite. ► Keep all sources of ignition far away while performing this procedure. ► Clean up spilled fuel immediately. ■ Fuel in tank Requirements ■ Fuel valve open (throttle out of stop position) Procedure Perform the procedure below to check the fuel flow.
  • Page 32 Troubleshooting Rammer Continued from the previous page. Does fuel flow from the fuel hose (b)? Yes ____ No ____ Replace the in-line fuel filter. Remove the stub of hose from the in-line fuel filter and reconnect the fuel hose (b). Continue with step 5.

  • Page 33: Testing The Ignition Module And Checking The Spark

    Rammer Troubleshooting Testing the Ignition Module and Checking the Spark Requirements ■ Ignition tester P/N 5000078836 ■ Engine removed Procedure Perform the procedure below to test the ignition module/check the spark. 1. Preset the gap of the ignition tester (a) to 4.2 mm (0.166 in.). 4.2 mm 0.166 in.

  • Page 34: Checking The Stop Switch

    Troubleshooting Rammer Checking the Stop Switch ■ Multimeter Requirements ■ Typical hand tools Background For both 2-stroke and 4-stroke powered Rammers, the throttle lever acts as the stop switch when it is placed in the STOP position. The stop switch is a normally open (NO) switch;...
  • Page 35 Rammer Troubleshooting Continued from the previous page. 3. On WM80 engines, disconnect the connector (c). WM80 wc_gr012496 4. Set the throttle/stop switch (d) to the STOP position. 5. On 4-stroke engines, check for continuity between the wire the engine housing. On 2-stroke engines, check for continuity across the connector.

  • Page 36: Conducting A Leak-Down Test

    Troubleshooting Rammer Conducting a Leak-Down Test ■ Leak down tester Requirements ■ Torque wrench Procedure Perform the procedure below to conduct a leak-down test. 1. Remove the spark plug (a). wc_gr013050 2. Set the piston at TDC using the starter rope. 3.

  • Page 37: Checking The Ignition Wiring

    Rammer Troubleshooting Checking the Ignition Wiring ■ Engine cool Requirements ■ Puller PN 5000046503 Note: The procedure below applies to the WM 80 engine. For other engines, see the engine manufacturer for more information. Procedure Perform the procedure below to remove check the ignition wiring. 1.

  • Page 38: Checking Engine Compression

    Troubleshooting Rammer Checking Engine Compression ■ Compression tester Requirements ■ Torque wrench Note: The procedure below applies to the WM 80 engine. For other engines, see the engine manufacturer for more information. Procedure Perform the procedure below to check engine combustion. 1.

  • Page 39: Checking For Vapor Lock

    Rammer Troubleshooting Checking for Vapor Lock ■ Fresh, non-oxygenated fuel Requirements ■ New fuel filter if applicable Background Loading conditions, fuel blend, and ambient temperature all add to the chances of a vapor lock condition. If the engine runs for approximately 45 minutes and then stops, there may be a vapor lock condition.

  • Page 40: Purging The Oil Lines

    Troubleshooting Rammer 3.10 Purging the Oil Lines For rammers with oil injection (BS 50-2i, BS 60-2i, BS 70-2i) If the rammer has a fuel tank (a) and an oil tank (b), it has oil injection. The oil lines may need purging. wc_gr010452 When As needed: when air bubbles are visible in the oil supply line or discharge line...
  • Page 41 Rammer Troubleshooting Continued from the previous page. Purging the Perform the procedure below to purge the oil discharge line. oil discharge 1. Locate the oil discharge line (c). line wc_gr012472 2. If air bubbles are visible in the oil discharge line, they must be manually purged using the following method: Disconnect the oil discharge line at the oil pump (d).

  • Page 42: Disassembly And Reassembly

    Disassembly and Reassembly Rammer Disassembly and Reassembly Draining the Ramming System Oil—BS50 ■ Approved container for drained oil Requirements 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.

  • Page 43: Refilling The Ramming System Oil - Bs50

    Rammer Disassembly and Reassembly Refilling the Ramming System Oil — BS50 ■ Teflon® tape Requirements 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.
  • Page 44 Disassembly and Reassembly Rammer Continued from the previous page. 5. Tip the rammer so that it is perpendicular with the ground to check oil level. 6. Oil is at the correct level when the oil fills 1/2 to 3/4 of the sight glass (a). wc_gr012861 7.

  • Page 45: Draining The Ramming System Oil-Bs60 And Bs70

    Rammer Disassembly and Reassembly Draining the Ramming System Oil—BS60 and BS70 ■ Approved container for drained oil Requirements 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.

  • Page 46: Refilling The Ramming System Oil-Bs60 And Bs70

    Disassembly and Reassembly Rammer Refilling the Ramming System Oil—BS60 and BS70 ■ Teflon® tape Requirements 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.
  • Page 47 Rammer Disassembly and Reassembly Continued from the previous page. 5. Tip the rammer so that it is perpendicular with the ground to check oil level. The oil is at the correct level when the oil fills 1/2 to 3/4 of the sight glass. 6.

  • Page 48: Removing The Ramming Shoe-Bs50

    Disassembly and Reassembly Rammer Removing the Ramming Shoe—BS50 ■ Torque wrench Requirements ■ Lifting device capable of lifting the machine ■ See chapter Technical Data for weights Procedure Perform the procedure below to remove the ramming shoe. To view an animation of this procedure, internet access is needed.
  • Page 49 Rammer Disassembly and Reassembly Continued from the previous page. 4. Raise the machine off the shoe (g) and secure it in position. 5. Remove the three rear plow bolts (e) and the three front plow bolts (f). Note: To prevent the plow bolts from spinning, press the plow bolt heads firmly into the bottom plate while removing nuts.

  • Page 50: Installing The Ramming Shoe-Bs50

    Disassembly and Reassembly Rammer Installing the Ramming Shoe—BS50 ■ Lifting device capable of lifting the machine Requirements ■ See chapter Technical Data for weights Procedure Perform the procedure below to install the ramming shoe. To view an animation of this procedure, internet access is needed.
  • Page 51 Rammer Disassembly and Reassembly Continued from the previous page. 2. Lower the machine to the ground and remove the lifting devices. Results The ramming shoe has now been installed. wc_tx004029gb_FM10.fm...

  • Page 52: Removing The Ramming Shoe-Bs60 And Bs70

    Disassembly and Reassembly Rammer Removing the Ramming Shoe—BS60 and BS70 ■ Torque wrench Requirements ■ Lifting device capable of lifting the machine ■ See chapter Technical Data for weights WARNING Crushing hazard. The machine may fall if not properly suspended during ramming shoe replacement.
  • Page 53 Rammer Disassembly and Reassembly Continued from the previous page. Note: Note the size and location of the plow bolts (e, f, and g) to aid during installation. 4. Remove the six plow bolts (e, f, and g). Note: To prevent the plow bolts from spinning, press the plow bolt heads firmly into the bottom plate while removing nuts.

