Wacker Neuson BS 700, BS 65, BS 650DS 70 / DS 720, BS 60, BS 650 Repair Manual
...
0114549en 010 0510
0114549EN
Repair Manual
Rammer
BS 50 / BS 60 / BS 70
BS 500 / BS 600 / BS 700
BS 65 / BS 650
DS 70 / DS 720
Copyright
notice
© Copyright 2010 by Wacker Neuson Corporation.
All rights, including copying and distribution rights, are reserved.
This publication may be photocopied by the original purchaser of the machine. Any
other type of reproduction is prohibited without express written permission from
Wacker Neuson Corporation.
Any type of reproduction or distribution not authorized by W acker Neuson Corporatio n
represents an infringement of valid copyrights. Violators will be prosecuted.
Tra d emarks
All trademarks referenced in this manual are the property of their respective owners.
Manufacturer
Wacker Neuson Corporation
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
Foreword
wc_tx001543gb.fm 3
Foreword
Machines covered in this manual.
Machine
documentation
Keep a copy of the Operator’s Manual with the machine at all times.
Use the separate Parts Book supplied with the machine to order replacement
parts.
If you are missing any of these documents, please contact Wacker Neuson
Corporation to order a replacement or visit 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.
BS 50-4 0009386, 0009415, 0620108, 0620071, 0620077, 0620078
BS 50-2 0009380, 0009382, 0009384, 0009410, 0009411, 0009413, 0620025,
0620048, 0620609, 0620610, 0620733, 0620609, 0620610, 0620733
BS 50-2i 0009332, 0009338, 0009383, 0009412, 0009414, 0009416, 0009473,
0620026, 0620611
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, 0620483, 0620563, 0620812, 0620813, 0620816,
0620819, 0620820
BS 60-2 0009388, 0009391, 0009417, 0009418, 0009421, 0620612
BS 60-2i 0009339, 0009393, 0009419, 0009420, 0620613, 0620614
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-V 0009396, 0009423
BS 650 0008209
DS 70 0009342, 0009402, 0009403, 0620049, 0620050, 0620052, 0620053,
0620054
Foreword
4 wc_tx001543gb.fm
Expectations
for
information in
this manual
This manual provides information and procedures to safely operate and main-
tain the above Wacker Neuson model(s). For your own safety and t o reduce the
risk of injury, carefully read, understand, and observe all instructions described
in this manual.
Wacker Neuson Corporation 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 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.
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 Neu-
son service center according to written instructions published by Wacker Neuson.
Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
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.
wc_br0114549en_010TOC.fm 5
Table of ContentsRammer Repair
Foreword 3
1 Safety Information 9
1.1 Signal Words Found in this Manual ...................................................... 9
1.2 Machine Description and Intended Use ............................................. 10
1.3 Operating Safety ................................................................................ 11
1.4 Operator Safety while using Internal Combustion Engines ................ 13
1.5 Service Safety .................................................................................... 14
2Tools 17
2.1 Recommended Special Tools ............................................................ 17
2.2 Recommended Repair Tools .............................................................. 18
3 Maintenance Schedules 19
3.1 Periodic Maintenance Schedule (BS 50/60/70-2, BS 65) ................... 19
3.2 Periodic Maintenance Schedule (BS 500/600/700/650) ..................... 20
3.3 Periodic Maintenance Schedule (BS 50/60/70-2i) .............................. 21
3.4 Periodic Maintenance Schedule (BS 500/600/700-oi) ........................ 22
3.5 Periodic Maintenance Schedule (DS 70) ........................................... 23
3.6 Periodic Maintenance Schedule (DS 720) ......................................... 24
4 Engine and Upper Machine Components 25
4.1 Removing the Silencing Cover ........................................................... 25
4.2 Replacing the Throttle Control (2010 and later 2-stroke models) ....... 26
4.3 Replacing the Throttle Control (2010 4-stroke models) ...................... 28
4.4 Throttle Control (pre-2010 models) .................................................... 31
4.5 Replacing the Stop Switch (2010 and later 2-stroke models) ............ 32
4.6 Replacing the Stop Switch (2010 and later 4-stroke models) ............ 35
4.7 Replacing the Guide Handle (2010 and later 2-stroke models) ......... 37
4.8 Replacing the Guide Handle (2010 and later 4-stroke models) ......... 40
4.9 Replacing the Guide Handle (pre-2010 models) ................................ 44
4.10 Shock Mounts ..................................................................................... 45
6 wc_br0114549en_010TOC.fm
Table of Contents Rammmer Repair
4.11 Tillotson Carburetor (BS 500/600/700/650 only) .................................46
4.12 Fuel Lines (BS 50/60/70-2, BS 65) ......................................................48
4.13 Fuel Tank (BS Models) ........................................................................49
4.14 Fuel Tank (DS Models) .......................................................................50
4.15 Fuel Tank Cap .....................................................................................52
4.16 Muffler (pre-2009 BS Models) .............................................................54
4.17 Engine Cooling Fins ............................................................................55
