Wacker Neuson BH 22 User manual

www.wackergroup.com
Operator´s Manual
Petrol-breaker
BH 22
BH 23
0109963en 003
03.2007

Table of contents
3
1. Foreword 11
2. Safety instructions 12
2.1 General ................................................................................................12
2.2 Operation .............................................................................................12
2.3 Safety checks ......................................................................................14
2.4 Maintenance ........................................................................................14
2.5 Transport .............................................................................................15
2.6 Maintenance checks ............................................................................15
3. Technical Data 16
4. Description 18
4.1 Applications .........................................................................................18
4.2 Description of function .........................................................................18
5. Transport to work site 19
6. Operation 20
6.1 Starting procedure ...............................................................................20
6.2 Engine .................................................................................................20
6.3 During operation ..................................................................................21
6.4 After operation .....................................................................................21
6.5 Notes for correct working procedure ...................................................22
7. Maintenance 23
7.1 Maintenance schedule ........................................................................23
7.2 Engine .................................................................................................23
7.3 Percussion system, crankcase ............................................................24
7.4 Assembly instructions ..........................................................................25
7.5 Assembly .............................................................................................26
8. Electric wirning diagramm for tools with remote cut-off 27
9. Labels 28
EC - Confornity Certificate 29
DIN EN ISO 9001 Certificate 31

T00940GB.fm 4
Important information
This machine has been provided with an EPA-certified engine.
Additional information can be found in the engine
manufacturer‘s notes.
Engine exhaust, some of its constitvents, and certain vehicle
components contain or emit chemicals known to the State of
California to cause cancer and birth defects or other reproduc-
tive harm.
WARNING
Caution
This engine is an EPA engine.
Adjusting the engine speed will interfere with EPA certification and
the emissions.
Only authorized personnel can make adjustments to this engine.
Please contact you nearest engine dealer or your Wacker Dealer for more
information.

T00953GB.fm 5
Emission Control System Information
Source of Emissions
The combustion process produces carbon monoxide, oxides of
nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of
nitrogen is very important because, under certain conditions, they
react to form photochemical smog when subjected to sunlight. Carbon
monoxide does not react in the same way, but it is toxic.
Wacker utilizes lean carburetor settings and other systems to reduce
the emissions of carbon monoxide, oxides of nitrogen, and
hydrocarbons.
The U.S. and California Clean Air Acts
EPA and California regulations require all manufacturers to furnish
written instructions describing the operation and maintenance of
emission control systems.
The following instructions and procedures must be followed in order to
keep the emissions from your Wacker engine within the emissions
standards.
Tampering and Altering
Tampering with or altering the emission control system may increase
emissions beyond the legal limit. Among those acts that constitute
tampering are:
•Removal or alteration of any part of the intake, fuel, or exhaust
systems.
•Altering or defeating the speed-adjusting mechanism to cause the
engine to operate outside its design parameters.
Problems That May Affect Emissions
If you are aware of any of the following symptoms, have your engine
inspected and repaired by your servicing dealer.
•Hard starting or stalling after starting.
•Rough idle.
•Misfiring or backfiring under load.
•Afterburning (backfiring).
•Black exhaust smoke or high fuel consumption.

T00953GB.fm 6
Replacement Parts
The emission control systems on your Wacker engine were designed,
built, and certified to conform with EPA and California emissions
regulations. We recommend the use of genuine Wacker parts
whenever you have maintenance done. These original-design
replacement parts are manufactured to the same standards as the
original parts, so you can be confident of their performance. The use
of replacement parts that are not of the original design and quality may
impair the effectiveness of your emission control system.
A manufacturer of an aftermarket part assumes the responsibility that
the part will not adversely affect emission performance. The
manufacturer or rebuilder of the part must certify that use of the part
will not result in a failure of the engine to comply with emission
regulations.
Maintenance
Follow the maintenance schedule. Remember that this schedule is
based on the assumption that your machine will be used for its
designed purpose. Sustained high-load or high-temperature operation,
or use in unusually wet or dusty conditions, will require more frequent
service.
OXYGENATED FUELS
Some conventional gasolines are being blended with alcohol or an
ether compound. These gasolines are collectively referred to as
oxygenated fuels. To meet clean air standards, some areas of the
United States and Canada use oxygenated fuels to help reduce
emissions.
If you use an oxygenated fuel, be sure it is unleaded and meets the
minimum octane rating requirement.
Before using an oxygenated fuel, try to confirm the fuel’s contents.
Some States / Provinces require this information to be posted on the
pump.
The following are EPA-approved percentages of oxygenates:
ETHANOL - (ethyl or grain alcohol) 10% by volume. You may use
gasoline containing up to 10% ethanol by volume. Gasoline containing
ethanol may be marketed under the name “Gasohol”.
MTBE - (methyl tertiary butyl ether) 15% by volume. You may use
gasoline containing up to 15% MTBE by volume.

