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0072046 B
0298 en

Rammer

BS 60Y

REPAIR MANUAL

0 0 7 2 0 4 6
INTRODUCTION

Information Contained Engine Repair

ln This Manual
This repair manual provides information and proce-
dures to safely operate, maintain and service the
WACKER Model BS 60Y Rammer. Step-by-step in-
structions and illustrations are provided whenever pos-
sible. Refer to this repair manual and the owner's
manual originally supplied with the unit whenever serv-
icing this machine.
Information
The BS 60Y is powered by a WACKER WM80 engine,
specifically designed for use on Rammers. The proce-
dures required to properly maintain and operate this
engine are described in this manual. For detailed repair
information refer to WACKER WM 80 Engine Repair
Manual, P/N 70142

It is the responsibility of the individual servicing this Additional Service Information

equipment to familiarize himself with its operating char-
acteristics and service procedures before attempting
any repairs. Repairs caused by misuse or neglect of
the unit should be brought to the attention of the opera-
tor, to prevent similar occurrences from happening in
the future.
Each machine was supplied with an owners manual
describing operating procedures and parts information.
This manual should be kept with the machine. If it
becomes lost, please contact Wacker Corporation to
order a replacement.

Should questions arise during the service or repair of this

equipment please contact your area WACKER Customer
Support Center. A complete listing of Support Centers ap-
pears on the front and rear covers of this manual.

This Manual covers machines with

Serial Numbers beginning:

4160 & Up

March, 1990

THE INFORMATION CONTAINED IN THIS MANUAL WAS BASED ON MACHINES IN PRODUCTION ATTHE TIME OF PUBLICATION. WACKER
CORPORATION RESERVES THE RIGHT TO CHANGE ANY PORTION OF THIS INFORMATION WITHOUT NOTICE.

1
MODEI_ IDENTIFICATION
Identification Plate
An identification plate listing the Model Number and Serial Number is attached to each machine and is located on
the machine crankcase. This plate should not be removed from the machine.
Please record the information found on this plate so it will be available should the identification plate become lost or
damaged. When ordering parts or requesting sen/ice information you will always be asked to specify the model and
serial number of the machine.

O WACKER
CORPORATION

Illla
Model
Serial No.
Weight
Year W/'iEl?
O

ll

Serial Number
The serial number found on the identification plate is a 6544 01243
nine digit number. Thefirst fourdigits identify the specific I
machine model (Bill of Material). The last five numbers Production Sequence
indicate the production sequence for that model.
Model Identification

2
 TABLE OF CONTENTS

USING THIS MANUAL

Safety Notes . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . .
Reference Numbers . . . . . . . .
Ordering Parts . . . . . . . . . . . . . U10'lU'lU'l

SAFETY
Safety Notes . . . . . . . .. . . . . .
Tools . . . . . . . . . . . . . .. . . . . .
Reference Numbers( ). . . . . .
Ordering Parts . . . . . . .. . . . . .
General Precautions . .. . . . . .
Service & Repair . . . . .. . . . . .
Operating Safety . . . . .. . . . . .
Engine Safety . . . . . . .. . . . . . \l O307U'lU'lU1Ul

TECHNICAL DATA
The Importance of Threadlocking Compounds . . . . . . . . . . .
Recommended Repair Tools. .
Special Tools . . . . . . . . . . . . . .
Breaking Down Threadlocking Compounds . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . .
Ramming system . . . . . . . . . . .
Carburetor . . . . . . . . . . . . . . . . QOKOQOQ CDQ

OPERATION
Gasoline\Oil Fuel Mix . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
New Machine Break-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MAINTENANCE
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13
Replaceable Cartridge Type Air Filter . . . . . . . . . . . . . . . . . . 13
High Capacity Permanent Air Filter . . . . . . . . . . . . . . . . . . . . 13
Cleaning High Capacity Air Filters . . . . . . . . . . . . . . . . . . . . . 14
Ramming System Lubrication . . . . . . . . . . . . . . . . . . . . . .. 15
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15
Ramming Shoe Hardware . . . . . . . . . . . . . . . . . . . . . . . . .. 15
Inspecting Machine Fasteners . . . . . . . . . . . . . . . . . . . . .. 15
Cleaning Engine Exhaust Ports. . . . . . . . . . . . . . . . . . . . . .. 16
Cleaning Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16
In-line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16
In-tank Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16
Cleaning Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17
Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . .. 17
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17

3
TABLE OF CONTENTS

ADJUSTMENTS
Adjusting Tillotson Carburetor . . . . . . . . . ..
Adjusting Bing Carburetor . . . . . . . . . . . . ..
High Altitude Operation . . . . . . . . . . . . . . ..
OPERATING PRINCIPLES
Applications . . . . . . . . . . . . . . . . . . . . . . . . .
Power Transmission . . . . . . . . . . . . . . . . . . .
Spring System . . . . . . . . . . . . . . . . . . . . . ..
Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricating System . . . . . . . . . . . . . . . . . . .
GUIDE HANDLE & ENGINE INSTALLATION
Assembly Drawing . . . . . . . . . . . . . . . . . . ..
Throttle Control . . . . . . . . . . . . . . . . . . . . . . .
Guide Handle & Shockmounts . . . . . . . . ..
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RAMMING SYSTEM
Assembly Drawing . . . . . . . . . . . . . . . . . . . .
Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ramming Shoe . . . . . . . . . . . . . . . . . . . . . ..
Sightglass . . . . . . . . . . . . . . . . . . . . . . . . . ..
Removing Spring Cover . . . . . . . . . . . . . . ..
Spring System . . . . . . . . . . . . . . . . . . . . . . ..
Protective Pipe . . . . . . . . . . . . . . . . . . . . . . ..
Inspecting Spring System . . . . . . . . . . . . . ..
CRANKCASE ASSEMBLY (S/N 6543 & below)
Assembly Drawing . . . . . . . . . . . . . . . . . . . . .
Crankgear & Connecting Rod . . . . . . . . . . ..
Clutch Drum & Bearings . . . . . . . . . . . . . . . . .
CRANKCASE ASSEMBLY (S/N 6544 & above)
Assembly Drawing . . . . . . . . . . . . . . . . . . . . . .
Crankgear & Connecting Rod . . . . . . . . . . . . .
Clutch Drum & Bearings . . . . . . . . . . . . . . . . .
TROUBLESHOOTING
Engine Hard Starting . . . . . . . . . . . . . . . . . . . .
Engine Starts But Runs Poorly . . . . . . . . . . . .
Engines Runs But Rammer Operates Poorly .
THREADLOCKING ADHESIVES & SEALANTS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . .. . .

4

Safety Notes
Proper service and repair procedures are vital to the
safe, reliable operation of any type of mechanical de-
vice.
The procedures described in this manual contain
NOTES, CAUTIONS and WARNINGS which must be
followed to prevent the possibility of improper service,
damage to the equipment or personal injury.
Notes: Notes appear in italics and contain additional
information important to a procedure.
CAUTION
Cautions provide information important to prevent er-
rors which could damage machine or components.
QWARNING
Wamings warn of conditions or practices which
could lead to personal injury or deathl
Read and follow all NOTES, CAUTIONS and WARN-
INGS included in instructions.
Tools
A recommended list of tools begins each sen/ice proce-
dure. These tools are the minimum required to prop-
erly complete a sen/ice procedure.
Since all possible problems encountered while repair-
ing the equipment cannot be anticipated, it is up to the
mechanic to use common sense and good judgment in
tool selection.
The use of any special tools is recommended only for
those operations where the use of conventional tools is
inadequate.
Before substituting another tool or procedure you
should be satisfied that neither personal injury nor
damage to the unit will result.
USING THIS MANUAL
Reference Numbers ( )
Repair procedures contain reference numbers en-
closed in parenthesis ( ). These numbers refer to the
item numbers shown on the assembly drawing at the
beginning of each repair section. They are included to
aid the mechanic in identifying parts and assembling
components.
Ordering Parts
The repair procedures contained in this manual do not
include part numbers. For parts replacement informa-
tion refer to the owner's manual originally supplied with
the unit.
If the original owner's manual has been lost, a replace-
ment manual may be ordered from WACKER Corpora-
tion. When ordering a replacement Parts Manual
please list model and serial number of machine.
Follow the instructions listed below when ordering parts
to ensure prompt and accurate delivery.
1. On all orders for sen/ice parts, include SERIAL
NUMBER and MODEL NUMBER of machine.
Shipment will be delayed if this information is not
included.
The identification plate listing the model and serial
number is attached to the crankcase of the ma-
chine.
2. Include correct description and part number from
- parts manual.
3. State exact shipping instructions including preferred
routing and complete destination address.
4. Do not return parts to factoiy or Customer Support
Center without first receiving written authorization
from WACKER Corporation. All authorized returns
must be shipped prepaid.
5
SAFETY

General Precautions
For your protection, the protection of others, and to prevent damage to the unit, read, understand and follow all
safety instructions. Failure to follow the safety notes listed below could cause damage to the equipment or result in
personal injury.

NEVER allow unfamiliar or inexperienced personnel to
operate the machine.
NEVER operate a defective unit in need of service or
repair.
NEVER operate a unit with safety device or guards
removed.
NEVER operate with fuel cap loose or missing.
NEVER leave machine running unattended. . long distances.
ALWAYS dress appropriately for job conditions and
wear specified safety devices such as a hard hat,
goggles and ear protection where required.
ALWAYS keep hands, feet and clothing away from
moving parts when operating or servicing equipment.
ALWAYS turn engine off, when leaving machine
unattended.
ALWAYS drain fuel tank when transporting machine

NEVER modify the equipment without express written
approval of the manufacturer.
NEVER use the machine for applications for which it
was not designed.
ALWAYS replace all missing and hard to read decals.
ALWAYS check and tighten all extemal fasteners at
regular intervals.

NEVER run machine indoors or in areas with limited

ventilation, unless sufficient ventilation or exhaust
hoses can be provided.

Service & Repair

The sen/ice 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 your area WACKER Customer
Support Center for assistance! WACKER Corporation maintains a staff of trained service specialists to answer your
questions and provide assistance and training.

/ @WARNING \

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.
\ J

6
 SAFETY

Operating Safety
/ MARNING \

Familiarity and experience are a prerequisite for safe operation !

The operator should read and become thoroughly familiar with the operating instructions furnished with the
machine, before operating this equipment. inexperienced operator's should receive instruction from someone
familiar with the equipment before being allowed to operate the machine. Before starting and while operating
machine:

1. Check that all safety devices and guards are in
place before starting machine! Do not operate
machine with safety devices or guards missing or
inoperative.
2. Immediately after start-up, check that all controls
are functioning properly! Do not operate ma-
chine unless all controls operate correctly.
3. Remain aware of the changing positions and
movement of other equipment and personnel on
the jobsite!
\ /
4- Be aware Of Surface eendiliens and use special
Cafe When Working 0" Uneven Qrellnd Of When
compacting coarse material.
5. Keep both hands firmly in contact with guide
handle while operating machine.
6. Operate rammer so shoe hits ground surface
flush. Hitting on tip or heel of shoe can damage
shoe and may make rammer difficult to control.

Engine Safety
Internal combustion engines present special hazards during operation and fueling. Failure to follow the safety
practices described below could result in severe injury or death.