4.18 Muffler (DS Models) ............................................................................56
4.19 Replacing the Carburetor (WM 80 engines) ........................................58
4.20 Replacing the WM 80 Engine (2010 and later models) .......................62
4.21 Replacing the WM 80 Engine (pre-2010 models) ...............................64
4.22 Replacing the Carburetor (WM 100 Engines) .....................................66
4.23 Replacing the WM 100 Engine ............................................................70
4.24 Removing the WM 90 Engine ..............................................................74
4.25 Engine (DS Models) ............................................................................76
4.26 Clutch (2- and 4-stroke models) ..........................................................78
4.27 Clutch (DS 720 only) ...........................................................................80
4.28 Clutch (DS 70 only) .............................................................................82
5 Ramming System 84
5.1 Bellows ................................................................................................84
5.2 Replacing the Ramming Shoe .............................................................87
5.3 Spring System Cover Removal and Installation ..................................90
5.4 Spring System .....................................................................................96
5.5 Inspecting the Spring System ..............................................................98
5.6 Protective Pipe ....................................................................................99
5.7 Ramming System Lubrication (BS 500/600/700/650, DS 720) .........100
5.8 Ramming System Lubrication (BS 50/60/70, BS 65, DS 70) ............102
6 Crankcase 104
6.1 Crank Gear and Connecting Rod ......................................................104
6.2 Crank Gear, Connecting Rod, and Adjuster Assembly (BS 650/65 only) 106
6.3 Clutch Drum ......................................................................................110
wc_br0114549en_010TOC.fm 7
Table of ContentsRammer Repair
7 Oil Injection (if equipped) 112
7.1 Testing the Float Switch (2010 and later models) ............................ 112
7.2 Replacing the Float Switch (2010 and later models) ........................ 114
7.3 Float Switch Testing and Replacement (pre-2010 models) ............. 116
7.4 Oil Line Check Valve ........................................................................ 118
7.5 Oil Pump / Cartridge Assembly ........................................................ 120
8 Low Oil Shutdown (if equipped) 123
8.1 Testing the Low Oil Unit ................................................................... 123
9 Troubleshooting 124
9.1 Engine Hard to Start ......................................................................... 124
9.2 Engine Does Not Start ...................................................................... 125
9.3 Engine Does Not Accelerate or Runs Poorly ................................... 125
9.4 Engine Overheats ............................................................................. 126
9.5 Rammer Does Not Tamp ................................................................. 126
9.6 Rammer Jumps Erratically ............................................................... 127
10 Technical Data 128
10.1 BS 50-2 ............................................................................................ 128
10.2 BS 50-4 ............................................................................................ 129
10.3 BS 500 .............................................................................................. 130
10.4 BS 500S ........................................................................................... 131
10.5 BS 50-2i ............................................................................................ 132
10.6 BS 500-oi .......................................................................................... 133
10.7 BS 60/70-2 ....................................................................................... 134
10.8 BS 60-4 ............................................................................................ 135
10.9 BS 600/700 ....................................................................................... 136
10.10 BS 600S ........................................................................................... 137
10.11 BS 60/70-2i ....................................................................................... 138
10.12 BS 600/700-oi ................................................................................... 139
10.13 BS 600/700 High Altitude ................................................................. 140
10.14 BS 65-V ............................................................................................ 141
10.15 BS 650 .............................................................................................. 142
8 wc_br0114549en_010TOC.fm
Table of Contents Rammmer Repair
10.16 DS 70 ................................................................................................144
10.17 DS 720 ..............................................................................................146
Rammer Repair Safety Information
wc_si000514gb.fm 9
1 Safety Information
1.1 Signal Words Found in this Manual
This manual contains DANGER, WARNING, CAUTION, NOTICE, and
NOTE signal words which must be followed to reduce the possibility
of personal injury, damage to the equipment, or improper 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.
