Wacker Neuson BS 50-4, Repair Manual

Page 1: ...www wackergroup com Vibratory Rammers BS 50 BS 60 BS 70 BS 500 BS 600 BS 700 BS 65 BS 650 DS 70 DS 720 REPAIR MANUAL 0114549 009 1107 en 0 1 1 4 5 4 9 ...

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Page 3: ...11 BS 60 4 0009340 0009422 0620000 0620051 0620109 0620110 0620072 0620073 0620074 BS 60 2 0009388 0009391 0009417 0009418 0009421 BS 60 2i 0009339 0009393 0009419 0009420 BS 600 0007551 0008205 0008207 0009076 0009077 0009307 BS 600 4 0009331 BS 600 oi 0009166 0009262 BS 600S 0009212 BS 70 2 0009397 0009399 0009424 0009425 0009427 BS 70 2i 0009341 0009401 0009426 0009428 BS 700 0007552 0008051 00...

Page 4: ...ons described in this manual THE INFORMATION CONTAINED IN THIS MANUAL IS BASED ON MACHINES MANUFACTURED UP TO THE TIME OF PUBLICATION WACKER CORPORATION RESERVES THE RIGHT TO CHANGE ANY PORTION OF THIS INFORMATION WITHOUT NOTICE CALIFORNIA Proposition 65 Warning Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of California to caus...

Page 5: ...2 BS 65 18 2 11 Periodic Maintenance Schedule BS 500 600 700 650 19 2 12 Periodic Maintenance Schedule BS 50 60 70 2i 20 2 13 Periodic Maintenance Schedule BS 500 600 700 oi 21 2 14 Periodic Maintenance Schedule DS 70 22 2 15 Periodic Maintenance Schedule DS 720 23 2 16 Transporting the Rammer BS Models 24 2 17 Transporting the Rammer DS Models 25 2 18 Long Term Storage BS Models 26 2 19 Long Term...

Page 6: ...dels 54 3 20 Clutch DS 720 only 56 3 21 Clutch DS 70 only 58 3 22 Engine Oil DS 720 Only 60 3 23 Engine Oil DS 70 only 62 3 24 Engine Oil BS 50 60 4 only 63 4 Ramming System 64 4 1 Bellows 64 4 2 Ramming Shoe 67 4 3 Spring System Cover Removal and Installation 68 4 4 Spring System 74 4 5 Inspecting the Spring System 76 4 6 Protective Pipe 77 4 7 Ramming System Lubrication BS 500 600 700 650 DS 720...

Page 7: ... Start 96 8 2 Engine Does Not Start 97 8 3 Engine Does Not Accelerate or Runs Poorly 97 8 4 Engine Overheats 98 8 5 Rammer Does Not Tamp 98 8 6 Rammer Jumps Erratically 99 9 Technical Data 100 9 1 BS 50 2 100 9 2 BS 50 4 101 9 3 BS 500 102 9 4 BS 500S 103 9 5 BS 50 2i 104 9 6 BS 500 oi 105 9 7 BS 60 70 2 106 9 8 BS 60 4 107 9 9 BS 600 700 108 9 10 BS 600S 109 9 11 BS 60 70 2i 110 9 12 BS 600 700 o...

Page 8: ...t follow this symbol to avoid possible injury or death DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Used without the safety alert symbol...

Page 9: ...ecommended by Wacker Damage to equipment and injury to the user may result 1 1 5 NEVER leave the machine running unattended 1 1 6 NEVER tamper with or disable the function of operating controls 1 1 7 NEVER use choke to stop engine 1 1 8 NEVER operate the machine in areas where explosions may occur 1 1 9 NEVER operate the rammer with the stroke adjusting cover open The locking lever rotates rapidly...

Page 10: ...he machine under such conditions 1 1 20 ALWAYS operate the rammer in such a way that there is no danger of it turning over or falling in when working near the edges of breaks pits slopes trenches and platforms 1 1 21 ALWAYS store the machine properly when it is not being used The machine should be stored in a clean dry location out of the reach of children 1 1 22 ALWAYS close fuel valve on engines...

Page 11: ...el the engine near an open flame 1 2 5 DO NOT spill fuel when refueling the engine 1 2 6 DO NOT run the engine near open flames 1 2 7 DO NOT run the machine indoors or in an enclosed area such as a deep trench unless adequate ventilation through such items as exhaust fans or hoses is provided Exhaust gas from the engine contains poisonous carbon monoxide gas exposure to carbon monoxide can cause l...

Page 12: ...y spark could ignite the fumes 1 3 7 DO NOT use gasoline or other types of fuels or flammable solvents to clean parts especially in enclosed areas Fumes from fuels and solvents can become explosive 1 3 8 ALWAYS replace the safety devices and guards after repairs and maintenance 1 3 9 ALWAYS keep the area around the muffler free of debris such as leaves paper cartons etc A hot muffler could ignite ...

Page 13: ... staff of trained service specialists to answer your questions and to provide assistance and training DO NOT remove bottom spring cover without first reading disassembly procedures or receiving instruction from someone familiar with its safe removal The spring cover is under heavy spring pressure and could cause a serious injury if the proper disassembly procedures are not followed DO NOT run the ...

Page 14: ...duction gears and connecting rod convert the engine s circular motion 4250 4450 rpm to the vertical stroking motion 600 750 blows per minute of the ramming system The gear reduction increases the available power to drive the ramming system through each stroke The connecting rod attached to the crank gear converts the circular rotation of the gears to the up and down stroking motion of the rammer 2...

Page 15: ...f equipment the repair and service procedures described in this manual specify the use of threadlocking compounds These compounds should be used where indicated to prevent the fasteners from becoming loose Although Loctite is referred to throughout this manual any equivalent type of sealant such as Hernon Prolock or Omnifit may be used Clean the screw threads and wipe off any oil or grease before ...