T00953GB.fm 7
METHANOL - (methyl or wood alcohol) 5% by volume. You may use
gasoline containing up to 5% methanol by volume, as long as it
contains cosolvents and corrosion inhibitors to protect the fuel system.
Gasoline containing more than 5% methanol by volume may cause
starting and/or performance problems. It may also damage metal,
rubber, and plastic parts of your fuel system.
If you notice any undesirable operating symptoms, try another service
station, or switch to another brand of gasoline.
Fuel system damage or performance problems resulting from the use
of an oxygenated fuel containing more than the percentages of
oxygenates mentioned above are not covered under warranty.
Emission Control System Warranty
Your new Wacker engine complies with the U.S. EPA emissions
regulations. Wacker provides the same emission warranty coverage
for engines sold in all 50 states.
YOUR WARRANTY RIGHTS AND OBLIGATIONS
All States
Wacker must warrant the emission control system on your engine for
the period of time listed below provided there has been no abuse,
neglect or improper maintenance of your engine. Where a warrantable
condition exists, Wacker will repair your engine at no cost to you
including diagnosis, parts and labor.
Your emission control system may include such parts as the
carburetor, the ignition system and the catalytic converter.
Also included may be hoses, connectors and other emission-related
assemblies.
MANUFACTURER’S WARRANTY COVERAGE:
The 1998 and later engines are warranted for two years. If any
emission-related part on your engine is defective, the part will be
repaired or replaced by Wacker.

T00953GB.fm 8
OWNER’S WARRANTY RESPONSIBILITY:
As the engine owner, you are responsible for the performance of the
required maintenance listed in your owner’s manual. Wacker
recommends that you retain all receipts covering maintenance on your
engine, but Wacker cannot deny warranty coverage solely for the lack
of receipts or for your failure to ensure the performance of all
scheduled maintenance.
As the engine owner, you should be aware that Wacker may deny you
warranty coverage if your engine or a part has failed due to abuse,
neglect, improper maintenance or unapproved modifications.
You are responsible for presenting your engine to a Wacker dealer as
soon as a problem exists. The warranty repairs should be completed
in a reasonable amount of time, not to exceed 30 days.
If you have any questions regarding your warranty rights and
responsibilities, you should contact your local Wacker dealer.
WARRANTY COVERAGE:
Wacker engines sold after January 1, 1998, are covered by this
Emission Control System Warranty for a period of two years from the
date of delivery to the original retail purchaser. This warranty is
transferable to each subsequent purchaser for the duration of the
warranty period.
Warranty repairs will be made without charge for diagnosis, parts or
labor. All defective parts replaced under this warranty become property
of Wacker. A list of warranted parts is located on the next page. Normal
maintenance items, such as spark plugs and filters, that are on the
warranted parts list are warranted up to the required replacement
interval only.
Wacker is also liable for damages to other engine components caused
by a failure of any warranted parts during the warranty period.
Only Wacker approved replacement parts may be used in the
performance of any warranty repairs and must be provided without
charge to the owner. The use of replacement parts not equivalent to
the original parts may impair the effectiveness of your engine emission
control system. If such a replacement part is used in the repair or
maintenance of your engine, and an authorized Wacker dealer
determines it is defective or causes a failure of a warranted part, your
claim for repair of your engine may be denied. If the part in question is
not related to the reason your engine requires repair, your claim will not
be denied.