f 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.
f 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.
f 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.
f To avoid possible minor or moderate injury from this type of hazard, obey all
safety messages that follow this signal word.
Safety Information Rammer Repair
10 wc_si000514gb.fm
1.2 Machine Description and Intended Use
This machine is a vibratory rammer. The Wacker Neuson Rammer
consists of a gasoline or diesel engine, a clutch, a fuel tank, a springloaded 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 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.
Rammer Repair Safety Information
wc_si000514gb.fm 11
1.3 Operating Safety
Operator qualifications
Only trained personnel are permitted to start, operate, and shut down
the machine. They also must meet the following qualifications:
• have received instruction on how to properly use the machine
• are familiar with required safety devices
The machine must not be accessed or operated by:
•children
• people impaired by alcohol or drugs
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 Corporation 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.
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
1.3.1 Never operate this machine in applications for which it is not intended.
1.3.2 Do not allow anyone to operate this equipment without proper training.
People operating this equipment must be familiar with the risks and
hazards associated with it.
1.3.3 Do not 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.
1.3.4 Do not operate the machine with unapproved accessories or
attachments.
Safety Information Rammer Repair
12 wc_si000514gb.fm
1.3.5 Never leave the machine running unattended.
1.3.6 Never tamper with or disable the function of operating controls.
1.3.7 Never use the choke to stop the engine.
1.3.8 Never operate the machine in areas where explosions may occur.
1.3.9 Read, understand, and follow procedures in the Operator’s Manual
before attempting to operate the machine.
1.3.10 Make 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.
1.3.11 Be sure operator is familiar with proper safety precautions and
operation techniques before using machine.
1.3.12 Always keep hands, feet, and loose clothing away from moving parts
of the machine.
1.3.13 Always use common sense and caution when operating the machine.
1.3.14 Always be sure the rammer will not tip over, roll, slide, or fall when not
being operated.
1.3.15 Always turn the engine OFF when the rammer is not being operated.
1.3.16 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.
1.3.17 When working near the edges of breaks, pits, slopes, trenches and
platforms, always operate the rammer in such a way that there is no
danger of it tipping over or falling in.
1.3.18 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.
1.3.19 Close fuel valve on engines equipped with one when machine is not
being operated.
1.3.20 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.
1.3.21 Do not transport the machine while it is running.
1.3.22 Do not tip the machine for cleaning or for any other reason.
Rammer Repair Safety Information
wc_si000514gb.fm 13
1.4 Operator Safety while using Internal Combustion Engines
Operating safety
When running the engine:
• Keep the area around exhaust pipe free of flammable materials.
• Check the fuel lines and the fuel tank for leaks and cracks before
starting 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.
• Replace 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.
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.
f 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.
f 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.
Safety Information Rammer Repair
14 wc_si000514gb.fm
• Do not refuel if the machine is positioned in a truck fitted with a
plastic bed liner. Static electricity can ignite the fuel or fuel
vapors.
1.5 Service Safety
A poorly maintained machine can become a safety hazard! In order
for the machine to operate safely and properly over a long period of
time, periodic maintenance and occasional repairs are necessary.