Page 16: ...gb fm 16 2 8 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 0117972 0116816 wc_gr001305rm 0153566 ...

Page 17: ...24 mm 27 mm 1 1 16 32 mm 38 mm 1 1 2 Open end wrench 13 mm Screwdriver Needle nose pliers Large diameter retaining ring pliers Rubber mallet Punch Bearing puller Slide hammer Drift pin Impact wrench Torque wrench up to 210 Nm 155 ft lbs Loctite 243 Shell Alvania RL 2 No 2 grease Hydraulic press Two threaded rods M8 x 120 mm and nuts Split puller Source of compressed air ...

Page 18: ... Check fuel line and fittings for cracks or leaks Replace as needed Tighten ramming shoe hardware Check engine cylinder screws Check external hardware Clean engine cooling fins Clean and check spark plug gap Replace spark plug Clean recoil starter Change ramming system oil Clean engine muffler and exhaust port Inspect crane lifting cable for wear damage or abuse Inspect fuel filter Change ramming ...

Page 19: ... oil level in sightglass Check fuel line and fittings for cracks or leaks Replace as needed Tighten ramming shoe hardware Check external hardware Clean engine cooling fins Clean and check spark plug gap Change engine oil Replace spark plug Clean recoil starter Change ramming system oil Inspect crane lifting cable for wear damage or abuse Inspect fuel filter Change ramming system oil after first 50...

Page 20: ...ightglass Check fuel line and fittings for cracks or leaks Replace as needed Tighten ramming shoe hardware Check engine cylinder screws Check external hardware Clean engine cooling fins Clean and check spark plug gap Replace spark plug Clean recoil starter Change ramming system oil Clean engine muffler and exhaust port Inspect crane lifting cable for wear damage or abuse Inspect fuel filter Change...

Page 21: ...tglass Check fuel line and fittings for cracks or leaks Tighten ramming shoe hardware Check engine cylinder screws Check external hardware Clean engine cooling fins Clean and check spark plug gap Replace spark plug Clean recoil starter Change ramming system oil Clean engine muffler and exhaust port Inspect crane lifting cable for wear damage or abuse Inspect fuel filter Inspect oil filter Change r...

Page 22: ...gs for cracks or leaks Replace as needed Check bellows for dam age and fit Tighten ramming shoe hardware Check external hardware Clean engine cooling fins Change engine oil Clean engine oil filter Clean recoil starter Change ramming system oil Inspect crane lifting cable for wear damage or abuse Check and adjust valve clearance Replace engine oil filter Check fuel filter clean or replace Perform i...

Page 23: ... or leaks Check bellows for damage and fit Tighten ramming shoe hardware Check external hardware Clean engine cooling fins Change engine oil Clean engine oil filter Clean recoil starter Change ramming system oil Inspect crane lifting cable for wear damage or abuse Check and adjust valve clearance Replace engine oil filter Check fuel filter clean or replace Perform initially after first 50 hours of...

Page 24: ...ices Repair or replace damaged lifting devices before lifting the rammer 2 16 3 Use the central lifting point a when lifting the rammer 2 16 4 Wacker Corporation recommends transporting rammers upright whenever possible A rammer should never be allowed to fall over Tie down the rammer to the transport vehicle to prevent it from tipping falling or rolling 2 16 5 If the rammer cannot be secured in t...

Page 25: ...ing the rammer 2 17 4 Wacker Corporation recommends transporting rammers upright whenever possible A rammer should never be allowed to fall over Tie down the rammer to the transport vehicle to prevent it from tipping falling or rolling 2 17 5 If the rammer cannot be secured in the upright position lay the rammer down only as shown Check for fuel leakage from the cap c Drain the fuel tank as requir...

Page 26: ...Pour approximately 30 ml 1 oz of clean SAE 10W30 engine oil into the cylinder through the spark plug opening 2 18 4 Pull the starter rope slowly to distribute oil in the engine 2 18 5 Re install the spark plug 2 19 Long Term Storage DS Models 2 19 1 Drain the fuel from the fuel tank 2 19 2 Start the engine and run it until remaining fuel is used 2 19 3 Cover the rammer and store in a clean dry loc...

Page 27: ...Rammer Repair General wc_tx000284gb fm 27 Notes ...

Page 28: ...ash point solvents for cleaning the air cleaner A fire or explosion could result 3 1 1 Remove the air cleaner cover a by turning the handle counterclockwise until the cover becomes loose and can be lifted out of the mount 3 1 2 Remove the precleaner c and the paper element b and inspect them for holes or tears Replace the precleaner and the paper element if they are damaged 3 1 3 Tap the paper ele...

Page 29: ...Rammer Repair Guide Handle and Engine wc_tx000285gb fm 29 ...

Page 30: ...g procedure 3 2 1 Remove the air cleaner cover a Remove the main paper filter element b and the secondary prefilter c and inspect them for holes or tears Replace the elements if they are damaged 3 2 2 Main paper filter element b Replace the main paper filter element if it appears heavily soiled and or when the yellow plunger of indicator appears in or near the red line 3 2 3 Prefilter c Clean it w...

Page 31: ...tears Replace the elements if they are damaged 3 3 2 Main paper filter element b Replace the main paper filter element if it appears heavily soiled 3 3 3 Prefilter c Clean the prefilter with low pressure compressed air When very soiled wash the prefilter in a solution of mild detergent and warm water Rinse it thoroughly in clean water Allow the prefilter to dry thoroughly before reinstalling Note ...

Page 32: ...ended 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 w c g r 0 0 1 3 0 9 r m a b c d e ...

