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
wc_br0114549en_008TOC.fm 6
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.

Rammer Repair Safety Information
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1.2 Operator Safety while using Internal Combustion Engines
Internal combustion engines present special hazards during operation
and fueling. Read and follow the warning instructions in the engine
Owner’s Manual and the safety guidelines below. Failure to follow the
warnings and safety standards could result in severe injury or death.
1.2.1 DO NOT smoke while operating the machine.
1.2.2 DO NOT smoke when refueling the engine.
1.2.3 DO NOT refuel a hot or running engine.
1.2.4 DO NOT refuel the engine near an open flame.
1.2.5 DO NOT spill fuel when refueling the engine.
1.2.6 DO NOT run the engine near open flames.
1.2.7 DO NOT run the machine indoors or in an enclosed area such as a
deep trench unless adequate ventilation, through such items as
exhaust fans or hoses, is provided. Exhaust gas from the engine
contains poisonous carbon monoxide gas; exposure to carbon
monoxide can cause loss of consciousness and may lead to death.
1.2.8 ALWAYS refill the fuel tank in a well-ventilated area.
1.2.9 ALWAYS replace the fuel tank cap after refueling.
1.2.10 ALWAYS check the fuel lines and the fuel tank for leaks and cracks
before starting the engine. Do not run the machine if fuel leaks are
present or the fuel lines are loose.
DANGER

Safety Information Rammer Repair
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1.3 Service Safety
A poorly maintained machine can become a safety hazard! In order
for the machine to operate safely and properly over a long period of
time, periodic maintenance and occasional repairs are necessary.
1.3.1 DO NOT attempt to clean or service the machine while it is running.
Rotating parts can cause severe injury.
1.3.2 DO NOT operate the machine without an air cleaner.
1.3.3 DO NOT remove air cleaner cover, paper element, or precleaner while
engine is running.
1.3.4 DO NOT alter engine speeds. Run the engine only at speeds specified
in the Technical Data Section.
1.3.5 DO NOT crank a flooded engine with the spark plug removed on
gasoline-powered engines. Fuel trapped in the cylinder will squirt out
the spark plug opening.
1.3.6 DO NOT test for spark on gasoline-powered engines if the engine is
flooded or the smell of gasoline is present. A stray spark could ignite
the fumes.
1.3.7 DO NOT use gasoline or other types of fuels or flammable solvents to
clean parts, especially in enclosed areas. Fumes from fuels and
solvents can become explosive.
1.3.8 ALWAYS replace the safety devices and guards after repairs and
maintenance.
1.3.9 ALWAYS keep the area around the muffler free of debris such as
leaves, paper, cartons, etc. A hot muffler could ignite the debris and
start a fire.
1.3.10 ALWAYS do periodic maintenance as recommended in the Operator’s
Manual.
1.3.11 ALWAYS clean debris from engine cooling fins.
1.3.12 ALWAYS replace worn or damaged components with spare parts
designed and recommended by Wacker Corporation.
1.3.13 ALWAYS disconnect the spark plug on machines equipped with
gasoline engines, before servicing, to avoid accidental start-up.
1.3.14 ALWAYS keep the machine clean and labels legible. Replace all
missing and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
1.3.15 ALWAYS follow instructions when disconnecting fuel lines. Failure to
do so may result in fuel squirting from fuel system.
WARNING

Rammer Repair Safety Information
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1.4 Service and Repair Safety
The service procedures contained in this manual are intended for use
by an individual equipped with the proper tools and equipment and
familiar with safe shop practices.
Should questions arise during the service or repair of this equipment
please contact WACKER for assistance! WACKER Corporation
maintains a staff of trained service specialists to answer your
questions and to provide assistance and training.
DO NOT remove bottom spring cover without first reading disassembly
procedures or receiving instruction from someone familiar with its safe
removal! The spring cover is under heavy spring pressure and could
cause a serious injury if the proper disassembly procedures are not
followed.
DO NOT run the engine while it is off the machine without first
removing the clutch! Centrifugal force will cause the clutch shoes to
separate and fly off the engine crankshaft with considerable force.
DANGER

General Rammer Repair
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2. General
2.1 Description
Rammers are designed to compact loose soils and gravel to prevent
settling and to provide a firm, solid base for the placement of footings,
concrete slabs, foundations, and other structures.
2.2 Power Transmission
BS 50, BS 60, BS70, BS 65, BS 500, BS 600, BS 700, and BS 650
Rammers are powered by the WACKER WM80 engine. The BS 50-4
and BS 60-4 Rammers are powered by the WACKER WM90 engine.
These gasoline engines are specifically designed for use on WACKER
Rammers.
The DS 720 and DS 70 Rammers are powered by a Yanmar diesel
engine, making it suitable for use in potentially explosive
environments.
The engine crankshaft turns a centrifugal clutch that allows the engine
to be disengaged from the ramming system during engine start-up and
idling.
The engine drives the ramming system through a set of reduction
gears and a connecting rod. The reduction gears and connecting rod
convert the engine’s circular motion (4250-4450 rpm) to the vertical
stroking motion (600-750 blows per minute) of the ramming system.
The gear reduction increases the available power to drive the ramming
system through each stroke. The connecting rod attached to the crank
gear converts the circular rotation of the gears to the up and down
stroking motion of the rammer.
2.3 Spring System
The spring system consists of a piston between two spring sets. The
piston is connected to the ram that is driven by the connecting rod
attached to the crank gear. Plastic bushings on either side of the piston
prevent the springs from bottoming out. The piston and spring sets are
housed in the spring cylinder that slides up and down inside the guide
cylinder.
The spring system has two functions. The spring system’s first function
is to store energy created by the engine and release it to the shoe
during its downward stroke. The spring system’s second function is to
isolate the shock that is created when the ramming shoe hits and
prevent it from being transmitted back to the rammer.