, QWARNING
DO NOT operate engine in an enclosed area or an
area with limited ventilation. Exhaust fumes contain
carbon monoxide, a deadly gas!
DO NOT fill tank near open flame or while smoking!
DO NOT fill fuel tank if engine is hot or while engine
is running!
\ J
\
DO NOT spill fuel while filling tank or run engine if an
odor of fuel is present! If fuel is spilled, wait until it
has evaporated or move the machine away from the
spill before running engine!
DO NOT touch or lean against hot exhaust pipes or
engine cylinder!
TECHNICAL DATA

The Importance of Breaking Down Threadlocking

Threadlocking Compounds
Due to the heavy vibration inherent in this type of
equipment, the repair and service procedures de-
scribed in this manual specify the use of threadlocking
compounds to secure bolts and nuts. These com-
pounds should be used where indicated to prevent
fasteners from becomming loose.
Although Loctite is referred to throughout this manual
any equivalent type sealant , such as Hernon, Prolock,
Omnifit, etc., may be used. Clean screw threads and
wipe off any oil or grease before applying threadlocking
compounds.
Compounds
High strength threadlockers can make the removal of
fasteners very difficult. If a bolt or nut resists separa-
tion, heat it directly using a small propane torch. Most
threadlocking compounds breakdown at temperatures
above 350F (175C).
When using heat to breakdown sealants make sure
soft parts such as seals and O-rings will not be dam-
aged.

For a complete listing of recommended sealing and

locking compounds refer to the Threadlocking and
Sealant Product List at the end of this manual.

Recommended Repair Tools

Socket or Box Wrench - 8mm, 10mm, 11mm, 13mm, 17mm, 19mm
Allen Wrench - 6mm, 8mm
Punch
Torque Wrench -184 Ft.Lbs. (250 Nm)
Rubber Mallet
Screwdriver
Pliers
Retaining Ring Pliers - Internal and External
Propane Torch
Arbor Press
Two M8 x 180 mm threaded rods with nuts

Special Tools

~21 ~-9
Q
it SPLIT PULLER
30920
SPLIT PULLER
25442
CLUTCH PULLER
49776
N 83I3 25321
F ,
. If
J*3|'(Qtlt
\ : \_/ _/
_
\ 5"

BEARING PULLER SET

25441 SIGHTGI-ASS TOOL WRENCH ATTACHMENT
aoeea 52644

8
 TECHNICAL DATA

Engine
Type WACKER WM 80 engine, single cylinder, 2-cycle,
air-cooled gasoline engine.

Ignition II/P9 Electronic - Transistor controlled Ignition (TCI)

Spark Plug Champion RL86C

Electrode Gap in. (mm) .025 (0.6-0.7)

Compression (cold) psi (kg/cm?) 120-140 (s - 9.7)
Clutch engagement rpm 3200 1

Idle Speed rpm 1 500

Operating Speed rpm 4800

Fuel type - Mixture Ratio Gas/oil mixture - 50:1

' On machines equipped with 2-shoe clutch, engagement speed is 2800 rpm. See page 27 for clutch removal.

Ramming system
Lubrication type SAE 10W40

Capacity OZ. (ml) 18 (530)

Carburetor Tillotson Tillotson Bing

(Single Needle) (Dual Needle)

High Speed Jet? Fixed #64 Adjustable Fixed #64

(Initial Adj.) (1 turn out)

Low Speed Jet 2 Adjustable Adjustable Fixed #40

(Initial Adj.) (1 turn out) (3/4 turn out)

Mounting Adapterz .472 (12) .472 (12) .433 (11)

Bore Dia - in. (mm)
2 When operating at altitudes above 5000 ft. (3000 m) jet sizes and bore in mounting adapter may be different than those listed. See page 19
OPERATION

CLOSE
\ OPEN

OPEN I \
'0
0
\B K ,
cl I
CHOKE $_- 1

TILLOTSON CARBURETOR

open
CLOSIZT7
ou.
_ ._... FILL P1.ue\
[CHOKE

PRIMING
. . .
BUTTON ' '
//////
k_\
II__I
i
BING CARBURETOR

FIG 1 OPERATION AND SERVICE

Gasoline/Oil Fuel Mix

U.S Metric
The gasoline/oil fuel ratio is 50:1.
Gas Oil Gas Oll
Note: On new machines use a 25:1 gas/oil fuel mixture
for the rst tank ll. This will provide additional lubrica- 1 Gal. 2.5 oz. 5 litres 100 ml
tion to engine components during their initial wear-in 3 Gal. 8.0 oz. 10 litres 200 ml
period. 5 Gal. 13.0 oz. 15 litres 300 ml
Thouroughly mix regular grade gasoline and two cycle
engine oil in a separate container. Avoid mixing the fuel CAUTION
in the tank on the machine.
Lubrication for two-cycle engines is provided by the
Use oil refined especially for two-cycle engines. These fuel mixture. Running the engine using straight gaso-
oils conform to BIA or NMMA standards and are rated line will cause the engine to seize and could damage
TC-W ll. Do not use oils produced for 4-cycle engine engine components.
lubrication.

The chart following lists the correct volumes of oil and

gas required for a 50:1 mixture.
10

Before Starting
1. Read SAFETY, pages 6 & 7.
2. Check oil level in ramming system. Oil should be
visible near center of sight glass. Do not run ma-
chine if oil does not appear in sight glass.
3. Fill fuel tank with correct fuel mixture.
Note: On machines equipped with the replaceable car-
tridge type air lter, remove metal cover and inspect
lter paper for dirt, tears or holes before starting en-
gine. DO NOToperate engine with a damaged air lter.
Starting
1. Push lever on fuel valve at bottom of tank down to
open fuel line.
2. Close choke lever on carburetor. If starting a warm
engine, choke should remain open.
3. Open throttle lever half way.
4. If the machine is equipped with a Bing carburetor,
press priming button on carburetor twice.
5. Pull starter rope using short, quick pulls until engine
starts.
6. Open choke lever as engine warms up.
7. Warm up cold engine by running at idle for a few
minutes before increasing throttle and engaging
clutch.
Stopping
1. Return throttle lever to idle.
2. Press stop botton on engine and hold down until
engine comes to a complete stop.
3. Close fuel valve on tank.
OPERATION
Note: If the needle valve in carburetor becomes
dirty or worn it may not seat correctly. Although
this often does not affect operation it can in some
cases allow fuel to leak into the engine cylinder
while the engine is off. To prevent this from hap-
pening, turn off the fuel valve after stopping the
machine
Q
Operation
Alter allowing the engine to warm up, open the throttle
and pull the rammer handle slightly upward and back.
Hold this position until proper ramming action is
achieved.
Avoid overthrottling rammer. This can damage the
shoe and make the rammer harder to control. Best
compaction is achieved when the rammer produces a
smooth, rythmic, tamping action.
Guide the rammer with the handle. Do not fight or try to
overpower the machine. Make sure the ramming shoe
hits parallel to the ground, not on its toe or heel. This
prolongs shoe life and ensures maximum compaction.
Avoid running machine at idle for long periods of time.
Excessive idling will cause carbon deposits to accumu-
late at the engine exhaust.
11
MAINTENANCE

Maintenance Schedule
Periodic Maintenance is essential to prolong machine life and maintain efficient operation. Use the schedule below
as a guide in setting up a preventative maintenance schedule.

Daily Every Every Every Every

Before week 2weeks month 3 months
Use or or or or
50 Hrs. 100 Hrs. 150 Hrs. 300 Hrs
Check oil level in sight glass.
Check cartridge type air fllter. Clean or replace
as required. (High capacity air filters do not require
cleaning.)
Check and clean dirt from engine cooling fins.
Clean and regap spark plug.
Check and tighten shoe hardware.
Check and tighten all external machine fasteners.
Remove and clean engine muffler and exhaust ports.
Replace cartridge type air filter. (High capacity air
lters do not need replacement unless damaged.)
Replace spark plug.
Replace in-line fuel filter.
(In-tank filters do not require replacement.)
Change ramming system oil.

New Machine Break-in

1. Check shoe hardware after first hour of operation and tighten as required. Refer to "Ramming Shoe Hardware"
in Maintenance Section.

2. Check all external fasteners after first 3 hours of operation. Tighten as required.

3. Change ramming system oil after first 50 hours of operation.

12
 MAINTENANCE

Air Cleaner
A clean, well maintained air cleaner system is vital to protect the engine against damage caused by dirt and dust.
Poor maintenance and damaged filters can quickly lead to costly repairs.

There are two types of air cleaners used on the BS 60Y. The replaceable cartridge type filter and the high capacity,
permanent type air filter.

Replaceable Cartridge Type Fllter

Inspect and clean daily. Replace every 100 hours or as
needed.
PROTECTIVE
COVER
The cartridge filter uses a dry pleated paper element,
enclosed in a protective cover. Follow procedure below
when servicing.

1. Remove filter by unsnapping the two spring clips

.' INSPECT SEALS AND
and removing protective cover. Cover air intake pas- | MOUNTING SURFACES.
sage in mount to prevent dirt from falling into intake ._m:@ GREASE LIGHTLY
\ / BEFORE ASSEMBLY
tube.
Z \
J
2. Clean filter by tapping it against your hand or using
light air pressure, blowing from the inside of the filter
\
out. Do not use cleaning agents.
MOUNT
3. Inspect filter and replace it if filter paper is wet,
heavily soiled or torn.
\

=1
4. Inspect seals on either end of filter. Replace filter if
seals are damaged or deformed, or if metal ends are
dented or kinked. Damaged seals may allow dirt to
by-pass the filter.

5. Clean and inspect the area where the filter seals FlG.2 AIR FILTER ASSEMBLY
seat on the mounting base and inside the cover.
Surfaces should be flat and free of dirt. Replace
damaged parts.

6. Coat filter seals lightly with grease before installa-

tion.

High Capacity Permanent Filter

The high capacity air filter is designed as a self cleaning
system which utilizes the action of the rammer to shake
dust and dirt loose from the filter element. It features an
open bottom design which allows dirt to drop free and
prevents it from accumulating around the filter element.
The high capacity air filter requires little or no main-
tenence and need only be inspected if the machine
begins to experience a power loss. A power loss may
occur, if the filter element becomes plugged. This can
happen when fine dust particles stick to the filter and
cannot be shaken loose or the machine was laid down
in mud or wet ground. Washing the filter will in most
cases remove these deposits and restore full power to
the engine.
13
MAINTENANCE

Cleaning High Capacity

Air Filters
This filter should only be removed if the machine is
experiencing a power loss, or it is apparent that it has
become plugged with dirt.
1. Remove the two locknuts and sealing washer from
the top of the air filter and lift filter off mount. _/
\Q/\./

2. Direct air pressure to inside of filter, through hole in I 's_

bottom, and remove as much dirt as possible.

3. Run fresh water into intake hole in filter. Continue

rinsing until water runs clear.

CAUTION
DO NOT use solvents, fuel oil, or gasoline to wash
RUN CLEAR WATER
THROUGH HOLE
""

filter. IN ELEMENT

4. Plug hole in element. Soak filter. in a solution of

warm water and low suds detergent for 15 minutes. FIG. 3 RINSING AIR FILTER ELEMENT
Longer periods (up to several hours) of soaking
may be required, depending on the amount of dirt
build-up on filter.

