Wacker Neuson BS 50-4 Repair Manual
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Wacker Neuson BS 50-4 Repair Manual

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REPAIR MANUAL
0
1
1
4
5
4
9
0114549
1107
Vibratory Rammers
BS 50 / BS 60 / BS 70
BS 500 / BS 600 / BS 700
BS 65 / BS 650
DS 70 / DS 720
009
en

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  • Page 1 www.wackergroup.com 0114549 1107 Vibratory Rammers BS 50 / BS 60 / BS 70 BS 500 / BS 600 / BS 700 BS 65 / BS 650 DS 70 / DS 720 REPAIR MANUAL...
  • Page 3 Rammer Repair Foreword This manual covers machines with Item Number: BS 50-4 0009386, 0009415, 0620108, 0620071, 0620077, 0620078 BS 50-2 0009380, 0009382, 0009384, 0009410, 0009411, 0009413, 0620025, 0620048 BS 50-2i 0009332, 0009338, 0009383, 0009412, 0009414, 0009416, 0009473, 0620026 BS 500...
  • Page 4 Foreword Rammer Repair Operating / Parts Information You must be familiar with the operation of this machine before you attempt to troubleshoot or make any repairs to it. Basic operating and maintenance procedures are described in the operator’s / parts manual supplied with the machine.

  • Page 5: Table Of Contents

    Rammer Repair Table of Contents Safety Information Operating Safety .................. 9 Operator Safety while using Internal Combustion Engines ....11 Service Safety ..................12 Service and Repair Safety ..............13 General Description ..................14 Power Transmission ................14 Spring System ..................14 Bellows ....................
  • Page 6 Table of Contents Rammer Repair Fuel Lines (BS 50/60/70-2, BS 65) ............38 3.10 Fuel Tank (BS Models) ................39 3.11 Fuel Tank (DS Models) ...............40 3.12 Fuel Tank Cap ..................42 3.13 Muffler (BS Models) ................44 3.14 Engine Cooling Fins ................45 3.15 Muffler (DS Models) ................46 3.16 Removing WM 80 Engine From BS Model Rammers ......48...
  • Page 7 Engine Overheats ................98 Rammer Does Not Tamp ..............98 Rammer Jumps Erratically ..............99 Technical Data BS 50-2 .................... 100 BS 50-4 .................... 101 BS 500 ....................102 BS 500S ................... 103 BS 50-2i .................... 104 BS 500-oi ..................105 BS 60/70-2 ..................

  • Page 8: Safety Information

    Safety Information Rammer Repair Safety Information This manual contains DANGER, WARNING, CAUTION, NOTICE and NOTE callouts which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

  • Page 9: Operating Safety

    Rammer Repair Safety Information Operating Safety Familiarity and proper training are required for the safe operation of the machine. Machines operated improperly or by untrained personnel can be dangerous. Read the operating instructions contained in both WARNING this manual and the Engine Manual and familiarize yourself with the location and proper use of all controls.
  • Page 10 Safety Information Rammer Repair 1.1.17 ALWAYS be sure the rammer will not tip over, roll, slide, or fall when not being operated. 1.1.18 ALWAYS turn the engine OFF when the rammer is not being operated. 1.1.19 ALWAYS guide the rammer in such a way that the operator is not squeezed between the rammer and solid objects.

  • Page 11: Operator Safety While Using Internal Combustion Engines

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

  • Page 12: Service Safety

    Safety Information Rammer Repair Service Safety A poorly maintained machine can become a safety hazard! In order for the machine to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. WARNING 1.3.1 DO NOT attempt to clean or service the machine while it is running.

  • Page 13: Service And Repair Safety

    Rammer Repair Safety Information Service and Repair Safety The service procedures contained in this manual are intended for use by an individual equipped with the proper tools and equipment and familiar with safe shop practices. Should questions arise during the service or repair of this equipment please contact WACKER for assistance! WACKER Corporation maintains a staff of trained service specialists to answer your...

  • Page 14: General

    Power Transmission BS 50, BS 60, BS70, BS 65, BS 500, BS 600, BS 700, and BS 650 Rammers are powered by the WACKER WM80 engine. The BS 50-4 and BS 60-4 Rammers are powered by the WACKER WM90 engine.

