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Wacker Neuson BS 50-2 Repair Manual

Manual is about: vibratory rammer

Summary of BS 50-2

  • Page 1

    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

  • Page 2

    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 wack...

  • Page 3: Foreword

    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 ...

  • Page 4: Foreword

    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 de...

  • Page 5: Table of Contents

    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 ....

  • Page 6: Table of Contents

    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) ................................

  • Page 7: Table of Contents

    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 replacem...

  • Page 8: Table of Contents

    8 wc_br0114549en_010toc.Fm table of contents rammmer repair 10.16 ds 70 ................................................................................................144 10.17 ds 720 ..............................................................................................146.

  • Page 9: Rammer Repair

    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 servic...

  • Page 10: Safety Information

    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 transmi...

  • Page 11: Rammer Repair

    Rammer repair safety information wc_si000514gb.Fm 11 1.3 operating safety operator qualifications only trained personnel are permitted to start, operate, and shut down the machine. They also must meet the following qualifications: • have received instruction on how to properly use the machine • are ...

  • Page 12: Safety Information

    Safety information rammer repair 12 wc_si000514gb.Fm 1.3.5 never leave the machine running unattended. 1.3.6 never tamper with or disable the function of operating controls. 1.3.7 never use the choke to stop the engine. 1.3.8 never operate the machine in areas where explosions may occur. 1.3.9 read,...

  • Page 13: Rammer Repair

    Rammer repair safety information wc_si000514gb.Fm 13 1.4 operator safety while using internal combustion engines operating safety when running the engine: • keep the area around exhaust pipe free of flammable materials. • check the fuel lines and the fuel tank for leaks and cracks before starting th...

  • Page 14: Safety Information

    Safety information rammer repair 14 wc_si000514gb.Fm • do not refuel if the machine is positioned in a truck fitted with a plastic bed liner. Static electricity can ignite the fuel or fuel vapors. 1.5 service safety a poorly maintained machine can become a safety hazard! In order for the machine to ...

  • Page 15: Rammer Repair

    Rammer repair safety information wc_si000514gb.Fm 15 1.5.4 do not alter engine speeds. Run the engine only at speeds specified in the technical data section. 1.5.5 do not crank a flooded engine with the spark plug removed on gasoline-powered engines. Fuel trapped in the cylinder will squirt out the ...

  • Page 16: Safety Information

    Safety information rammer repair 16 wc_si000514gb.Fm 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 dis...

  • Page 17: Rammer Repair

    Rammer repair tools wc_tx001544gb.Fm 17 2 tools 2.1 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 18: Tools

    Tools rammer repair wc_tx001544gb.Fm 18 2.2 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 large-diameter retai...

  • Page 19: Rammer Repair

    Rammer repair maintenance schedules wc_tx001545gb.Fm 19 3 maintenance schedules 3.1 periodic maintenance schedule (bs 50/60/70-2, bs 65) the table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points req...

  • Page 20: Maintenance Schedules

    Maintenance schedules rammer repair 20 wc_tx001545gb.Fm 3.2 periodic maintenance schedule (bs 500/600/700/650) the table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and ...

  • Page 21: Rammer Repair

    Rammer repair maintenance schedules wc_tx001545gb.Fm 21 3.3 periodic maintenance schedule (bs 50/60/70-2i) the table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and equi...

  • Page 22: Maintenance Schedules

    Maintenance schedules rammer repair 22 wc_tx001545gb.Fm 3.4 periodic maintenance schedule (bs 500/600/700-oi) the table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and e...

  • Page 23: Rammer Repair

    Rammer repair maintenance schedules wc_tx001545gb.Fm 23 3.5 periodic maintenance schedule (ds 70) daily before starting after first 5 hours every week or 25 hours every month or 100 hours every 3 months or 300 hours every 5 months or 500 hours check fuel level. 3 check engine oil level. 3 check air ...

  • Page 24: Maintenance Schedules

    Maintenance schedules rammer repair 24 wc_tx001545gb.Fm 3.6 periodic maintenance schedule (ds 720) the table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and equipment. D...

  • Page 25: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 25 4 engine and upper machine components 4.1 removing the silencing cover see graphic: wc_gr007457 recommended tools ratchet wrench torque wrench hex key or hex socket: 5 mm loctite 243 (blue) remove the four socket head cap screws (...

  • Page 26: Rammer Repair

    Engine and upper machine components rammer repair 26 wc_tx001546gb.Fm 4.2 replacing the throttle control (2010 and later 2-stroke models) requirements • machine shut down and cool • torque wrench removal perform the procedure below to remove the throttle control. 4.2.1 remove the silencing cover. Se...

  • Page 27: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 27 installation perform the procedure below to install the throttle control. 4.2.1 connect the throttle control (c) to the machine with bolt (h) and hardware (b) . Adjust the nut on the throttle control lever so that the lever moves ...

  • Page 28: Rammer Repair

    Engine and upper machine components rammer repair 28 wc_tx001546gb.Fm 4.3 replacing the throttle control (2010 4-stroke models) requirements • machine shut down and cool • torque wrench removal perform the procedure below to remove the throttle control. 4.3.1 remove the silencing cover. See topic re...

