Wacker BS50,BS60,BS70,BS500,BS600, Repair Manual

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

Copyright notice © Copyright 2010 by Wacker Neuson Corporation. 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 Corporation. Any type of reproduction or distribution not authorized by Wacker Neuson Corporation represents an infringement of valid copyrights. Violators will be prosecuted. Trademarks All trademarks referenced in this manual are the property of their respective owners. Manufacturer Wacker Neuson Corporation N92W15000 Anthony Avenue Menomonee Falls, WI 53051 U.S.A. Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957 www.wackerneuson.com

Foreword wc_tx001543gb.fm 3 Foreword Machines covered in this manual. Machine documentation Keep a copy of the Operator’s Manual with the machine at all times. Use the separate Parts Book supplied with the machine to order replacement parts. If you are missing any of these documents, please contact Wacker Neuson Corporation to order a replacement or visit www.wackerneuson.com. When ordering parts or requesting service information, be prepared to provide the machine model number, item number, revision number, and serial number. BS 50-4 0009386, 0009415, 0620108, 0620071, 0620077, 0620078 BS 50-2 0009380, 0009382, 0009384, 0009410, 0009411, 0009413, 0620025, 0620048, 0620609, 0620610, 0620733, 0620609, 0620610, 0620733 BS 50-2i 0009332, 0009338, 0009383, 0009412, 0009414, 0009416, 0009473, 0620026, 0620611 BS 500 0007550, 0008048, 0008049, 0008204, 0009074, 0009075 BS 500-4 0009329 BS 500-oi 0009165, 0009343 BS 500S 0009211 BS 60-4 0009340, 0009422, 0620000, 0620051, 0620109, 0620110, 0620072, 0620073, 0620074, 0620483, 0620563, 0620812, 0620813, 0620816, 0620819, 0620820 BS 60-2 0009388, 0009391, 0009417, 0009418, 0009421, 0620612 BS 60-2i 0009339, 0009393, 0009419, 0009420, 0620613, 0620614 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, 0008052, 0008206, 0009078, 0009079, 0009308 BS 700-oi 0009167, 0009328 BS 65-V 0009396, 0009423 BS 650 0008209 DS 70 0009342, 0009402, 0009403, 0620049, 0620050, 0620052, 0620053, 0620054

Foreword 4 wc_tx001543gb.fm Expectations for information in this manual This manual provides information and procedures to safely operate and main- tain the above Wacker Neuson model(s). For your own safety and to reduce the risk of injury, carefully read, understand, and observe all instructions described in this manual. Wacker Neuson Corporation expressly reserves the right to make technical modifications, even without notice, which improve the performance or safety standards of its machines. The information contained in this manual is based on machines manufactured up until the time of publication. Wacker Neuson 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 cause cancer and birth defects or other reproductive harm. Laws pertaining to spark arresters NOTICE: State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed to prevent accidental dis- charge of sparks or flames from the engine exhaust. Spark arresters are qualified and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator. Manufacturer’s approval This manual contains references to approved parts, attachments, and modifications. The following definitions apply: Approved parts or attachments are those either manufactured or provided by Wacker Neuson. Approved modifications are those performed by an authorized Wacker Neu- son service center according to written instructions published by Wacker Neu- son. Unapproved parts, attachments, and modifications are those that do not meet the approved criteria. Unapproved parts, attachments, or modifications may have the following conse- quences: 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.

wc_br0114549en_010TOC.fm 5 Table of Contents Rammer Repair Foreword 3 1 Safety Information 9 1.1 Signal Words Found in this Manual ...................................................... 9 1.2 Machine Description and Intended Use ............................................. 10 1.3 Operating Safety ................................................................................ 11 1.4 Operator Safety while using Internal Combustion Engines ................ 13 1.5 Service Safety .................................................................................... 14 2 Tools 17 2.1 Recommended Special Tools ............................................................ 17 2.2 Recommended Repair Tools .............................................................. 18 3 Maintenance Schedules 19 3.1 Periodic Maintenance Schedule (BS 50/60/70-2, BS 65) ................... 19 3.2 Periodic Maintenance Schedule (BS 500/600/700/650) ..................... 20 3.3 Periodic Maintenance Schedule (BS 50/60/70-2i) .............................. 21 3.4 Periodic Maintenance Schedule (BS 500/600/700-oi) ........................ 22 3.5 Periodic Maintenance Schedule (DS 70) ........................................... 23 3.6 Periodic Maintenance Schedule (DS 720) ......................................... 24 4 Engine and Upper Machine Components 25 4.1 Removing the Silencing Cover ........................................................... 25 4.2 Replacing the Throttle Control (2010 and later 2-stroke models) ....... 26 4.3 Replacing the Throttle Control (2010 4-stroke models) ...................... 28 4.4 Throttle Control (pre-2010 models) .................................................... 31 4.5 Replacing the Stop Switch (2010 and later 2-stroke models) ............ 32 4.6 Replacing the Stop Switch (2010 and later 4-stroke models) ............ 35 4.7 Replacing the Guide Handle (2010 and later 2-stroke models) ......... 37 4.8 Replacing the Guide Handle (2010 and later 4-stroke models) ......... 40 4.9 Replacing the Guide Handle (pre-2010 models) ................................ 44 4.10 Shock Mounts ..................................................................................... 45