  • Page 15: Bellows

    Rammer Repair General Bellows The bellows provides a flexible joint between the ramming system and the upper machinery. It seals out dust and dirt and provides a clean path for recirculating oil. Lubricating System The rammers use a sealed-oil-bath lubricating system. Oil is distributed to the gears, the bearings, the springs, and the other moving parts by the up and down action of the ramming system.

  • Page 16: Recommended Special Tools

    General Rammer Repair 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_tx000284gb.fm...

  • Page 17: Recommended Repair Tools

    Rammer Repair General 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 18: Periodic Maintenance Schedule (Bs 50/60/70-2, Bs 65)

    General Rammer Repair 2.10 Periodic Maintenance Schedule (BS 50/60/70-2, BS 65) After Every Every Every Daily first week month 3 months Every before or 25 or 100 or 300 Year starting hours hours hours hours Check fuel level. Check air filter indicator. Replace as needed.

  • Page 19: Periodic Maintenance Schedule (Bs 500/600/700/650)

    Rammer Repair General 2.11 Periodic Maintenance Schedule (BS 500/600/700/650) Every Every Every Daily After week month 3 months Every before first or 25 or 100 or 300 Year starting 5 hours hours hours hours Check fuel level. Check engine oil level.

  • Page 20: Periodic Maintenance Schedule (Bs 50/60/70-2I)

    General Rammer Repair 2.12 Periodic Maintenance Schedule (BS 50/60/70-2i) After Every Every Every Daily first week month 3 months Every before or 25 or 100 or 300 Year starting hours hours hours hours Check fuel level. Check engine oil level. Check air filter indicator.

  • Page 21: Periodic Maintenance Schedule (Bs 500/600/700-Oi)

    Rammer Repair General 2.13 Periodic Maintenance Schedule (BS 500/600/700-oi) After Every Every Every Daily first week month 3 months Every before or 25 or 100 or 300 Year starting hours hours hours hours Check fuel level. Inspect air filter. Replace as needed.

  • Page 22: Periodic Maintenance Schedule (Ds 70)

    General Rammer Repair 2.14 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 23: Periodic Maintenance Schedule (Ds 720)

    Rammer Repair General 2.15 Periodic Maintenance Schedule (DS 720) 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 rammer oil level in sightglass.

  • Page 24: Transporting The Rammer (Bs Models)

    General Rammer Repair 2.16 Transporting the Rammer (BS Models) See Graphic: wc_gr000050 2.16.1 Always shut off the engine and close the fuel valve when transporting the rammer. 2.16.2 Make sure lifting devices have enough capacity to lift the rammer. See identification plate on rammer for weight.

  • Page 25: Transporting The Rammer (Ds Models)

    Rammer Repair General 2.17 Transporting the Rammer (DS Models) See Graphic: wc_gr000063 2.17.1 Always shut off the engine and close the fuel valve when transporting the rammer. 2.17.2 Make sure lifting devices have enough capacity to lift the rammer. See identification plate on rammer for weight.

  • Page 26: Long-Term Storage (Bs Models)

    General Rammer Repair 2.18 Long-Term Storage (BS Models) 2.18.1 Drain the fuel from the tank. 2.18.2 Start the engine and run it until remaining fuel is used. 2.18.3 Remove the spark plug. Pour approximately 30 ml (1 oz.) of clean SAE 10W30 engine oil into the cylinder through the spark plug opening.
  • Page 27 Rammer Repair General Notes wc_tx000284gb.fm...

  • Page 28: Guide Handle And Engine

    Guide Handle and Engine Rammer Repair Guide Handle and Engine Air Cleaner (BS 500/600/700/650, DS720) See Graphic: wc_gr001307rm The rammer is equipped with a dual element air cleaner. Under normal operating conditions the elements will not require scheduled cleaning and should not be removed from the rammer. If the elements do become plugged with dirt, the engine will begin to lose power.
  • Page 29 Rammer Repair Guide Handle and Engine wc_tx000285gb.fm...

  • Page 30: Air Cleaner (Bs 50/60/70-2, Bs 65, Ds 70)

    Guide Handle and Engine Rammer Repair Air Cleaner (BS 50/60/70-2, BS 65, DS 70) See Graphic: wc_gr001168 NEVER use gasoline or other types of low flash point solvents for cleaning the air filter. A fire or explosion could result. WARNING NOTICE: NEVER run engine without main paper filter element (b).