T00953GB.fm 9
TO OBTAIN WARRANTY SERVICE:
You must take your Wacker product along with proof of original
purchase date, at your expense, to any Wacker authorized dealer
during their normal business hours. Claims for repair or adjustment
found to be caused solely by defects in material or workmanship will
not be denied because the engine was not properly maintained and
used.
EXCLUSIONS:
FAILURES OTHER THAN THOSE RESULTING FROM DEFECTS IN
MATERIAL OR WORKMANSHIP ARE NOT COVERED BY THIS
WARRANTY. THIS WARRANTY DOES NOT EXTEND TO
EMISSION CONTROL SYSTEMS OR PARTS WHICH ARE
AFFECTED OR DAMAGED BY OWNER ABUSE, NEGLECT,
IMPROPER MAINTENANCE, MISUSE, MISFUELING, IMPROPER
STORAGE, ACCIDENT AND/OR COLLISION, THE
INCORPORATION OF, OR ANY USE OF, ANY ADD-ON OR
MODIFIED PARTS, UNSUITABLE ATTACHMENTS, OR THE
UNAUTHORIZED ALTERATION OF ANY PART.
THIS WARRANTY DOES NOT COVER REPLACEMENT OF
EXPENDABLE MAINTENANCE ITEMS MADE IN CONNECTION
WITH REQUIRED MAINTENANCE SERVICES AFTER THE ITEM’S
FIRST SCHEDULED REPLACEMENT AS LISTED IN THE
MAINTENANCE SECTION OF THE PRODUCT OWNER’S MANUAL,
SUCH AS SPARK PLUGS AND FILTERS.
DISCLAIMER OF CONSEQUENTIAL DAMAGE AND LIMITATIONS
OF IMPLIED WARRANTIES:
WACKER DISCLAIMS ANY RESPONSIBILITY FOR INCIDENTAL
OR CONSEQUENTIAL DAMAGES SUCH AS LOSS OF TIME OR
THE USE OF THE POWER EQUIPMENT, OR ANY COMMERCIAL
LOSS DUE TO THE FAILURE OF THE EQUIPMENT; AND ANY
IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS
WRITTEN WARRANTY. THIS WARRANTY IS APPLICABLE ONLY
WHERE THE U.S. EPA EMISSION CONTROL SYSTEM
WARRANTY REGULATION IS IN EFFECT.

T00953GB.fm 10
SYSTEMS COVERED
BY THIS WARRANTY
PARTS
DESCRIPTIONS
FUEL METERING CARBURETOR ASSEMBLY
EXHAUST SYSTEM MUFFLER
AIR INDUCTION AIR FILTER HOUSING
AIR FILTER ELEMENT*
IGNITION FLYWHEEL MAGNETO
IGNITION MODULE
SPARK PLUG CAP
SPARK PLUG*
MISCELLANEOUS
PARTS
TUBING, FITTINGS, SEALS, GASKETS
AND CLAMPS ASSOCIATED
WITH THESE LISTED ITEMS
* Indicates expendable maintenance items.

Vorwort.fm 11
Foreword
1. Foreword
For your own safety and protection from bodily injuries, carefully read,
understand and follow the safety instructions in this manual.
Please operate and maintain your Wacker machine in accordance with
the instructions in this manual. Your Wacker machine will reward your
attention by giving trouble-free operation and a high degree of
availability.
Replace faulty or defective components Immediately.
All rights, especially the right for copying and distribution are reserved
Copyright 2007 by Wacker Construction Equipment AG
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express permission in writing from Wacker Construction Equipment AG.
Any type or manner of reproduction, distribution or storage on data
carriers or storage mediums not authorized by Wacker represents an
infringement of valid copyrights and will be prosecuted. We expressly
reserve the right to make technical modifications - even without due
notice - which aim at improving our machines or increasing their safety
standards.

Safety instructions
SV00044GB.fm 12
2. Safety instructions
for the use of drilling and breaking hammers with combustion
engines
2.1 General
2.1.1 Drilling and breaking hammers may only be operated by persons who
∗are at least 18 years of age,
∗are physically and mentally fit for this job,
∗have been instructed in operating drilling and breaking hammers and
proven their ability for the job to the employer
∗may be expected to carry out the job they are charged with carefully.
The persons must be assigned the job of operating drilling and
breaking hammers by the employer.
2.1.2 Drilling and breaking hammers are to be applied for their proper use.
Both the manufacturer’s operating instructions and these safety
instructions have to be observed.
2.1.3 The persons charged with the operation of these hammers have to be
made familiar with the necessary safety measures relating to the
machine. In case of extraordinary uses, the employer shall give the
necessary additional instructions.
2.1.4 It is possible that these drilling and breaking hammers exceed the
admissible sound level of 89 dB(A). Operators must wear personal
hearing protection if the admissible assessment sound level equals or
exceeds 89 dB (A).
2.2 Operation
2.2.1 The function of operation levers or elements is not to be influenced or
rendered ineffective.
2.2.2 Before going on breaks, the operator has to switch of the engine and
has to place the drilling and breaking hammer in such a manner that it
cannot turn over.
2.2.3 Wear safety goggles in order to avoid injuries to the eyes.
2.2.4 We recommend wearing suitable working gloves.
2.2.5 Wear safety shoes while working with drilling and breaking hammers.