Page 33: ...throttle cable from the throttle cam lever 3 5 5 Remove the silencing cover 3 5 6 Remove the four hex head cap screws d that hold the guide handle to the shock mounts e When reinstalling the guide handle apply Loctite 243 and torque the screws to 23 Nm 17 ft lbs 3 5 7 Move the guide handle down and away from the shock mounts 3 5 8 Lift the guide handle from the rammer Note To inspect or change the...

Page 34: ...shock mounts if they are torn or damaged 3 6 3 Remove the four socket head cap screws b that hold the shock mounts to the crankcase On Rammers with guards remove the guards c from the crankcase Then remove the screws that hold the shock mounts to the guard When reinstalling the shock mounts apply Loctite 243 or an equivalent to the screws and torque them to 34 Nm 25 ft lbs Note Replace the shock m...

Page 35: ... Loosen the clamp screws d 3 7 4 Slide the throttle cable e through the clamp until there is slack f in the throttle cable and the stop lever activates the stop button g 3 7 5 Tighten the clamp screws 3 7 6 Place the throttle control in the IDLE position h 3 7 7 Check that the stop button is not activated There should be a gap i between the stop lever and the stop button 3 7 8 Adjust the cable at ...

Page 36: ...ns to the carburetor can be made to improve its performance All modifications must be performed by an authorized WACKER dealer Contact WACKER Corporation for more information High altitude operations involve modifications to the engine air fuel mixture At normal altitudes these modifications can be damaging to the engine components When returning the rammer to normal altitude operation remember to...

Page 37: ...oval 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 When reinstalling the carburetor apply Loctite 243 and torque the screws to 5 4 Nm 4 0 ft lbs Note It is not necessary to disconnect the throttle cable to remove the carburetor ...

Page 38: ...Remove the protective guard 3 9 4 Pinch off both the fuel feed line c and the vent line d as close to the carburetor as possible 3 9 5 Carefully remove the fuel lines and drain the fuel left in the fuel lines into an approved 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 Dispose of this liq...

Page 39: ...ich drains off Dispose of this liquid in accordance with environmental protection legislation 3 10 5 Remove the four socket head cap screws that hold the fuel tank to the guide handle When reinstalling the fuel tank apply Loctite 243 and torque the screws to 9 4 Nm 6 9 ft lbs 3 10 6 Unscrew the filter d from the fuel tank Note It is not necessary to separate the fuel valve from the fuel filter unl...

Page 40: ...of this liquid in accordance with environmental protection legislation 3 11 3 Remove the M6 screw that holds the fuel tank to the guide handle When reinstalling the fuel tank apply Loctite 243 and torque the screw to 9 4 Nm 6 9 ft lbs 3 11 4 To remove the fuel filter b unscrew the two nuts e holding the fuel supply valve d to the fuel tank The fuel supply valve will come off 3 11 5 Unscrew the cap...

Page 41: ...Rammer Repair Guide Handle and Engine wc_tx000285gb fm 41 wc_gr001313rm a b d e c f ...

Page 42: ...f g 3 12 6 Clean all parts with soapy water and rinse thoroughly DO NOT use chemical solvents To reassemble the fuel tank cap 3 12 1 Insert the green umbrella valve d into the top side of the baffle b Press on the valve to seat it properly in the baffle 3 12 2 Re install the diaphragm g and attach the diaphragm retainer f with the two screws e Torque the screws to 0 28 Nm 2 5 in lbs being careful ...

Page 43: ...Rammer Repair Guide Handle and Engine wc_tx000285gb fm 43 e b c d wc_gr004562 a g f ...

Page 44: ... guard b to the muffler d When reinstalling the muffler guard apply Loctite 243 and torque the screws to 35 Nm 25 ft lbs 3 13 2 Remove the two socket head cap screws f holding the muffler and the muffler guard to the engine cylinder When reinstalling the muffler and the muffler guard apply Loctite 243 and torque the screws to 23 Nm 17 ft lbs 3 13 3 Remove the two socket head cap screws c located i...

Page 45: ...M 80 engine is air cooled so dirt accumulation between the cylinder ribs may cause the engine to overheat Use a screwdriver to remove any dirt that is impacted between the cylinder ribs Clean the entire area using compressed air wc_gr001314rm a b c d e f a d e f 18 Nm 13 ft lbs 18 Nm 13 ft lbs 35 Nm 25 ft lbs 23 Nm 17 ft lbs 23 Nm 17 ft lbs ...

Page 46: ...mance and hard starting Factors contributing to this problem include Dirty air filter causing the engine to run rich Excessive engine idling 3 15 1 Remove the two nuts b and two screws c holding the muffler to the engine cylinder When reinstalling the muffler apply Loctite 243 and torque the screws to 23 Nm 17 ft lbs 3 15 2 Remove the muffler 3 15 3 Remove any carbon deposits on the engine exhaust...

Page 47: ...Rammer Repair Guide Handle and Engine wc_tx000285gb fm 47 w c _ g r 0 0 1 3 1 5 r m a c b d ...

Page 48: ... 6 Tilt the engine down and away to remove it from the crankcase NOTICE The rammer tips easily when the engine is removed DO NOT run the engine while it is off the machine unless the clutch e has been removed Running the engine with the clutch attached to the crankshaft will cause the clutch shoes to separate and fly off Installation 3 16 7 Position the engine onto the machine Using Loctite 234 or...

Page 49: ...Rammer Repair Guide Handle and Engine wc_tx000285gb fm 49 wc_gr002935 d a b e c d ...

Page 50: ...e the M8 x 16 bolt and washer d securing the guard to the engine 3 17 6 Remove the M8 bolt and washer e securing the guard to the rammer crankcase 3 17 7 Remove the six M8 bolts f securing the lower guard to the engine and remove the guard 3 17 8 Remove the wire running from the engine to the low oil unit if equipped 3 17 9 Loosen the retainer g from the throttle cable Pry open the clamp h and rem...