  • Page 31: Air Cleaner (Bs 50/60-4)

    Rammer Repair Guide Handle and Engine Air Cleaner (BS 50/60-4) See Graphic: wc_gr001306 NEVER use gasoline or other types of low flash point solvents for cleaning the air filter. A fire or explosion could result. WARNING NOTICE: NEVER run the engine without the main paper air filter (b). Severe engine damage will occur.

  • Page 32: Silencing Cover

    Guide Handle and Engine Rammer Repair Silencing Cover See Graphic: wc_gr001309rm 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). When reinstalling the silencing cover, apply Loctite 243 and torque the screws to 9.4 Nm (6.9 ft.lbs.).

  • Page 33: Guide Handle

    Rammer Repair Guide Handle and Engine Guide Handle See Graphic: wc_gr003704 Recommended Tools Ratchet Wrench Socket: 10 mm Screwdriver Pliers Loctite 243 (Blue) 3.5.1 Close the fuel valve. 3.5.2 Disconnect the fuel line. 3.5.3 Loosen the throttle cable holder. 3.5.4 Disconnect the throttle cable from the throttle cam lever.

  • Page 34: Shock Mounts

    Guide Handle and Engine Rammer Repair Shock Mounts See Graphic: wc_gr003705 Recommended Tools Ratchet Wrench Torque Wrench Loctite 243 (blue) 3.6.1 Remove the silencing cover, the air cleaner, and the guide handle. 3.6.2 Inspect the shock mounts (a) and make sure that they are securely mounted to the crankcase.

  • Page 35: Throttle Control

    Rammer Repair Guide Handle and Engine Throttle Control See Graphic: wc_gr003876 3.7.1 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.). To adjust the throttle cable: 3.7.2 Place the throttle lever in the STOP position (c).

  • Page 36: Tillotson Carburetor (Bs 500/600/700/650 Only)

    Guide Handle and Engine Rammer Repair 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 37 Rammer Repair Guide Handle and Engine 3.8.4 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. 3.8.5 Loosen the air duct clamps and remove the air duct. 3.8.6 Remove the two socket head cap screws (c) holding the carburetor to the engine.

  • Page 38: Fuel Lines (Bs 50/60/70-2, Bs 65)

    Guide Handle and Engine Rammer Repair 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: 3.9.1 Shut off the engine by moving the throttle through the detent to the off position (a).

  • Page 39: Fuel Tank (Bs Models)

    Rammer Repair Guide Handle and Engine 3.10 Fuel Tank (BS Models) See Graphic: wc_gr001312rm 3.10.1 Remove the silencing cover. 3.10.2 Close the fuel valve (a). 3.10.3 Disconnect the fuel line (b) from the fuel tank. Disconnect the vent line (c) where used. 3.10.4 Drain the fuel into a suitable container.

  • Page 40: Fuel Tank (Ds Models)

    Guide Handle and Engine Rammer Repair 3.11 Fuel Tank (DS Models) See Graphic: wc_gr001313rm 3.11.1 Remove the silencing cover. 3.11.2 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 41 Rammer Repair Guide Handle and Engine wc_gr001313rm wc_tx000285gb.fm...

  • Page 42: Fuel Tank Cap

    Guide Handle and Engine Rammer Repair 3.12 Fuel Tank Cap See Graphic: wc_gr004562 To disassemble and clean the fuel tank cap: 3.12.1 Grasp the fuel tank cap (a) in one hand and the baffle (b) in the other. 3.12.2 Pull and twist the baffle left and right to separate it from the fuel tank cap.
  • Page 43 Rammer Repair Guide Handle and Engine wc_gr004562 wc_tx000285gb.fm...

  • Page 44: Muffler (Bs Models)

    Guide Handle and Engine Rammer Repair 3.13 Muffler (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 45: Engine Cooling Fins

    Rammer Repair Guide Handle and Engine 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 3.14 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 46: Muffler (Ds Models)

    Guide Handle and Engine Rammer Repair 3.15 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 47 Rammer Repair Guide Handle and Engine w c _ g r 0 0 1 3 1 5 r m wc_tx000285gb.fm...

