Wacker neuson Bs 50-4s, bs 50-4as Operating instructions

Repair Manual

Vibratory Rammer

5100018465 01 1015

5100018465

All rights, including copying and distribution rights, are reserved.

This publication may be photocopied by the original purchaser of the

machine. Any other type of reproduction is prohibited without express

written permission from Wacker Neuson Production Americas LLC.

Any type of reproduction or distribution not authorized by Wacker

Neuson Production Americas LLC represents an infringement of valid

copyrights. Violators will be prosecuted.

Trademarks

All trademarks referenced in this manual are the property of their

respective owners.

Manufacturer

Wacker Neuson Production Americas LLC

N92W15000 Anthony Avenue

Menomonee Falls, WI 53051 U.S.A.

Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957

www.wackerneuson.com

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Rammer Foreword

Foreword

SAVE THESE INSTRUCTIONS—This manual contains important instructions for

the machine models below. These instructions have been written expressly by

Wacker Neuson Production Americas LLC and must be followed during installation,

operation, and maintenance of the machines.

Machine

identification

A nameplate listing the model number, item number, revision number, and serial

number is attached to this machine. The location of the nameplate is shown above.

Serial number

(S/N)

For future reference, record the serial number in the space provided below. You will

need the serial number when requesting parts or service for this machine.

Machine Item Number

BS 50-4s, BS 50-4As 5200000644, 5200000662, 5200000679, 5200000680,

5200018226, 5200018219, 5100015099

BS 60-4s, BS 60-4As 5200000647, 5200000648, 5200000667, 5200000668,

5200000674, 5200000675, 5200014910, 5200018231,

5200018232, 5200018233, 5200022984, 5100015123

BS 70-4As 5100015124, 5100015126

Machine Item Number

BS 50-2i 5200000642, 5200000643, 5200000657, 5200000658,

5200000659, 5200000660, 5200000661, 5200000678,

5200000687, 5200011099, 5100016650, 5200025428,

5200025429, 5100014907, 5100016648, 5100016649

BS 60-2i 5200000645, 5200000646, 5200000664, 5200000665,

5200000682, 5200000689, 5200000690, 5100014908

BS 70-2i 5200000649, 5200000650, 5200000672, 5200000673,

5100014909, 5100016653

Machine Item Number

BS 50-2 5200000641, 5200000652, 5200000653, 5200000654,

5200000655, 5200000656, 5200000685, 5200000686

BS 60-2 5200000663, 5200000688, 5200019205

BS 70-2 5200000670, 5200000671

wc_gr011588

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Rammer

Foreword

Machine

documentation

■From this point forward in this documentation, Wacker Neuson Production

Americas LLC will be referred to as Wacker Neuson.

■Keep a copy of the Operator’s Manual with the machine at all times.

■For spare parts information, please see your Wacker Neuson Dealer, or visit the

Wacker Neuson website at http://www.wackerneuson.com/.

■When ordering parts or requesting service information, be prepared to provide

the machine model number, item number, revision number, and serial number.

Expectations

for

information in

this manual

■This manual provides information and procedures to safely operate and

maintain the above Wacker Neuson model(s). For your own safety and to

reduce the risk of injury, carefully read, understand, and observe all instructions

described in this manual.

■Wacker Neuson expressly reserves the right to make technical modifications,

even without notice, which improve the performance or safety standards of its

machines.

■The information contained in this manual is based on machines manufactured

up until the time of publication. Wacker Neuson reserves the right to change any

portion of this information without notice.

■The illustrations, parts, and procedures in this manual refer to Wacker Neuson

factory-installed components. Your machine may vary depending on the

requirements of your specific region.

CALIFORNIA

Proposition

65 Warning

Combustion exhaust, some of its constituents, and certain vehicle components

contain or emit chemicals known to the State of California to cause cancer and

birth defects or other reproductive harm.