Page 51: ...Rammer Repair Guide Handle and Engine wc_tx000285gb fm 51 d e j f wc_gr001954 b l a c k wc_gr003661 ...

Page 52: ...holder 3 18 4 Disconnect the throttle cable 3 18 5 Remove the four M10 nuts a that hold the engine to the crankcase When reinstalling the engine torque the nuts to 49 Nm 36 ft lbs 3 18 6 Tilt the engine down and away to remove it from the crankcase NOTICE The rammer tips easily when the engine is removed DO NOT run the engine while it is detached from the machine unless the clutch has been removed...

Page 53: ...Rammer Repair Guide Handle and Engine wc_tx000285gb fm 53 w c _ g r 0 0 1 3 1 7 r m a ...

Page 54: ... but do not completely remove it from the engine crankshaft This will protect the crankshaft threads from the clutch puller screw 3 19 4 Screw the clutch puller P N 0117972 c or other suitable puller into the small holes in the clutch and turn the center screw against the end of the crankshaft until the clutch hub breaks free of the taper Note When reinstalling the clutch make sure the taper in th...

Page 55: ...Rammer Repair Guide Handle and Engine wc_tx000285gb fm 55 w c _ g r 0 0 1 3 1 8 r m b a c BS Models ...

Page 56: ...completely remove it from the engine crankshaft This will protect the crankshaft threads from the clutch puller screw 3 20 4 Screw the clutch puller P N 0153566 c or other suitable puller into the small holes in the clutch and turn the center screw against the end of the crankshaft until the clutch hub breaks free of the taper Note When reinstalling the clutch make sure the taper in the clutch hub...

Page 57: ...Rammer Repair Guide Handle and Engine wc_tx000285gb fm 57 c a b wc_gr001319rm DS 720 Models ...

Page 58: ... sharply to help break the bolt loose Note Loosen the bolt but do not completely remove it from the engine crankshaft This will protect the crankshaft threads from the clutch puller screw 3 21 4 Screw the clutch puller P N 0153566 c or other suitable puller into the small holes in the clutch and turn the center screw against the end of the crankshaft until the clutch hub breaks free of the taper I...

Page 59: ...Rammer Repair Guide Handle and Engine wc_tx000285gb fm 59 DS 70 Models wc_gr002372rm a b c ...

Page 60: ... through the engine It may take up to 45 minutes for the oil level to recover Oil change 3 22 1 Let the engine warm up then shut it off 3 22 2 Place the rammer so that the engine is level 3 22 3 Unscrew the engine oil drain plug b and let oil flow out 3 22 4 Screw in the oil drain plug 3 22 5 Fill with approximately 800 ml 27 oz of oil through the oil fill opening Refer to Check oil level above Oi...

Page 61: ...Rammer Repair Guide Handle and Engine wc_tx000285gb fm 61 w c _ g r 0 0 1 3 2 0 r m H L a a b c ...

Page 62: ...off Dispose of this liquid in accordance with environmental protection legislation 3 23 2 Place the rammer so that the engine is level 3 23 3 Remove the oil fill plug a and drain the plug b to drain the oil 3 23 4 Install the drain plug b 3 23 5 Fill the engine crankcase with the recommended oil up to the level of the plug opening c Do not thread in the dipstick to check the oil level See section ...

Page 63: ...s off Dispose of this liquid in accordance with environmental protection legislation 3 24 2 Place the rammer so that the engine is level 3 24 3 Remove the oil fill plug a and drain the plug b to drain the oil 3 24 4 Install the drain plug b 3 24 5 Fill the engine crankcase with the recommended oil up to the level of the plug opening c Do not thread in the dipstick to check the oil level See sectio...

Page 64: ...ion Ramming System Lubrication 4 1 2 Remove the four socket head cap screws c that secure the ramming system to the crankcase 4 1 3 Stand on the ramming shoe and pull up hard on the crankcase until the end plugs h are visible 4 1 4 Drive out the end plugs and piston pin g holding the connecting rod to the ram Do not reuse the end plugs 4 1 5 Lift the upper machinery from the ramming system 4 1 6 R...

Page 65: ...1 14 Press the guide cylinder a onto the bellows with a strong downward push 4 1 15 Partially tighten the spring clamp onto the bellows 4 1 16 Install a new O ring b 4 1 17 Position the upper machinery over the guide cylinder 4 1 18 Align the connecting rod inside the ram 4 1 19 Install the piston pin g and new end plugs h Note Use new end plugs whenever the piston pin has been removed Note To aid...

Page 66: ...ign 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 4 1 23 Tighten the clamps and torque them to 13 5 Nm 10 ft lbs 4 1 24 Fill the ramming system with clean oil as described in section Ramming System Lubrication 4 1 25 Run the rammer for several minutes and check it for oil leaks around the guide cylinder and the ...

Page 67: ...ew locknuts and torque the screws to 85 5 Nm 63 ft lbs 4 2 4 Check torque on the screws after five hours of use For BS 700 Optional 13 Plastic Ramming shoe 4 2 5 Remove the four locknuts b holding the ramming shoe to the spring cylinder When reinstalling the ramming shoe torque the locknuts to 79 Nm 58 ft lbs 4 2 6 Lift the rammer off the ramming shoe 4 2 7 To detach the bottom plate e remove the ...

Page 68: ...lace the spring cylinder in a hydraulic press and position the head of the press in firm contact with the spring system cover 4 3 4 Lock the press and remove the remaining two screws 4 3 5 Slowly release the press and allow the springs to expand 4 3 6 After all the spring pressure is released remove the spring system cover the gasket and the bottom spring set Hydraulic Press Installation Method 4 ...