SV00044GB.fm 13
Safety instructions
2.2.6 Drilling and breaking hammers are always to be operated with both
hands on the handles provided for this purpose.
2.2.7 When working with drilling and breaking hammers, especially when
carrying out drilling jobs, the operator has to have a firm stand,
particularly when working on scaffolding and ladders.
2.2.8 Drilling and breaking hammers are to be guided such that hand injuries
caused by solid objects are avoided. When carrying out demolition
jobs at elevated places, special care is required to prevent the machine
or the operator from falling.
2.2.9 Avoid body contact with earthed components. When breaking
connecting passages, make sure that there are no electric wires or gas
pipes. No one may stay in the room to which the passage is broken
through, as there is danger of injuries because of falling stones or
tools.
2.2.10 During operation the tool holder must be closed. Tools and tool holder
must be checked for wear in order to guarantee proper functioning of
holder.
2.2.11 The operation of this machine may cause broken - off pieces to be
flung away. Therefore, during operation, no one except the operator is
to come near this machine.
2.2.12 Switch off the engine of drilling and breaking hammers before
changing tools.
2.2.13 The tools always have to be in perfect conditions.
2.2.14 Do not smoke or handle open fire near this machine.
2.2.15 The tank lid must fit tightly. Shut fuel cock if available when stopping
the engine. For long distance transports of machines operated by fuel
of fuel-mixtures, the fuel tank has to be drained competely.
Leaky fuel tanks may cause explosions and must therefore be
replaced immediately.
2.2.16 Stop engine before filling fuel tank. When refilling fuel tank, do not
allow fuel to come into contact with the hot parts of the engine or spill
onto the ground.

Safety instructions
SV00044GB.fm 14
2.2.17 Make sure that sufficient fresh air is available when operating drilling
and breaking hammers with combustion engines in enclosed areas,
tunnels, adits, or deep trenches. For this particular use we offer
electrically driven drilling and breaking hammers.
2.2.18 Do not operate this machine in areas where explosions may occur.
2.3 Safety checks
2.3.1 Drilling and breaking hammers may only be operated with all safety
devices installed.
2.3.2 Before starting operation, the operator has to check that all control and
safety devices function properly.
2.3.3 Before starting operation, the overload clutch of drilling hammers has
to be checked for proper functioning.
2.3.4 In case of defects of the safety devices or other defects reducing the
operational safety of the drilling and breaking hammers, the supervisor
has to be informed immediately.
2.3.5 The machine must to be switched off immediately in case of defects
jeopardizing the operational safety of the equipment.
2.4 Maintenance
2.4.1 Only use original spare parts. Modifications to this machine, including
the adjustment of the maximum engine speed set by the manufacturer,
are subject to the express approval of WACKER. In case of
nonobservance all liabilities shall be refused.
2.4.2 Stop engine and pull off spark plug cap (if available) before carrying
out maintenance jobs, to avoid unintentional starting of the machine.
Deviations from this are only allowed if the maintenance job requires a
running engine.
2.4.3 Take care when checking the ignition system.
The electronic ignition system produces a very high voltage.
2.4.4 All safety devices must be reinstalled properly immediately after
maintenance and repair jobs have been completed.

SV00044GB.fm 15
Safety instructions
2.5 Transport
2.5.1 When being transported on vehicles, precautions have to be taken that
these hammers do not slip or turn over.
2.6 Maintenance checks
2.6.1 According to the conditions and frequency of use, drilling and breaking
hammers have to be checked for safe operation at least once a year
by skilled technicians, such as those found at WACKER-service
depots and have to be repaired if necessary.
Please also observe the corresponding rules and regulations valid in your
country.