Laws

pertaining to

spark

arresters

NOTICE: State Health Safety Codes and Public Resources Codes specify that in

certain locations spark arresters be used on internal combustion engines that use

hydrocarbon fuels. A spark arrester is a device designed to prevent accidental

discharge of sparks or flames from the engine exhaust. Spark arresters are

qualified and rated by the United States Forest Service for this purpose. In order to

comply with local laws regarding spark arresters, consult the engine distributor or

the local Health and Safety Administrator.

Manufacturer’s

approval

This manual contains references to approved parts, attachments, and

modifications. The following definitions apply:

■Approved parts or attachments are those either manufactured or provided by

Wacker Neuson.

■Approved modifications are those performed by an authorized Wacker

Neuson service center according to written instructions published by Wacker

Neuson.

■Unapproved parts, attachments, and modifications are those that do not

meet the approved criteria.

Serial Number:

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Rammer Foreword

Unapproved parts, attachments, or modifications may have the following

consequences:

■Serious injury hazards to the operator and persons in the work area

■Permanent damage to the machine which will not be covered under warranty

Contact your Wacker Neuson dealer immediately if you have questions about

approved or unapproved parts, attachments, or modifications.

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Rammer

Foreword

Table of Contents

Rammer

wc_br5100018465_FM10TOC.fm 7

Foreword 3

1 Safety Information 11

1.1 Signal Words Used in this Manual ..................................................... 11

1.2 Machine Description and Intended Use ............................................. 12

1.3 Safety Guidelines for Operating the Machine ..................................... 13

1.4 Safety Guidelines for Lifting the Machine ........................................... 14

1.5 Service Safety .................................................................................... 15

1.6 Operator Safety while Using Internal Combustion Engines ............... 17

2 Operation 18

2.1 Recommended Fuel—4 stroke ........................................................... 18

2.2 Recommended Fuel—2 stroke ........................................................... 19

2.3 Starting, Operating, and Stopping the Machine—WM 100 ................ 21

2.4 Starting, Operating, and Stopping the Machine—Honda ................... 23

2.5 Starting, Operating, and Stopping the Machine ................................. 25

2.6 Low Oil Shut-Off Switch—WM100 ..................................................... 27

2.7 Low Oil Shut-Off Switch—Honda ....................................................... 28

3 Troubleshooting 29

3.1 Diagnosing Starting Issues ................................................................. 29

3.2 Diagnosing Performance Issues ........................................................ 30

3.3 Checking the Fuel Flow ...................................................................... 31

3.4 Testing the Ignition Module and Checking the Spark ......................... 33

3.5 Checking the Stop Switch .................................................................. 34

3.6 Conducting a Leak-Down Test ........................................................... 36

3.7 Checking the Ignition Wiring ............................................................... 37

3.8 Checking Engine Compression .......................................................... 38

3.9 Checking for Vapor Lock .................................................................... 39

3.10 Purging the Oil Lines .......................................................................... 40

4 Disassembly and Reassembly 42

4.1 Draining the Ramming System Oil—BS50 ......................................... 42

4.2 Refilling the Ramming System Oil — BS50 ....................................... 43

4.3 Draining the Ramming System Oil—BS60 and BS70 ........................ 45

4.4 Refilling the Ramming System Oil—BS60 and BS70 ......................... 46

4.5 Removing the Ramming Shoe—BS50 ............................................... 48

4.6 Installing the Ramming Shoe—BS50 ................................................. 50

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4.7 Removing the Ramming Shoe—BS60 and BS70 ...............................52