Page 69: ...Rammer Repair Ramming System wc_tx000286gb fm 69 wc_gr001324rm Hydraulic Press Method ...

Page 70: ...ystem cover is under heavy pressure It must be carefully removed and installed using either the hydraulic press the threaded rod or the spring box tool method If the spring system cover is removed incorrectly the springs can eject with enough force to cause serious injury or death 4 3 21 Remove the spring system cover the gasket and the bottom spring set Threaded Rod Installation Method 4 3 22 Ins...

Page 71: ...Rammer Repair Ramming System wc_tx000286gb fm 71 wc_gr001325rm Threaded Rod Method ...

Page 72: ...anded and the pressure is released The spring system cover is under heavy pressure It must be carefully removed and installed using either the hydraulic press the threaded rod or the spring box tool method If the spring system cover is removed incorrectly the springs can eject with enough force to cause serious injury or death 4 3 8 Remove the spring system cover the gasket and the bottom spring s...

Page 73: ...326 4 3 1 5 3 2 4 5 1 3 4 5 2 Screw Position Qty Machine 1 2 BS45Y BS52Y ES45Y ES52Y 2 2 BS60Y GVR151Y 3 3 BS62Y BS65y BS600 BS650 BS700 BS60 2i BS70 2i BS65V BS60 4 DS72Y DS720 DS70 4 3 BS92Y BS105Y 5 3 BS500 BS50 2I BS50 4 Schraube position st La posicion del tornillo La position de vis ...

Page 74: ... 3 Loosen the nut d on the impact bushing puller to allow the yoke c to set on the flange surface of the rammer and the jaws to reach the bottom of the impact bushing 4 4 4 Push the jaws a of the impact bushing puller over the impact bushing b until it seats at the bottom of the impact bushing 4 4 5 Tighten the nut on the impact bushing puller to remove the impact bushing as shown in the graphic a...

Page 75: ... lbs BS 600 700 250 Nm 184 ft lbs 4 4 14 Press a new impact bushing m onto the end of the ram and seat it by hitting the end of the impact bushing with a rubber mallet 4 4 15 Reinstall the spring set n 4 4 16 Install a new gasket o 4 4 17 Reinstall the spring system cover p using one of the three methods described in section Spring System Cover Removal and Installation Apply Loctite 243 and torque...

Page 76: ...is worn or damaged 4 5 1 Remove the springs from the cylinder and check them for minimum spring free height and maximum spring height difference per the table below Replace the springs if they do not meet the given specifications 4 5 2 If a spring has broken inspect the inside of the spring cylinder wall for burrs gouges and cracks as follows Slide the piston guide inside the cylinder Check that t...

Page 77: ...43 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 4 6 2 Remove the socket head cap screws c To reinstall the protective pipe apply Loctite 243 and torque the screws to 24 Nm 18 ft lbs 4 6 3 Reassemble the rammer following the previous procedures c wc_gr001330rm ...

Page 78: ...e top of the rammer See section Technical Data for oil quantity and type Change the ramming system oil after the first 50 hours of operation and then after every 300 hours of use Oil change 4 7 1 Remove the oil fill plug c and the seal ring 4 7 2 BS 500 Remove the sightglass BS 600 700 650 DS720 Remove the drain plug b 4 7 3 Tilt the rammer back until it is resting on its handle 4 7 4 Allow the oi...

Page 79: ... BS 65 DS 70 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 Holes drilled in the piston allow the oil to be distributed from the bottom of the rammer to the crankcase Oil in the ramming system must be maintained at the ...

Page 80: ... Remove the sightglass a BS 60 70 65 DS 70 Remove the drain plug b 4 8 2 Tilt the rammer back until it is resting on its handle 4 8 3 Allow the oil to drain 4 8 4 Screw in the oil drain plug Torque to 54 Nm 40 ft lbs 4 8 5 Wrap the sightglass threads with Teflon tape 4 8 6 Remove sightglass and fill with oil See Technical Data for oil quantity and type Install the sightglass Torque to 9 Nm 6 6 ft ...

Page 81: ...Rammer Repair Ramming System wc_tx000286gb fm 81 Notes ...

Page 82: ...to the slots on each side of the cover and pry off the cover The cover will come out with the crank gear g and the connecting rod k attached Note The crankcase cover cannot be removed until the connecting rod is detached from the ram 5 1 7 Reach through the slotted hole m in the crank gear and release the large retaining ring f 5 1 8 Thread two M8 socket head cap screws or threaded rods through th...

Page 83: ...ss the connecting rod assembly onto the crank gear and secure it in place with the small retaining ring 5 1 19 Push the complete crank gear assembly into the bearing housing and seat the retaining ring in the groove 5 1 20 Replace the o ring b 5 1 21 Assemble the cover to the crankcase Torque the screws to 49 Nm 36 ft lbs 5 1 22 Connect the crankcase to the ramming system as follows Position the u...

Page 84: ...Crankcase Rammer Repair wc_tx000287gb fm 84 wc_gr001333rm p o n m f ...

Page 85: ...crews 31 from the bearing mount 16 5 2 6 Insert a screwdriver on each side of the bearing mount and pry it off The bearing mount and cover will come out with the crank gear 20 and the connecting rod 24 attached Note The bearing mount and cover cannot be removed until the connecting rod is detached from the ram 5 2 7 Remove the snap ring 25 then pry off the connecting rod assembly 24 with two pry b...

Page 86: ...maged 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 Replace the needle bearings and oil seal together 5 2 14 Remove the O ring 18 and discard it 5 2 15 The clutch drum needle bearing 17 will remain intact in the bearing mount Inspect it for wear and if damaged remove and replace it ...