  • Page 54: Installing The Ramming Shoe-Bs60 And Bs70

    Disassembly and Reassembly Rammer Installing the Ramming Shoe—BS60 and BS70 ■ Lifting device capable of lifting the machine Requirements ■ See chapter Technical Data for weights WARNING Crushing hazard. The machine may fall if not properly suspended during ramming shoe replacement. ►...
  • Page 55 Rammer Disassembly and Reassembly Continued from the previous page. 2. Lower the machine to the ground and remove the lifting devices. Result The ramming shoe has now been installed. wc_tx004029gb_FM10.fm...

  • Page 56: Removing The Lifting Cable

    Disassembly and Reassembly Rammer Removing the Lifting Cable Procedure Perform the procedure below to remove the lifting cable. To view an animation of this procedure, internet access is needed. To view the animation, click on the video icon or scan the QR code with a smart phone.

  • Page 57: Installing The Lifting Cable

    Rammer Disassembly and Reassembly 4.10 Installing the Lifting Cable ■ Loctite® 243 Requirements ■ Torque wrench Procedure Perform the procedure below to install the lifting cable. To view an animation of this procedure, internet access is needed. To view the animation, click on the video icon or scan the QR code with a smart phone.

  • Page 58: Removing The Oil Tank-Bs 50-2I

    Disassembly and Reassembly Rammer 4.11 Removing the Oil Tank—BS 50-2i ■ Approved container for drained oil Requirements ■ Fuel tank removed ■ Plastic sheet to protect work surface Procedure Perform the procedure below to remove the oil tank. To view an animation of this procedure, internet access is needed.
  • Page 59 Rammer Disassembly and Reassembly Continued from the previous page. 3. Remove the hose and wire from the clamp (c). wc_gr012669 4. Lift the oil tank up from the machine, open the oil tank cap, and drain the oil into an approved container. 5.

  • Page 60: Installing The Oil Tank-Bs 50-2I

    Disassembly and Reassembly Rammer 4.12 Installing the Oil Tank—BS 50-2i ■ Loctite® 243 Requirements ■ Torque wrench ■ 2-cycle engine oil Procedure Perform the procedure below to install the oil tank. To view an animation of this procedure, internet access is needed.
  • Page 61 Rammer Disassembly and Reassembly Continued from the previous page. 3. Clean and apply Loctite® 243 to the four screws (a) and fasten the oil tank (b) to the machine with the four screws and washers. Torque the four screws to 9.4 Nm (6.9 ft.lbs.).

  • Page 62: Removing The Fuel Tank

    Disassembly and Reassembly Rammer 4.13 Removing the Fuel Tank WARNING Fuel is flammable and may ignite. ► Keep all sources of ignition far away while performing this procedure. ► Clean up spilled fuel immediately. ■ Approved container for drained fuel Requirements ■...
  • Page 63 Rammer Disassembly and Reassembly Continued from the previous page. 5. Remove and retain the clamp (f) for reuse during installation of the fuel tank. Note: Graphic is representative only; your machine may vary. wc_gr012661 6. Remove the six screws (j) and lift the fuel tank (g) from the guide handle (h). Result The fuel tank has now been removed.

  • Page 64: Installing The Fuel Tank

    Disassembly and Reassembly Rammer 4.14 Installing the Fuel Tank WARNING Fuel is flammable and may ignite. ► Keep all sources of ignition far away while performing this procedure. ► Clean up spilled fuel immediately. ■ Loctite® 243 Requirements ■ Torque wrench Procedure Perform the procedure below to install the fuel tank.
  • Page 65 Rammer Disassembly and Reassembly Continued from the previous page. 3. Install the clamp (f) and tighten the screw. 4. Hold the end of the fuel hose (e) near the fuel filter (c) and screw the fuel filter to the fuel tank. 5.

  • Page 66: Removing The Bellows

    Disassembly and Reassembly Rammer 4.15 Removing the Bellows ■ Punch Requirements ■ Rubber mallet ■ Two wood blocks 2” x 4” x 8” (5cm x 10cm x 20cm) Background The bellows should be warm. If possible, place machine in sunshine or near heat source to warm the bellows.
  • Page 67 Rammer Disassembly and Reassembly Continued from the previous page. 5. Drive out the two end plugs (n) and the piston pin (o) that holds the connecting rod to the ram (c). Note: Do not reuse the end plugs. wc_gr012840 6. With the aid of an assistant, lift and remove the crankcase from the ramming system.

  • Page 68: Installing The Bellows

    Disassembly and Reassembly Rammer 4.16 Installing the Bellows CAUTION Pinch point hazard. Hands and/or fingers may become pinched between the cylinder guide and the bellows during installation. ► Keep hands open with palms on the top of the cylinder guide when installing the cylinder guide into the bellows.
  • Page 69 Rammer Disassembly and Reassembly Continued from the previous page. 2. Use a piece of air hose (g) or similar, wrap it around inside the folds of the bellows. Note: This will keep the bellows from collapsing and aid in installation. wc_gr012849 3.
  • Page 70 Disassembly and Reassembly Rammer Continued from the previous page. 11.Place the two wood blocks (h and k) on the cylinder guide. wc_gr012850 12.With the aid of an assistant, position the crankcase on the two wood blocks and align the crankcase connecting rod (q) with the ram (j). 13.Install the piston pin (n) and new end plugs (m).
  • Page 71 Rammer Disassembly and Reassembly Continued from the previous page. 17.Lay the rammer flat on the ground and align the protective pipe (f) with the crankcase. wc_gr012851 18.Position the upper clamp (c) so the adjustment screw is 90° from the sight glass (p).

  • Page 72: Removing The Carburetor-Wm80 Oil Injected

    Disassembly and Reassembly Rammer 4.17 Removing the Carburetor—WM80 oil injected WARNING Fuel is flammable and may ignite. ► Keep all sources of ignition far away while performing this procedure. ► Clean up spilled fuel immediately. ■ Approved container for drained fuel Requirements ■...
  • Page 73 Rammer Disassembly and Reassembly Continued from the previous page. NOTICE: To avoid breaking the fittings, do not pull the hoses off the carburetor fittings. Use a utility knife to cut hose as close to the fitting as possible. Carefully cut the remaining hose from the fitting. 6.
  • Page 74 Disassembly and Reassembly Rammer Continued from the previous page. 11.Remove two screws (q) and two washers (r) to disassemble the air tube adapter (s), upper gasket (t), carburetor (u), lower gasket (v), and the carburetor adapter (w). wc_gr012664 This procedure continues on the next page. wc_tx004029gb_FM10.fm...
  • Page 75 Rammer Disassembly and Reassembly Continued from the previous page. 12.Disassemble the carburetor as needed. wc_gr012678 Result The carburetor has now been removed. wc_tx004029gb_FM10.fm...