4.8 Installing the Ramming Shoe—BS60 and BS70 .................................54

4.9 Removing the Lifting Cable .................................................................56

4.10 Installing the Lifting Cable ...................................................................57

4.11 Removing the Oil Tank—BS 50-2i ......................................................58

4.12 Installing the Oil Tank—BS 50-2i ........................................................60

4.13 Removing the Fuel Tank .....................................................................62

4.14 Installing the Fuel Tank .......................................................................64

4.15 Removing the Bellows .........................................................................66

4.16 Installing the Bellows ...........................................................................68

4.17 Removing the Carburetor—WM80 oil injected ....................................72

4.18 Installing the Carburetor—WM80 oil injected ......................................76

4.19 Removing the Carburetor—WM80 non-oil injected .............................79

4.20 Installing the Carburetor—WM80 non-oil injected ...............................83

4.21 Removing the Carburetor—Robin .......................................................86

4.22 Installing the Carburetor—Robin .........................................................90

4.23 Removing the Carburetor—Honda ......................................................94

4.24 Installing the Carburetor—Honda ........................................................98

4.25 Removing the Engine—WM 80 .........................................................101

4.26 Installing the Engine—WM 80 ...........................................................105

4.27 Removing the Engine—Honda ..........................................................109

4.28 Installing the Engine—Honda ............................................................112

4.29 Removing the Engine—Robin ...........................................................115

4.30 Installing the Engine—Robin .............................................................119

4.31 Removing the Upper Machinery ........................................................122

4.32 Installing the Upper Machinery ..........................................................124

4.33 Removing the Crankcase ..................................................................126

4.34 Installing the Crankcase ....................................................................129

4.35 Removing the Clutch .........................................................................132

4.36 Installing the Clutch ...........................................................................133

4.37 Removing the Clutch Drum ...............................................................134

4.38 Installing the Clutch Drum .................................................................137

4.39 Removing the Oil Pump ....................................................................140

4.40 Installing the Oil Pump ......................................................................143

4.41 Removing the Spring System Cover—Hydraulic Press Method .......145

4.42 Installing the Spring System Cover—Hydraulic Press Method .........148

4.43 Removing the Spring System Cover—Spring Box Tool ....................151

4.44 Installing the Spring System Cover—Spring Box Tool ......................155

4.45 Removing the Upper Spring Set ........................................................159

4.46 Installing the Upper Spring Set ..........................................................161

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Rammer

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4.47 Testing the Float Switch ................................................................... 163

4.48 Replacing the Float Switch ............................................................... 166

5 Technical Data 172

5.1 BS 50-4s ........................................................................................... 172

5.2 BS 50-4As ........................................................................................ 173

5.3 BS 60-4s ........................................................................................... 174

5.4 BS 60-4As ........................................................................................ 175

5.5 BS 70-4As ........................................................................................ 176

5.6 Sound Measurements ...................................................................... 177

5.7 Vibration Measurements .................................................................. 178

5.8 Dimensions ....................................................................................... 179

6 Technical Data 181

6.1 BS 50-2i ............................................................................................ 181

6.2 BS 50-2i Operating Weight ............................................................... 181

6.3 BS 60-2i ............................................................................................ 182

6.4 BS 60-2i Operating Weight ............................................................... 182

6.5 BS 70-2i ............................................................................................ 183

6.6 BS 70-2i Operating Weight ............................................................... 183

6.7 BS 50-2 ............................................................................................ 184

6.8 BS 50-2 Operating Weight ............................................................... 184

6.9 BS 60-2 ............................................................................................ 185

6.10 BS 60-2 Operating Weight ............................................................... 185

6.11 BS 70-2 ............................................................................................ 186

6.12 BS 70-2 Operating Weight ............................................................... 186

6.13 BS 65-V ............................................................................................ 187

6.14 BS 65-V Operating Weight ............................................................... 187

6.15 Sound Measurements ...................................................................... 188

6.16 Vibration Measurements .................................................................. 189

6.17 Dimensions—BS 50-2i, BS 50-2 ...................................................... 190

6.18 Dimensions—BS 60-2i, BS 60-2, BS 70-2i, BS 70-2, BS 65-V ........ 191

Table of Contents Rammer

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Rammer Safety Information

1 Safety Information

1.1 Signal Words Used in this Manual

This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE

signal words which must be followed to reduce the possibility of personal injury,

damage to the equipment, or improper service.