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).
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 Corporation 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.
1.5.1 Do not attempt to clean or service the machine while it is running.
Rotating parts can cause severe injury.
1.5.2 DO NOT operate the machine without an air cleaner.
1.5.3 DO NOT remove air cleaner cover, paper element, or precleaner while
engine is running.
WARNING
Rammer Repair Safety Information
wc_si000514gb.fm 15
1.5.4 DO NOT alter engine speeds. Run the engine only at speeds specified
in the Technical Data Section.
1.5.5 Do not crank a flooded engine with the spark plug removed on
gasoline-powered engines. Fuel trapped in the cylinder will squirt out
the spark plug opening.
1.5.6 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.
1.5.7 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.
1.5.8 ALWAYS replace the safety devices and guards after repairs and
maintenance.
1.5.9 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.
1.5.10 ALWAYS do periodic maintenance as recommended in the Operator’s
Manual.
1.5.11 ALWAYS clean debris from engine cooling fins.
1.5.12 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.
1.5.13 Disconnect the spark plug on machines equipped with gasoline
engines, before servicing, to avoid accidental start-up.
1.5.14 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.
1.5.15 ALWAYS follow instructions when disconnecting fuel lines. Failure to
do so may result in fuel squirting from fuel system.
1.5.16 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 Neuson for assistance! Wacker Neuson
Corporation maintains a staff of trained service specialists to answer
your questions and to provide assistance and training.
WARNING
Safety Information Rammer Repair
16 wc_si000514gb.fm
DO NOT remove bottom spring cover without first reading disassembly
procedures or receiving instruction from someone familiar with its safe
removal! The spring cover is under heavy spring pressure and could
cause a serious injury if the proper 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.
Rammer Repair Tools
wc_tx001544gb.fm 17
2Tools
2.1 Recommended Special Tools
See Graphic: wc_gr001305rm
P/N 0081423 Spring box tool
P/N 0117972 Clutch puller
P/N 0153566 Clutch puller (DS 70 only)
P/N 0116816 Impact bushing puller
0081423
0117972
0116816
wc_gr001305rm
0153566
Tools Rammer Repair
wc_tx001544gb.fm 18
2.2 Recommended Repair Tools
Hex key or socket: 4 mm, 5 mm, 6 mm, 8 mm
Ratchet wrench
Extension
Sockets: 10 mm, 13 mm, 17 mm, 19 mm (3/4”), 24 mm,
27 mm (1-1/16”), 32 mm, 38 mm (1-1/2”)
Open-end wrench: 13 mm
Screwdriver
Needle-nose pliers
Large-diameter 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
Rammer Repair Maintenance Schedules
wc_tx001545gb.fm 19
3 Maintenance Schedules
3.1 Periodic Maintenance Schedule (BS 50/60/70-2, BS 65)
The table below lists basic machine maintenance. Tasks designated
with check marks may be performed by the operator. Tasks
designated with square bullet points require special training and
equipment.
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.
3
Check air filter indicator. Replace
as needed.
3
Check ramming system oil level in
sightglass.
3
Check fuel line and fittings for
cracks or leaks. Replace as
needed.
Tighten ramming shoe hardware.
Check engine cylinder screws.
Check external hardware.
33
Clean engine cooling fins.
3
Clean and check spark plug gap.
Replace spark plug.
Clean recoil starter.
3
Change ramming system oil.*
Clean engine muffler and exhaust
port.
Inspect lifting cable for wear,
damage, or abuse.
3
Inspect fuel filter.
3
* 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.
Maintenance Schedules Rammer Repair
20 wc_tx001545gb.fm
3.2 Periodic Maintenance Schedule (BS 500/600/700/650)
The table below lists basic machine maintenance. Tasks designated
with check marks may be performed by the operator. Tasks
designated with square bullet points require special training and
equipment.
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.
3
Inspect air filter. Replace as
needed.
3
Check oil level in sightglass.
3
Check fuel line and fittings for
cracks or leaks. Replace as
needed.