Rammer Repair General
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2.4 Bellows
The bellows provides a flexible joint between the ramming system and
the upper machinery. It seals out dust and dirt and provides a clean
path for recirculating oil.
2.5 Lubricating System
The rammers use a sealed-oil-bath lubricating system. Oil is
distributed to the gears, the bearings, the springs, and the other
moving parts by the up and down action of the ramming system. The
ramming system carries the oil into the crankcase through holes drilled
in the spring system piston and the spring cylinder.
2.6 Threadlocking Compounds
Due to the heavy vibration inherent in this type of equipment, the repair
and service procedures described in this manual specify the use of
threadlocking compounds. These compounds should be used where
indicated to prevent the fasteners from becoming loose.
Although Loctite® is referred to throughout this manual, any equivalent
type of sealant such as Hernon, Prolock, or Omnifit may be used.
Clean the screw threads and wipe off any oil or grease before applying
a threadlocking compound.
For a complete list of recommended sealing and locking compounds,
refer to the Use of Threadlockers and Sealants chart at the end of this
Repair Manual.
2.7 Torque Values
The torque values for the referenced fasteners are detailed in the
repair procedures. For a complete list of the recommended torque
values, refer to the Torque Values chart at the end of this Repair
Manual or in the Rammer Parts Book.

General Rammer Repair
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2.8 Recommended Special Tools
See Graphic: wc_gr001305rm
P/N 0081423 Spring box tool
P/N 0117972 Clutch puller
P/N 0153566 Clutch puller (DS 70 only)
P/N 0116816 Impact bushing puller
0081423 0117972 0116816
wc_gr001305rm
0153566

Rammer Repair General
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2.9 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 retaining-ring pliers
Rubber mallet
Punch
Bearing puller
Slide hammer
Drift pin
Impact wrench
Torque wrench (up to 210 Nm [155 ft.lbs.])
Loctite 243
Shell Alvania RL 2 (No. 2) grease
Hydraulic press
Two threaded rods M8 x 120 mm and nuts
Split puller
Source of compressed air

General Rammer Repair
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2.10 Periodic Maintenance Schedule (BS 50/60/70-2, BS 65)
Daily
before
starting
After
first
5
hours
Every
week
or 25
hours
Every
month
or 100
hours
Every
3 months
or 300
hours
Every
Year
Check fuel level. 
Check air filter indicator. Replace
as needed. 
Check ramming system oil level in
sightglass. 
Check fuel line and fittings for
cracks or leaks. Replace as
needed.

Tighten ramming shoe hardware. 
Check engine cylinder screws. 
Check external hardware. 
Clean engine cooling fins. 
Clean and check spark plug gap. 
Replace spark plug. 
Clean recoil starter. 
Change ramming system oil.* 
Clean engine muffler and exhaust
port. 
Inspect crane lifting cable for
wear, damage, or abuse. 
Inspect fuel filter. 
* Change ramming system oil after first 50 hours of operation.
Note: If engine performance is poor, check, clean, and replace air filter elements as needed.

Rammer Repair General
wc_tx000284gb.fm 19
2.11 Periodic Maintenance Schedule (BS 500/600/700/650)
Daily
before
starting
After
first
5 hours
Every
week
or 25
hours
Every
month
or 100
hours
Every
3 months
or 300
hours
Every
Year
Check fuel level. Check engine oil
level. 
Inspect air filter. Replace as
needed. 
Check oil level in sightglass. 
Check fuel line and fittings for
cracks or leaks. Replace as
needed.

Tighten ramming shoe hardware. 
Check external hardware. 
Clean engine cooling fins. 
Clean and check spark plug gap. 
Change engine oil. 
Replace spark plug. 
Clean recoil starter. 
Change ramming system oil.* 
Inspect crane lifting cable for wear,
damage, or abuse. 
Inspect fuel filter. 
* Change ramming system oil after first 50 hours of operation.
Note: If engine performance is poor, check, clean, and replace air filter elements as needed.

General Rammer Repair
wc_tx000284gb.fm 20
2.12 Periodic Maintenance Schedule (BS 50/60/70-2i)
Daily
before
starting
After
first
5
hours
Every
week
or 25
hours
Every
month
or 100
hours
Every
3 months
or 300
hours
Every
Year
Check fuel level. 
Check engine oil level. 
Check air filter indicator. Replace
as needed. 
Check ramming system oil level
in sightglass. 
Check fuel line and fittings for
cracks or leaks. Replace as
needed.

Tighten ramming shoe hardware. 
Check engine cylinder screws. 
Check external hardware. 
Clean engine cooling fins. 
Clean and check spark plug gap. 
Replace spark plug. 
Clean recoil starter. 
Change ramming system oil.* 
Clean engine muffler and
exhaust port. 
Inspect crane lifting cable for
wear, damage, or abuse. 
Inspect fuel filter. 
* Change ramming system oil after first 50 hours of operation.
Note: If engine performance is poor, check, clean, and replace air filter elements as needed.