  • Page 76: Installing The Carburetor-Wm80 Oil Injected

    Disassembly and Reassembly Rammer 4.18 Installing the Carburetor—WM80 oil injected WARNING Fuel is flammable and may ignite. ► Keep all sources of ignition far away while performing this procedure. ► Clean up spilled fuel immediately. ■ Torque wrench Requirements ■ Loctite® 243 Procedure Perform the procedure below to install the carburetor.
  • Page 77 Rammer Disassembly and Reassembly Continued from the previous page. 2. Assemble the air tube adapter (s), upper gasket (t), carburetor (u), and lower gasket (v) to the carburetor adapter (w) with screws (q) and washers (r). Torque screws to 5 Nm (4 ft.lbs.). wc_gr012664 3.
  • Page 78 Disassembly and Reassembly Rammer Continued from the previous page. 6. Connect the air tube (d) to the air tube adapter and tighten clamp (e). wc_gr012662 7. Install the throttle cable (c) and tighten the screw (g). 8. Install the spark plug wire (f) into the retainer clip. 9.

  • Page 79: Removing The Carburetor-Wm80 Non-Oil Injected

    Rammer Disassembly and Reassembly 4.19 Removing the Carburetor—WM80 non-oil injected WARNING Fuel is flammable and may ignite. ► Keep all sources of ignition far away while performing this procedure. ► Clean up spilled fuel immediately. ■ Plastic sheet to protect work surface Requirements ■...
  • Page 80 Disassembly and Reassembly Rammer Continued from the previous page. NOTICE: To avoid breaking the fittings, do not pull the hoses off the carburetor fittings. Use a utility knife to cut hose as close to the fitting as possible. Carefully cut the remaining hose from the fitting. 6.
  • Page 81 Rammer Disassembly and Reassembly Continued from the previous page. 10.Remove two screws (p) and two washers (q) to disassemble the air tube adapter (r), upper gasket (s), carburetor (t), lower gasket (u), and the carburetor adapter (v). wc_gr012668 This procedure continues on the next page. wc_tx004029gb_FM10.fm...
  • Page 82 Disassembly and Reassembly Rammer Continued from the previous page. 11.Disassemble the carburetor as needed. wc_gr012679 Result The carburetor has now been removed. wc_tx004029gb_FM10.fm...

  • Page 83: Installing The Carburetor-Wm80 Non-Oil Injected

    Rammer Disassembly and Reassembly 4.20 Installing the Carburetor—WM80 non-oil injected WARNING Fuel is flammable and may ignite. ► Keep all sources of ignition far away while performing this procedure. ► Clean up spilled fuel immediately. ■ Torque wrench Requirements ■ Loctite® 243 Procedure Perform the procedure below to install the carburetor.
  • Page 84 Disassembly and Reassembly Rammer Continued from the previous page. 2. Assemble the air tube adapter (r), upper gasket (s), carburetor (t), and lower gasket (u) to the carburetor adapter (v) with screws (p) and washers (q). Torque screws to 5 Nm (4 ft.lbs.). wc_gr012668 3.
  • Page 85 Rammer Disassembly and Reassembly Continued from the previous page. 5. Install the spark plug wire (f) in the retainer clip. wc_gr012662 6. Connect the air tube (d) and tighten the clamp (e). 7. Install the throttle cable (c) and tighten the screw (g). 8.

  • Page 86: Removing The Carburetor-Robin

    Disassembly and Reassembly Rammer 4.21 Removing the Carburetor—Robin WARNING Fire hazard. Fuel is flammable and may ignite. ► Keep all sources of ignition far away while performing this procedure. ► Clean up spilled fuel immediately. ■ Approved container for drained fuel Requirements ■...
  • Page 87 Rammer Disassembly and Reassembly Continued from the previous page. NOTICE: To avoid breaking the fittings, do not pull the hoses off the carburetor fittings. Use a utility knife to cut hose as close to the fitting as possible. Carefully cut the remaining hose from the fitting. 4.
  • Page 88 Disassembly and Reassembly Rammer Continued from the previous page. 7. Loosen the clamp (n) and disconnect the hose (m). wc_gr012674 8. Remove the governor linkage (x) and the spring (y) connecting the governor (w) to the carburetor assembly. 9. Remove two nuts (o) and remove the air intake (p), the two gaskets (u), and the carburetor (v).
  • Page 89 Rammer Disassembly and Reassembly Continued from the previous page. 11.Disassemble the carburetor as needed. wc_gr012675 Result The carburetor has now been removed. wc_tx004029gb_FM10.fm...

  • Page 90: Installing The Carburetor-Robin

    Disassembly and Reassembly Rammer 4.22 Installing the Carburetor—Robin WARNING Fuel is flammable and may ignite. ► Keep all sources of ignition far away while performing this procedure. ► Clean up spilled fuel immediately. ■ Torque wrench Requirements ■ Loctite® 243 Procedure Perform the procedure below to install the carburetor.
  • Page 91 Rammer Disassembly and Reassembly Continued from the previous page. 2. Install the two screws (q) into the carburetor adapter (s). wc_gr012674 3. Install the two screws (t) fastening the gasket (r) and the carburetor adapter (s) to the engine. 4. Install the two gaskets (u), the carburetor (v), and the air intake (p) to the carburetor adapter (s).
  • Page 92 Disassembly and Reassembly Rammer Continued from the previous page. 7. Connect the vent hose (k), fuel filter hose (j), and fuel hose (e) to the carburetor fittings. wc_gr012854 This procedure continues on the next page. wc_tx004029gb_FM10.fm...
  • Page 93 Rammer Disassembly and Reassembly Continued from the previous page. 8. Connect the air tube (f) to the air intake and tighten the clamp (g). wc_gr012692 9. Apply Loctite® 243 to the four screws (h) and fasten the carburetor guard (a) to the machine.

