Wacker Neuson BS 50-4 Operating instructions

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
0114549

Rammer Repair Foreword
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This manual covers machines with Item Number:
BS 50-4 0009386, 0009415, 0620108, 0620071, 0620077, 0620078
BS 50-2 0009380, 0009382, 0009384, 0009410, 0009411, 0009413, 0620025,
0620048
BS 50-2i 0009332, 0009338, 0009383, 0009412, 0009414, 0009416, 0009473,
0620026
BS 500 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
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, 0008052, 0008206, 0009078, 0009079, 0009308
BS 700-oi 0009167, 0009328
BS 65 0009396, 0009423
BS 650 0008209
DS 70 0009342, 0009402, 0009403, 0620049, 0620050, 0620052, 0620053,
0620054
DS 720 0008200, 0008203, 0009309

Foreword Rammer Repair
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Operating / Parts Information
You must be familiar with the operation of this machine before you
attempt to troubleshoot or make any repairs to it. Basic operating and
maintenance procedures are described in the operator’s / parts
manual supplied with the machine. The operator’s / parts manual
should be kept with the machine. Use it to order replacement parts
when needed. If this manual becomes lost, please contact Wacker
Corporation to order a replacement.
Damage caused by misuse or neglect of the unit should be brought to
the attention of the operator, to prevent similar occurrences from
happening in the future.
This manual provides information and procedures to safely repair and
maintain the above Wacker model(s). For your own safety and
protection from injury, carefully read, understand, and observe all
instructions 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 cause cancer and birth defects or other reproductive
harm.
All rights, especially copying and distribution rights, are reserved.
Copyright 2007 by Wacker Corporation
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.
Any type of reproduction or distribution not authorized by Wacker
Corporation represents an infringement of valid copyrights, and
violators will be prosecuted. We expressly reserve the right to make
technical modifications, even without due notice, which aim at
improving our machines or their safety standards.
WARNING

Rammer Repair Table of Contents
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1. Safety Information 8
1.1 Operating Safety .................................................................................. 9
1.2 Operator Safety while using Internal Combustion Engines ................ 11
1.3 Service Safety .................................................................................... 12
1.4 Service and Repair Safety .................................................................. 13
2. General 14
2.1 Description ......................................................................................... 14
2.2 Power Transmission ........................................................................... 14
2.3 Spring System .................................................................................... 14
2.4 Bellows ............................................................................................... 15
2.5 Lubricating System ............................................................................. 15
2.6 Threadlocking Compounds ................................................................ 15
2.7 Torque Values .................................................................................... 15
2.8 Recommended Special Tools ............................................................ 16
2.9 Recommended Repair Tools .............................................................. 17
2.10 Periodic Maintenance Schedule (BS 50/60/70-2, 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 Storage (DS Models) ....................................................... 26
3. Guide Handle and Engine 28
3.1 Air Cleaner (BS 500/600/700/650, DS720) ........................................ 28
3.2 Air Cleaner (BS 50/60/70-2, BS 65, DS 70) ....................................... 30
3.3 Air Cleaner (BS 50/60-4) .................................................................... 31
3.4 Silencing Cover .................................................................................. 32
3.5 Guide Handle ..................................................................................... 33
3.6 Shock Mounts ..................................................................................... 34
3.7 Throttle Control ................................................................................... 35
3.8 Tillotson Carburetor (BS 500/600/700/650 only) ................................ 36