  • Page 48: Removing Wm 80 Engine From Bs Model Rammers

    Guide Handle and Engine Rammer Repair 3.16 Removing WM 80 Engine From BS Model Rammers See Graphic:wc_gr002935 Removal: 3.16.1 Stop the machine and allow it to cool. 3.16.2 Remove the carburetor. See section Removing Carburetor. 3.16.3 Remove the muffler guard (a) (if equipped) and the muffler (b). 3.16.4 Disconnect the connector (c) from the stop switch.
  • Page 49 Rammer Repair Guide Handle and Engine wc_gr002935 wc_tx000285gb.fm...

  • Page 50: Removing Wm 90 Engine From Bs Model Rammers

    Guide Handle and Engine Rammer Repair 3.17 Removing WM 90 Engine From BS Model Rammers See Graphic: wc_gr001954, wc_gr003661, wc_gr001956, and wc_gr001957 3.17.1 Disconnect the spark plug cap (a) from the spark plug. 3.17.2 Disconnect the fuel line (b) from the carburetor and plug the line. 3.17.3 Disconnect the stop switch wire (c).
  • Page 51 Rammer Repair Guide Handle and Engine wc_gr003661 wc_gr001954 wc_tx000285gb.fm...

  • Page 52: Engine (Ds Models)

    Guide Handle and Engine Rammer Repair 3.18 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 3.18.1 Close the fuel valve. 3.18.2 Disconnect the fuel lines.
  • Page 53 Rammer Repair Guide Handle and Engine w c _ g r 0 0 1 3 1 7 r m wc_tx000285gb.fm...

  • Page 54: Clutch (Bs Models)

    Guide Handle and Engine Rammer Repair 3.19 Clutch (BS Models) See Graphic: wc_gr01318rm Recommended Tools Impact wrench Torque wrench Socket: 17 mm Needle-nose pliers Clutch puller P/N 0117972 Removal 3.19.1 Remove the engine from the rammer. 3.19.2 Check the condition of the clutch shoes (a) and replace them if necessary.
  • Page 55 Rammer Repair Guide Handle and Engine BS Models w c _ g r 0 0 1 3 1 8 r m wc_tx000285gb.fm...

  • Page 56: Clutch (Ds 720 Only)

    Guide Handle and Engine Rammer Repair 3.20 Clutch (DS 720 only) See Graphic: wc_gr001319rm Recommended Tools Impact wrench Torque wrench Needle-nose pliers Clutch puller P/N 0153566 Removal 3.20.1 Remove the engine from the rammer. 3.20.2 Check the condition of the clutch shoes (a) and replace them if necessary.
  • Page 57 Rammer Repair Guide Handle and Engine DS 720 Models wc_gr001319rm wc_tx000285gb.fm...

  • Page 58: Clutch (Ds 70 Only)

    Guide Handle and Engine Rammer Repair 3.21 Clutch (DS 70 only) See Graphic: wc_gr002372rm Recommended Tools Impact wrench Torque wrench Needle-nose pliers Clutch puller P/N 0153566 Removal 3.21.1 Remove the engine from the rammer. 3.21.2 Check the condition of the clutch shoes (a) and replace them if necessary.
  • Page 59 Rammer Repair Guide Handle and Engine DS 70 Models wc_gr002372rm wc_tx000285gb.fm...

  • Page 60: Engine Oil (Ds 720 Only)

    Guide Handle and Engine Rammer Repair 3.22 Engine Oil (DS 720 Only) See Graphic: wc_gr001320rm, wc_gr000057 Engine oil Check oil level: Tilt the machine backwards approximately 15° until the engine is level by placing a wedge under the shoe. The oil surface should reach NO HIGHER THAN the bottom of the filler neck “H”, but no lower than “L”...
  • Page 61 Rammer Repair Guide Handle and Engine w c _ g r 0 0 1 3 2 0 r m wc_tx000285gb.fm...