Page 87: ... the adjusting plate 6 over the Belville spring washers lining up pin 30 at position 1 5 2 24 Place the clamping ring 5 over the adjusting plate Apply Loctite 243 to the screws 12 and torque to 9 5 Nm 7 ft lbs Tighten the screws evenly to compress the Belville spring washers 5 2 25 Fit the yoke 4 over the eccentric drive shaft 23 and secure in place with pin 13 Secure the pin with the two retainin...

Page 88: ...move the engine 5 3 6 Remove the four socket head cap screws from the front cover 5 3 7 Insert a screwdriver into the slots on each side of the cover and pry off the cover The cover will come out with the crank gear and the connecting rod attached Note The crankcase cover cannot be removed until the connecting rod is detached from the ram 5 3 8 Remove the small retaining ring b from the clutch dru...

Page 89: ...aft seal with the open side facing toward the bearing 5 3 18 Press the clutch drum into the crankcase 5 3 19 Secure the clutch drum with the small retaining ring 5 3 20 Assemble the cover to the crankcase Apply Loctite 243 and torque the screws to 49 Nm 36 ft lbs 5 3 21 Connect the crankcase to the ramming system as follows a Position the upper machinery over the guide cylinder b Align the connect...

Page 90: ...s and the connector is fully seated at the engine b continue 6 1 3 Unplug the float switch wire from the engine 6 1 4 Insert a jumper wire into the terminal on the engine to connect the two terminal leads 6 1 5 Start the engine and run it at idle If the engine continues to run for more than 45 seconds the float switch is faulty and must be replaced If the engine still shuts off within 25 seconds t...

Page 91: ...Rammer Repair Oil Injection if equipped wc_tx000288gb fm 91 6 1 12 Ensure that the float switch plug is fully seated in the connector on the back of the engine wc_gr001526 a b c d ...

Page 92: ...ring Measure how much vacuum it takes to operate the oil line check valve A vacuum reading of more than 2 psi after initial release is grounds for replacing the oil line check valve Note The oil line check valve is only available by replacing the entire hose assembly Newly installed oil line check valves and those that have lost their prime require priming There are two methods of priming the oil ...

Page 93: ...Rammer Repair Oil Injection if equipped wc_tx000288gb fm 93 wc_gr001527 a b ...

Page 94: ...the cartridge assembly from the crankcase 6 3 5 Separate the oil pump from the cartridge assembly Inspect the plastic gear on the cartridge assembly for damage If the plastic gear is damaged replace it Testing Ensure that the oil tank is full of oil and that the oil line from the tank to the pump is not kinked or loose 6 3 6 Open the bleed screw on the front of the pump until oil flows out Tighten...

Page 95: ...battery to the low oil unit as shown A functioning low oil unit should flash at a steady rate If the low oil unit does not flash at a steady rate it has failed replace it If the low oil unit does flash at a steady rate continue 7 1 5 Grasp the sensors c with your fingertips This action will change the capacitance of the sensors and will change the flashing action duty cycle of the low oil unit fro...

Page 96: ...plugs are fouled 1 Clean or replace the spark plug Measure the electrode gap Incorrect spark plug 1 Must use resistor type spark plug to operate correctly The muffler or exhaust port is dirty Remove and clean the muffler Clean the exhaust port The crankshaft seals are leak ing Check replace the seals see the WM 80 Engine Repair Manual The fuel mixture adjustment is incorrect 1 Set the adjusting sc...

Page 97: ...lace the ignition module On machines with oil injection the float switch has failed Replace the float switch Problem Symptom Reason Remedy The air filters are dirty Clean or replace the filters There is too much oil in the fuel 1 Drain the fuel from the tank Fill with new mixed fuel The spark plug is fouled 1 Clean or replace the spark plug Set the electrode gap Incorrect spark plug 1 Must use res...

Page 98: ...ins and the blades Problem Symptom Reason Remedy The muffler or the exhaust port is plugged Remove and clean the muffler Clean the exhaust port The clutch is damaged Remove and replace the clutch The connecting rod in the ramming system is broken Disassemble the crankcase Inspect and replace any damaged components The crankgear is broken Disassemble the crankcase Inspect and replace any damaged co...

Page 99: ...mble the spring cylinder Inspect and replace any damaged components There are damaged parts in the spring cylinder assembly Disassemble the spring cylinder Inspect and replace any damaged components There are damaged parts in the crankcase assembly Disassemble the crankcase Inspect and replace any damaged components There is soil buildup on the ramming shoe Clean and inspect the shoe The engine sp...

Page 100: ...pion RL95YC Electrode Gap mm in 0 5 020 Cylinder Head Compression cold bar cm3 psi 8 0 9 7 120 140 Air Cleaner type Three stage with cyclonic precleaner Engine Lubrication oil grade With standard two cycle oil use 50 1 ratio With Wacker two cycle or other oil meeting the NMMA TC W3 specification a ratio from 50 1 to 100 1 can be used Fuel Tank Capacity l qts 3 0 3 2 Fuel Consumption l qt hr 1 0 1 ...

Page 101: ...pe NGK BM4A or BMR4A Electrode Gap mm in 0 6 0 7 0 023 0 028 Cylinder Head Compression cold bar cm3 psi 8 0 9 7 120 140 Air Cleaner type Three stage with cyclonic precleaner Engine Lubrication oil grade SAE 10W30 SE SF or higher Engine Oil Capacity ml oz 300 10 Fuel Tank Capacity l qts 3 0 3 2 Fuel type Regular unleaded gasoline Fuel Consumption l qt hr 1 2 1 3 Running Time hour 2 5 Ramming System...