Technical Data
TD00656GB.fm 16
3. Technical Data
BH 22
Item no. 0007890 0007953
with remonte cut-off
Length x width x height (without tool)
mm: 790 x 450 x 333
Operating weight (mass) without tool
kg: 23
Shaft for breaking tools ø 27x80
Percussion rate
min-1:1330 - 1350
Single drill work
(at tip of tool)
J (mkp):
45 (4,5)
Power transmission From engine via centrifugal clutch, crank
mechanism, spring-loaded percussion system to
tool
Drive motor 2-stroke petrol engine
Displacement
cm3:80
Engine speed
min-1:4350 - 4400
Special lubricating grease grease Retinax LX2
Fuel
Pol mixture-Petrol: 1:50 (1:100)
Fuel consumption
l/h: 1,2
Tank capacity
l: 1,8
Sound pressure level at operators station
LPA: 100 dB(A)
The weighted effective acceleration value, deter-
mined according to EN ISO 5349
m/s2:
is10

Technical Data
TD00656GB.fm 17
BH 23
Item no. 0007891 0007892 0007893 0007894
0008595
with
remonte
cut-off
Length x width x height (without tool)
mm: 790 x 450 x 333 845 x 450 x 333
Operating weight (mass) without tool
kg: 23
Shaft for breaking tools ø 27x80 SW
25x108
SW
28x152 SW 28x160
Percussion rate
min-1:1300 - 1330
Single drill work
(at tip of tool)
J (mkp):
55 (5,5)
Power transmission From engine via centrifugal clutch, crank mechanism,
spring-loaded percussion system to tool
Drive motor 2-stroke petrol engine
Displacement
cm3:80
Engine speed
min-1:4250
Special lubricating grease Fett Retinax LX2
Fuel
Pol mixture-Petrol: 1:50 (1:100)
Fuel consumption
l/h: 1,2
Tank capacity
l: 1,8
Sound pressure level at operators sta-
tion
LPA:
101 dB(A)
The weighted effective acceleration
value, determined according to EN ISO
5349
m/s2:
is 12

Description
T00931GB.fm 18
4. Description
4.1 Applications
BH 22:
In track laying to pack ballast under railway sleepers. If the appropriate
tools are used, it is also fit for breaking concrete and asphalt as well as
soil interspersed with pebbles, cobbles and boulders; for demolition
jobs in concrete, brickwork and other construction materials (natural,
undisturbed and frozen soils) etc.; for the ripping of roads and
concrete, asphalt, tar as well as wood or rock paving stones; for cutting
clay, loam, peat as well as salt, breaking up compacted or packed-
down soils; for the ramming of stakes, poles and earth rods or spikes
with the corresponding tools.
BH 23:
For breaking concrete and asphalt as well as rubble-laden ground, for
demolishing concrete, masonry and similar building materials
(undisturbed and frozen ground) etc., for ripping up roads and
concrete, asphalt, tar as well as wood-block and stone paving, for
cutting off clay, loam, turf and salts, for breaking compacted or tamped
ground, for ramming in posts and earth rods.In track laying to pack
ballast under railway sleepers.
4.2 Description of function
4.2.1 The engine, which is flanged to the crankcase and is held in place by
3 screws. drives the percussion system over a gear transmission and
a connecting rod. The engine torque is transmitted by means of a
centrifugal clutch.
4.2.2 The centrifugal clutch interrupts the flow of power to the percussion
system at low engine speeds, thus allowing for a perfect idling of the
engine.
4.2.3 The engine can be switched off with the stop button or the fuel tap.
4.2.4 The drive engine works according to the 2-stroke principle, and is
started mechanically by means of a recoilstarter. The engine is air
cooled and the air necessary for combustion is directed through the air
filter.
4.2.5

Transport to work site
T01119GB.fm 19
5. Transport to work site
Conditions:
∗Only use appropriate lifting gear with a minimum load-bearing capacity
of 30 kg when transporting the Wacker equipment.
∗Always switch off motor during transport!
∗Tie down the Wacker equipment when transporting it on the load-
carrying surface of a transport vehicle.
Note: Also refer to the specifications in safety instruction.

Operation
T01120GB.fm 20
6. Operation
6.1 Starting procedure
6.1.1 Inserting the tool
∗Swing catch (9) at tool holder (11) outwards.
∗Clean shank (10) and grease slightly.
∗Insert tool as far as possible.
∗Press catch (9) back against tool holder (11).
Only use sharp tools!
Only use tools with shank (10) in perfect conditions to avoid rebound
blows.
6.2 Engine
Fuel
Standard: 2 cycle oil/gasoline mixing ration of 1:50 or alternatively
1:100. Use 2-cycle engine oil of one of the following specifications:
NMMA TC-W3, API TC, JASO FC or ISO EGD. Unleaded gasoline
may aso be used!
Starting
Open fuel cock. If engine is cold close the choke at the carburettor.
Hold throttle control lever in middle position. Pull hard on starter rope
(max. 60 cm) until engine starts. Do not allow starter rope to snap back.
After starting engine open starter flap.