  • Page 62: Engine Oil (Ds 70 Only)

    Guide Handle and Engine Rammer Repair 3.23 Engine Oil (DS 70 only) See Graphic: wc_gr000066 and wc_gr000067 3.23.1 Drain the oil while the engine is still warm. 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 63: Engine Oil (Bs 50/60-4 Only)

    Rammer Repair Guide Handle and Engine 3.24 Engine Oil (BS 50/60-4 only) See Graphic: wc_gr002431 and wc_gr000067 3.24.1 Drain the oil while the engine is still warm. 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 64: 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 65 Rammer Repair Ramming System wc_gr001321rm Installation 4.1.9 Oil the inner edges of the bellows. 4.1.10 Place the lower clamp (f) on the protective pipe (j). 4.1.11 Press the bellows (e) onto the protective pipe (j) with a strong downward push. 4.1.12 Partially tighten the clamp onto the bellows.
  • Page 66 Ramming System Rammer Repair 4.1.20 Fasten the guide cylinder to the crankcase. Apply Loctite 243 and torque the screws to 43 Nm (32 ft.lbs.). 4.1.21 Lay the rammer flat on the ground and align the protective pipe with the upper machinery. 4.1.22 Position the clamps so that the clamp screws (k) are in line with the sightglass (m).

  • Page 67: Ramming Shoe

    Rammer Repair Ramming System Ramming Shoe See Graphic: wc_gr001323rm Recommended Tools Ratchet wrench Torque wrench Socket: 19 mm Damage to the ramming shoe usually occurs due to loose hardware and improper operation. Operating the rammer with loose screws causes the ramming shoe to pound itself against the spring cylinder. Hitting the ground with the edge of the ramming shoe can cause the ramming shoe to wear out and crack.

  • Page 68: 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 69 Rammer Repair Ramming System Hydraulic Press Method wc_gr001324rm wc_tx000286gb.fm...
  • Page 70 Ramming System Rammer Repair See Graphic: wc_gr001325rm Threaded Rod Removal Method 4.3.15 Remove the ramming shoe per section Ramming Shoe. Separate the ramming system from the upper machinery per section Bellows. 4.3.16 Remove the two socket head cap screws that are opposite of each other on the spring system cover.
  • Page 71 Rammer Repair Ramming System Threaded Rod Method wc_gr001325rm wc_tx000286gb.fm...
  • Page 72 Ramming System Rammer Repair See Graphic: wc_gr001326 Spring Box Tool Removal Method 4.3.1 Remove the ramming shoe per section Ramming Shoe. Separate the ramming system from the upper machinery per section Bellows. 4.3.2 Align three holes in the spring box tool (a) with three socket head cap screws in the spring system cover.
  • Page 73 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_tx000286gb.fm...

  • Page 74: 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 4.4.1 Remove the ramming shoe and separate the ramming system from the upper machinery.
  • Page 75 Rammer Repair Ramming System Assembly 4.4.10 Slide the ram (e) into the spring cylinder (h). 4.4.11 Reinstall the bushing (f) and the spring set (g). 4.4.12 Reinstall the piston guide (j). 4.4.13 Replace the locknut (k) and torque it to: BS 500 - 210 Nm (155 ft.lbs.) BS 600/700 - 250 Nm (184 ft.lbs.).

  • Page 76: Inspecting The Spring System

    Ramming System Rammer Repair Inspecting the Spring System See Graphic: wc_gr001329rm Over time, the constant compression and release of the spring pressure can cause the springs to wear out. If the rammer feels to be hitting with less force, it is possible that the springs are worn and should be replaced.

  • Page 77: 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. 4.6.1 Remove the bellows following the procedures in section Bellows.

  • Page 78: 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 79: Ramming System Lubrication (Bs 50/60/70, Bs 65, Ds 70)

    Rammer Repair Ramming System 4.7.9 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 Ramming System Lubrication (BS 50/60/70, BS 65, DS 70) See Graphic: wc_gr001331rm Recommended Tools...
  • Page 80 Ramming System Rammer Repair Check oil level: Check the oil level in the sightglass (a) daily before starting the rammer. When checking the oil, make sure the rammer is on a flat, level surface. The oil level should fill 1/2–3/4 of the sightglass. If the oil is not visible, oil must be added through the sightglass port.
  • Page 81 Rammer Repair Ramming System Notes wc_tx000286gb.fm...