  • Page 29: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 29 continued from the previous page. 4.3.5 remove the bolt (h) and hardware (b) . 4.3.6 remove the throttle lever (c) from the machine. Result the removal procedure is now complete. Installation perform the procedure below to install...

  • Page 30: Rammer Repair

    Engine and upper machine components rammer repair 30 wc_tx001546gb.Fm continued from the previous page. 4.3.3 support the throttle cable with new wire ties (d) . 4.3.4 install the clamp (c) . 4.3.5 connect the throttle cable at the swivel (a) and the clamp (b) . 4.3.6 reinstall the silencing cover. ...

  • Page 31: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 31 4.4 throttle control (pre-2010 models) see graphic: wc_gr003876 4.4.1 adjust the nut (a) on the throttle control lever (b) so that the lever moves freely but still holds its position while the rammer is operating. The recommended ...

  • Page 32: Rammer Repair

    Engine and upper machine components rammer repair 32 wc_tx001546gb.Fm 4.5 replacing the stop switch (2010 and later 2-stroke models) requirements • machine shut down and cool • torque wrench removal perform the procedure below to remove the stop switch. 4.5.1 remove the silencing cover. See topic re...

  • Page 33: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 33 continued from the previous page. 4.5.6 remove the screws (g) that hold the throttle control bracket to the machine and pull the throttle control bracket (e) (with stop switch) from the machine. 4.5.7 pull the stop switch (f) and ...

  • Page 34: Rammer Repair

    Engine and upper machine components rammer repair 34 wc_tx001546gb.Fm continued from the previous page. 4.5.2 install the throttle control bracket and the stop switch (f) with screws (g) .Torque the screws to 10 nm (7 ft.Lbs.). 4.5.3 reconnect the stop switch wiring (c) to the engine. 4.5.4 reinstal...

  • Page 35: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 35 4.6 replacing the stop switch (2010 and later 4-stroke models) requirements • machine shut down and cool • torque wrench removal perform the procedure below to remove the stop switch. 4.6.1 remove the silencing cover. See topic re...

  • Page 36: Rammer Repair

    Engine and upper machine components rammer repair 36 wc_tx001546gb.Fm continued from the previous page. Installation perform the procedure below to install the stop switch. 4.6.1 slide the stop switch (h) into the throttle control bracket and thread the wiring through the throttle control bracket. 4...

  • Page 37: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 37 4.7 replacing the guide handle (2010 and later 2-stroke models) requirements • machine shut down and cool • loctite® 243 removal perform the procedure below to remove the guide handle. 4.7.1 remove the silencing cover. See topic r...

  • Page 38: Rammer Repair

    Engine and upper machine components rammer repair 38 wc_tx001546gb.Fm continued from the previous page. 4.7.9 remove the screws that hold the guide handle (g) to the shock mounts and remove the guide handle from the machine. Result the removal procedure is now complete. Installation perform the proc...

  • Page 39: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 39 continued from the previous page. 4.7.4 thread the upper fuel line (b) through the hole (d) in the guide handle and connect it to the fuel tank. 4.7.5 install the fuel tank with screws (a) . Torque the screws to 9 nm (6 ft.Lbs.). ...

  • Page 40: Rammer Repair

    Engine and upper machine components rammer repair 40 wc_tx001546gb.Fm 4.8 replacing the guide handle (2010 and later 4-stroke models) requirements • machine shut down and cool • torque wrench • loctite® 243 removal perform the procedure below to remove the guide handle. 4.8.1 remove the silencing co...

  • Page 41: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 41 continued from the previous page. 4.8.8 remove the screws (e) that hold the fuel tank to the guide handle. 4.8.9 disconnect the upper fuel line (b) from the tank. Thread the fuel line through the hole in the guide handle (d) , the...

  • Page 42: Rammer Repair

    Engine and upper machine components rammer repair 42 wc_tx001546gb.Fm installation perform the procedure below to install the guide handle. 4.8.1 install the guide handle (g) to the shock mounts. Use loctite® 243 on the screws and torque the screws to 24 nm (18 ft.Lbs.). 4.8.2 feed the hoses through...

  • Page 43: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 43 continued from the previous page. 4.8.5 install the throttle stop and the throttle control bracket with screw (i) . Torque the screw to 9 nm (6 ft.Lbs.). 4.8.6 install the fuel valve with screws (a) . Torque the screws to 3 nm (2 ...

  • Page 44: Rammer Repair

    Engine and upper machine components rammer repair 44 wc_tx001546gb.Fm 4.9 replacing the guide handle (pre-2010 models) see graphic: wc_gr003704 recommended tools ratchet wrench socket: 10 mm screwdriver pliers loctite 243 (blue) 4.9.1 close the fuel valve. 4.9.2 disconnect the fuel line. 4.9.3 loose...

  • Page 45: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 45 4.10 shock mounts see graphic: wc_gr003705 recommended tools ratchet wrench torque wrench loctite 243 (blue) 4.10.1 remove the silencing cover, the air cleaner, and the guide handle. 4.10.2 inspect the shock mounts (a) and make su...