CAUTION PLUG HOLE TIGHTLY TO

PREVENT DIRTY WATER
FROM ENTERING INSIDE OF
Hole must be sealed tightly with a cork or tape so ELEMENT.
that inside of filter is water tight. If inside of filter is
contaminated with dirty water the complete filter
must be replaced.

5. Remove filter from water and repeat rinsing proce-

dure described_i_n step 3. Allow the filter to air dry in
a dust free area overnight
(@_/ 2 / .
CAUTION \ _ ._// _._/
7

DO NOT use direct heat to speed up drying, filter

elements may be damaged.

6. The rubber grommet provides the main seal be-

tween the filter and intake tube. Inspect rubber FIG. 4 WASHING AIR FILTER ELEMENT
grommet before installing filter back on mount. Re-
place grommet if it appears worn or damaged in any
way.

Note:To ease installation and prevent tearing or

pulling rubber grommet loose from lter, grease
inside of grommet lightly before installing lter on
mount.
14
 MAINTENANCE

Ramming System Lubrication Ramming Shoe Hardware

Oil for lubrication is carried throughout the ramming
system by the action of the machine. Holes drilled in
the piston and ram allow oil to be distributed from the
bottom of the rammer up to the crankcase. The oil in
the ramming system must be maintained at the correct
level to ensure that this system operates efficiently.
Check the oil level in the sightglass daily before starting
the rammer. When checking oil make sure the rammer
is on a flat, level surface. The oil level should fill 1/2-3/4
of the sight glass. Add oil through the fill plug located
just above the bellows at the front of the machine.
Oil Type - SAE 10W40
Capacity - 18 oz.(530 ml)
Changing Oil
Change ramming system oil every 300 hours. On new
machines change oil after first 50 hours of operation.
To change oil:
Damaged shoes are most often the result of loose
hardware. The bolts on new shoes seat themselves
during the first hour of operation and can become loose
during this time.
On new machines or after replacing the shoe, check and
tighten shoe hardware alterthe first hour of use. Inspect
it every 50 hours thereafter. .
Secure loose bolts using Loctite 290, or equivalent. The
penetrating action of this locking compound allows it to
coat the bolt thread without the need to remove the nut.
Torque bolts to values listed below.
SECURE LOOSE NUTS
WITH LOCTITE 290
' 58 FT.LBS.
OR EQUIVALENT (79 Nm)

1. Remove fill plug on guide cylinder for venting.

2. Remove drain plug below sightglass and tilt rammer

back until it rests on the guide handle.
-
e\ \_/ /\ @ 1&1
.__

:2
k) 18 FI'.LBS
(25 Nm)
3. Replace drain plug. Stand machine upright and fill
through plug opening on top of guide cylinder with 18
oz. (530 ml) of SAE 10W40. FIG. 5 TIGHTENING RAMMING SHOE

CAUTION
DO NOT overfill the ramming system. Excessively high
oil levels can create a hydraulic lock in the ramming
system. This can result in erratic operation and could
cause damage to the engine clutch, ramming system
Inspecting Machine Fasteners
and shoe. Even though threadlocking compounds like Loctite are
used extensively on machine fasteners, the constant
pounding and vibration of the machine may cause
FILL \"-y/ screws and nuts to loosen.
PLUG I6 I I
Inspect all external hardware once a week or every 50
E2 ZDRAIN
hours. Secure loose hardware with Loctite 241, or an
equivalent type threadlocking compound. Torque to
correct values. If locknuts become loose, it maybe
PLUG

E-5
necessary to replace them.
V \V \/
On new machines check hardware after first 3 hours of
operation.
\\

FIG. 4 DRAINING RAMMING SYSTEM OIL

15
MAINTENANCE

Cleaning Engine Exhaust Ports

Carbon deposits can form in the muffler and the cylinder
exhaust port. lfallowed to accumulatethey willgradually
restrict exhaust passages, resulting in poor engine per-
formance and hard starting. Factors contributing to this
problem include:
Too much oil in fuel mixture.
Dirty air filter causing the engine to run rich.
Excessive engine idling.
Dirty carburetor.
at \.-<m : SOAK MUFFLER IN
CARBURETOR CLEANER
TO REMOVE CARBON
DEPOSITS.
Avoid these conditions to reduce maintenance on the
engine.

Cleaning
1. Remove muffler from engine. Use a 10mm offset
wrench, to removethe two mounting nuts holding it to
the engine cylinder
2. Crank engine until piston is at thetop of its stroke and FIG. 6 EXHAUST SYSTEM
covering exhaust port. This will prevent dirt from
entering the engine cylinder while the muffler is off.
3. Clean the engine exhaust port using a blunt scraper
and remove any carbon deposits. Inspect the gasket.
Replace it if it is torn or cracked.
4. Soak muffler in carburetor cleaner or similar cleaning
agent for several hours and allow carbon deposits to
break up.

5. Drain muffler and blow dry.

Fuel Filter
Dirt is the primary cause of carburetor problems.
Unfiltered fuel can quickly plug the small fuel pasages in \./

the carburetor. Never run the engine without a fuel filter

in the system.

In-line Filters
On machines equipped with an in-line fuel filter, replace
the filter and fuel lines every 150 hours of operation. @>Kto ;_C_
e&\\/
IN-TANK FILTER
NO REPLACEMENT
In-tank Filters IN-LINE FILTER j
REQUIRED

RE PLACE EVERY 150

The in-tank fuel filter is located inside the rammer fuel HOURS.

tank. This filter has a larger surface area than the smaller
in-line filter and does not require replacement. For
service see page 25. FIG. 7 FUEL FILTER TYPES

16
 MAINTENANCE

Cleaning Engine Storage

The WACKER WM 80 engine is air cooled and depends
on the cooling fins on the cylinder to help dissipate heat.
Dirt accumulation between the cylinder ribs can cause
the engine to overheat.
Inspect and keep the engine cooling fins clean. Use a
screwdriver and remove impacted dirt between the ribs.
Clean entire area using compressed air.
Transporting the Machine
Drain the fuel tank when transporting the machine long
distances. Lay the machine on its side with the gas cap
up. Avoid laying or throwing loose objects on top of the
unit.
If the machine is being transported standing up, it must
be tied and secured in place to prevent it from tipping.
If storing the unit longerthan 30 days the following steps
are recommended.
1. Drain fuel from tank.
2. Start engine and run it until remaining fuel left in
carburetor is used.
3. Lay machine down on its front. Remove spark plug
and pour approximately 1 oz (30 ml) of SAE 30W
engine oil into cylinder through spark plug hole.
4. Pull starter rope slowly to crank engine and distribute
oil in cylinder.
5. Replace spark plug.
6. Change ramming system oil.

If lifting the machine using a fork lift or othertype of lifting 7. On machines equipped with replaceable cartridge
device, use the center protection bar provided on the type air filter, remove and inspect filter. Clean or
guide handle to attach straps or chains. replace filter as necessary.

8. Inspect unit for signs of damage, loose bolts, and oil

leaks.

9. Store unit in an upright position and secure it in place

it
$1
to avoid tipping. If possible store unit indoors away
E} A

T r
from moisture. If the machine must be kept outside
keep it covered.
4
5I
I

-Z ll

FIG. 8 LIFTING MACHINE

17
ADJUSTMENTS

Adjusting Tillotson Carburetor

Single Needle Carburetors
The single needle Tillotson carburetor uses a fixed high
speed fuel jet and adjustable low speed jet. Only low
speed adjustment is required and is used to adjust both
the engine idle speed and low speed fuel mixture.
1 . Preset low speed adjustment by turning in the adjust- EEK
ing screw fingertight until it bottoms out and then
backing it out 1 turn.

2. Start engine and allow it towarm up by ru nning at high

j@\,_\
1 ,
speed for a few minutes. tr v \
3. Close engine throttle control and open choke.
IDLE AND LOW SPEED
Note: Throttle is completely closed when tang on ADJUSTING SCREW
thottle lever contacts stop on carburetor.
4. Turn low speed adjusting screw in or out until engine FIG. 9 LOW SPEED MIXTURE ADJUSTMENT
idle speed is adjusted to 1500 - 1600 rpm. (SINGLE NEEDLE CARBURETORS)

5. Check operation by running machine at high speed.

If engine bogs down, low speed adjustment may be
set too lean. Turn in low speed adjusting screw HIGH SPEED
slightly and recheck high speed operation. ADJUSTING SCREW
I .
CAUTION \2 8 |_ow SPEED
.
.5! I ADJUSTING sonrzw
The engine is lubricated by the fuel mixture, running
the engine lean could cause it to overheat. Q 7/
Dual Needle Carburetors O) T
IDLE STOP
Dual needle carburetors require both high and low speed / SCREW

adjustment. In addition these carburetors are equipped

with an idle stop screw to adjust engine idle speed.
!I\
la; \-

1. Tum in both adjusting screws fingertight untill they

bottom out, then back out as listed below.
FIG. 10 LOW AND HIGH SPEED ADJUSTMENTS
(DUAL NEEDLE CARBURETORS)
Low speed adjustment - 3/4 turn out
High speed adjustment - 1 turn out.
4. Run machine at high speed and repeat for high speed
2. Start engine and allow machine to warm up by jet.
operating at high speed for a few minutes.
Note: It is generally better to adjust the engine to run
3. Close engine throttle and open choke. Use a tachom- a little rich ratherthan too lean. Running lean reduces
eter and check engine speed while turning low speed engine lubrication and could increase wear on the
adjustment in and out to adjust for highest rpm. engine.

18
 ADJUSTMENTS

Adjusting Bing Carburetor

The Bing carburetor is equipped with fixed fuel jets for
both high and low speed operation. No fuel mixture IDLE STOP
adjustments are required. scnEw

Setting Idle Speed

Start engine and allow it to warm up for several minutes. \'. 711$?
"33, 13/
Close throttle control at guide handle. Tum idle stop
screw in or out and adjust idle speed to 1500-1600 rpm. \ 1%

0$1~
FIG 11 IDLE SPEED ADJUSTMENT FOR BING CARB

High Altitude Operation

The WM 80 engine used in this machine is designed to
operate most efficiently at altitudes upto 5000 ft. (3000 m)
At altitudes above 5000 ft. (3000 m) minor modifications
to the carburetor can be made to improve performance.
All modifications must be performed by an authorized
WACKER dealer. Contact your area WACKER Cus-
tomer Support Center for more information

CAUTION
High altitude modifications involve adjustments to the
engine air/fuel mixture. At normal altitudes these adjust-
ments can be damaging to engine components. When
retuming the machine to low altitude operation remem-
ber to set the engine back to its standard specifications.
OPERATING PRINCIPLES

Applications Lubricating System

Rammers are designed to compact loose soils to pre- The BS 60Y like all WACKER Rammers uses a sealed
vent settling and provide a firm base for footings, con- oil bath lubricating system.
crete slabs, foundations and other structures.
The up and down motion of the ramming system carries
Power Transmission oil up into the crankcase through holes drilled in the
spring system piston and spring cylinder. Oil is distrib-
The BS 60Y Rammer is powered by the WACKER uted throughout the machine providing lubrication to
WM 80 engine. This engine is specifically designed for gears, bearings, springs and other moving parts.
use on rammers. The engine crankshaft turns a centrifu-
galclutchwhich allowstheenginetobedisengagedfrom This system has two benefits.
the ramming system during engine start-up and while
idling. 1. It provides continuous and reliable lubrication to all
machine components.
The engine drives the ramming system through a set of
transmission gears and connecting rod. The transmis- 2. It eliminates maintenance to the ramming system
sion gears reduce the relatively high engine speed system except for periodic oil changes.
(4500 rpm) to the 600-750 rpm needed by the ramming
system. This gear reduction also increases available
powerto drive the ramming system through each stroke.
Aconnecting rod attached to the crank gear converts the
circular rotation of the engine and gears to the up and
down stroking motion of the rammer.