NOTICE: Used without the safety alert symbol, NOTICE indicates a situation

which, if not avoided, could result in property damage.

Note: A Note contains additional information important to a procedure.

This is the safety alert symbol. It is used to alert you to potential personal hazards.

►Obey all safety messages that follow this symbol.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death

or serious injury.

►To avoid death or serious injury from this type of hazard, obey all safety mes-

sages that follow this signal word.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in

death or serious injury.

►To avoid possible death or serious injury from this type of hazard, obey all safety

messages that follow this signal word.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result in

minor or moderate injury.

►To avoid possible minor or moderate injury from this type of hazard, obey all

safety messages that follow this signal word.

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Rammer

Safety Information

1.2 Machine Description and Intended Use

This machine is a vibratory rammer. The Wacker Neuson Rammer consists of a

gasoline or diesel engine, a clutch, a fuel tank, a spring-loaded ramming system, a

ramming shoe, and a handle. The engine transmits power through the ramming

system and ramming shoe, generating percussive impact force to compact soil.

The operator guides and controls the machine from behind using the handle.

This machine is intended to be used for compacting cohesive, mixed, and granular

soils in confined areas.

This machine has been designed and built strictly for the intended use described

above. Using the machine for any other purpose could permanently damage the

machine or seriously injure the operator or other persons in the area. Machine

damage caused by misuse is not covered under warranty.

The following are some examples of misuse:

■Using the machine as a ladder, support, or work surface

■Using the machine to carry or transport passengers or equipment

■Using the machine as a hammer or for other demolition work

■Attaching the machine to any other machine

■Operating the machine outside of factory specifications

■Operating the machine in a manner inconsistent with all warnings found on the

machine and in the Operator’s Manual

This machine has been designed and built in accordance with the latest global

safety standards. It has been carefully engineered to eliminate hazards as far as

practicable and to increase operator safety through protective guards and labeling.

However, some risks may remain even after protective measures have been taken.

They are called residual risks. On this machine, they may include exposure to:

■Heat, noise, exhaust, and carbon monoxide from the engine

■Fire hazards from improper refueling techniques

■Fuel and its fumes

■Personal injury from improper lifting techniques or operating techniques

To protect yourself and others, make sure you thoroughly read and understand the

safety information presented in this manual before operating the machine.

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Rammer Safety Information

1.3 Safety Guidelines for Operating the Machine

Operator

training

Before operating the machine:

■Read and understand the operating instructions contained in all manuals

delivered with the machine.

■Familiarize yourself with the location and proper use of all controls and safety

devices.

■Contact Wacker Neuson for additional training if necessary.

When operating this machine:

■Do not allow improperly trained people to operate the machine. People

operating the machine must be familiar with the potential risks and hazards

associated with it.

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 familiar with required safety devices

The machine must not be accessed or operated by:

■children

■people impaired by alcohol or drugs

Application

area

Be aware of the application area.

■Keep unauthorized personnel, children, and pets away from the machine.

■Remain aware of changing positions and the movement of other equipment and

personnel in the application area/job site.

■Identify whether special hazards exist in the application area, such as toxic

gases or unstable ground conditions, and take appropriate action to eliminate

the special hazards before using the machine.

Be aware of the application area.

■Do not operate the machine in areas that contain flammable objects, fuels, or

products that produce flammable vapors.

Safety

devices,

controls, and

attachments

Only operate the machine when:

■All safety devices and guards are in place and in working order.

■All controls operate correctly.

■The machine is set up correctly according to the instructions in the Operator’s

Manual.

■The machine is clean.

■The machine’s labels are legible.

To ensure safe operation of the machine:

■Do not operate the machine if any safety devices or guards are missing or

inoperative.

■Do not modify or defeat the safety devices.

■Only use accessories or attachments that are approved by Wacker Neuson.

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Rammer

Safety Information

Safe

operating

practices

When operating this rammer:

■Remain aware of the rammer’s moving parts. Keep hands, feet, and loose

clothing away from the rammer’s moving parts.