  • Page 46: Rammer Repair

    Engine and upper machine components rammer repair 46 wc_tx001546gb.Fm 4.11 tillotson carburetor (bs 500/600/700/650 only) see graphic: wc_gr001308rm recommended tools ratchet wrench torque wrench hex key or hex socket: 4 mm, 6 mm screwdriver loctite 243 (blue) the tillotson carburetor uses a fixed l...

  • Page 47: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 47 4.11.4 close the fuel valve and disconnect the fuel line from the carburetor. See the section fuel lines for removal of fuel and vent lines for models bs 50/60/70/65. 4.11.5 loosen the air duct clamps and remove the air duct. 4.11...

  • Page 48: Rammer Repair

    Engine and upper machine components rammer repair 48 wc_tx001546gb.Fm 4.12 fuel lines (bs 50/60/70-2, bs 65) see graphic: wc_gr001493 always follow the instructions when disconnecting the fuel lines. Failure to do so may result in fuel leaking from the fuel system. To disconnect the fuel lines: 4.12...

  • Page 49: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 49 4.13 fuel tank (bs models) see graphic: wc_gr001312rm 4.13.1 remove the silencing cover. 4.13.2 close the fuel valve (a). 4.13.3 disconnect the fuel line (b) from the fuel tank. Disconnect the vent line (c) where used. 4.13.4 drai...

  • Page 50: Rammer Repair

    Engine and upper machine components rammer repair 50 wc_tx001546gb.Fm 4.14 fuel tank (ds models) see graphic: wc_gr001313rm 4.14.1 remove the silencing cover. 4.14.2 disconnect the fuel supply line (f) and fuel return line (c) from the fuel tank and drain the fuel into a suitable container. Note: in...

  • Page 51: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 51 wc_gr001313rm a b d e c f.

  • Page 52: Rammer Repair

    Engine and upper machine components rammer repair 52 wc_tx001546gb.Fm 4.15 fuel tank cap see graphic: wc_gr004562 to disassemble and clean the fuel tank cap: 4.15.1 grasp the fuel tank cap (a) in one hand and the baffle (b) in the other. 4.15.2 pull and twist the baffle left and right to separate it...

  • Page 53: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 53 e b c d wc_gr004562 a g f.

  • Page 54: Rammer Repair

    Engine and upper machine components rammer repair 54 wc_tx001546gb.Fm 4.16 muffler (pre-2009 bs models) see graphic: wc_gr001314rm recommended tools ratchet wrench torque wrench hex key: 5 mm hex key or hex socket: 6 mm socket: 19 mm (3/4”) loctite 243 (blue) carbon deposits can form in the muffler ...

  • Page 55: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 55 4.17 engine cooling fins recommended tools screwdriver compressed air the wacker wm 80 engine is air cooled, so dirt accumulation between the cylinder ribs may cause the engine to overheat. Use a screwdriver to remove any dirt tha...

  • Page 56: Rammer Repair

    Engine and upper machine components rammer repair 56 wc_tx001546gb.Fm 4.18 muffler (ds models) see graphic: wc_gr001315rm recommended tools ratchet wrench torque wrench hex key: 5 mm hex key or hex socket: 6 mm socket: 19 mm (3/4”) loctite 243 (blue) carbon deposits can form in the muffler (a) and i...

  • Page 57: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 57 w c _ g r 0 0 1 3 1 5 r m = ? > @.

  • Page 58: Rammer Repair

    Engine and upper machine components rammer repair 58 wc_tx001546gb.Fm 4.19 replacing the carburetor (wm 80 engines) removal removing walbro carburetor (auto-release choke models) 4.19.1 stop the machine and allow it to cool. 4.19.2 remove the carburetor guard (a) . 4.19.3 loosen the hose clamp and r...

  • Page 59: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 59 continued from the previous page. 4.19.7 have a container ready, then remove the oil hose (h) and drain it. 4.19.8 make sure the throttle is in the off position. This position also closes the fuel valve. Then, remove the fuel hose...

  • Page 60: Rammer Repair

    Engine and upper machine components rammer repair 60 wc_tx001546gb.Fm installation perform the procedure below to install the carburetor 4.19.1 assemble the adapter (j) , lower gasket (l) , flange (k), and upper gasket (o) to the carburetor (i) . Note: the gaskets are not interchangeable. 4.19.2 con...

  • Page 61: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 61 4.19.4 slide the throttle cable (e) through the adapter (f) and reconnect it to the clamp (d) . 4.19.5 install the air duct (b) with the hose clamp. 4.19.6 using loctite® 243 on the screws, install the carburetor guard (a) . Resul...

  • Page 62: Rammer Repair

    Engine and upper machine components rammer repair 62 wc_tx001546gb.Fm 4.20 replacing the wm 80 engine (2010 and later models) requirements • engine cool • carburetor removed removal perform the procedure below to remove the engine. 4.20.1 remove the carburetor. 4.20.2 remove the muffler (a) . 4.20.3...

  • Page 63: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 63 installation perform the procedure below to install the engine. 4.20.1 install the engine (d) to the machine with three screws. Torque the screws to 28 nm (20 ft.Lbs.). 4.20.2 reconnect the wiring (c) to the switches. 4.20.3 insta...