  • Page 94: Removing The Carburetor-Honda

    Disassembly and Reassembly Rammer 4.23 Removing the Carburetor—Honda WARNING Fire hazard. Fuel is flammable and may ignite. ► Keep all sources of ignition far away while performing this procedure. ► Clean up spilled fuel immediately. ■ Approved container for drained fuel Requirements ■...
  • Page 95 Rammer Disassembly and Reassembly Continued from the previous page. NOTICE: To avoid breaking the fittings, do not pull the hoses off the carburetor fittings. Use a utility knife to cut hose as close to the fitting as possible. Carefully cut the remaining hose from the fitting. 6.
  • Page 96 Disassembly and Reassembly Rammer Continued from the previous page. 10.Remove the governor rod (f) and the spring (g) connecting the governor arm to the carburetor. wc_gr012684 This procedure continues on the next page. wc_tx004029gb_FM10.fm...
  • Page 97 Rammer Disassembly and Reassembly Continued from the previous page. 11.Remove the two nuts (n) from the two stud bolts (o). wc_gr012685 12.Remove the elbow (p), the gasket (r), and the carburetor (q) from the two stud bolts (o). 13.Remove five gaskets (s), (t), (u), (w), and (y), one plate (v), and one insulator (x) from the two stud bolts (o).

  • Page 98: Installing The Carburetor-Honda

    Disassembly and Reassembly Rammer 4.24 Installing the Carburetor—Honda WARNING Fire hazard. Fuel is flammable and may ignite. ► Keep all sources of ignition far away while performing this procedure. ► Clean up spilled fuel immediately. ■ Torque wrench Requirements ■ Plastic sheet to protect work surface Procedure Perform the procedure below to install the carburetor.
  • Page 99 Rammer Disassembly and Reassembly Continued from the previous page. 5. Install the governor rod (f) and the spring (g) connecting the governor arm to the carburetor. wc_gr012684 This procedure continues on the next page. wc_tx004029gb_FM10.fm...
  • Page 100 Disassembly and Reassembly Rammer Continued from the previous page. 6. Connect the fuel filter hose (m), the vent hose (j), and the fuel hose (h) to the carburetor fittings. wc_gr012683 7. Connect the breather tube (k) to the carburetor. 8. Connect the air tube (d) and tighten the hose clamp (e). wc_gr012682 9.

  • Page 101: Removing The Engine-Wm 80

    Rammer Disassembly and Reassembly 4.25 Removing the Engine—WM 80 ■ Machine shut down and cool Requirements ■ Carburetor removed Procedure Perform the procedure below to remove the WM 80 engine. To view an animation of this procedure, internet access is needed. To view the animation, click on the video icon or scan the QR code with a smart phone.
  • Page 102 Disassembly and Reassembly Rammer Continued from the previous page. 3. Remove the screw (c) and the muffler assembly (d). wc_gr012879 This procedure continues on the next page. wc_tx004029gb_FM10.fm...
  • Page 103 Rammer Disassembly and Reassembly Continued from the previous page. 4. Remove the two screws (e) and the bracket (f). wc_gr012880 5. Disconnect the stop switch connector (g) and the float switch connector (h) (if equipped). This procedure continues on the next page. wc_tx004029gb_FM10.fm...
  • Page 104 Disassembly and Reassembly Rammer Continued from the previous page. 6. Remove the screws (j) on each side and remove the engine (k). wc_gr012881 Result The engine has now been removed. wc_tx004029gb_FM10.fm...

  • Page 105: Installing The Engine-Wm 80

    Rammer Disassembly and Reassembly 4.26 Installing the Engine—WM 80 ■ Torque wrench Requirements ■ Loctite® 243 Procedure Perform the procedure below to install the engine. To view an animation of this procedure, internet access is needed. To view the animation, click on the video icon or scan the QR code with a smart phone.
  • Page 106 Disassembly and Reassembly Rammer Continued from the previous page. 2. Apply Loctite® 243 to the screws (e) and fasten the bracket (f) to the machine. Torque the screws to 24 Nm (18 ft.lbs.). wc_gr012880 3. Connect the stop switch connector (g) and the float switch connector (h) (if equipped).
  • Page 107 Rammer Disassembly and Reassembly Continued from the previous page. 4. Hold the muffler flush to the bottom of the engine. Apply Loctite® 243 to the screw (a). Install and torque the screw to 18 Nm (13 ft.lbs.). 5. Apply Loctite® 243 to the screw (b). Install and torque the screw to 24 Nm (18 ft.lbs.).
  • Page 108 Disassembly and Reassembly Rammer Continued from the previous page. 6. Apply Loctite® 243 to the screw (c). Install and torque the screw to 24 Nm (18 ft.lbs.). wc_gr012879 7. Install the carburetor. See topic Installing the Carburetor—WM80 oil injected or Installing the Carburetor—WM80 non-oil injected.

  • Page 109: Removing The Engine-Honda

    Rammer Disassembly and Reassembly 4.27 Removing the Engine—Honda ■ Machine shut down and cool Requirements ■ Carburetor removed Procedure Perform the procedure below to remove the GX100 (Honda) engine. 1. Remove the carburetor. See topic Removing the Carburetor—Honda. 2. Loosen the screw (b) and the nut (c) and remove the throttle cable (d) from the engine.
  • Page 110 Disassembly and Reassembly Rammer Continued from the previous page. 4. Remove the screw (g) and the wire (f) from the engine. wc_gr012895 5. Disconnect the wire (h). This procedure continues on the next page. wc_tx004029gb_FM10.fm...
  • Page 111 Rammer Disassembly and Reassembly Continued from the previous page. 6. Remove the wire tie (p) fastening the low-oil shutdown switch wire to the lower engine guard. wc_gr012896 7. Remove the two screws (q) and remove the low-oil shutdown switch from the lower engine guard (o).

  • Page 112: Installing The Engine-Honda

    Disassembly and Reassembly Rammer 4.28 Installing the Engine—Honda ■ Torque wrench Requirements ■ Loctite® 243 Procedure Perform the procedure below to install the GX100 (Honda) engine. 1. With the aid of an assistant, install the engine (j), the heat shield (k), and the two engine mounting nuts (e).
  • Page 113 Rammer Disassembly and Reassembly Continued from the previous page. 6. Fasten the wire (f) to the engine with the screw (g). wc_gr012895 7. Connect the wire (h). This procedure continues on the next page. wc_tx004029gb_FM10.fm...
  • Page 114 Disassembly and Reassembly Rammer Continued from the previous page. 8. Install the throttle cable (d) to the engine and tighten the nut (c) and screw (b). wc_gr012894 9. Apply Loctite® 243 to the two engine mounting nuts (e) and the two engine mounting nuts on the opposite side of the machine.