  • Page 82: Crankcase

    Crankcase Rammer Repair Crankcase Crank Gear and Connecting Rod See Graphic: wc_gr001332rm, wc_gr001333rm 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 5.1.1 Remove the four socket head cap screws that secure the ramming system to the crankcase.
  • Page 83 Rammer Repair Crankcase 5.1.14 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. w c _ g r 0 0 1 3 3 2 r m Assembly 5.1.15 If the needle bearing was removed, press a new bearing into the cover until the outer race is flush with the flange surface.
  • Page 84 Crankcase Rammer Repair wc_gr001333rm wc_tx000287gb.fm...

  • Page 85: Crank Gear, Connecting Rod, And Adjuster Assembly (Bs 650/65 Only)

    Rammer Repair Crankcase 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 86 Crankcase Rammer Repair 5.2.13 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 87 Rammer Repair Crankcase Assembly 5.2.16 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. 5.2.17 Press the ball bearing (27) into the connecting rod. 5.2.18 Press the connecting rod assembly (24) onto the eccentric drive shaft (23) and secure it in place with the small snap ring (25).

  • Page 88: 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 5.3.1 Remove the four socket head cap screws that secure the ramming system to the crankcase.
  • Page 89 Rammer Repair Crankcase wc_gr001335rm Assembly 5.3.14 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 90: Oil Injection (If Equipped)

    Oil Injection (if equipped) Rammer Repair Oil Injection (if equipped) Float Switch Testing and Replacement See Graphic: wc_gr001526 NOTICE: Never 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 91 Rammer Repair Oil Injection (if equipped) 6.1.12 Ensure that the float switch plug is fully seated in the connector on the back of the engine. wc_gr001526 wc_tx000288gb.fm...

  • Page 92: 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 93 Rammer Repair Oil Injection (if equipped) wc_gr001527 wc_tx000288gb.fm...

  • Page 94: Oil Pump / Cartridge Assembly

    Oil Injection (if equipped) Rammer Repair Oil Pump / Cartridge Assembly See Graphic: wc_gr001528 If the rammer was used for a long period of time, 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 95: 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: 7.1.1 Remove the lower engine guard (a).

  • Page 96: 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 97: 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 98: 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 99: 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 100: Technical Data

    Technical Data Rammer Repair Technical Data BS 50-2 Item Number: BS 50-2 0009380, 0009382, 0009384, 0009410 0009411, 0009413, 0620025, 0620048 Rammer Engine Model WM80 type Engine Speed - full 4400 ± 100 Engine Speed - idle 1800 ± 100 Clutch Engagement 2500 ±...
  • Page 101 Rammer Repair Technical Data BS 50-4 Item Number: BS 50-4 BS 50-4s 0009386, 0620077 0620071, 0620078 0620108 Rammer Engine Model WM90 type Engine Speed - full 4300 ± 100 Engine Speed - idle 2000 ± 100 Clutch Engagement 2500 ± 100...
  • Page 102 Technical Data Rammer Repair BS 500 Item Number: BS 500 0007550, 0008048 0008049, 0009074, 0009075 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...

  • Page 103: Bs 500S

    Rammer Repair Technical Data BS 500S Item Number: BS 500S 0009211 Rammer Engine Model type WM80 Engine Speed - full 4700 ± 100 Engine Speed - idle 1800 ± 100 Clutch Engagement 2800 ± 100 Spark Plug type Champion RL95YC Electrode Gap 0.5 (.020) mm (in.)

  • Page 104: Bs 50-2I

    Technical Data Rammer Repair BS 50-2i Item Number: BS 50-2i BS 50-2i 0009332, 0009338 0009383 0009414, 0009416 0009412 0009473, 0620026 Rammer Engine Model WM80 type Engine Speed - full 4400 ± 100 4600 ± 100 Engine Speed - idle 1800 ± 100 Clutch Engagement 2500 ±...