  • Page 64: Rammer Repair

    Engine and upper machine components rammer repair 64 wc_tx001546gb.Fm 4.21 replacing the wm 80 engine (pre-2010 models) see graphic:wc_gr002935 removal: 4.21.1 stop the machine and allow it to cool. 4.21.2 remove the carburetor. See section removing carburetor. 4.21.3 remove the muffler guard (a) (i...

  • Page 65: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 65 wc_gr002935 d a b e c d.

  • Page 66: Rammer Repair

    Engine and upper machine components rammer repair 66 wc_tx001546gb.Fm 4.22 replacing the carburetor (wm 100 engines) requirements • machine shut down and cool • loctite® 243 or equivalent • torque wrench removal perform the procedure below to remove the engine. 4.22.1 disconnect the spark plug. 4.22...

  • Page 67: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 67 continued from the previous page. 4.22.6 disconnect the hose (e) . 4.22.7 remove screw (f) and disconnect the linkage. 4.22.8 remove the carburetor (g) . Result the removal procedure is now complete..

  • Page 68: Rammer Repair

    Engine and upper machine components rammer repair 68 wc_tx001546gb.Fm installation perform the procedure below to install the carburetor. 4.22.1 install the carburetor (g) , gaskets (h) , and adapter (i) . 4.22.2 reconnect the linkage with screw (f) . 4.22.3 reconnect the hose (e) . 4.22.4 reconnect...

  • Page 69: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 69 continued from the previous page. 4.22.6 reconnect the throttle cable (b) . 4.22.7 install the side guard (a) . Result the replacement procedure is now complete..

  • Page 70: Rammer Repair

    Engine and upper machine components rammer repair 70 wc_tx001546gb.Fm 4.23 replacing the wm 100 engine requirements • machine shut down and cool • loctite® 243 or equivalent • torque wrench • two wire ties removal perform the procedure below to remove the engine. 4.23.1 remove the carburetor. See to...

  • Page 71: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 71 continued from the previous page. 4.23.6 remove the heat shield (a) . 4.23.7 disconnect the throttle cable (x) at the swivel (y) and the clamp (z) . 4.23.8 remove the nuts that hold the engine and remove the engine (e) from the ma...

  • Page 72: Rammer Repair

    Engine and upper machine components rammer repair 72 wc_tx001546gb.Fm installation perform the procedure below to install the engine. 4.23.1 apply loctite® 243 to the four engine studs (w) . 4.23.2 slide the engine (e) (with clutch installed) into the machine. 4.23.3 loosely install the support brac...

  • Page 73: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 73 continued from the previous page. 4.23.5 fit the lower guard to the support bracket. Then, using loctite® 243 on the screws, install the lower guard (c) to the engine. Torque the screws to 25 nm (18 ft.Lbs.). Torque the support br...

  • Page 74: Rammer Repair

    Engine and upper machine components rammer repair 74 wc_tx001546gb.Fm 4.24 removing the wm 90 engine see graphic: wc_gr001954, wc_gr003661, wc_gr001956, and wc_gr001957 4.24.1 disconnect the spark plug cap (a) from the spark plug. 4.24.2 disconnect the fuel line (b) from the carburetor and plug the ...

  • Page 75: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 75 d e j f wc_gr001954 b l a c k wc_gr003661.

  • Page 76: Rammer Repair

    Engine and upper machine components rammer repair 76 wc_tx001546gb.Fm 4.25 engine (ds models) see graphic: wc_gr001317rm recommended tools ratchet wrench torque wrench socket: 19 mm (3/4”) hex key: 5 mm hex key or hex socket: 4 mm, 6 mm screwdriver 4.25.1 close the fuel valve. 4.25.2 disconnect the ...

  • Page 77: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 77 w c _ g r 0 0 1 3 1 7 r m =.

  • Page 78: Rammer Repair

    Engine and upper machine components rammer repair 78 wc_tx001546gb.Fm 4.26 clutch (2- and 4-stroke models) see graphic: wc_gr007517 recommended tools impact wrench torque wrench socket: 17 mm needle-nose pliers clutch puller p/n 0117972 removal 4.26.1 remove the engine from the rammer. 4.26.2 check ...

  • Page 79: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 79 bs models.

  • Page 80: Rammer Repair

    Engine and upper machine components rammer repair 80 wc_tx001546gb.Fm 4.27 clutch (ds 720 only) see graphic: wc_gr001319rm recommended tools impact wrench torque wrench needle-nose pliers clutch puller p/n 0153566 removal 4.27.1 remove the engine from the rammer. 4.27.2 check the condition of the cl...

  • Page 81: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 81 c a b wc_gr001319rm ds 720 models.

  • Page 82: Rammer Repair

    Engine and upper machine components rammer repair 82 wc_tx001546gb.Fm 4.28 clutch (ds 70 only) see graphic: wc_gr002372rm recommended tools impact wrench torque wrench needle-nose pliers clutch puller p/n 0153566 removal 4.28.1 remove the engine from the rammer. 4.28.2 check the condition of the clu...

  • Page 83: Rammer Repair

    Rammer repair engine and upper machine components wc_tx001546gb.Fm 83 ds 70 models wc_gr002372rm a b c.