  • Page 115: Removing The Engine-Robin

    Rammer Disassembly and Reassembly 4.29 Removing the Engine—Robin ■ Machine shut down and cool Requirements Procedure Perform the procedure below to remove the Robin engine. 1. Disconnect the wire (b) and remove the screw (c). 2. Remove the wires (b and d) from the grommet on top of the carburetor guard (a).
  • Page 116 Disassembly and Reassembly Rammer Continued from the previous page. 3. Remove the carburetor guard (a). wc_gr012883 4. Remove the low-oil shutdown switch (e) from the lower guard (f). 5. Remove the lower guard (f). 6. Remove the two nuts (h) and the support bracket (g). wc_gr012884 This procedure continues on the next page.
  • Page 117 Rammer Disassembly and Reassembly Continued from the previous page. 7. Remove the air intake tube (j). wc_gr012886 8. Label the fuel hoses to aid in re-installation. 9. Clamp if necessary, then cut the fuel filter hose (k), fuel hose (m), and the vent hose (l) close to the carburetor fittings and drain the fuel into an approved container.
  • Page 118 Disassembly and Reassembly Rammer Continued from the previous page. 10.Disconnect the throttle cable (n). wc_gr012885 11.Remove the two nuts (p), the heat shield (q), and the engine (r). Result The engine has now been removed. wc_tx004029gb_FM10.fm...

  • Page 119: Installing The Engine-Robin

    Rammer Disassembly and Reassembly 4.30 Installing the Engine—Robin ■ Torque wrench Requirements ■ Loctite® 243 Procedure Perform the procedure below to install the WM 100 engine. 1. Install the engine (r), the heat shield (q), and two engine mounting nuts (p). Do not tighten nuts (p) at this time.
  • Page 120 Disassembly and Reassembly Rammer Continued from the previous page. 3. Connect the air intake tube (j) and the hoses (k, l, and m). wc_gr012886 4. Install the lower guard (f), the low-oil shutdown switch (e), and the support bracket (g). wc_gr012884 5.
  • Page 121 Rammer Disassembly and Reassembly Continued from the previous page. 7. Apply Loctite® 243 to the four screws and fasten the carburetor guard (a) to the machine. Torque the screws to 25 Nm (18 ft.lbs.). wc_gr012883 8. Install the wire (d) through the rubber grommet on the carburetor guard and fasten to the engine shroud with the screw (c).

  • Page 122: Removing The Upper Machinery

    Disassembly and Reassembly Rammer 4.31 Removing the Upper Machinery ■ Punch Requirements ■ Two wood blocks 2” x 4” x 8” (5cm x 10cm x 20cm) Procedure Perform the procedure below to remove the upper machinery. To view an animation of this procedure, internet access is needed.
  • Page 123 Rammer Disassembly and Reassembly Continued from the previous page. 5. Drive out the two end plugs (e) and the piston pin (f) that holds the connecting rod to the ram (c). Note: Do not reuse the end plugs. wc_gr012833 6. With the aid of an assistant, lift and remove the crankcase from the ramming system.

  • Page 124: Installing The Upper Machinery

    Disassembly and Reassembly Rammer 4.32 Installing the Upper Machinery ■ Punch Requirements ■ New end plugs ■ New O-ring ■ Loctite® 243 ■ Two wood blocks 2” x 4” x 8” (5cm x 10cm x 20cm) Procedure Perform the procedure below to install the upper machinery. To view an animation of this procedure, internet access is needed.
  • Page 125 Rammer Disassembly and Reassembly Continued from the previous page. 6. Apply Loctite® 243 to the four screws (a). Note: When reusing bolts, clean the threads thoroughly before use. wc_gr012853 7. Fasten the upper machinery to the ramming system with four screws (a) and washers.

  • Page 126: Removing The Crankcase

    Disassembly and Reassembly Rammer 4.33 Removing the Crankcase ■ 2-Jaw bearing puller Requirements ■ Large diameter retaining ring pliers ■ Hydraulic press ■ Split puller ■ Slide hammer ■ Upper machinery removed ■ Engine removed ■ Oil pump removed (oil-injected machines only (BSxx-2i)) Procedure Perform the procedure below to remove the crankcase.
  • Page 127 Rammer Disassembly and Reassembly Continued from the previous page. 5. Remove the six screws (f) and remove the guide handle assembly (g) from the crankcase. wc_gr012873 This procedure continues on the next page. wc_tx004029gb_FM10.fm...
  • Page 128 Disassembly and Reassembly Rammer Continued from the previous page. 6. Reach through the slotted hole (q) in the crank gear and release the large retaining ring (m). wc_gr012874 7. Thread two M8 socket head cap screws, or threaded rods, through the pusher holes (p) in the crank gear.

  • Page 129: Installing The Crankcase

    Rammer Disassembly and Reassembly 4.34 Installing the Crankcase ■ New O-ring Requirements ■ Loctite® 243 ■ Large diameter retaining ring pliers ■ Hydraulic press Procedure Perform the procedure below to install the crankcase. To view an animation of this procedure, internet access is needed.
  • Page 130 Disassembly and Reassembly Rammer Continued from the previous page. 6. Push the complete crank gear assembly into the bearing housing of the front crankcase cover (b). wc_gr012876 7. Reach through the slotted hole (q) in the crank gear and seat the large retaining ring (m) in the groove.
  • Page 131 Rammer Disassembly and Reassembly Continued from the previous page. 11.Install the guide handle assembly (g) to the crankcase using six screws (f). Apply Loctite® 243 and torque the screws to 31 Nm (23 ft.lbs.). wc_gr012873 12.Re-install the engine. See topic Installing the Engine. 13.Re-install the upper machinery.

  • Page 132: Removing The Clutch

    Disassembly and Reassembly Rammer 4.35 Removing the Clutch ■ Machine shut down and cool Requirements ■ Engine removed ■ Clutch puller P/N 5000117972 Procedure Perform the procedure below to remove the clutch. To view an animation of this procedure, internet access is needed.

  • Page 133: Installing The Clutch

    Rammer Disassembly and Reassembly 4.36 Installing the Clutch ■ Torque wrench Requirements Procedure Perform the procedure below to install the clutch. To view an animation of this procedure, internet access is needed. To view the animation, click on the video icon or scan the QR code with a smart phone.

  • Page 134: Removing The Clutch Drum

    Disassembly and Reassembly Rammer 4.37 Removing the Clutch Drum ■ Upper machinery removed Requirements ■ Engine removed ■ Hydraulic press ■ Slide hammer ■ Engine removed Procedure Perform the procedure below to remove the clutch drum. To view an animation of this procedure, internet access is needed.
  • Page 135 Rammer Disassembly and Reassembly Continued from the previous page. 5. Remove the small retaining ring (k) from the clutch drum shaft (m). wc_gr012870 6. Press the clutch drum shaft (m) from the crankcase. Inspect the clutch drum shaft for wear or damage and replace it if necessary. This procedure continues on the next page.
  • Page 136 Disassembly and Reassembly Rammer Continued from the previous page. 7. Remove the shaft seal (n) and the retaining ring (p). wc_gr012871 8. Press the clutch drum bearing (q) from the crankcase. Inspect the clutch drum bearing for wear or damage and replace it if necessary. 9.