Spring System
The spring system consists of two spring sets with a
piston in between. The piston is connected to the ram
which is driven by the connecting rod attached to the
crankgear. Plastic stoppers on either side of the piston
prevent the springs from bottoming.
The spring system has two functions. One is to store the
energy developed by the engine and release it to the
shoe during its downward stroke. The second to isolate
the shock created when the ramming shoe hits and
prevent it from being transmitted up into the machine.
The spring sets and piston are housed in the spring
cylinder which slides up and down inside a guide cylin-
der.

Bellows
The bellows provides a flexible joint between the ram-
ming system and upper machinery. It seals out dirt and
dust and provides a clean path for recirculating oil.

20
 OPERATIN G PRI NCIPLES

CLUTCH DRUM
\

OIL
/ "\
SEAL
\
i
/(Z

CFIANKGEAFI S

GUI DE
CONNECTIN GE CYUNDER
ROD

TOP
SPRING SET

SPRING
/ CYLINDER

o||_ /
PORTS
\ TOP
STOPPER

BELLOWS

BOTTOM
SPRING ""d______,_ STOPPER
CYLINDER
COVER
BOTTOM
T SPRING SET

RAMMING
SHOE
L

FIG. 1 2 CROSS-SECTION OF RAMME RASSEMBLY

GUIDE HANDLE & ENGINE INSTALLATION

Assembly Drawing
9
B Ill E/jj

5 1 I2
4 \ 5 \_/ 0/
_._/

3 %\\ S

M/
2 _/
/ 0

\/

_/I8
v V I5 @__n

Assembly Notes V
S/= 37
as
25 Keep taper on clutch hub and engine
crankshaft absolutely clean and dry. Y
/<\
'-''\tL
_
9//19
33 Grease inside of rubber grommet before __Z @~20
installing air cleaner on mount.

30 32
19 at
\
../QS- /
I/'
\"" - S22
.

s/I 0
. S-V
i 25
5;

i W23

6 26
21 24

22
 GUIDE HANDLE & ENGINE INSTALLATION

Tcrque Notes Sealant

Loctite (Omnifit)
Torque
Ft. Lbs. (Nm)
23 Engine Mounting Bolts 242 (150) 20 (27)
27 Engine Clutch Nut - 25 (33)

Parts Listing
Ref. Description QlY- as
Guide Handle ...................................... ..
Hex Hd. Screw (M8 x20) ..................... ..
Lockwasher ............................ ..
._ K.<.\ ,
Protective Plate ....................... ..
Screw (M8 x 18) ........................ \ \,/
Clamp ..................................... .. -52; -_M/
\IO3U'l-kCDI\)l Locknut ................................... .. I
Thottle Control Lever .............. ..
81:
9
Screw (M5 x 22) ............ ..
Fuel cap ........................ ..
.\ \
41

10 Fuel Tank ..................... ..

11 Screw (M8 x 25) ............ ..
12 Washer ......................... .. \

13 Collar ............................ ..
14 O-Ring .......................... .. 4-IX
15 In-tank Fuel Filter .......... ..
16 Fuel Valve ..................... ..
17 Nut ................................ .. Replaceable Cartridge Type Air Cleaner
18 Fuel Valve Gasket ........ ..
19 Locknut ................................... ..
20 Washer Seal ........................... .. Ref. Description Qty
21 High Capacity Air Cleaner ....... ..
22 Alr Cleaner Mount ................... .. 38 Cover ................... ..
23 Soc. Hd. Screw ....................... .. 39 Filter Cartridge
24 WM 80 Engine ........................ .. 40 Clip . - . . . - | | - - - - - . . . - . . - - - - - - . - - - - - . . - . - - - - - - - - - - - - . - - - - --
25 Clutch ................................................. .. 41 Mount ............ .. - - - . . . - - . . - - - - - - - - - - - - - . - - . . . --

26 Spacer ................................................ .. 42 Clamp ............ .. - - - - - - - - . . . - - - - - - - - - - - - - - - | - . --

27 Locknut ............................................... .. 43 Air Tube ........ .. - | - - -- - - | - - . - - - - - - - | - - - - - - - - | - - - - .-

28 Shockmount .................................... .. 44 Clamp ............ .. - | - - ~- - - ~ - - | | | - - - - - - - - - - - - . - . - - - - - -1
29 Lockwasher .................. .. 45 Screw (M8 x 20) .................................. .. NL_L-L_LN-L_L
30 Hex Hd. Screw (M8 x 30) .................... ..
31 Washer ................................... ..
32 Soc. Hd Screw (M8 x 25) ..........
33 Grommet ...................... ..
34 Clamp ........................... ..
35 Fuel Llne ...................... ..
36 Throttle Cable Casing ............. ..
37 Thottle Cable .......................... ..

23
GUIDE HANDLE & ENGINE INSTALLATION

Guide Handle & Shockmounts

Recommended Tools
Socket Wrench - 8mm, 11mm, 13mm
Screwdriver
Pliers

1. Close fuel valve (16) under fuel tank and disconnect

fuel line (35).

2. Remove the clamps (6) which hold the throttle cable

(36) to the handle.

3. Remove the throttle lever (8) from the handle.

fa s
Note: It is not necessary to disconnect the throttle
cable from the throttle lever or carburetor.
4. Remove the bolts(2) which hold the guide handle to
the shockmounts and lift handle assembly from
rammer.
5. Inspect shockmounts (28) and make sure they are
mounted securely to crankcase. Replace mounts if
they are torn or damaged.
Note: Replace shockmounts as a set.
FFIG. 13 SHOCKMOUNT INSTALLATION
6. Secure shockmounts to crankcase using capscrews
(30) and lockwashers (29).
7. Place guide handle over rammer and mount to
shockmounts.
8. Mount throttle lever (8) to handle and replace clamps
(6) and fuel line (35).

Check shockmount bolts after first three hours of opera-

tion and tighten if necessary.

LEVER TENSION
,_, ADJUSTMENT
Throttle Control
The throttle control lever is equipped with an adjusting
screw which can be used to increase or decrease the \
pressure on the lever. Adjust pressure so that lever \
moves freely but still holds its position while machine is

\
J /
operating. /
To adjust pressure tum screw in or out. On machines
using the clamp-on type throttle lever, pressure can be
set by adjusting the double nut arrangement on the
throttle control. FIG. 14 THROTTLE CONTROL

24
 GUIDE HANDLE & ENGINE INSTALLATION

Fuel Tank
1.Disconnect fuel line, open fuel valve and drain fuel
from tank.

.6/"
(Q
LWARNING
Gasoline is a highly volitile liquid. Drain and
store gasoline into a suitable container de-
signed for holding it. Gasoline fumes are com-
bustible. Do not drain gasoline in an enclosed
a\!.~
area where fumes can accumulate or in areas
near gas pilot lights. METAL
COLLAR I
2. Remove filter and fuel valve from tank. Do not sepa-
rate valve from filter unless necessary for replace-
ment of parts. O-RING
() FILTER

3. Inspect filter and replace it if mesh element is torn or

punctured. Clean element by rinsing it in clean fuel. SKET
Do not allow dirty or unfiltered fuel to enter inside of
element.

SP)
SCREW NUT ON FILTER
4. Clean inside of tank and remove any sediment. FINGERTIGHT THEN
BACK OFF 1 TURN.

5. Install filter in tank.

Note: The metal ring around the bottom of the fuel
tank is used to maintain the threaded tbetween the
tank and lterandprevent fuel from leaking. It should FIG. 15 FUEL TANK AND FILTER ASSEMBLY
not be removed.
To replace fuel valve on filter it is important to make
sure enough of the plastic threads on the filter engage
the coupling nut to prevent them from stripping when
attaching fuel valve.
1. Remove nut from fuel valve.

2. Screw nut on fuel filter fingertight, then back off one

full turn. Do not try to force nut completely on filter or
threads on filter may be damaged.
3. Place gasket on fuel valve and screw fuel valve into
nut. Position valve as desired and tighten.
GUIDE HANDLE & ENGINE INSTALLATION

Engine
Recommended Tools
Socket Wrench - 13mm
Allen Wrench - 6mm
Box Wrench - 8mm, 10mm
Flathead Screwdriver
1. Remove protection plate (4) from handle.
LOCKNUT
2. Remove the two nuts (19) and washers (20) from top
of air cleaner and lift air cleaner (21) off mount.
\g
4
3. Remove four screws (32) holding air cleaner mount. I
4. Loosen clamp which holds air tube to bottom of air ( \" SEAASLING

cleaner mount and lift mount off engine. E w HER

5 - Remove muffler. V ft
- at X
\ -

6. Remove the two nuts holding the carburetor to the

engine and pull carburetor and airtube assembly off.
It is not necessary to disconnect the throttle cable.
7. Use a 6mm Allen wrench and remove the 3 engine
mounting bolts (23). Tilt engine down and away to
6 44%;
remove it from crankcase. soc. HD. SCREW
M8 x 30
20 F1'.LBS (27 Nm)
CAUTION
Machine willtip more easily when engine is removed. [/ \
A
'

Attach engine in reverse order taking note of the follow-

ing
- Inspect intake and exhaust gaskets and replace if FIG. 16 wrouurme ENGINE.
damaged.
- Torque engine mounting bolts to 20 ft.lbs. (27 Nm)
- Make sure clutch shoes and inside of clutch drum
are clean and dry.

&WARNlNG

DO NOT run engine while it is off the machine unless clutch

has been removed. Running engine with clutch still on will
cause clutch shoes to separate and fly off.

26
 GUIDE HANDLE & ENGINE INSTALLATION

Clutch
Recommended Tools
Socket Wrench - 17mm
Impact Wrench
Clutch Puller - 49776
1. Remove engine from machine as desribed in previ-
ous section.
2. Clutch shoes and springs can be replaced without
removing clutch from engine. Separate clutch shoes
by removing springs from either side of clutch.
3. To remove complete clutch, use an air impact wrench
and 17 mm socket. If an impact wrench is not
available rap wrench handle sharply to help break CLUTCH PULLER
49776
nut loose.
4. Place clutch puller P/N 49776 around clutch shoes
and turn center screw in against end of crankshaft SPACER
until clutch hub breaks free of taper. 25 FT.LBS.
(33 Nm) @ :s:2=z:s:z: :z:s;2;e;s;s;2
When installing clutch make sure taper in clutch hub
and on engine crankshaft is clean and dry. Surfaces
must be absolutely free of any oil or grease. EH 1111111-I
Secure clutch to hub using spacer and nut. Torque nut
to 25 ft.lbs. (33 Nm)
FIG. 17 4-SHOE CLUTCH.
Note: Ifconverting from a 2-shoe to a 4-shoe clutch, be
sure to replace the lockwasher with the spacerprovided.