6 wc_br0114549en_010TOC.fm Table of Contents Rammmer Repair 4.11 Tillotson Carburetor (BS 500/600/700/650 only) ................................. 46 4.12 Fuel Lines (BS 50/60/70-2, BS 65) ...................................................... 48 4.13 Fuel Tank (BS Models) ........................................................................ 49 4.14 Fuel Tank (DS Models) ....................................................................... 50 4.15 Fuel Tank Cap ..................................................................................... 52 4.16 Muffler (pre-2009 BS Models) ............................................................. 54 4.17 Engine Cooling Fins ............................................................................ 55 4.18 Muffler (DS Models) ............................................................................ 56 4.19 Replacing the Carburetor (WM 80 engines) ........................................ 58 4.20 Replacing the WM 80 Engine (2010 and later models) ....................... 62 4.21 Replacing the WM 80 Engine (pre-2010 models) ............................... 64 4.22 Replacing the Carburetor (WM 100 Engines) ..................................... 66 4.23 Replacing the WM 100 Engine ............................................................ 70 4.24 Removing the WM 90 Engine .............................................................. 74 4.25 Engine (DS Models) ............................................................................ 76 4.26 Clutch (2- and 4-stroke models) .......................................................... 78 4.27 Clutch (DS 720 only) ........................................................................... 80 4.28 Clutch (DS 70 only) ............................................................................. 82 5 Ramming System 84 5.1 Bellows ................................................................................................ 84 5.2 Replacing the Ramming Shoe ............................................................. 87 5.3 Spring System Cover Removal and Installation .................................. 90 5.4 Spring System ..................................................................................... 96 5.5 Inspecting the Spring System .............................................................. 98 5.6 Protective Pipe .................................................................................... 99 5.7 Ramming System Lubrication (BS 500/600/700/650, DS 720) ......... 100 5.8 Ramming System Lubrication (BS 50/60/70, BS 65, DS 70) ............ 102 6 Crankcase 104 6.1 Crank Gear and Connecting Rod ...................................................... 104 6.2 Crank Gear, Connecting Rod, and Adjuster Assembly (BS 650/65 only) 106 6.3 Clutch Drum ...................................................................................... 110

wc_br0114549en_010TOC.fm 7 Table of Contents Rammer Repair 7 Oil Injection (if equipped) 112 7.1 Testing the Float Switch (2010 and later models) ............................ 112 7.2 Replacing the Float Switch (2010 and later models) ........................ 114 7.3 Float Switch Testing and Replacement (pre-2010 models) ............. 116 7.4 Oil Line Check Valve ........................................................................ 118 7.5 Oil Pump / Cartridge Assembly ........................................................ 120 8 Low Oil Shutdown (if equipped) 123 8.1 Testing the Low Oil Unit ................................................................... 123 9 Troubleshooting 124 9.1 Engine Hard to Start ......................................................................... 124 9.2 Engine Does Not Start ...................................................................... 125 9.3 Engine Does Not Accelerate or Runs Poorly ................................... 125 9.4 Engine Overheats ............................................................................. 126 9.5 Rammer Does Not Tamp ................................................................. 126 9.6 Rammer Jumps Erratically ............................................................... 127 10 Technical Data 128 10.1 BS 50-2 ............................................................................................ 128 10.2 BS 50-4 ............................................................................................ 129 10.3 BS 500 .............................................................................................. 130 10.4 BS 500S ........................................................................................... 131 10.5 BS 50-2i ............................................................................................ 132 10.6 BS 500-oi .......................................................................................... 133 10.7 BS 60/70-2 ....................................................................................... 134 10.8 BS 60-4 ............................................................................................ 135 10.9 BS 600/700 ....................................................................................... 136 10.10 BS 600S ........................................................................................... 137 10.11 BS 60/70-2i ....................................................................................... 138 10.12 BS 600/700-oi ................................................................................... 139 10.13 BS 600/700 High Altitude ................................................................. 140 10.14 BS 65-V ............................................................................................ 141 10.15 BS 650 .............................................................................................. 142

8 wc_br0114549en_010TOC.fm Table of Contents Rammmer Repair 10.16 DS 70 ................................................................................................ 144 10.17 DS 720 .............................................................................................. 146

Rammer Repair Safety Information wc_si000514gb.fm 9 1 Safety Information 1.1 Signal Words Found in this Manual This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE signal words which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. NOTICE: Used without the safety alert symbol, NOTICE indicates a situation which, if not avoided, could result in property damage. Note: A Note contains additional information important to a procedure. This is the safety alert symbol. It is used to alert you to potential personal hazards. Obey all safety messages that follow this symbol. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. To avoid death or serious injury from this type of hazard, obey all safety messages that follow this signal word. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. To avoid possible death or serious injury from this type of hazard, obey all safety messages that follow this signal word. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. To avoid possible minor or moderate injury from this type of hazard, obey all safety messages that follow this signal word.

Safety Information Rammer Repair 10 wc_si000514gb.fm 1.2 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. The operator guides and controls the machine from behind using the handle. This machine is intended to be used for compacting cohesive, mixed, and granular soils in confined areas. This machine has been designed and built strictly for the intended use described above. Using the machine for any other purpose could permanently damage the machine or seriously injure the operator or other persons in the area. Machine damage caused by misuse is not covered under warranty. The following are some examples of misuse: • Using the machine as a ladder, support, or work surface • Using the machine to carry or transport passengers or equipment • Using the machine as a hammer or for other demolition work • Attaching the machine to any other machine • Operating the machine outside of factory specifications • Operating machine in a manner inconsistent with all warnings found on the machine and in the Operator’s Manual This machine has been designed and built in accordance with the latest global safety standards. It has been carefully engineered to eliminate hazards as far as practicable and to increase operator safety through protective guards and labeling. However, some risks may remain even after protective measures have been taken. They are called residual risks. On this machine, they may include exposure to: • Heat, noise, exhaust, and carbon monoxide from the engine • Fire hazards from improper refueling techniques • Fuel and its fumes • Personal injury from improper lifting techniques or operating techniques To protect yourself and others, make sure you thoroughly read and understand the safety information presented in this manual before operating the machine.

Wacker BS50,BS60,BS70,BS500,BS600, Repair Manual

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