  • Page 137: Installing The Clutch Drum

    Rammer Disassembly and Reassembly 4.38 Installing the Clutch Drum ■ Hydraulic press Requirements ■ Assistant ■ Slide hammer ■ Punch ■ Torque wrench ■ Loctite® 243 ■ Shell gadus S2 V100 2 grease or equivalent Procedure Perform the procedure below to install the clutch drum. To view an animation of this procedure, internet access is needed.
  • Page 138 Disassembly and Reassembly Rammer Continued from the previous page. 2. Press the clutch drum bearing (q) into the crankcase and secure the clutch drum bearing with the retaining ring (p). wc_gr012871 3. Pack the shaft seal (n) with grease. Install the shaft seal with the open side facing the bearing (q).
  • Page 139 Rammer Disassembly and Reassembly Continued from the previous page. 5. Secure the clutch drum (m) with the small retaining ring (k). wc_gr012870 6. Install the front cover (h) to the crankcase. Apply Loctite® 243 and torque screws (g) to 49 Nm (36 ft. lbs.). wc_gr012869 wc_gr012868 7.

  • Page 140: Removing The Oil Pump

    Disassembly and Reassembly Rammer 4.39 Removing the Oil Pump Background Oil-injection machines can run up to 65 hours on one tank of oil. If the machine 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 141 Rammer Disassembly and Reassembly Continued from the previous page. 4. Separate the pump (d) from the cartridge portion. 5. Inspect the gear (e) for damage. If the gear is damaged, replace it. wc_gr012856 6. Open the bleed screw (g) until oil flows from the output nipple (f), then close the bleed screw.
  • Page 142 Disassembly and Reassembly Rammer Continued from the previous page. 8. Remove the cartridge assembly (j), O-ring (k), and gasket (m). Inspect parts for damage. Replace if necessary. wc gr012863 Result The oil pump has now been removed. wc_tx004029gb_FM10.fm...

  • Page 143: Installing The Oil Pump

    Rammer Disassembly and Reassembly 4.40 Installing the Oil Pump ■ Torque wrench Requirements ■ 2-cycle engine oil ■ Syringe Procedure Perform the procedure below to install the oil pump. To view an animation of this procedure, internet access is needed. To view the animation, click on the video icon, or scan the QR code with a smart phone.
  • Page 144 Disassembly and Reassembly Rammer Continued from the previous page. 2. Install the oil pump to the machine using three screws (c). Torque the screws to 9.5 Nm (7 ft.lbs.). wc_gr012855 3. With a syringe (n) connected to one end of the output oil hose (b), set the other end into a source of 2-cycle engine oil (p).

  • Page 145: Removing The Spring System Cover-Hydraulic Press Method

    Rammer Disassembly and Reassembly 4.41 Removing the Spring System Cover—Hydraulic Press Method ■ Hydraulic press Requirements ■ Upper machinery removed ■ Bellows removed ■ Ramming shoe removed ■ Three M8 x 206 mm Torx head guide screws (PN 5000046252) Background There are two methods for removing the spring system cover: The preferred method is using the special spring box tool P/N 5000081423.
  • Page 146 Disassembly and Reassembly Rammer Continued from the previous page. 3. Remove all but two of the screws (a) that hold the spring system cover to the spring cylinder. wc_gr012689 4. Install three M8 x 206 mm guide screws (x) through the spring system cover and into the spring cylinder.
  • Page 147 Rammer Disassembly and Reassembly Continued from the previous page. 9. After all the spring pressure is released, remove the three M8 x 206 mm guide screws (x), spring system cover (b), gasket (d), and lower spring set (c). wc_gr012830 Result The spring system cover has now been removed.

  • Page 148: Installing The Spring System Cover-Hydraulic Press Method

    Disassembly and Reassembly Rammer 4.42 Installing the Spring System Cover—Hydraulic Press Method ■ Hydraulic press Requirements ■ Loctite® 243 ■ Three M8 x 206 mm Torx head guide screws (PN 5000046252) Background There are two methods for removing the spring system cover: The preferred method is using the special spring box tool P/N 5000081423.
  • Page 149 Rammer Disassembly and Reassembly Continued from the previous page. 1. Install the lower spring set (c), new gasket (d), and spring system cover (b) into the spring cylinder. wc_gr012830 2. Install three M8 x 206 mm guide screws (x) through the spring system cover and into the spring cylinder.
  • Page 150 Disassembly and Reassembly Rammer Continued from the previous page. 3. Center the lower spring set (c) and the spring system cover (b) under the hydraulic press ram. wc_gr012852 4. Align the holes in the spring system cover (b) as close as possible with the holes in the spring cylinder.

  • Page 151: Removing The Spring System Cover-Spring Box Tool

    Rammer Disassembly and Reassembly 4.43 Removing the Spring System Cover—Spring Box Tool ■ Spring box tool P/N 5000081423 Requirements ■ Loctite® 243 ■ Upper assembly removed ■ Bellows removed ■ Ramming shoe removed Background There are two methods for removing the spring system cover: The preferred method is using the special spring box tool P/N 5000081423.
  • Page 152 Disassembly and Reassembly Rammer Continued from the previous page. Screw Position Qty. Machine Schraube position Maschine La posicion del tornillo Cont. Máquina La position de vis Qté. Machine BS60-2i, BS70-2i, BS60-4, DS70 BS50-2I, BS50-4 wc_gr012831 Note: Spring box tool P/N 5000081423 This procedure continues on the next page.
  • Page 153 Rammer Disassembly and Reassembly Continued from the previous page. 3. Align three holes in the spring box tool (a) with the three screws (b) in the spring system cover. wc_gr012832 4. Remove the three screws (b). 5. Insert the three spring box screws (c) through the three selected holes in the spring box tool and turn the screws into the spring cylinder until they bottom out.
  • Page 154 Disassembly and Reassembly Rammer Continued from the previous page. 7. With the threaded rod (d) holding the spring system cover (e) in place, remove the remaining screws (b) from the spring system cover. wc_gr012834 8. Slowly loosen the threaded rod (d) until the springs have fully expanded and the pressure is released.