■When working near the edges of pits, slopes, trenches, and platforms, always

operate the rammer in such a way that there is no possibility of it tipping over or

falling in.

When operating this rammer:

■Do not operate a rammer in need of repair.

■Do not tamper with or disable the function of the operating controls.

■Do not leave the rammer running unattended.

■Do not consume the operating fluids used in this machine. Depending on your

machine model, these operating fluids may include water, wetting agents, fuel

(gasoline, diesel, kerosene, propane, or natural gas), oil, coolant, hydraulic fluid,

heat transfer fluid (propylene glycol with additives), battery acid, or grease.

Personal

Protective

Equipment

(PPE)

Wear the following Personal Protective Equipment (PPE) while operating this

machine:

■Close-fitting work clothes that do not hinder movement

■Safety glasses with side shields

■Hearing protection

■Safety-toed footwear

After Use

■Stop the engine when the machine is not being operated.

■Close the fuel valve on engines equipped with one when the machine is not

being operated.

■Ensure that the machine will not tip over, roll, slide, or fall when not being

operated.

■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.

1.4 Safety Guidelines for Lifting the Machine

When lifting the machine:

■Make sure slings, chains, hooks, ramps, jacks, forklifts, cranes, hoists, and any

other type of lifting device used is attached securely and has enough weight-

bearing capacity to lift or hold the machine safely. See section Technical Data

for machine weight.

■Remain aware of the location of other people when lifting the machine.

■Only use the lifting points and tie-downs described in the Operator’s Manual.

■Make sure the transporting vehicle has sufficient load capacity and platform size

to safely transport the machine.

To reduce the possibility of injury:

■Do not stand under the machine while it is being lifted or moved.

■Do not get onto the machine while it is being lifted or moved.

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Rammer Safety Information

1.5 Service Safety

Service

training

Before servicing or maintaining the machine:

■Read and understand the instructions contained in all manuals delivered with

the machine.

■Familiarize yourself with the location and proper use of all controls and safety

devices.

■Only trained personnel shall troubleshoot or repair problems occurring with the

machine.

■Contact Wacker Neuson for additional training if necessary.

When servicing or maintaining this machine:

■Do not allow improperly trained people to service or maintain the machine.

Personnel servicing or maintaining the machine must be familiar with the

associated potential risks and hazards.

Precautions

When servicing or maintaining the machine:

■Read and understand the service procedures before performing any service to

the machine.

■All adjustments and repairs must be completed before operating the machine.

Do not operate the machine with a known problem or deficiency.

■All repairs and adjustments shall be completed by a qualified technician.

■Turn off the machine before performing maintenance or making repairs.

■Remain aware of the machine’s moving parts. Keep hands, feet, and loose

clothing away from the machine’s moving parts.

■Re-install the safety devices and guards after repair and maintenance

procedures are complete.

Machine

modifications

When servicing or maintaining the machine:

■Use only accessories/attachments that are approved by Wacker Neuson.

When servicing or maintaining the machine:

■Do not defeat safety devices.

■Do not modify the machine without the express written approval of Wacker

Neuson.

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Rammer

Safety Information

Replacing

parts and

labels

■Replace worn or damaged components.

■Replace all missing and hard-to-read labels.

■When replacing electrical components, use components that are identical in

rating and performance to the original components.

■When replacement parts are required for this machine, use only Wacker

Neuson replacement parts or those parts equivalent to the original in all types of

specifications, such as physical dimensions, type, strength, and material.

Cleaning

When cleaning and servicing the machine:

■Keep the machine clean and free of debris such as leaves, paper, cartons, etc.

■Keep the labels legible.

When cleaning the machine:

■Do not clean the machine while it is running.

■Never use gasoline or other types of fuels or flammable solvents to clean the

machine. Fumes from fuels and solvents can become explosive.