  • Page 84: Ramming System

    Ramming system rammer repair 84 wc_tx001547gb.Fm 5 ramming system 5.1 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 syste...

  • Page 85: Rammer Repair

    Rammer repair ramming system wc_tx001547gb.Fm 85 installation 5.1.9 oil the inner edges of the bellows. 5.1.10 place the lower clamp (f) on the protective pipe (j). 5.1.11 press the bellows (e) onto the protective pipe (j) with a strong downward push. 5.1.12 partially tighten the clamp onto the bell...

  • Page 86: Ramming System

    Ramming system rammer repair 86 wc_tx001547gb.Fm 5.1.20 fasten the guide cylinder to the crankcase. Apply loctite 243 and torque the screws to 43 nm (32 ft.Lbs.). 5.1.21 lay the rammer flat on the ground and align the protective pipe with the upper machinery. 5.1.22 position the clamps so that the c...

  • Page 87: Rammer Repair

    Rammer repair ramming system wc_tx001547gb.Fm 87 5.2 replacing the ramming shoe requirements • torque wrench • lifting device capable of lifting the machine removal perform the procedure below to remove the shoe. 5.2.1 support the machine with a lifting device capable of lifting the weight of the ma...

  • Page 88: Ramming System

    Ramming system rammer repair 88 wc_tx001547gb.Fm installation follow the guidelines below when installing the shoes. 5.2.7 the plow bolts (m , n, and o) and (l and j) as well as hex bolts (a and b) have different lengths. Use the longer of the bolts where needed. 5.2.8 when reusing bolts, clean the ...

  • Page 89: Rammer Repair

    Rammer repair ramming system wc_tx001547gb.Fm 89 notes.

  • Page 90: Ramming System

    Ramming system rammer repair 90 wc_tx001547gb.Fm 5.3 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 t...

  • Page 91: Rammer Repair

    Rammer repair ramming system wc_tx001547gb.Fm 91 5.3.14 attach the ramming system to the upper machinery. Wc_gr001324rm hydraulic press method.

  • Page 92: Ramming System

    Ramming system rammer repair 92 wc_tx001547gb.Fm see graphic: wc_gr001325rm threaded rod removal method 5.3.15 remove the ramming shoe per section ramming shoe. Separate the ramming system from the upper machinery per section bellows. 5.3.16 remove the two socket head cap screws that are opposite of...

  • Page 93: Rammer Repair

    Rammer repair ramming system wc_tx001547gb.Fm 93 wc_gr001325rm threaded rod method.

  • Page 94: Ramming System

    Ramming system rammer repair 94 wc_tx001547gb.Fm see graphic: wc_gr001326 spring box tool removal method 5.3.1 remove the ramming shoe per section ramming shoe. Separate the ramming system from the upper machinery per section bellows. 5.3.2 align three holes in the spring box tool (a) with three soc...

  • Page 95: Rammer Repair

    Rammer repair ramming system wc_tx001547gb.Fm 95 spring box tool method a b d c wc_gr001326 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, bs1...

  • Page 96: Ramming System

    Ramming system rammer repair 96 wc_tx001547gb.Fm 5.4 spring system see graphic: wc_gr001327rm, wc_gr001328rm recommended tools impact wrench socket: 32 mm or 24mm (bs 500 only) deep well drift pin torque wrench rubber mallet impact bushing puller p/n 0116816 loctite 243 (blue) disassembly 5.4.1 remo...

  • Page 97: Rammer Repair

    Rammer repair ramming system wc_tx001547gb.Fm 97 assembly 5.4.10 slide the ram (e) into the spring cylinder (h). 5.4.11 reinstall the bushing (f) and the spring set (g). 5.4.12 reinstall the piston guide (j). 5.4.13 replace the locknut (k) and torque it to: bs 500 - 210 nm (155 ft.Lbs.) bs 600/700 -...

  • Page 98: Ramming System

    Ramming system rammer repair 98 wc_tx001547gb.Fm 5.5 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 ar...

  • Page 99: Rammer Repair

    Rammer repair ramming system wc_tx001547gb.Fm 99 5.6 protective pipe see graphic: wc_gr001330rm recommended tools ratchet wrench torque wrench extension hex socket: 6 mm loctite 243 (blue) if the protective pipe becomes loose or damaged, it must be replaced on the spring cylinder. 5.6.1 remove the b...

  • Page 100: Ramming System

    Ramming system rammer repair 100 wc_tx001547gb.Fm 5.7 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...

  • Page 101: Rammer Repair

    Rammer repair ramming system wc_tx001547gb.Fm 101 5.7.9 reinstall the seal-ring and the fill plug. Torque the fill plug to 47 nm (35 ft.Lbs.). Note: an alternate method of changing the oil is to drain and fill the oil from the sightglass. Wc_gr001331rm b a c.

  • Page 102: Ramming System

    Ramming system rammer repair 102 wc_tx001547gb.Fm 5.8 ramming system lubrication (bs 50/60/70, bs 65, ds 70) background lubricating oil is distributed throughout the ramming system by the action of the rammer. Holes drilled in the piston carry oil from the bottom of the rammer to the crankcase as th...