  • Page 155: Installing The Spring System Cover-Spring Box Tool

    Rammer Disassembly and Reassembly 4.44 Installing the Spring System Cover—Spring Box Tool ■ Spring box tool P/N 5000081423 Requirements ■ Loctite® 243 ■ New gasket Background There are two methods for installing the spring system cover: The preferred method is using the special spring box tool P/N 5000081423. For those who don't have the special tool, the hydraulic press method used.
  • Page 156 Disassembly and Reassembly Rammer Continued from the previous page. Spring Box Tool Method Screw Position Qty. Machine Schraube position Maschine La posicion del tornillo Cont. Máquina La position de vis Qté. Machine BS60-2i, BS70-2i, BS60-4, DS70 BS50-2I, BS50-4 wc_gr012831 Note: Spring box tool P/N 5000081423 This procedure continues on the next page.
  • Page 157 Rammer Disassembly and Reassembly Continued from the previous page. 1. Install the bottom spring set (g) into the spring cylinder. wc_gr012887 2. Place a new gasket (f) onto the spring cylinder. 3. Align the three holes in the spring box tool (a) with the three holes in the spring system cover (e).
  • Page 158 Disassembly and Reassembly Rammer Continued from the previous page. 9. Remove the spring box screws (c) and remove the spring box tool (a). wc_gr012888 10.Install the remaining three screws (b) that hold the spring system cover to the spring cylinder. Torque the screws to 24 Nm (18 ft.lbs.). 11.Install the ramming shoe.

  • Page 159: Removing The Upper Spring Set

    Rammer Disassembly and Reassembly 4.45 Removing the Upper Spring Set ■ Drift pin Requirements ■ Rubber mallet ■ Impact bushing puller P/N 5000116816 ■ Ramming shoe removed ■ Spring system cover removed ■ Lower springs removed Procedure Perform the procedure below to remove the upper spring set. To view an animation of this procedure, internet access is needed.
  • Page 160 Disassembly and Reassembly Rammer Continued from the previous page. 4. Tighten the nut (d) on the impact bushing puller to remove the impact bushing (b) and discard the impact bushing. wc_gr012843 5. Place a drift pin through the holes on the end of the ram (e) to prevent the ram from turning.

  • Page 161: Installing The Upper Spring Set

    Rammer Disassembly and Reassembly 4.46 Installing the Upper Spring Set ■ Drift pin Requirements ■ Rubber mallet ■ Loctite® 243 Procedure Perform the procedure below to install the upper spring set. To view an animation of this procedure, internet access is needed.
  • Page 162 Disassembly and Reassembly Rammer Continued from the previous page. 7. Using one of the two recommended methods, re-install the lower springs and the spring system cover. 8. Re-install the ramming shoe. Result The upper spring set has now been installed. wc_tx004029gb_FM10.fm...

  • Page 163: Testing The Float Switch

    Rammer Disassembly and Reassembly 4.47 Testing the Float Switch 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 prevents ignition. A severed float switch wire will also prevent ignition.
  • Page 164 Disassembly and Reassembly Rammer Continued from the previous page. 2. Disconnect the float switch connector (c). wc_gr012835 3. Check the continuity of the float switch by measuring across the connector terminals (x). wc_gr012836 Does the float switch have continuity? Yes ____ No ____ The float switch is OK.
  • Page 165 Rammer Disassembly and Reassembly Continued from the previous page. 4. Reconnect the float switch. 5. Apply Loctite® 243 to the three screws (b) and fasten the carburetor guard (a) to the machine. Torque the screws to 23 Nm (17 ft.lbs.). wc_gr012693 Result The float switch has now been tested.

  • Page 166: Replacing The Float Switch

    Disassembly and Reassembly Rammer 4.48 Replacing the Float Switch ■ Machine shut down and cool Requirements ■ Approved container for drained oil ■ Plastic sheet to protect work surface ■ Torque wrench ■ Loctite® 243 Procedure Perform the procedure below to replace the float switch. To view an animation of this procedure, internet access is needed.
  • Page 167 Rammer Disassembly and Reassembly Continued from the previous page. 3. Disconnect the stop switch (e) and the float switch (f). wc_gr012845 Note: For ease of installation, record the routing of the float switch wire. 4. Remove the screw (c) and the clamp (d). 5.
  • Page 168 Disassembly and Reassembly Rammer Continued from the previous page. 6. Cut the oil hose (h) from the float switch (m). Remove and retain the clamp (k) for re-use during installation. wc_gr012847 7. Using two flathead screwdrivers, one on either side of the float switch (m), pry the float switch out of the oil filter assembly (n).
  • Page 169 Rammer Disassembly and Reassembly Continued from the previous page. Installation 1. Route and connect the float switch connector (f) and re-connect the stop switch connector (e). wc_gr012845 2. Install the clamp (d) and the screw (c). 3. Before installing the new float switch (m), apply oil to the shaft (p). wc_gr012848 4.
  • Page 170 Disassembly and Reassembly Rammer Continued from the previous page. 5. Remove 3/8 in. (10 mm) off the end of the oil hose (h). 10 mm (3/8 in.) wc_gr012666 6. Insert the float switch (m) into the oil filter (n). 7. Install the clamp (k) and connect the oil hose (h) to the float switch (m). 8.
  • Page 171 Rammer Disassembly and Reassembly Continued from the previous page. 9. Apply Loctite® 243 to the three screws (b) and fasten the carburetor guard (a) to the machine. Torque the screws to 23 Nm (17 ft.lbs.). wc_gr012693 Result The float switch has now been replaced. wc_tx004029gb_FM10.fm...

  • Page 172: Technical Data

    Technical Data Rammer Technical Data BS 50-4s Machine BS 50-4s Item number 5200000644 5200000679 5200000662 5200000680 Engine model WM 100 Operating weight kg (lb) 63 (139) Engine speed–operating 3,950 ± 100 4,200 ± 100 Engine speed–idle 2,000 ± 100 Clutch Engagement 2,650 ±...

  • Page 173: Bs 50-4As

    Rammer Technical Data BS 50-4As Machine BS 50-4As Item number 5200018219 5100015099 5200018226 Engine model Honda GX100 Honda GXR120 Operating weight kg (lb) 64 (141) Engine speed–operating 3,950 ± 100 4,200 ± 100 3,950 ± 100 Engine speed–idle 1,850 ± 150 Clutch Engagement 2,650 ±...

  • Page 174: Bs 60-4S

    Technical Data Rammer BS 60-4s Machine BS 60-4s Item number 5200000647 5200000648 5200000667 5200000668 5200000674 5200022984 5200000675 Engine model WM 100 Operating weight kg (lb) 71 (156) Engine speed–operating 3,950 ± 100 4,200 ± 100 Engine speed–idle 2,000 ± 100 Clutch Engagement 2,650 ±...

  • Page 175: Bs 60-4As

    Rammer Technical Data BS 60-4As Machine BS 60-4As Item number 5200014910 5100015123 5200018231 5200018232 5200018233 Engine model Honda GX100 Honda GXR120 Operating weight kg (lb) 72 (158) Engine speed–operating 3,950 ± 100 4,200 ± 100 3,950 ± 100 Engine speed–idle 1,850 ±...