Table of Contents Rammer Repair
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3.9 Fuel Lines (BS 50/60/70-2, BS 65) ......................................................38
3.10 Fuel Tank (BS Models) ........................................................................39
3.11 Fuel Tank (DS Models) .......................................................................40
3.12 Fuel Tank Cap .....................................................................................42
3.13 Muffler (BS Models) .............................................................................44
3.14 Engine Cooling Fins ............................................................................45
3.15 Muffler (DS Models) ............................................................................46
3.16 Removing WM 80 Engine From BS Model Rammers .........................48
3.17 Removing WM 90 Engine From BS Model Rammers .........................50
3.18 Engine (DS Models) ............................................................................52
3.19 Clutch (BS Models) .............................................................................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) ...........78
4.8 Ramming System Lubrication (BS 50/60/70, BS 65, DS 70) ..............79
5. Crankcase 82
5.1 Crank Gear and Connecting Rod ........................................................82
5.2 Crank Gear, Connecting Rod, and Adjuster Assembly
(BS 650/65 only) ..................................................................................85
5.3 Clutch Drum ........................................................................................88

Rammer Repair Table of Contents
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6. Oil Injection (if equipped) 90
6.1 Float Switch Testing and Replacement .............................................. 90
6.2 Oil Line Check Valve .......................................................................... 92
6.3 Oil Pump / Cartridge Assembly .......................................................... 94
7. Low Oil Shutdown (if equipped) 95
7.1 Testing the Low Oil Unit ..................................................................... 95
8. Troubleshooting 96
8.1 Engine Hard to 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-oi ................................................................................... 111
9.13 BS 600/700 High Altitude ................................................................. 112
9.14 BS 65-V ............................................................................................ 113
9.15 BS 650 .............................................................................................. 114
9.16 DS 70 ............................................................................................... 116
9.17 DS 720 ............................................................................................. 118

Safety Information Rammer Repair
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1. Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE and
NOTE callouts which must be followed to reduce the possibility of
personal injury, damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that 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, NOTICE indicates a
hazardous situation which, if not avoided, could result in property
damage.
Note: Contains additional information important to a procedure.
DANGER
WARNING
CAUTION

Rammer Repair Safety Information
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1.1 Operating Safety
Familiarity and proper training are required for the safe operation of the
machine. Machines operated improperly or by untrained personnel
can be dangerous. Read the operating instructions contained in both
this manual and the Engine Manual and familiarize yourself with the
location and proper use of all controls. Inexperienced operators should
receive instruction from someone familiar with the machine before
being allowed to operate it.
1.1.1 NEVER operate this machine in applications for which it is not
intended.
1.1.2 NEVER allow anyone to operate this equipment without proper
training. People operating this equipment must be familiar with the
risks and hazards associated with it.
1.1.3 NEVER touch the engine or muffler while the engine is on or
immediately after it has been turned off. These areas get hot and may
cause burns.
1.1.4 NEVER use accessories or attachments that are not recommended 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 and could catch on skin or clothing,
causing injury.
1.1.10 ALWAYS read, understand, and follow procedures in the Operator’s
Manual before attempting to operate the machine.
1.1.11 ALWAYS be sure that all other persons are at a safe distance from the
machine. Stop the machine if people step into the working area of the
machine.
1.1.12 ALWAYS be sure operator is familiar with proper safety precautions
and operation techniques before using machine.
1.1.13 ALWAYS wear protective clothing appropriate to the job site when
operating the machine.
1.1.14 ALWAYS wear hearing protection when operating equipment.
1.1.15 ALWAYS keep hands, feet, and loose clothing away from moving parts
of the machine.
1.1.16 ALWAYS use common sense and caution when operating the
machine.
WARNING

Safety Information Rammer Repair
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1.1.17 ALWAYS be sure the rammer will not tip over, roll, slide, or fall when
not being operated.
1.1.18 ALWAYS turn the engine OFF when the rammer is not being operated.
1.1.19 ALWAYS guide the rammer in such a way that the operator is not
squeezed between the rammer and solid objects. Special care is
required when working on uneven ground or when compacting coarse
material. Make sure to stand firmly when operating the 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 equipped with one when
machine is not being operated.
1.1.23 ALWAYS operate machine with all safety devices and guards in place
and in working order. DO NOT modify or defeat safety devices. DO
NOT operate machine if any safety devices or guards are missing or
inoperative.