  • Page 103: Rammer Repair

    Rammer repair ramming system wc_tx001547gb.Fm 103 5.8.4 remove the sightglass. Clean the threads of the sightglass, then wrap the threads with teflon tape. 5.8.5 add oil to the machine through the sightglass opening in the housing. 5.8.6 stand the machine upright to check the oil level. Add enough o...

  • Page 104: Crankcase

    Crankcase rammer repair 104 wc_tx001548gb.Fm 6 crankcase 6.1 crank gear and connecting rod see graphic: wc_gr007520 recommended tools hex key: 8 mm 2-jaw bearing puller large diameter retaining-ring pliers hydraulic press screwdriver split puller slide hammer torque wrench loctite® 243 (blue) remova...

  • Page 105: Rammer Repair

    Rammer repair crankcase wc_tx001548gb.Fm 105 6.1.14 the needle bearing (c) remains intact in the crankcase cover. Inspect the needle bearing for wear and, if damaged, remove it by using a slide hammer or similar pulling device. Assembly 6.1.15 if the needle bearing was removed, press a new bearing i...

  • Page 106: Crankcase

    Crankcase rammer repair 106 wc_tx001548gb.Fm 6.2 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 ...

  • Page 107: Rammer Repair

    Rammer repair crankcase wc_tx001548gb.Fm 107 6.2.13 the crankgear needle bearing (19), oil seal (11), and ball bearing (10) remain intact in the bearing mount. • examine the needle bearings for wear. • if damaged, replace the needle bearings by removing the large retain- ing ring (8) holding the bal...

  • Page 108: Crankcase

    Crankcase rammer repair 108 wc_tx001548gb.Fm assembly 6.2.16 if the needle bearing (17) was removed, apply loctite 609 to a new needle bearing and press it into the bearing mount until the outer race is flush with the flange surface. 6.2.17 press the ball bearing (27) into the connecting rod. 6.2.18...

  • Page 109: Rammer Repair

    Rammer repair crankcase wc_tx001548gb.Fm 109 notes.

  • Page 110: Crankcase

    Crankcase rammer repair 110 wc_tx001548gb.Fm 6.3 clutch drum see graphic: wc_gr001335rm recommended tools hex key: 8 mm large diameter retaining-ring pliers hydraulic press screwdriver slide hammer torque wrench loctite 243 (blue) shell alvania rl2 removal 6.3.1 remove the four socket head cap screw...

  • Page 111: Rammer Repair

    Rammer repair crankcase wc_tx001548gb.Fm 111 assembly 6.3.14 if the needle bearing was removed, press a new bearing into the cover until the outer race is flush with the flange surface. Notice: keep the inside of the clutch drum absolutely free of any oil and grease. 6.3.15 press the clutch drum bal...

  • Page 112: Oil Injection (If Equipped)

    Oil injection (if equipped) rammer repair 112 wc_tx001549gb.Fm 7 oil injection (if equipped) 7.1 testing the float switch (2010 and later models) background the function of the float switch is to prevent the engine from running without oil in the oil tank. If the oil tank is low on oil, the float sw...

  • Page 113: Rammer Repair

    Rammer repair oil injection (if equipped) wc_tx001549gb.Fm 113 7.1.3 check the continuity of the float switch by measuring across the connector. Does the float switch have continuity? 7.1.4 reconnect the float switch. 7.1.5 reinstall the carburetor guard. Yes ____ no ____ the float switch is ok. The...

  • Page 114: Oil Injection (If Equipped)

    Oil injection (if equipped) rammer repair 114 wc_tx001549gb.Fm 7.2 replacing the float switch (2010 and later models) requirements • new float switch • 2-cycle engine oil removal perform the procedure below to remove the float switch. 7.2.1 remove the silencing cover. See topic removing the silencin...

  • Page 115: Rammer Repair

    Rammer repair oil injection (if equipped) wc_tx001549gb.Fm 115 continued from the previous page. 7.2.6 unscrew the float switch assembly (e) from the oil tank. 7.2.7 remove the float switch and wiring from the machine. Installation perform the procedure below to install the float switch. 7.2.1 screw...

  • Page 116: Oil Injection (If Equipped)

    Oil injection (if equipped) rammer repair 116 wc_tx001549gb.Fm 7.3 float switch testing and replacement (pre-2010 models) see graphic: wc_gr001526 notice: do not bypass the float switch except during testing; engine failure may occur. The function of the float switch is to prevent the engine from ru...

  • Page 117: Rammer Repair

    Rammer repair oil injection (if equipped) wc_tx001549gb.Fm 117 wc_gr001526 a b c d.

  • Page 118: Oil Injection (If Equipped)

    Oil injection (if equipped) rammer repair 118 wc_tx001549gb.Fm 7.4 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. Lookin...

  • Page 119: Rammer Repair

    Rammer repair oil injection (if equipped) wc_tx001549gb.Fm 119 wc_gr001527 a b.

  • Page 120: Oil Injection (If Equipped)

    Oil injection (if equipped) rammer repair 120 wc_tx001549gb.Fm 7.5 testing/replacing the oil pump background oil-injection rammers can run up to 65 hours on one tank of oil. If the rammer has been used for a long period of time, and it does not appear to have used any oil and the oil line check valv...