Tighten ramming shoe hardware.
Check external hardware.
33
Clean engine cooling fins.
3
Clean and check spark plug gap.
Change engine oil.
Replace spark plug.
Clean recoil starter.
3
Change ramming system oil.*
Inspect lifting cable on rammer for
wear, damage, or abuse.
3
Inspect fuel filter.
3
* 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 Maintenance Schedules
wc_tx001545gb.fm 21
3.3 Periodic Maintenance Schedule (BS 50/60/70-2i)
The table below lists basic machine maintenance. Tasks designated
with check marks may be performed by the operator. Tasks
designated with square bullet points require special training and
equipment.
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.
3
Check engine oil level.
3
Check air filter indicator. Replace as
needed.
3
Check ramming system oil level in
sightglass.
3
Check fuel line and fittings for cracks or
leaks. Replace as needed.
Tighten ramming shoe hardware.
Check engine cylinder screws.
Check external hardware.
33
Clean engine cooling fins.
3
Clean and check spark plug gap.
Replace spark plug.
Clean recoil starter.
3
Change ramming system oil.*
Clean engine muffler and exhaust port.
Inspect lifting cable for wear, damage,
or abuse.
Inspect fuel filter.
3
* 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.
Maintenance Schedules Rammer Repair
22 wc_tx001545gb.fm
3.4 Periodic Maintenance Schedule (BS 500/600/700-oi)
The table below lists basic machine maintenance. Tasks designated
with check marks may be performed by the operator. Tasks
designated with square bullet points require special training and
equipment.
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.
Inspect air filter. Replace as
needed.
Check engine oil level.
Check ramming system oil level
in sightglass.
Check fuel line and fittings for
cracks or leaks.
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. Inspect oil 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 Maintenance Schedules
wc_tx001545gb.fm 23
3.5 Periodic Maintenance Schedule (DS 70)
Daily
before
starting
After
first
5
hours
Every
week
or
25 hours
Every
month
or
100 hours
Every 3
months or
300 hours
Every 5
months or
500 hours
Check fuel level.
3
Check engine oil level.
3
Check air filter indicator.
Replace as needed.
3
Check rammer oil level in
sightglass.
3
Check fuel line, cap and
fittings for cracks or leaks.
Replace as needed.
3
Check bellows for damage and fit.
3
Tighten ramming shoe
hardware.
Check external hardware.
33
Clean engine cooling fins.
3
Change engine oil.*
Clean engine oil filter.*
Clean recoil starter.
Change ramming system
oil.*
Inspect lifting cable for
wear, damage, or abuse.
Check and adjust valve
clearance. **
Replace engine oil filter.
Check fuel filter, clean or
replace.
* Perform initially after first 50 hours of operation.
Note: If engine performance is poor, check, clean, and replace air filter elements as needed.
** Perform initially after first 25 hours of operation.
Maintenance Schedules Rammer Repair
24 wc_tx001545gb.fm
3.6 Periodic Maintenance Schedule (DS 720)
The table below lists basic machine maintenance. Tasks designated
with check marks may be performed by the operator. Tasks
designated with square bullet points require special training and
equipment.
Daily
before
starting
After
first
5
hours
Every
week
or
25 hours
Every
month
or
100 hours
Every 3
months or
300 hours
Every 5
months or
500 hours
Check fuel level.
Check engine oil level.
Check rammer oil level in
sightglass.
Check fuel line, cap and
fittings for cracks or leaks.
Check bellows for damage
and fit.
Tighten ramming shoe
hardware.
Check external hardware.
Clean engine cooling fins.
Change engine oil.*
Clean engine oil filter.*
Clean recoil starter.
Change ramming system
oil.*
Inspect crane lifting cable for
wear, damage, or abuse.
Check and adjust valve
clearance.**
Replace engine oil filter.
Check fuel filter, clean or
replace.
* Perform initially after first 50 hours of operation.
** Perform initially after first 25 hours of operation.
Note: If engine performance is poor, check, clean, and replace air filter elements as needed.