Page 102: ...ngagement rpm 2800 100 Spark Plug type Champion RL95YC Electrode Gap mm 0 5 Cylinder Head Compression cold bar cm3 8 0 9 7 Air Cleaner type Dual Element Engine Lubrication oil grade With standard two cycle oil use 50 1 ratio With Wacker two cycle or two cycle oil per NMMA TC W3 API TC JASO FC or ISO EGD specifications use 100 1 or 50 1 ratio Ramming System Lubrication oil grade SAE 10W30 Ramming S...

Page 103: ...pm 2800 100 Spark Plug type Champion RL95YC Electrode Gap mm in 0 5 020 Cylinder Head Compression cold bar cm3 psi 8 0 9 7 120 140 Engine Lubrication oil grade With standard two cycle oil use 50 1 ratio With Wacker two cycle or two cycle oil per NMMA TC W3 API TC JASO FC or ISO EGD specifications 100 1 or 50 1 ratio Ramming System Lubri cation oil grade SAE 10W30 Ramming System Capacity ml oz 562 ...

Page 104: ...5 0 020 Cylinder Head Compression cold bar cm3 psi 8 0 9 7 120 140 Air Cleaner type Three stage with cyclonic precleaner Engine Lubrication oil grade With standard two cycle oil use 50 1 ratio With Wacker two cycle or other oil meeting the NMMA TC W3 specification a ratio from 50 1 to 100 1 can be used Fuel Tank Capacity l qts 3 0 3 2 Fuel type Regular unleaded gasoline Fuel Consumption l qt hr 1 ...

Page 105: ...ed idle rpm 1800 100 Clutch Engagement rpm 2800 100 Spark Plug type Champion RL95YC Electrode Gap mm in 0 5 0 020 Cylinder Head Compression cold bar cm3 psi 8 0 9 7 120 140 Engine Lubrication oil grade Wacker two cycle or two cycle oil per NMMA TC W3 API TC JASO FC or ISO EGD specifications Ramming System Lubrication oil grade SAE 10W30 Ramming System Capacity ml oz 562 19 ...

Page 106: ...pe Champion RL95YC Electrode Gap mm in 0 5 0 020 Cylinder Head Compression cold bar cm3 psi 8 0 9 7 120 140 Air Cleaner type Three stage with cyclonic precleaner Engine Lubrication oil grade With standard two cycle oil use 50 1 ratio With Wacker two cycle or other oil meeting the NMMA TC W3 specification a ratio from 50 1 to 100 1 can be used Fuel Tank Capacity l qts 3 0 3 2 Fuel Consumption l qt ...

Page 107: ...park Plug type NGK BM4A or BMR4A Electrode Gap mm in 0 6 0 7 0 002 0 030 Cylinder Head Compression cold bar cm3 psi 8 0 9 7 120 140 Air Cleaner type Three stage with cyclonic precleaner Engine Lubrication oil grade SAE 10W30 SE SF or higher Engine Oil Capacity ml oz 300 10 Fuel Tank Capacity l qts 3 0 3 2 Fuel type Regular unleaded gasoline Fuel Consumption l qt hr 1 2 1 3 Running Time hour 2 5 Ra...

Page 108: ...utch Engagement rpm 2800 100 Spark Plug type Champion RL95YC Electrode Gap mm in 0 5 0 020 Cylinder Head Compression cold bar cm3 psi 8 0 9 7 120 140 Air Cleaner type Dual Element Engine Lubrication oil grade With standard two cycle oil use 50 1 ratio With Wacker two cycle or two cycle oil per NMMA TC W3 API TC JASO FC or ISO EGD specifications 100 1 or 50 1 ratio Ramming System Lubrication oil gr...

Page 109: ...pm 2800 100 Spark Plug type Champion RL95YC Electrode Gap mm in 0 5 0 020 Cylinder Head Compression cold bar cm3 psi 8 0 9 7 120 140 Engine Lubrication oil grade With standard two cycle oil use 50 1 ratio With Wacker two cycle or two cycle oil per NMMA TC W3 API TC JASO FC or ISO EGD specifications 100 1 or 50 1 ratio Ramming System Lubrication oil grade SAE 10W30 Ramming System Capacity ml oz 890...

Page 110: ...5 0 020 Cylinder Head Compression cold bar cm3 psi 8 0 9 7 120 140 Air Cleaner type Three stage with cyclonic precleaner Engine Lubrication oil grade With standard two cycle oil use 50 1 ratio With Wacker two cycle or other oil meeting the NMMA TC W3 specification a ratio from 50 1 to 100 1 can be used Fuel Tank Capacity l qts 3 0 3 2 Fuel type Regular unleaded gasoline Fuel Consumption l qt hr 1 ...

Page 111: ... 100 Engine Speed idle rpm 1800 100 Clutch Engagement rpm 2800 100 Spark Plug type Champion RL95YC Electrode Gap mm in 0 5 0 020 Cylinder Head Compression cold bar cm3 psi 8 0 9 7 120 140 Engine Lubrication oil grade Wacker two cycle or two cycle oil per NMMA TC W3 API TC JASO FC or ISO EGD specifications Ramming System Lubrication oil grade SAE 10W30 Ramming System Capacity ml oz 890 30 ...

Page 112: ...rpm 2800 100 Spark Plug type Champion RL95YC Electrode Gap mm in 0 5 0 020 Cylinder Head Compression cold bar cm3 psi 8 0 9 7 120 140 Air Cleaner type Dual Element Engine Lubrication oil grade With standard two cycle oil use 50 1 ratio With Wacker two cycle or two cycle oil per NMMA TC W3 API TC JASO FC or ISO EGD specifications 100 1 or 50 1 ratio Ramming System Lubrication oil grade SAE 10W30 Ra...