  • Page 105: Bs 500-Oi

    Rammer Repair Technical Data 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.) 0.5 (0.020)
  • Page 106 Technical Data Rammer Repair BS 60/70-2 Item Number: BS 60-2 BS 60-2 BS 70-2 0009388 0009391 0009397 0009417 0009418 0009399 0009421 0009424 0009425 0009427 Rammer Engine Model WM80 type Engine Speed - full 4400 ± 100 4600 ± 100 Engine Speed - idle 1800 ±...
  • Page 107 Rammer Repair Technical Data BS 60-4 Item Number: BS 60-4 BS 60-4s 0009340, 0620000 0620072, 0620073 0620051, 0620109 0620074 0620110 Rammer Engine Model WM90 type Engine Speed - full 4300 ± 100 Engine Speed - idle 2000 ± 100 Clutch Engagement 2500 ±...
  • Page 108 Technical Data Rammer Repair BS 600/700 Item Number: BS 600 BS 700 0007551, 0008207 0007552, 0008051 0009076, 0009307 0008052, 0009308 Rammer Engine Model type WM80 Engine Speed - full 4350 ± 100 Engine Speed - idle 1800 ± 100 Clutch Engagement 2800 ±...

  • Page 109: Bs 600S

    Rammer Repair Technical Data 9.10 BS 600S Item Number: BS 600S 0009212 Rammer Engine Model type WM80 Engine Speed - full 4600 ± 100 Engine Speed - idle 1800 ± 100 Clutch Engagement 2800 ± 100 Spark Plug type Champion RL95YC Electrode Gap mm (in.) 0.5 (0.020)

  • Page 110: Bs 60/70-2I

    Technical Data Rammer Repair 9.11 BS 60/70-2i Item Number: BS 60-2i BS 60-2i BS 70-2i 0009339 0009393 0009341 0009419 0009420 0009401 0009426 0009428 Rammer Engine Model WM80 type Engine Speed - full 4400 ± 100 4600 ± 100 Engine Speed - idle 1800 ±...

  • Page 111: Bs 600/700-Oi

    Rammer Repair Technical Data 9.12 BS 600/700-oi Item Number: BS 600-oi BS 700-oi 0009166, 0009262 0009167, 0009328 Rammer Engine Model type WM80 Engine Speed - full 4350 ± 100 Engine Speed - idle 1800 ± 100 Clutch Engagement 2800 ± 100 Spark Plug type Champion RL95YC...

  • Page 112: Bs 600/700 High Altitude

    Technical Data Rammer Repair 9.13 BS 600/700 High Altitude Item Number: BS 600 BS 700 0009077 0009079 Rammer Engine Model type WM80 Engine Speed - full 4350 ± 100 Engine Speed - idle 1800 ± 100 Clutch Engagement 2800 ± 100 Spark Plug type Champion RL95YC...

  • Page 113: Bs 65-V

    Rammer Repair Technical Data 9.14 BS 65-V Item Number: BS 65-V 0009396, 0009423 Rammer Engine Model WM80 type Engine Speed - full 4400 ± 100 Engine Speed - idle 1800 ± 100 Clutch Engagement 2500 ± 100 Spark Plug Champion RL95YC type Electrode Gap 0.5 (0.020)
  • Page 114 Technical Data Rammer Repair 9.15 BS 650 Item Number: BS 650 0008209 Rammer Engine Model type WM80 Engine Speed - full 4350 ± 100 Engine Speed - idle 1800 ± 100 Clutch Engagement 2800 ± 100 Spark Plug type Champion RL95YC Electrode Gap Cylinder Head 8.0–9.7...
  • Page 115 Rammer Repair Technical Data NOTES wc_td000112gb.fm...
  • Page 116 Technical Data Rammer Repair 9.16 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 117 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 Rated Power 3.1 (4.1)
  • Page 118 Technical Data Rammer Repair 9.17 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 119 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 120 Technical Data Rammer Repair wc_td000112gb.fm...
  • Page 121 Threadlockers and Sealants Threadlockers and Sealants Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant.
  • Page 122 Threadlockers and Sealants Threadlockers and Sealants (continued) Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant.
  • Page 123 Torque Values Torque Values Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE 10.9 12.9 Size ft.lb. ft.lb. ft.lb. Metric Inch Metric Inch 7/32 – 9/32 – 5/16 – – – – 11/16 – – – 15/16 –...
  • Page 124 Torque Values Torque Values (continued) Inch Fasteners (SAE) Size ft.lb. ft.lb. ft.lb. Metric Inch Metric Inch No.4 – 3/32 No.6 5/16 – 7/64 No.8 11/32 – 9/64 No.10 – – 5/32 – 7/16 – 3/32 5/16 – – 9/16 – 5/16 7/16 –...
  • Page 126 Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90 Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957 Wacker Asia Pacific Operations ·...

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