CLUTCH PUI-I-ER *
49776
EIEIEIEI
I
-'
We%i%&1i&ii%&2f
Ql

I as=;:z:z:2:z=z:;:;=z:z=z=s:z:; I
,255252525;izizizizizizizisizi;
5:555:-Ii zi2E2Eii%s%;i;izi;%2ifs%i%i%5F

LOCKWASHER
25 FT.LBS.
(33 Nm)
\ iIi
Q 111! |
ails

FIG. 18 2 -SHOE CLUTCH

_\-\
A
My
_,_L/
_,Q/ /
/
/QM
ggV(R
i
/
g EMA
3VK
%/_ g%%

A '7
_ _| _ _
 RAMMING SYSTEM

Torque Notes Sealant Torque

Loctite (Omnifit) Ft. Lbs. (Nm)
12 Sightglass - 5 (7)
14 Drain Plug - 14 (19)
17 Piston 271 (200) 184 (250)
19 Piston Nut 271 (200) 184 (250
22 Spring Cyl. Cover 242 (150) 18 (25)
27,28 Shoe Bolts 290 (130LL) 58 (79)
30 Guide Cyl. Bolts 271 (200) 63 (86)
I 'l11readed pistons only. DO NOT use sealanton non-threaded pistons.

Parts List Assembly Notes

Ref. Description Qty. 4 Position clamp for bellows with bolt positioned
to the back.
Fill Plug .................................................
Sealing Ring 5 Warm bellows and oil edges to ease
Guide Cylinder ...................................... installation.
Clamp ............ ..
Bellows .......................................... .. 12 Wrap threads on sight glass with teflon tape
Pin ............... .. before assembly.
Washer ............................................... ..
\lOU'l-kOJ|\)-\ Retaining Ring ................................... .. I'DO3 Heat bottom of pipe to approx. 400-450F
9 Ram .................................................. .. (200-230C), when installing on spring cylin-
10 Bushing ................................................ der. Seal inside joint using Loctite 290.
11 Locknut ............................................... ..
12 Sightglass
13 Sealing Ring
14 Drain Plug
15 Spring Set
16 Top Stopper
17 Piston ................................................. ..
18 Lockwasher
19 Nut (M22 x 1.5) ................................... .. Q WARNING
20 Bottom Stopper ................................... .. The spring cylinder cover is under heavy spring
21 Gasket ........ .. pressure. Follow disassembly procedures care-
22 Cover .......... .. fully when removing and installing. See page 32.
23 Lockwasher
24 Screw (M8 x 25) .................................. ..
25 Spring Cylinder ....................................
26 Protective Pipe .................................... ..
27 Plow Blot (M12 x 75) ........................... ..
28 Plow Bolt (M12 x 100) ...........................
29 Gasket ................................................ ..
30 Hex. Hd. Screw (M12 x 35) ................. ..
31 Shoe .......................... ..

29
RAMMING SYSTEM

Bellows
Damage to the bellows usually occurs while working in
extremely confined areas where foundations and walls
can rub against it. Damage also occurs due to poor
storage during transportation where loose objects can
cut or puncture it.
Clean and inspect the bellows periodically fordamage or
leaks. Keep bottom and top clamps tight. DRIVEOUTPIN Z
TO SEPARATE RAMMING I Z
SYSTEM FROM -
When replacing the bellows, the crankcase must be CRANKOASE
separated from the ramming system following the proce-
dure described below. \

CAUTION
Operation with a leaking or damaged bellows will allow RETAINING
dirt to bedrawn in and mix with the oil insidethe machine. RING
The oil will distribute the dirt throughout the rammer and
necessitate complete disassembly of the machine to WASHER
clean bearings and other internal parts.

Recommended Tools FIG. 19 SEPARATING RAMMING SYSTEM

Wrench - 3/4" (19 mm)

Retaining Ring Pliers pulling up hard on guide cylinder until bellows is free
Punch Do not use sharp objects to pry bellows off.
Rubber Mallet
Screwdriver 8. Remove bottom bellows clamp and pull bellows (5)
from protective pipe (26).
Removal
1. Drain oil from rammer.
Installation
2. Use a 3/4" (19 mm) wrench and remove the four bolts
(30) which secure the ramming system to the crank- 1. Oil top of bellows (5) and slip it on over guide cylinder
case. (3). Tighten upper clamp (4). Position clamp so that
screw is to inside of machine.
3. Pull crankcase up and away from guide cylinder (3)
until pin (6) holding connecting rod to ram (9) is Note: The bellows will install easierifit is kept warm.
visible.
2. Lightly oil upper lip of protective pipe (26). Lowerthe
Note: The connecting rod should be rotated to its guide cylinder with the bellows attached over the
lowest point inside the crankcase to reduce spring spring cylinder and onto protective pipe (12). Press
pressure. Pull up hard on crankcase to rotate rod. bellows on with a strong downward push.

4. Hold crankcase and guide cylinder open using a 3. Tighten lower bellows clamp.
wood block so pin in ram remains exposed.
4. Install guide cylinder gasket (29).
5. Remove retaining rings (8) and washers (7) holding
pin and drive pin out. . 5 Position upper machinery over guide cylinder. Align
connecting rod inside ram and install pin (6). Replace
6. Lift upper machinery from ramming system. washers (7) and retaining rings (8).

7. Remove top bellows clamp (4). Stand on ramming 6. Fasten guide cylinder (3) to crankcase. Tighten bolts
shoe and rap bellows using a rubber mallet while to 63 ft.lbs. (86 Nm).

so I
 RAMMING SYSTEM

Ramming Shoe
Fill rammer with clean oil (SAE 10W40) to center of Most damage to ramming shoes occurs due to improper
sightglass - Approx. 18 oz. (530 ml) operation and loose hardware. Hitting withthetip or heel
of the shoe may cause the shoe to crack and wear.
Run machine for several minutes and check for oil Operating the machine with loose bolts will cause the
leaks around guide cylinder and bellows. shoe to pound itself against the spring cylinder.
If replacement of the shoe becomes necessary the
complete shoe assembly, including the bottom wear
plate, should be installed. The wear plate shapes itselfto
the shoe during use and in many cases will not fit well on
GASKET a new shoe.
_/
Recommended Tools
lx
fa-'9
19 mm Socket Wrench
Torque Wrench
euros
cvunpen Replacement
cs FT.LBS.
(as Nm) 1. Remove the 4 locknuts (11) holding the ramming
shoe to the spring cylinder.
fa
/

Note: If the bolts spin in the shoe, tack weld the bolt
heads lightly to bottom of the wearplate.

2. Lift complete machine assembly olfshoe and remove

plowbolts (27,28) and shoe.
BELLOWS
3. If plowbolts are in good condition they can be reused.
.-Q
Use a wire brush and clean threads thoroughly re-
moving any dirt, grease or dryed threadlocking com-
pound.

4. lnstall shoe, using new locknuts. Rotate plowbolts in

shoe until they feel to be properly seated in notches
on bottom plate and tighten evenly.
WRAP THREADS ON Torque shoe bolts to 58 ft.lbs. (79 Nm)
SIGHTGLASS WITH
SPRING -- TEFLON TAPE
CYLINDER Check nuts afterfirst hour of use. Referto Maintenance.

SW - \ *
Sightglass
\ \ When installing a new sightglass, wrap threads with
@
teflon tape and torque to 5 ft. lbs. (7 Nm).
If sightglass does not include a hex head, use sightglass
sa FT.LBS. (79 Nm)
tool P/N 30688 to remove and install.

FIG. 20 INSTALLING BELLOWS AND SHOE

31
RAMMING SYSTEM

Removing Spring Cover

Recommended Tools
Wrench - 13 mm
Arbor Press
Two Threaded Rods and Nuts - M8 x 120 mm
The spring cover is under heavy spring pressure and 3
must be removed carefully following one of the two rs-
procedures described below.
4

Press Method
1. Remove shoe and separate ramming system from
upper machinery following procedures described _ ,
under BELLOWS.
BE SURE SPRINGS
2. Remove all but two bolts (24) holding cover (22) to HAVE EXPANDED
z COMPLETELY
spring cylinder 25). (APPROX. 5"-6")
BEFORFERFl;lEASlNG
3. Place spring cylinder in press as shown in Fig. 21,
with the head of press firmly in contact with cover. L./, '
4. Lock press in this position and remove remaining two
I
ti , Is '
screws.
5. Slowly release press allowing springs to expand.
6. After all spring pressure is released, remove cover
(22) and bottom spring set (15).
/
FIG. 21 REMOVING SPRING COVER- PRESS METHOD

Threaded Rod Method

1. Remove shoe and separate ramming system from
upper machinery following procedures described \
earlier. g 5

5 M8 x 120 mm
2. Remove two bolts (24) opposite each other on cover. g THREADED ROD

E v E3
3. Screw two M8 x 120 threaded rods securely in <1
0

bottom of spring cylinder (25) until they bottom.

4. Tu rn a nut down over each rod until it contacts cover.
:o

5. With nuts holding cover, remove remaining bolts (24).

6. Back off on nuts evenly allowing springs to expand

until spring pressure is fully released.
ZQWARNING
Make sure threaded rods are not turning out of
cylinder while backing off nuts.
7. Remove cover and bottom spring set
((5
FIG. 22 nervrovme snnmes - THREADED non METHOD

32
 RAMMING SYSTEM

Spring System
Recommended Tools
Pliers
Tool - P/N 52644
Propane Torch
Torque Wrench - 184 ft. lbs. (250 Nm)
Arbor Press
Threaded Rods - M8 x 120
Nuts - M8
Loctite 271 or equivalent

Drsassembly
Separate ramming system from upper machinery
and remove bottom spring cover as described in
previous procedures.
Pull bottom stopper (20) from end of ram by grasping
it tightly with your hand or pair of pliers and pulling it
sharply sideways.
6. Alter piston is removed from ram, upper stopper and
spring set can be removed from spring cylinder
Inspect springs and spring cylinder for wear as de-
scribed on page 35, before installing them back in
ramming system.

Clamp flats on head of ram in a vise to prevent ram

from turning.
Heat nut (19) using a small propane torch to break-
down threadlocking compound. Use a 1-1/4" deep
well socket and remove nut.
Remove threaded piston (17) by heating it first to
breakdown sealant. Attach tool P/N 52644 and turn it
off.
Note: Ifpiston does not have the two counterbored
holes in it forattachment oftool, itis a non-threaded
piston and should slide off the ram.
Assembly
1. Slide ram into spring cylinder and install top stopper
(16) and spring set.
2. lnstallpiston(17). If piston isthreaded, apply Loctite
271 , or equivalent, to threads and torque to 184 ft.lbs.
(250 Nm) using tool P/N 52644.
DO NOT use threadlocking compound on
non-threaded piston.