Personal

Protective

Equipment

(PPE)

Wear the following Personal Protective Equipment (PPE) while servicing or

maintaining this machine:

■Close-fitting work clothes that do not hinder movement

■Safety glasses with side shields

■Hearing protection

■Safety-toed footwear

In addition, before servicing or maintaining the machine:

■Tie back long hair.

■Remove all jewelry (including rings).

Safe service

practices

■Do not alter engine speeds. Run the engine only at speeds specified in

Technical Data.

■Do not operate the machine without an air cleaner.

■Disconnect the spark plug before servicing to avoid accidental start-up.

■Do not crank a flooded engine with the spark plug removed. Fuel trapped in the

cylinder will squirt out the spark plug opening.

■Do not test for spark if the engine is flooded or the smell of gasoline is present.

A stray spark could ignite the fumes.

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Rammer Safety Information

1.6 Operator Safety while Using Internal Combustion Engines

Operating

safety

When running the engine:

■Keep the area around the exhaust pipe free of flammable materials.

■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.

When running the engine:

■Do not smoke while operating the machine.

■Do not run the engine near sparks or open flames.

■Do not touch the engine or muffler while the engine is running or immediately

after it has been turned off.

■Do not operate a machine when its fuel cap is loose or missing.

■Do not start the engine if fuel has spilled or a fuel odor is present. Move the

machine away from the spill and wipe the machine dry before starting.

Refueling

safety

When refueling the engine:

■Clean up any spilled fuel immediately.

■Refill the fuel tank in a well-ventilated area.

■Re-install the fuel tank cap after refueling.

■Do not smoke.

■Do not refuel a hot or running engine.

■Do not refuel the engine near sparks or open flames.

■Use suitable tools for refueling (for example, a fuel hose or a funnel).

■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.

WARNING

Internal combustion engines present special hazards during operation and fueling.

Failure to follow the warnings and safety standards could result in severe injury or

death.

►Read and follow the warning instructions in the engine owner’s manual and the

safety guidelines below.

DANGER

Exhaust gas from the engine contains carbon monoxide, a deadly poison.

Exposure to carbon monoxide can kill you in minutes.

►NEVER operate the machine inside an enclosed area, such as a tunnel, unless

adequate ventilation is provided through such items as exhaust fans or hoses.

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Rammer

Operation

2 Operation

The information regarding the operation of the machine included in this manual is

condensed. Refer to the Operator’s Manual for complete operating instructions.

Always read, understand, and follow the procedures in the Operator’s Manual

when operating the machine.

2.1 Recommended Fuel—4 stroke

This engine is certified to operate on automotive unleaded gasoline. Use only

fresh, clean gasoline. Gasoline containing water or dirt will damage fuel system.

Use of

oxygenated

fuels

Some conventional gasolines are blended with alcohol. These gasolines are

collectively referred to as oxygenated fuels. If you use an oxygenated fuel, be sure

it is unleaded and meets the minimum octane rating requirement.

Before using an oxygenated fuel, confirm the fuel’s contents. Some states and

provinces require this information to be posted on the fuel pump.

The following is the Wacker Neuson approved percentage of oxygenates:

ETHANOL - (ethyl or grain alcohol) 10% by volume. You may use gasoline

containing up to 10% ethanol by volume (commonly referred to as E10). Gasoline

containing more than 10% ethanol (such as E15, E20, or E85) may not be used

because it could damage the engine.

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.

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Rammer Operation

2.2 Recommended Fuel—2 stroke

For rammers with oil injection (BS 50-2i, BS 60-2i, BS 70-2i)

If the rammer has a fuel tank (a) and an oil tank (b), it has oil injection—No

premixing of the gasoline and oil is required. Mixing of the gasoline and oil is

done automatically by the machine.

Fill the fuel tank with regular unleaded gasoline. Fill the oil tank with Wacker

Neuson two-cycle oil (or an equivalent). See chapter Technical Data for fuel and oil

specifications.