  • Page 121: Rammer Repair

    Rammer repair oil injection (if equipped) wc_tx001549gb.Fm 121 continued from the previous page. 7.5.5 separate the pump from the cartridge portion of the pump assembly. The cartridge may remain in the engine. 7.5.6 inspect the gear (c) for damage. If the gear is damaged, replace it. 7.5.7 open the ...

  • Page 122: Oil Injection (If Equipped)

    Oil injection (if equipped) rammer repair 122 wc_tx001549gb.Fm continued from the previous page. 7.5.9 remove the cartridge assembly (g) . Result the removal procedure is now complete. Installation perform the procedure below to install the oil pump. 7.5.1 slide the cartridge assembly (g) into the c...

  • Page 123: Rammer Repair

    Rammer repair low oil shutdown (if equipped) wc_tx001550gb.Fm 123 8 low oil shutdown (if equipped) 8.1 testing the low oil unit see graphic: wc_gr003673 the function of the low oil unit is to prevent the engine from running after startup if the engine is low on oil. To test the low oil unit: 8.1.1 r...

  • Page 124: Troubleshooting

    Troubleshooting rammer repair 124 wc_tx000291gb.Fm 9 troubleshooting 9.1 engine hard to start (1)does not apply to the ds 720 or ds 70 rammer. 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 ta...

  • Page 125: Rammer Repair

    Rammer repair troubleshooting wc_tx000291gb.Fm 125 9.2 engine does not start (1) does not apply to the ds 720 or ds 70 rammer. 9.3 engine does not accelerate or runs poorly (1) does not apply to the ds 720 or ds 70 rammer. Problem / symptom reason / remedy there is no fuel in the tank. Add fuel. The...

  • Page 126: Troubleshooting

    Troubleshooting rammer repair 126 wc_tx000291gb.Fm 9.4 engine overheats (1) does not apply to the ds 720 or ds 70 rammer. 9.5 rammer does not tamp problem / symptom reason / remedy there is not enough oil in the fuel mix (1) . Drain the fuel from the tank and fill it with new mixed fuel. The carbure...

  • Page 127: Rammer Repair

    Rammer repair troubleshooting wc_tx000291gb.Fm 127 9.6 rammer jumps erratically problem / symptom reason / remedy there is oil or grease on the clutch. Inspect and clean the clutch. The spring(s) in the ramming system are broken or worn. Disassemble the spring cylinder. Inspect and replace any damag...

  • Page 128: Technical Data

    Technical data rammer repair 128 wc_td000112gb.Fm 10 technical data 10.1 bs 50-2 item number: bs 50-2 0009380, 0009382, 0009384, 0009410 0009411, 0009413, 0620025, 0620048 0620609, 0620610, 0620733 rammer engine model type wm80 engine speed - full rpm 4400 ± 100 engine speed - idle rpm 1800 ± 100 cl...

  • Page 129: Rammer Repair

    Rammer repair technical data wc_td000112gb.Fm 129 10.2 bs 50-4 item number: bs 50-4s 0620071, 0620078 0620811 rammer engine model type wm90 engine speed - operating rpm 4200 ± 100 engine speed - idle rpm 2000 ± 100 clutch engagement rpm 2500 ± 100 max. Rated power @ rated speed kw(hp) 2.1 (2.8) @ 42...

  • Page 130: Technical Data

    Technical data rammer repair 130 wc_td000112gb.Fm 10.3 bs 500 item number: bs 500 0007550, 0008048 0008049, 0009074, 0009075 rammer engine model type wm80 engine speed - full rpm 4400 ± 100 engine speed - idle rpm 1800 ± 100 clutch engagement rpm 2800 ± 100 spark plug type champion rl95yc electrode ...

  • Page 131: Rammer Repair

    Rammer repair technical data wc_td000112gb.Fm 131 10.4 bs 500s item number: bs 500s 0009211 rammer engine model type wm80 engine speed - full rpm 4700 ± 100 engine speed - idle rpm 1800 ± 100 clutch engagement rpm 2800 ± 100 spark plug type champion rl95yc electrode gap mm (in.) 0.5 (.020) cylinder ...

  • Page 132: Technical Data

    Technical data rammer repair 132 wc_td000112gb.Fm 10.5 bs 50-2i item number: bs 50-2i 0009332, 0009338 0009414, 0009416 0009473, 0620026, 0620611 bs 50-2i 0009383 0009412 rammer engine model type wm80 engine speed - full rpm 4400 ± 100 4600 ± 100 engine speed - idle rpm 1800 ± 100 clutch engagement ...

  • Page 133: Rammer Repair

    Rammer repair technical data wc_td000112gb.Fm 133 10.6 bs 500-oi item number: bs 500-oi 0009165, 0009343 rammer engine model type wm80 engine speed - full rpm 4400 ± 100 engine speed - idle rpm 1800 ± 100 clutch engagement rpm 2800 ± 100 spark plug type champion rl95yc electrode gap mm (in.) 0.5 (0....