Fl
r Ti
Q4
o
P/N 52644
M] 3'51 P WRENCH ATTACHMENT
FOR REMOVING
I | lmli 11 jl THREADED TYPE
PISTON

\ CLAMP HEAD OF
RAM IN VISE
PISTON WITHOUT
COUTERBORE IS
NON-THREADED
TYPE
4

0'

FIG. 23 REMOVING THREADED TYPE PISTON

33
RAMMING SYSTEM

Spring System
Assembly Cont'd
3. Install lockwasher(18) and nut (19). Secure nut using
Loctite 271, or equivalent, and torque to 184 ft.lbs.
(250 Nm).
4. Press bottom stopper (20) on end of ram.
m
I RAM

5. Install bottom spring set, gasket, (21) and cover (22) I

following one of the two methods described below
Refer to Figs. 21 and 22.
- '-: -' Y4 SPRING
Press Method UPPER CYLINDER

Center the cover (22) on top of springs. Align holes in STOP /

EYE
cover as close as possible with those in spring 51-
i4, I
cylinder, or place dowels or steel rods in holes to act :E 5% .;

as guide pins. Use a press and compress springs until i-i

cover rests on spring cylinder. Install bolts and 1a4 Fl'.LBS.(250 Nm) _ V g
lockwashers. Secure bolts using Loctite 271 and LOCTITE 271 ; | I 2;
torque to 18 ft. lbs. (25 Nm) 5 . ' PISTON
:: :1;
151 3*
Threaded Rod Method
Screw two threaded rods into spring cylinder and 3 .1 ;
place gasket and coveroverthem. Compress springs 5 6?: ,-Q :;
ex: S1:-21515
using two nuts screwed down over rods until cover
makes contact with spring cylinder. Install bolts and
I ea
|) LOCKWASHER
lockwashers. Secure bolts using Loctite 271 and 2; s;as;z -
z2W52 5215 21 = 2 ;2 ;2:;s 5 5em125 123 5 L i;IE
-

torque to 18 ft. lbs. (25 Nm)

E
fW __
STOP Pf,,
_.;,-5? -1;-__-_'._'!I=-:1: %;i;%;i;.;2_._,
Protective Pipe 25252is5sizizizizizisi i i i i i.5 E?-"I""llllIji

Recommended Tools
GASKET
18 FT. LBS. (25 Nm)
Propane Torch LOCTITE 271
Hot Plate
Rubber Mallet
Loctite 290, or equivalent
FIG. 24 SPRING SYSTEM ASSEMBLY
If protective pipe becomes loose or damaged, it must
be replaced or reseated on spring cylinder.
1 Separate spring system assembly from upper ma-
chinery and remove bellows.
2. Place spring cylinder upside down on a flat, hard
surface. Use a propane torch and heat around base
of pipe. After pipe is hot, tap around it using a rubber
mallet to break it free of spring cylinder.

Note: Remove plastic sightglass from pipe before

heating to prevent it from melting.

Inspect pipe thoroughly and replace it if any small

cracks are seen or fit is loose.

34
 RAMMING SYSTEM

Protective Pipe Cont'd

3. To assemble, first clean and dry mating surfaces on
spring cylinder and pipe. Remove any grease or oil. . .
Heat pipe evenly on a hot plate 400-450 F (200- E SEAL AROUND JOINT
2 5 usrue LOCTITE 290
230) and drop it down over spring cylinder. Make E on E QUIVALENT
sure hole for sightglass is in line with oil drain plug.
HEAT BASE OF PIPE
Use a rubber mallet and tap around upper edge of FOR REMOVAL AND
pipe to make sure it is seated completely down on INSTALLATION 2 _
spring cylinder.
4. Apply Loctite 290, or equivalent, around inside joint LINE UP HQLES
FOR SIGHTGLASS
between pipe and spring cylinder while still warm. AND DRAIN PLUG
Allow to cool before continuing assembly.
llll
5252222253252ii ? Ii

FIG. 25 INSTALLING PROTECTIVE PIPE

Inspecting Spring System

Over time the constant compression and release of
spring pressure can cause the springs to wear and s/1s"
fatigue. If the rammer feels to be hitting with less force, (5 ml
it is possible that the springs are worn and should be
replaced.

l l lfl l
A broken spring will cause the rammer to jump errati-
cally. This condition is more noticeable on hard soils. Do 6-7/16
not run the rammer if a broken spring is suspected, doing (163 mm)

so may damage other machine parts.

Replace both top and bottom springs sets together even
if only one set is worn or damaged.
f l l l l l!_,4 f
MINIMUM SPRING MAXIMUM SPRING HEIGHT
HEIGHT DIFFERENCE
Checking Spring Wear
FIG. 26 SPRING WEAR
1. Remove springs (15) from cylinder and check free
height.
Inspecting Spring Cylinder
E WARNING 1. If a spring has broken, inspect the inside ofthe spring
Springs are under pressure. Follow procedures cylinder wall for burrs, gouges and cracks.
described under Removing Spring Cover.
2. Slide piston inside cylinder. Check that piston moves
freely but without excessive side play.
2. Replace springs if free height is less than 6-7/16"
(163 mm) 3. Hone cylinder to remove ridges and burrs cut into the
OR cylinder wall by spring movement. Springs are under
Compare height of bottom and top springs. Replace pressure! Follow recommended service procedures
springs if height difference exceeds 3/16" (5 mm). when removing them from machine.

35
CRANKCASE ASSEMBLY (S/N 6543 & below)

Assembly Drawing

CAUTION
Upper machinery must be separated from ramming
system before removing cover. See page 30.

34
\r@ s ( 1 .
2,?
2

1s W I
. / s \,\ *" " ~
I/%.?-\ ./i/
3
\ , /,/ /
. g .
233% I
/I
36
 CRANKCASE ASSEMBLY (S/N 6543 & below)

Torque Notes Sealant Torque

Loctite (Omnifit) Ft. Lbs. (Nm)
1 Cover Bolts 242 (150) 1s(25)
3 Plug 271 (200) 45 (51)

Parts Listing Assembly Notes

Ref. Description Qty 2&6 Secure inner bearing races with Loctite 609,
Retaining Compound.
1 Soc. Hd. Screw (M8 x 25)
2 {Needle Bearing (outer race) . 15 Secure connecting rod bushing with Loctite
Needle Bearing(inner race)... 609, Retaining Compound
3 Plug ...................................... ..
4 Sealing Ring ................... 22 Fill seal cavity with Shell Alvania No.2 grease.
5 Cover ................................... ..
6 Needle Bearing (outer race) . 23 Clean and dry inside of clutch drum before
Needle Bearing (inner race) . installing engine.
New
9
Retaining Ring ..................... ..
Retaining Ring ..................... ..
Ball Bearing ......................... ..
10 Retaining Ring ..................... ..
11 Crankgear ............................ ..
12 Connecting Rod Assembly _Ll|L_ LL_ LL_ l.L_ m

(Includes Items 13, 14, 15)

13 Ball Bearing ......................... ..
14 Retaining Ring ..................... ..
15 Bushing ................................ ..
16 Retaining Ring .
17 Gasket ................................. ..
18 Crankcase ............................ ..
19 Retaining Ring ..................... ..
20 Ball Bearing ........................ ..
21 Retaining Ring .................... ..
22 Oil Seal ............................... ..
23 Clutch drum ......................... .. _L _LLl L_ LL_ -L

37
 CRAN KCASE ASSEMBLY (S/N 6543 & below)

Crankgear & Connecting Rod

Recommended Tools
Allen Wrench - 6mm
Bearing Pullers
Retaining Ring Pliers
Torque Wrench
Arbor Press
Propane Torch
Tools - 25441, 30920
Loctite 609, 242 (or equivalent)

Drsassembly
Separate crankcase from ramming system following BEARING PULLER SET
procedures described under BELLOWS. (P/N 25441)
Note: The crankcase cover cannot be removed until SPLITPULLER
the connecting rod is disconnected from the ram (P/N 25322) -5-
inside the machine.

Remove the six bolts (1) from front cover. Insert two
ofthe bolts into threaded holes in cover. Turn bolts in
until cover breaks free of crankcase.The cover will
come out with crankgear and connecting rod at- E NW5
tached.
':Z:::::Z' 1
'~:-:-:~:~:~.;. -:-:-:-::- :-:-: - ,.;:;:;:;:;
Reach through slotted hole in crankgear and release
I,5;i;isi%%;
large retaining ring (10). Z;Z;1;I;Z;Zi'_E;I

CRANKCASE
Remove plug (3) and washer (4) from front of cover. oovrzn
Place cover in arbor press and press down on end of
FIG 27 REMOVING NEEDLE BEARING INNER RACE
shaft through front of cover until crankgear is free.

To replace needle bearing (6), use tool P/N 30920

and tvvojaw pullerto pull inner race from end of shaft.
Remove outer race using split puller P/N 25441 as
shown in Fig.27. Remove retaining ring (7) from
inside of cover. Place puller inside bearing and turn in
center bolt until it is flush with bottom of puller. Draw
SPLIT PUU_ER
bearing race out by turning down on hex nut on bolt. (P/N 30920)

Remove small retaining ring (16) holding connecting

rod to crankgear shaft.
Pry connecting rod (12) from shaft using a couple of
screwdrivers. CRANKGEAR

Remove large retaining ring (14) holding connecting

rod bearing and press bearing out using an arbor
press.
/
||||
Enur u u u n
To replace bushing (15) in bottom of rod heat it first
using a small propane torch to breakdown retaining
compound, then press it out.
FIG. 28 REMOVING NEEDLE BEARING OUTER RACE

38
 ORAN KCASE ASSEMBLY (S/N 6543 & below)

Assembly
Lubricate connecting rod bearing (13) with SAE 40 W
oil. Press bearing into connecting rod and replace
retaining ring (14).
If bottom bushing (15) is being replaced, clean inside
of bore on rod and outside diameter of bushing
thoroughly to remove any oil or grease. Apply Loctite
609, or an equivalent type retaining compound, to
inside of bore on rod and press new bushing in place.
Install connecting rod assembly on crankgear shaft.
Press it in place against shaft shoulder. Secure
assembly on shaft using small retaining ring (16).
Clean and dry end of crankgear shaft and inside
diameter of needle bearing inner race (6a). Apply
Loctite 609, or an equivalent type retaining com-
pound, around end of crankgear shaft and press on
needle bearing inner race.
Oil needle bearing outer race(6b), press it into crank-
case cover (5) and install retaining ring (7).
Press crankgear assembly into cover. Reach
through slotted hole in gearface and set large retain-
ing ring (1 0) in groove to secure crankgear assembly
in place.

Lubricate bearing (9) with oil and press it on crank-
shaft. Secure in place with retaining ring (8).
Note: Place large retaining ring (10) loosely behind
bearing so it is in place for step 7.
Install plug (3) and washer (4) in front of cover. Mount
cover, crankcase assembly and gasket (1 7) to crank-
case. Tighten mounting screws (1 ) to 18 ft.lbs. (25
Nm)

18 FI'.LBS.(25 Nm)
LOCTITE 242

(1) (17)

mm _ (a) (9) (13) (14) 716)

(5) _''_IE'T'
9%?
I E- "ewe
I
=2231?:i i?ii?i5?**1 g

I'll 1
.. . lllili
Wm iiae
M.
(1 SECURE BUSHING USING
2 LOCTITE 609 RETAINING
COMPOUND. MOUNT FLUSH
_ WITH BOTH SIDES OF ROD

I6) (7) T I <10)

(63) mwww ;;:;;:;

APPLY LOCTITE 609 RETAINING

COMPOUND TO SECURE INNER Y
BEARING RACE

FIG. 29 CRANKCASE ASSEMBLY

39
 CRANKCASE ASSEMBLY (S/N 6543 & below)

Clutch Drum & Bearings

Recommended Tools
Tools - 25441 , 25442
Bearing Pullers
Loctite 609, Retaining Compound or equivalent
Shell Alvania No.2 Grease.