Page 113: ... 5 0 020 Cylinder Head Compression cold bar cm3 psi 8 0 9 7 120 140 Air Cleaner type Three stage with cyclonic precleaner Engine Lubrication oil grade With standard two cycle oil use 50 1 ratio With Wacker two cycle or other oil meeting the NMMA TC W3 specification a ratio from 50 1 to 100 1 can be used Fuel Tank Capacity l qts 3 0 3 2 Fuel Consumption l qt hr 1 2 1 3 Running Time hour 2 5 Ramming...

Page 114: ... 2800 100 Spark Plug type Champion RL95YC Electrode Gap mm 0 5 Cylinder Head Compression cold bar cm3 8 0 9 7 Air Cleaner type Dual Element Engine Lubrication oil grade With standard two cycle oil use 50 1 ratio With Wacker two cycle or two cycle oil per NMMA TC W3 API TC JASO FC or ISO EGD specifications 100 1 or 50 1 ratio Ramming System Lubrication oil grade SAE 10W30 Ramming System Capacity ml...

Page 115: ...Rammer Repair Technical Data wc_td000112gb fm 115 NOTES ...

Page 116: ...050 DS 70 0620052 0620053 0620054 Rammer Operating weight kg lbs 83 183 Percussion rate 2 strokes min 670 Single stroke work J mkp 100 Stroke of ramming shoe up mm in to 71 2 78 Ramming system lubrication oil grade SAE 10W30 Ramming system oil capacity ml oz 890 30 2 Percussion rate can be adjusted with the throttle lever ...

Page 117: ...EWSA L48EE DWK3 Rated Power kW Hp 3 1 4 1 Displacement cm in 211 12 8 Engine Speed full load rpm 3450 Engine Speed idle rpm 1050 150 Engine Speed clutch engagement rpm 2500 200 Valve Clearance cold mm in 0 15 0 006 Air Cleaner type Dual Element Engine Lubrication oil grade CC or better 1 Engine Oil Capacity ml oz 800 27 Fuel type No 2 Diesel cetane 45 Fuel Tank Capacity l gals 4 2 1 1 Fuel consump...

Page 118: ...ev 116 and higher 0008203 Rev 115 and higher DS 720 0009309 Rammer Operating weight kg lbs 75 165 Percussion rate 2 strokes min 650 700 Single stroke work J mkp 100 Stroke of ramming shoe up mm in to 75 3 Ramming system lubri cation oil grade SAE 10W30 Ramming system oil capacity ml oz 890 30 2 Percussion rate can be adjusted with the throttle lever ...

Page 119: ...r Engine Model L40AE DWK2 L48EE DWK3 Rated Power kW Hp 3 1 4 2 3 5 4 7 Displacement cm in 199 12 1 211 12 8 Engine Speed full load rpm 3600 Engine Speed idle rpm 1200 200 Engine Speed clutch engagement rpm 2000 200 Valve Clearance cold mm in 0 15 0 006 Air Cleaner type Dual Element Engine Lubrication oil grade CC or better 1 Engine Oil Capacity ml oz 800 27 Fuel type No 2 Diesel cetane 45 Fuel Tan...

Page 120: ...Technical Data Rammer Repair wc_td000112gb fm 120 ...

Page 121: ...1 5 ml 17380 50 ml Loctite 271 277 Hernon 427 Omnifit 1550 220M Red High strength for all threads up to 25 mm 1 Heat parts before disassembly Temp range 54 to 149 C 65 to 300 F 29312 5 ml 26685 10 ml 73285 50 ml Loctite 290 Hernon 431 Omnifit 1710 230LL Green Medium to high strength for locking preassembled threads and for sealing weld porosity wicking Gaps up to 0 13 mm 0 005 Temp range 54 to 149...

Page 122: ...nts follow instructions on container The sealants listed are recommended for use on Wacker equipment TYPE Europe COLOR USAGE PART NO SIZE Loctite 496 Hernon 110 Omnifit Sicomet 7000 Clear Instant adhesive for bonding rubber metal and plastics general purpose For gaps up to 0 15 mm 0 006 Read caution instructions before using Temp range 54 to 82 C 65 to 180 F 52676 1oz Loctite Primer T Hernon Prime...

Page 123: ... 5 M4 2 9 26 4 1 36 4 9 43 7 9 32 3 M5 6 0 53 8 5 6 10 7 8 5 16 4 M6 10 7 14 10 17 13 10 5 M8 25 18 35 26 41 30 13 1 2 6 M10 49 36 69 51 83 61 17 11 16 8 M12 86 63 120 88 145 107 19 3 4 10 M14 135 99 190 140 230 169 22 7 8 12 M16 210 155 295 217 355 262 24 15 16 14 M18 290 214 405 298 485 357 27 1 1 16 14 M20 410 302 580 427 690 508 30 1 1 4 17 1 ft lb 1 357 Nm in lb 1 inch 25 4 mm 8 8 10 9 12 9 ...

Page 124: ...o 8 2 5 22 3 5 31 4 7 42 9 11 32 9 64 No 10 3 6 32 5 1 45 6 8 60 3 8 5 32 1 4 8 1 6 12 9 16 12 7 16 3 32 5 16 18 13 26 19 33 24 13 1 2 1 4 3 8 31 23 45 33 58 43 9 16 5 16 7 16 50 37 71 52 94 69 16 5 8 3 8 1 2 77 57 109 80 142 105 19 3 4 3 8 9 16 111 82 156 115 214 158 13 16 5 8 152 112 216 159 265 195 24 15 16 1 2 3 4 271 200 383 282 479 353 1 1 8 5 8 1 ft lb 1 357 Nm in lb 1 inch 25 4 mm ...

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Page 126: ... 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 Skyline Tower Suite 2303 23 F 39 Wang Kwong Road Kowloon Bay Hong Kong Tel 852 2406 60 32 Fax 852 2406 60 21 ...