Rammer Repair Engine and Upper Machine Components
wc_tx001546gb.fm 25
4 Engine and Upper Machine Components
4.1 Removing the Silencing Cover
See Graphic: wc_gr007457
Recommended Tools
Ratchet Wrench
Torque Wrench
Hex Key or Hex Socket: 5 mm
Loctite 243 (Blue)
Remove the four socket head cap screws (b) that hold the silencing
cover (a) to the guide handle (c). When reinstalling the silencing cover,
apply Loctite 243 and torque the screws to 9.4 Nm (6.9 ft.lbs.).
Engine and Upper Machine Components Rammer Repair
26 wc_tx001546gb.fm
4.2 Replacing the Throttle Control (2010 and later 2-stroke models)
Requirements
• Machine shut down and cool
• Torque wrench
Removal
Perform the procedure below to remove the throttle control.
4.2.1 Remove the silencing cover. See topic Removing the Silencing Cover.
4.2.2 Remove the carburetor guard (a).
4.2.3 Loosen the swivel (d) and slide the throttle cable and casing (e) from
the carburetor adapter (f).
4.2.4 Remove the bolt (h) and hardware (b).
4.2.5 Remove the throttle control
(c) from the machine.
Result
The throttle control has now been removed.
Rammer Repair Engine and Upper Machine Components
wc_tx001546gb.fm 27
Installation
Perform the procedure below to install the throttle control.
4.2.1 Connect the throttle control (c) to the machine with bolt (h) and
hardware (b). Adjust the nut on the throttle control lever so that the
lever moves freely but still holds its position while the rammer is
operating. The recommended torque value is 2.9 Nm (2.1 ft.lbs.).
4.2.2 Connect the throttle cable to the machine at point (g).
4.2.3 Connect the throttle cable to the carburetor. To do so:
a. Place the throttle control (c) in the full throttle position with a 0.76
mm (0.030 in.) feeler gauge between the throttle control and the
machine.
b. Rotate the throttle lever (x) so that it is tight against the carburetor
adapter (f).
c. Thread the throttle cable (e) through the carburetor adapter and
through the swivel (d). Pull the throttle cable taught, then tighten the
swivel screw.
d. Release the throttle lever.
4.2.4 Install the carburetor guard
(a). Torque the screws to 23 Nm (16 ft.lbs.)
Result
The replacement procedure is now complete.
Engine and Upper Machine Components Rammer Repair
28 wc_tx001546gb.fm
4.3 Replacing the Throttle Control (2010 4-stroke models)
Requirements
• Machine shut down and cool
• Torque wrench
Removal
Perform the procedure below to remove the throttle control.
4.3.1 Remove the silencing cover. See topic Removing the Silencing Cover.
4.3.2 Disconnect the throttle cable at the swivel (a) and the clamp (b).
4.3.3 Remove the clamp (c).
4.3.4 Clip the wire ties (d).
This procedure continues on the next page.
Rammer Repair Engine and Upper Machine Components
wc_tx001546gb.fm 29
Continued from the previous page.
4.3.5 Remove the bolt (h) and hardware (b).
4.3.6 Remove the throttle lever (c) from the machine.
Result
The removal procedure is now complete.
Installation
Perform the procedure below to install the throttle control.
4.3.1 Connect the throttle lever (c) to the machine with bolt (h) and
hardware (b). Adjust the nut on the throttle control lever so that the
lever moves freely but still holds its position while the rammer is
operating. The recommended torque value is 2.9 Nm (2.1 ft.lbs.).
4.3.2 Connect the throttle cable to the machine at point
(g).
This procedure continues on the next page.
Engine and Upper Machine Components Rammer Repair
30 wc_tx001546gb.fm
Continued from the previous page.
4.3.3 Support the throttle cable with new wire ties (d).
4.3.4 Install the clamp (c).
4.3.5 Connect the throttle cable at the swivel (a) and the clamp (b).
4.3.6 Reinstall the silencing cover.
Result
The replacement procedure is now complete.
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