  • Page 134: Technical Data

    Technical data rammer repair 134 wc_td000112gb.Fm 10.7 bs 60/70-2 item number: bs 60-2 0009388 0009417 0009421 0620612 bs 60-2 0009391 0009418 bs 70-2 0009397 0009399 0009424 0009425 0009427 rammer engine model type wm80 engine speed - full rpm 4400 ± 100 4600 ± 100 engine speed - idle rpm 1800 ± 10...

  • Page 135: Rammer Repair

    Rammer repair technical data wc_td000112gb.Fm 135 10.8 bs 60-4 item number: bs 60-4 0009340 0620000 0620051 0620109 0620110 bs 60-4s 0620072 0620074 0620483 0620563 0620073 rev 201 and lower bs 60-4s 0620073 rev 202 and higher rammer engine model type wm90 wm100 engine speed - operating rpm 4200 ± 1...

  • Page 136: Technical Data

    Technical data rammer repair 136 wc_td000112gb.Fm 10.9 bs 600/700 item number: bs 600 0007551, 0008207 0009076, 0009307 bs 700 0007552, 0008051 0008052, 0009308 rammer engine model type wm80 engine speed - full rpm 4350 ± 100 engine speed - idle rpm 1800 ± 100 clutch engagement rpm 2800 ± 100 spark ...

  • Page 137: Rammer Repair

    Rammer repair technical data wc_td000112gb.Fm 137 10.10 bs 600s item number: bs 600s 0009212 rammer engine model type wm80 engine speed - full rpm 4600 ± 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) cylinde...

  • Page 138: Technical Data

    Technical data rammer repair 138 wc_td000112gb.Fm 10.11 bs 60/70-2i item number: bs 60-2i 0009339 0009419 0620613 0620614 bs 60-2i 0009393 0009420 bs 70-2i 0009341 0009401 0009426 0009428 rammer engine model type wm80 engine speed - full rpm 4400 ± 100 4600 ± 100 engine speed - idle rpm 1800 ± 100 c...

  • Page 139: Rammer Repair

    Rammer repair technical data wc_td000112gb.Fm 139 10.12 bs 600/700-oi item number: bs 600-oi 0009166, 0009262 bs 700-oi 0009167, 0009328 rammer engine model type wm80 engine speed - full rpm 4350 ± 100 engine speed - idle rpm 1800 ± 100 clutch engagement rpm 2800 ± 100 spark plug type champion rl95y...

  • Page 140: Technical Data

    Technical data rammer repair 140 wc_td000112gb.Fm 10.13 bs 600/700 high altitude item number: bs 600 0009077 bs 700 0009079 rammer engine model type wm80 engine speed - full rpm 4350 ± 100 engine speed - idle rpm 1800 ± 100 clutch engagement rpm 2800 ± 100 spark plug type champion rl95yc electrode g...

  • Page 141: Rammer Repair

    Rammer repair technical data wc_td000112gb.Fm 141 10.14 bs 65-v item number: bs 65-v 0009396, 0009423 rammer engine model type wm80 engine speed - full rpm 4400 ± 100 engine speed - idle rpm 1800 ± 100 clutch engagement rpm 2500 ± 100 spark plug type champion rl95yc electrode gap mm (in.) 0.5 (0.020...

  • Page 142: Technical Data

    Technical data rammer repair 142 wc_td000112gb.Fm 10.15 bs 650 item number: bs 650 0008209 rammer engine model type wm80 engine speed - full rpm 4350 ± 100 engine speed - idle rpm 1800 ± 100 clutch engagement rpm 2800 ± 100 spark plug type champion rl95yc electrode gap mm 0.5 cylinder head compressi...

  • Page 143: Rammer Repair

    Rammer repair technical data wc_td000112gb.Fm 143 notes.

  • Page 144: Technical Data

    Technical data rammer repair 144 wc_td000112gb.Fm 10.16 ds 70 item number: ds 70 0009342 0009402 0009403 ds 70 0620049 0620050 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...

  • Page 145: Rammer Repair

    Rammer repair technical data wc_td000112gb.Fm 145 item number: ds 70 0009342 0009402 0009403 ds 70 0620049 0620050 ds 70 0620052 0620053 0620054 engine engine type single cylinder, air cooled, 4-stroke diesel engine engine make yanmar engine model l48ee- dwk3 l48v4lf9t 9ewsa l48ee- dwk3 max. Rated p...

  • Page 146: Technical Data

    Technical data rammer repair 146 wc_td000112gb.Fm 10.17 ds 720 item number: ds 720 0008200 rev. 115 and lower 0008203 rev. 114 and lower ds 720 0008200 rev. 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 ...

  • Page 147: Rammer Repair

    Rammer repair technical data wc_td000112gb.Fm 147 item number: ds 720 0008200 rev. 115 and lower 0008203 rev. 114 and lower ds 720 0008200 rev. 116 and higher 0008203 rev. 115 and higher ds 720 0009309 engine engine type single cylinder, air cooled, 4-stroke diesel engine engine make yanmar engine m...

  • Page 148

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  • Page 149: Click Below To Find More

    Click below to find more mipaper at www.Lcis.Com.Tw mipaper at www.Lcis.Com.Tw.