  • Page 176: Bs 70-4As

    Technical Data Rammer BS 70-4As Machine BS 70-4As Item number 5100015124, 5100015126 Engine model Honda GXR120 Operating weight kg (lb) 80 (177) Engine speed–operating 3,950 ± 100 Engine speed–idle 1,850 ± 150 Clutch Engagement 2,650 ± 100 Max. rated power @ rated speed kW (hp) 2.80 (3.75) Spark plug...

  • Page 177: Sound Measurements

    Rammer Technical Data Sound Measurements Products are tested for sound pressure level in accordance with EN 500-4:2011. Sound power level is tested in accordance with European Directive 2000/14/EC - Noise Emission in the Environment by Equipment for use outdoors. Sound Pressure at Operator’s Guaranteed Sound Power Machine Location dB(A)

  • Page 178: Vibration Measurements

    Technical Data Rammer Vibration Measurements Products are tested for hand/arm vibration (HAV) level in accordance with ISO 5349, EN1033, and EN500-4 where applicable. Machine HAV m/sec HAV ft/sec BS 50-4s 5200000644 30.2 5200000662 BS 50-4s 5200000679 16.1 BS 50-4s 5200000680 28.2 BS 50-4As 5200018219...

  • Page 179: Dimensions

    Rammer Technical Data Dimensions wc_gr011607 mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) BS 50-4s 673 (26.5) 343 (13.5) 940 (37.0) 280 (11.0) 337 (13.27) BS 50-4As BS 60-4s 673 (26.5) 343 (13.5) 965 (38.0) 280 (11.02) 336 (13.25) BS 60-4As BS 70-4As 673 (26.5)
  • Page 180 Technical Data Rammer Notes wc_td000553gb_FM10.fm...

  • Page 181: Technical Data

    Four-stage with cyclonic precleaner Fuel specification type Regular unleaded gasoline (minimum 85 octane) Oil specification, 2-cycle type Wacker Neuson 2-cycle or other fully synthetic oil meeting the NMMA TC-W3, JASO FD, or ISO-L-EGD specification. Oil tank capacity L (qt) 1.3 (1.4)

  • Page 182: Bs 60-2I

    Four stage with cyclonic precleaner Fuel specification type Regular unleaded gasoline Oil specification, 2-cycle type Wacker Neuson two-cycle or other fully synthetic oil meeting the NMMA TC-W3, JASO FD, or ISO-L-EGD specification Oil tank capacity L (qt) 1.3 (1.4) Fuel tank capacity L (qt) 3.0 (3.2)

  • Page 183: Bs 70-2I

    Four stage with cyclonic precleaner Fuel specification type Regular unleaded gasoline Oil specification, 2-cycle type Wacker Neuson two-cycle or other fully synthetic oil meeting the NMMA TC-W3, JASO FD, or ISO-L-EGD specification Oil tank capacity L (qt) 1.3 (1.4) Fuel tank capacity L (qt) 3.0 (3.2)

  • Page 184: Bs 50-2 Operating Weight

    — 50:1 – 100:1 Oil specification, 2-cycle — Use only Wacker Neuson two-cycle or other fully synthetic oil meeting the NMMA TC-W3, JASO FD, or ISO-L-EGD specification. A gasoline/oil ratio in a range from 50:1 to 100:1 can be used. For optimum engine performance and durability, a 100:1 ratio with a fully synthetic oil meeting the specification described above is preferred.

  • Page 185: Bs 60-2 Operating Weight

    Regular unleaded gasoline (minimum 85 octane) Oil specification, 2-cycle — Use only Wacker Neuson two-cycle or other fully synthetic oil meeting the NMMA TC-W3, JASO FD, or ISO-L-EGD specification. A gasoline/oil ratio in a range from 50:1 to 100:1 can be used.

  • Page 186: Bs 70-2 Operating Weight

    — 50:1 – 100:1 Oil specification, 2-cycle — Use only Wacker Neuson two-cycle or other fully synthetic oil meeting the NMMA TC-W3, JASO FD, or ISO-L-EGD specification. A gasoline/oil ratio in a range from 50:1 to 100:1 can be used. For optimum engine performance and durability, a 100:1 ratio with a fully synthetic oil meeting the specification described above is preferred.

  • Page 187: Bs 65-V

    — 50:1 – 100:1 Oil specification, 2-cycle — Use only Wacker Neuson two-cycle or other fully synthetic oil meeting the NMMA TC-W3, JASO FD, or ISO-L-EGD specification. A gasoline/oil ratio in a range from 50:1 to 100:1 can be used. For optimum engine performance and...

  • Page 188: Sound Measurements

    Technical Data Rammer 6.15 Sound Measurements Products are tested for sound pressure level in accordance with EN 500-4:2011. Sound power level is tested in accordance with European Directive 2000/14/EC - Noise Emission in the Environment by Equipment for use outdoors. Sound Pressure at Operator’s Guaranteed Sound Power Machine...

  • Page 189: Vibration Measurements

    Rammer Technical Data 6.16 Vibration Measurements Products are tested for hand/arm vibration (HAV) level in accordance with ISO 5349, EN1033, and EN500-4 where applicable. Machine Item number HAV m/sec HAV ft/sec 5200000642, 5200000643, 32.1 5200000659, 5200000660, 5200000658, 5200000678, BS 50-2i 5200025428, 5200025429 5200000661, 5200000657, 17.7...

  • Page 190: Dimensions-Bs 50-2I, Bs 50-2

    Technical Data Rammer 6.17 Dimensions—BS 50-2i, BS 50-2 mm (in.) (26.5) (13.5) (37.0) wc_gr011405 BS 50-2i BS 50-2 mm (in.) mm (in.) 5200000642 5200000656 280 (11.03) 337 (13.27) 5200000660 5200000686 5200000687 5200000678 5200025428 5200000643 5200000641 250 (9.84) 337 (13.25) 5200000658 5200000654 5200000659 5200000685...

  • Page 191: Dimensions-Bs 60-2I, Bs 60-2, Bs 70-2I, Bs 70-2, Bs 65-V

    Rammer Technical Data 6.18 Dimensions—BS 60-2i, BS 60-2, BS 70-2i, BS 70-2, BS 65-V mm (in.) (26.5) (13.5) (38.0) wc_gr011411 BS 60-2i BS 60-2 mm (in.) mm (in.) 5200000645 5200000663 280 (11.02) 336 (13.25) 5200000664 5200000688 5200000689 5200019205 5200000682 5200000646 —...
  • Page 194 Wacker Neuson Production Americas LLC, 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.

This manual is also suitable for:

Bs 70-4asBs 60-4s, bs 60-4asBs 70-2iBs 50-2Bs 50-2iBs 60-2i ... Show all

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