Drsassembly

'2'
Separate upper machinery from ramming system
following procedures described under BELLOWS.

Note: The crankcase cover cannot be removed until

the connecting rod is disconnected from the ram
Wis
inside the machine.

Remove engine and clutch from machine. I I

Remove front cover and crankgear assembly from
machine.
Remove small retaining ring (19) from clutch drum
shaft and press clutch drum (23) from housing. CLUTCH DRUM
SHAFT

Pry out oil seal (22).

Remove large retaining ring (21) from housing and

press out bearing (20).
SPLIT PULLER
(25442)
ll
If needle bearing (2) is being replaced use split puller
P/N 25442. Heat bearing to breakdown sealant.
Place split puller over bearing race as shown in Fig.
30 and use a two jaw puller to pull it off end of shaft.. FIG. 30 REMOVING NEEDLE BEARING OUTER RACE

To remove needle bearing outer race from cover use

bearing puller set P/N 25441. Install split puller
P/N 25321 inside of bearing. Turn center bolt of puller
in to draw out bearing. BEARING PULLER SET
I / (P/N 25441)

INSTALL SPLIT PULLER

E (P/N 25321) UNDER BEARING
-: a ;:

IIIIIIIIII-L
IIII

E Q

cacgsggse
FIG. 31 REMOVING NEEDLE BEARING INNER RACE

40
 CRAN KCASE ASSEMBLY (S/N 6543 & below)

Assembly
1. Press clutch drum bearing (20) into crankcase hous-
ing. Secure in place with retaining ring (21).
2. Fill oil seal (22) with Shell Alvania No.2 grease and
press it into housing with seal lips facing in.
6- Install CraI1kC8Se C0ver assembly.
Note: Make sure clutch drum shaft lines up with
needle bearing by lining up dowel pin in crankcase
with dowel pin hole in cover.

3. Clean and dry end of clutch drum shaft and inner 7. Install engine on machine.
bearing race (6a) to remove oil and grease. Apply
Loctite 609, or an equivalent type retaining com-
pound, to clutch drum shaft and press on inner
bearing race. Race should be flush with end of shaft.
4. Press clutch drum (23) into crankcase housing. In-
stall retaining ring.
5. Press needle bearing outer race (6b) into crankcase
cover.

(19) (20) (21) (22)

18 FT.LBS.(25 Nm) PACK SEAL CAVITY WlTl-l
LOCTITE 242 (6 bl SHELL ALVANIA NO.2
GREASE

__:.:._. . :________\
; _
5 IILJ
; r_l:I
I Iii
5 ii:
.__
..........\

QQMOQL
l

(23)
III E CLEAN AND DRY INSIDE OF
CLUTCH DRUM
BEFORE INSTALLING ENGINE

(66)
SECURE TO SHAFT WITH
LOCTITE 609 OR
EQUIVALENT.

00000000:

FIG. 32 CLUTCH DRUM ASSEMBLY

41
CRAN KCASE ASSEMBLY (S/N 6544 & above)

Assembly Drawing

CAUTION
Upper machinery must be separated from ramming
system before removing cover. See page 30.

I2
Hugo /
7?"t

@\&\

Q
Cd
~
/(a
'

I /,
.55
J\\ Q10 ,
"
f
l\ '3
I ./
W
/

/a \\//>;,a / /; Q X
\
20

. I/ ' 0 I

\ IEIF

/ . Q QMQIQ
I 0

\III

42
 CRAN KCASE ASSEMBLY (S/N 6544 & above)

Torque Notes Sealant Torque

Loctite (Omnifit) Ft. Lbs. (Nm)
V 1 Cover Bolts 222(so) I 1a(25)

Parts Listing Assembly Notes

Ref. Description Qty 3 Fill seal cavity with Shell Alvania No.2 grease.

Soc. Hd. Screw (M8 x 25) 4 Clean and dry inside of clutch drum before
Needle Bearing ................................... .. installing engine.
Oil Seal .............................................. ..
Clutch drum .................... .. 2,7 Secure inner bearing races with Loctite 609,
........ .. Retaining Com pound.
Needle Bearing ................................... ..
Retaining Ring .................................... .. 15* Secure connecting rod bushing with Loctite
m\IO')U'l-I>O |\J* Retaining Ring ................ .. 609, Retaining Compound
9 Ball Bearing ........................................ ..
10 Retaining Ring .................................... ..
11 Crankgear ........................................... ..
12 Connecting Rod Assembly .................. .. l._LL_L- _L-L- _LLm

(Includes Items 13, 14)

13 Ball Bearing ........................................ ..
14 Retaining Ring .................................... ..
15 * Bushing .............................................. ..
16 Retaining Ring .................................... ..
17 Gasket ................................................ ..
18 Crankcase .......................................... ..
19 Retaining Ring .................................... ..
20 Ball Bearing ........................................ ..
21 Retaining Ring ...................... .. _l.l_A_Lli|-LLl

* Bushing (15) not required with later style connecting rod.

43
 CRAN KCASE ASSEMBLY (S/N 6544 & above)

Crankgear & Connecting Rod

Recommended Tools
Allen Wrench - 6mm
Bearing Pullers
Retaining Ring Pliers
Torque Wrench
Arbor Press
Propane Torch
Tools - 25441, 30920
Loctite 609, 242 (or equivalent)

Drsassembly
Separate crankcase from ramming system following
procedures described under BELLOWS. BEARING PULLER SET
(P/N 25441)

Note: The crankcase cover cannot be removed until

the connecting rod is disconnected from the ram SPLITPULLER I
(P/N 25322) HEX NUT
inside the machine.

Remove the six bolts (1) from front cover. Insert a

screwdriver into the slotted holes provided on each
side ofcover and pry cover off.The coverwill come out CRANKCASE
COVER
gig E 53;;
55; = E521
with crankgear and connecting rod attached. \ 15131;.
:::
.1.; Z 5;;
.;: Z ::1
:;:5;5
:::
532553:
_:;;;;;;
-.-5522 % 5:52.-.
.;;;:;:;;; Z ;:;;;;;;;;
.zEs%s
5.55:5:
:::::::f::: ;:::.: 2 ::j:f:f:{ ::;:;:;:::::
Reach through slotted hole in crankgear and release 1;1;1;I;Z;Z;I;Z;1; g I-I-I; I G I;I_I_I;';
2;5;S;E;5;;2;E;3;5 'E;E;E;EjE Z 555555555;
;SI;IjI;I;1;I;S;I
5;E;E;E;E;E;E;E;E5E
5; E;3;E;E;EgE;E;E;E;E _E;E;EgE;E Z g5;E;Ej?; E;E5E;5;;Z;;E;E;E ;:-
large retaining ring (10). 15; ~E1ElIE1EIEIE1SIEIZ I{iE1EIE-E Z E=E=E5IIE= E1313IE2rEIEZIi J55

Insert two M8 bolts through the pusher holes pro-

vided in crankgear and push crankgear assembly
from cover. FIG 33 REMOVING NEEDLE BEARING INNER RACE

To replace needle bearing (6), heat bearing to break-

down sealant then use tool P/N 30920 as shown in
Fig. 34 to pull inner race from end of shaft. Remove
outer race using split puller P/N 25441 as shown in
Fig.33. Remove retaining ring (7) from inside of
cover. Place puller inside bearing and turn in center
bolt until it is flush with bottom of puller. Draw bearing SPLIT PULLER
race out by turning hex nut on bolt down. (P/N 30920)

Remove small retaining ring (16) holding connecting

rod to crankgear shaft.

Pry connecting rod (12) from shaft using a couple of

H CRANKGEAR
screwdrivers.
Remove large retaining ring (14) holding connecting
rod bearing and press bearing out using an arbor
/
press.

To replace bushing (15) in bottom of rod heat it first jg

nnui
using a small propane torch to breakdown retaining
compound, then press it out. Note: Newer style rods FIG. 34 REMOVING NEEDLE BEARING OUTER RACE
do not use a bushing.
44
 CRANKCASE ASSEMBLY (S/N 6544 & above)

Assembly
Lubricate connecting rod bearing (1 3) with SAE 40 W 5. Clean and dry end of crankgear shaft and inside
oil. Press bearing into connecting rod and replace diameter of needle bearing inner race (6). Apply
retaining ring (14). Loctite 609, or an equivalent type retaining com-
pound, around end of crankgear shaft and press on
If bottom bushing (15) is being replaced, clean inside needle bearing inner race.
of bore on rod and outside diameter of bushing
thoroughly to remove any oil or grease. Apply Loctite 6. Oil needle bearing outer race, press it into crankcase
609, or an equivalent type retaining compound, to cover (5) and install retaining ring (7).
inside of bore on rod and press new bushing in place.
7. Press crankgear assembly into cover. Reach
Note: On later style machines the connecting rod is through slotted hole in gearface and set large retain-
hardened and bushing (15) is not used. ing ring (10) in groove to secure crankgear assembly
in place.
Install connecting rod assembly on crankgear shaft.
Press it in place against shaft shoulder. Secure 8. Mount cover assembly to crankcase with O-ring (1 7).
assembly on shaft using small retaining ring (16). Tighten mounting bolts to to 18 ft.lbs. (25 Nm) and
secure them using Loctite 222, or an equivalent low
Place large retaining ring (10) loosely behind bearing strength threadlocking sealant.
so it is in place for step 7.

Lubricate bearing (9) with oil and press it on crank-

shaft. Secure in place with retaining ring (8).

(68) (7) (17)

(3) (9) (13) (1 4)
1 I I

K
l;Iif|||||
" "$9<82
I t9t!l-
-;;;;5;I-" L
:3; it """""" "
QOQOW.
3;; air
15;; til
:;:;: ti _
55:; ii
:55: ii
5:51; ii
-M",7-W. ,
...........
_-2_._1_!.
l l l l l l l-Il l l
[III (I 6)

(5) (10) mwwv

(Bb) %
SECURE INNER RACE WITH
LOCTITE 609. MOUNT FLUSH
WITH END OF SHAFT. (1 5) on MACHINES snu. EQUIPPED
wrm BUSHING, secunrz ausnme
usme LOCTITE eos RETAINING
COMPOUND.

FIG. 35 CRANKCASE ASSEMBLY

45
 CF-IAN KCASE ASSEMBLY (S/N 6544 & above)

Clutch Drum & Bearings

Recommended Tools
Tools - 25441 , 25442
Bearing Pullers
Loctite 609, Retaining Compound or equivalent
Shell Alvania No.2 Grease.

Drsassembly
Separate upper machinery from ramming system
following procedures described under BELLOWS.

Note: The crankcase cover cannot be removed until

the connecting rod is disconnected from the ram
inside the machine.

Remove engine from machine.

Remove front cover and crankgear assembly from

machine.

Remove small retaining ring (19) from clutch drum

shaft and press clutch drum (4) from housing. CLUTCH DRUM

Pry out oil seal (3). SPUT PULLER

nuni SHAFT

(25442)
Remove large retaining ring (21) from housing and
press out bearing (20).

If needle bearing (2) is being replaced, use split puller

P/N 25442. Heat bearing race first to breakdown
sealant. Place split puller over bearing race as shown
in Fig. 36 and pull inner bearing race from shaft. FIG. 36 REMOVING NEEDLE BEARING OUTER RACE

To remove needle bearing outer race from crank-

case, heat area around bearing using a small pro-
pane torch. Place a small pin against bearing as
shown in Fig. 37 and press bearing out. PUSHER
PIN
CRANKCASE -
t
.,_
513:2
.;.;.;<.
..
-:-:-.<>
74-144

FIG. 36 REMOVING NEEDLE BEARING INNER RACE

46
 CRANKCASE ASSEMBLY (S/N 6544 & above)

Assembly
Press clutch drum bearing (20) into crankcase hous- 6. Install crankcase cover assembly. Secure mounting
ing. Secure in place with retaining ring (21). screws with Loctite 222, or an equivalent low strength
threadlocking sealant. Torque to 18 ft. lbs. (25 Nm).
Fill oil seal (3) with Shell Alvania No.2 grease and
press it into housing with seal lips facing in. Install engine on machine.

Clean and dry end of clutch drum shaft and inner

bearing race (6a) to remove oil and grease. Apply
Loctite 609, or an equivalent type retaining com-
pound, to clutch drum shaft and press on inner
bearing race. Race should be ush with end of shaft.

Press needle bearing outer race (6b) into crankcase.

Press clutch drum (4) into crankcase housing. Install
retaining ring.

(eh) <19) <20) (3) (3,

PACK SEAL CAVITY WITH
SHELL ALVANIA NO.2

T GREASE
--------- --

,.;.;.;
E5535;
;;;;;;;__
,__._Q E: "
/E 1 I I
0 ||l
mm iWtlito
I

::-: ;~::I-:~:-:~:-:-:~:-:-.-:-:-:-:-'
M rm

I
(4)
CLEAN AND DRY INSIDE
OF CLUTCH DRUM

S
W
Ill
5;;
BEFORE INSTALLING ENGINE

=?=5=515=511=====1==F11:===:I====:1==:1====1 $3 15:5

~11 iii
S E551
vil :'1
g___/ :;:
..
(58)
SECURE TO SHAFT WITH
LOCTITE 609 OR

ll\, . EQUIVALENT.

FIG. 37 CLUTCH DRUM ASSEMBLY

47
TROUBLESHOOTING

Engine Hard Starting

Air Filter is dirty Clean or replace filter.

Too much oil in fuel. Drain fuel from tank. Fill

with new mix. 50:1

Clean or replace spark plug

Fouled spark plug Measure electrode gap.

ENGINE HARD Muffler or exhaust port Remove muffler and clean

TO START. dirty. exhaust ports.

Engine crankshaft seals Check/replace seal. See

leaking. WM 80 Engine Manual.

Fuel mixture ad'ustme

] nt Set adjusting screws and
incorrect clean fixed jets.

Inspect piston and cylinder.

i Engine compression low. See engine manual.

In-line filter or fuel line Replace fuel filter. Inspect

plugged or kinked fuel lines.

i Spark plug fouled. Clean or replace plug.

Measure electrode gap.
ENGINE DOES
NOT START.

Fuel valve closed Open valve.

Fuel mixture adjustment Set adjusting screws and

incorrect clean fixed jets.
 TROUBLESHOOTING

Engine Starts But Runs Poorly

Air Filter is dirty Clean or replace filter.

Too much oil in fuel. Drain fuel from tank. Fill

with new mix. 50:1

Clean or replace spark

Fouled spark plug plug. Measure electrode
gap.

ENGINE DOES NOT Muffler or exhaust port Remove mufer and clean
ACCELERATEOR exhaust ports.
dirty.
RUNS POORLY

Engine crankshaft seals Check/replace seal. See

leaking. WM 80 Engine Manual.

Fuel mixture adjustment Set adjusting screws and

incorrect clean fixed jets.

Air leak in carburetor Check all connections.

system.

Drain fuel and remix fuel.

Not enough oil in fuel mix. 50:1

ENGINE Carburetor fuel mix set Reset carbureter

OVERHEATS too lean. adjustments.

Cooling fins packed with Remove dirt.

dirt.
TROUBLESHOOTING

Engine Runs But Rammer Operates Poorly

_ Damaged clutch Remove and replace

clutch.

i Broken connecting rod in

ramming system.
RAMMER DOES
NOT POUND.
Disassemble crankcase
Broken crankgear. inspect and replace
damaged parts.

Broken pinion on
clutchdrum shaft.

ii or grease on C|utch ii? InSpeC'[ and Clean CIUtCh

i Spring(s) in ramming
system broken or worn. Disassemble spring
cylinder. Inspect and
replace damaged parts.
Damaged pans in spring
cylinder assembly.
RAMMER
JUMPS
ERRATICALLY Disassemble crankcase.
Damaged parts in Inspect and replace
crankcase assembly. damaged parts.

Soil build-up on ramming Inspect and clean shoe.

shoe.

Check ground surface

*iIGround surface too hard. conditions.

50
 SEALANTS

Use Of Threadlockers and Sealants

Threadlocking adhesives and sealants are specified throughout this manual and should be used where indicated.
Threadlocking compounds normally break down at temperatures above 350 F (175 C). If a screw or bolt is hard
to remove, heat it using a small propane torch to break down sealant. When applying sealants, follow instructions
on container. The sealants listed below are recommended for use on WACKER equipment.

TYPE
( ) = Europe COLOR USAGE PART NO. - SIZE

Loctite 222 Purple Low strength, for locking threads smaller than 1/4" (6 mm). 73287 - 10 ml
Hemon 420 Hand tool removable.
Omnifit1150(50M) Temp. range, -65 to 300 degrees F (-54 to 149 degrees C)

Loctite 243 Blue Medium strength, for locking threads larger than 1/4' (6 mm). 29311 - .5 ml
Hernon 423 Hand tool removable. 17380 - 50 ml
Omnifit 1350 (100M) Temp. range, -65 to 300 degrees F (-54 to 149 degrees C)

Loctite 271 /277 Red High strength, for all threads up to 1" (25 mm). 29312 - .5 ml
Hernon 427 Heat parts before disassembly. 26685 - 10 ml
Omnifit 1550 (220M) Temp. range, -65 to 300 degrees F (-54 to 149 degrees C) 73285 - 50 ml

Loctite 290 Green Medium to high strength, for locking preassembled threads 28824 - .5 ml
Hemon 431 and for sealing weld porosity (wicking). 25316 - 10 ml
Omnifit 1710 (230LL) Gaps up to 0.005" (0.13 mm)
Temp. range, -65 to 300 degrees F (-54 to 149 degrees C)

Loctite 609 Green Medium strength retaining compound for slip or press fit 29314 - .5 ml
Hemon 822 of shafts, bearings, gears, pulleys, etc.
Omnifit 1730 (230L) Gaps up to 0.005" (0.13 mm)
Temp. range, -65 to 300 degrees F (-54 to 149 degrees C)

Loctite 545 Brown Hydraulic sealant 79356 50 ml

Hernon 947 Temp. range, -65 to 300 degrees F (-54 to 149 degrees C)
Omnifit1150(50M)

Loctite 592 White Pipe sealant with Teflon for moderate pressures. 26695 - 6 ml
Hernon 920 Temp. range, -65 to 300 degrees F (-54 to 149 degrees C) 73289 - 50 ml
Omnifit 790

Loctite 51 5 Purple Form-in-place gasket for flexible joints. 70735 - 50 ml

Hernon 910 Fills gaps up to 0.05" (1.3 mm)
Omnifit 10 Temp. range, -65 to 300 degrees F (-54 to 149 degrees C)

Loctite 496 Clear Instant adhesive for bonding rubber, metal and plastics;
Hernon 110 general purpose. 52676 - 1 OZ.
Omnifit Sicomet 7000 For gaps up to 0.006 (0.15 mm)
Read caution instructions before using.
Temp. range, -65 to 180 degrees F (-54 to 82 degrees C)

Loctite Primer T Aerosol Fast curing primer for threadlocking, retaining and 2006124 - 6 oz.
Hernon Primer 10 Spray sealing compounds. Must be used with stainless steel
Omnifit VC Activator hardware. Recommended for use with gasket sealants.
TORQUE VALUES

Metric Fasteners (DIN)

TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE

A

+ll<-
Size Ft.Lb. Nm Ft.Lb. Nm Ft.Lbs. Nm Inch Metric Inch Metric
M3 "11 1.2 *14 1.6 *19 2.1 7/32 5.5 2.5

M4 '26 2.9 *36 4.1 "43 4.9 9/32 7 3

M5 *53 6.0 6 8.5 7 10 5/16 8 4

M6 7 10 10 14 13 17 10 5

M8 18 25 26 35 30 41 1/2 13 6

M10 36 49 51 69 61 83 11/16 17 8

M12 63 86 88 120 107 145 3/4 19 10

M14 99 1 35 140 190 169 230 7/8 22 12

M16 155 210 217 295 262 355 15/16 24 14

M18 214 290 298 405 357 485 1-1/16 27 14

M20 302 410 427 580 508 690 1-1/4 30 17

Inch Fasteners (SAE)

+ll<-
$ SAE8 i
Size Ft.Lb. Nm Ft.Lb. Nm Ft.Lbs. Nm Inch Metric Inch Metric
No.4 "6 0.7 *14 1.0 *12 1.4 1/4 5.5 3/32

No.6 '12 1.4 *17 1.9 *21 2.4 5/16 8 7/64

No.8 *22 2.5 *31 3.5 *42 4.7 11/32 9 9/64

No.10 "32 3.6 *45 5.1 *60 6.8 3/8 5/32

1/4 6 8.1 9 12 12 16 7/16 3/32

5/16 13 18 19 26 24 33 1/2 13 1/4

3/8 23 31 33 45 43 58 9/16 5/16

7/16 37 50 52 71 69 94 5/8 16 3/8

1/2 57 77 80 109 105 142 3/4 19 3/8

9/16 82 111 115 156 158 214 13/16

5/8 112 152 159 216 195 265 15/16 24 1/2

3/4 200 271 282 383 353 479 1-1/8 5/8

1 |=1_|_b_ = 1_357 Nm * = In.Lb. 1 Inch = 25.4 mm

Wacker Construction Equipment AG Preuenstrae 41 D-80809 Mnchen Tel.: +49-(0)89-354 02 - 0 Fax: +49 - (0)89-354 02-390
Wacker Corporation P.O. Box 9007 Menomonee Falls, WI 53052-9007 Tel. : +1-(1)(262) 255-0500 Fax: +1-(1)(262) 255-0550 Tel. : (800) 770-0957
Wacker Asia Pacific Operations Sunley Center, Unit 912, 9/F 9 Wing Qin Street, Kwai Chung, N.T. Hong Kong Tel. + 852 2406 60 32 Fax: + 852 2406 60 21