Wacker Neuson WM 80 User manual

0162695en 003 0610

0162695EN

Repair Manual

Engine

WM 80

Copyright

notice

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 Wacker Neuson Corporation

represents an infringement of valid copyrights. Violators will be prosecuted.

Trademarks

All trademarks referenced in this manual are the property of their respective owners.

Manufacturer

Wacker Neuson 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_tx001528gb.fm 3

Foreword

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.

Expectations

for

information in

this manual

This manual provides information and procedures to repair the above Wacker

Neuson model(s). For your own safety and to reduce the risk of injury, carefully

read, understand, and observe all instructions described in this manual.

Wacker Neuson 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 dis-

charge 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 modifica-

tions. 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 Neu-

son.

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

meet the approved criteria.

Unapproved parts, attachments, or modifications may have the following conse-

quences:

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.

Foreword

4 wc_tx001528gb.fm

WM 80 Table of Contents

wc_br0162695en_003TOC.fm 5

Foreword 3

1 Safety Information 9

1.1 Signal Words Used in this Manual ....................................................... 9

1.2 Safety Guidelines for Operating the Machine ..................................... 10

1.3 Operator Safety while Using Internal Combustion Engines ............... 12

1.4 Service Safety .................................................................................... 13

2 Technical Data 14

2.1 Engine Specifications ......................................................................... 14

2.2 Tune-up Specifications ....................................................................... 15

2.3 Carburetor Specifications for Bing, and Tillotson (Standard**) .......... 16

2.4 Operating and Idle Speeds ................................................................. 19

3 Maintenance 20

3.1 Periodic Maintenance Schedule ......................................................... 20

3.2 Storage ............................................................................................... 21

3.3 General Air Filter Maintenance ........................................................... 21

3.4 Cartridge-Type Air Filter ..................................................................... 22

3.5 Disc-Type Air Filter ............................................................................. 23

3.6 Low-Maintenance Air Filter ................................................................. 24

3.7 Dual-Element Air Cleaner ................................................................... 25

3.8 Three-Stage Air Cleaners ................................................................... 26

3.9 Engine Cleaning ................................................................................. 28

3.10 Spark Plug .......................................................................................... 28

3.11 Muffler ................................................................................................ 28

3.12 Fuel Filter ........................................................................................... 30

3.13 Fuel Hoses ......................................................................................... 30

4 Starting and Ignition 31

4.1 Starter Assembly Exploded View ....................................................... 31

4.2 Disassembling the Starter .................................................................. 32

Table of Contents WM 80

6 wc_br0162695en_003TOC.fm

4.3 Inspecting the Starter ..........................................................................32

4.4 Assembling the Starter ........................................................................33

4.5 Replacing the Starter Rope .................................................................34

4.6 Ignition System Diagram ...................................................................36

4.7 Ignition System Operation ...................................................................37

4.8 Checking Spark ...................................................................................38

4.9 Using Ignition Tester ...........................................................................39

4.10 Setting Air Gap ....................................................................................40

4.11 Replacing the Ignition Module .............................................................42

5 Carburetor Basics 46

5.1 Brands Used ........................................................................................46

5.2 Walbro Carburetor Operation ..............................................................47

5.3 Versions of Tillotson Carburetor ..........................................................54

5.4 Tillotson Carburetor Operation ............................................................55

5.5 Bing Carburetor Operation ..................................................................61

5.6 Carburetor Adapters ............................................................................64

6 Carburetor Replacement 66

6.1 Replacing the Walbro Carburetor (auto-release choke models) .........66

6.2 Removing Walbro Carburetor (standard choke models) .....................70

6.3 Removal, Tillotson with composite adapter .........................................72

6.4 Tillotson with Straight-Through Adapters ............................................74

6.5 Tillotson with Elbow Adapters .............................................................74

6.6 Bing .....................................................................................................75

7 Carburetor Overhaul 76

7.1 Walbro Carburetor Exploded View (auto-release choke models) .......76

7.2 Walbro Carburetor Components (auto-release choke models) ...........77

7.3 Rebuilding the Walbro Carburetor (auto-release choke models) ........78

7.4 Walbro Carburetor Exploded View (standard choke models) .............84

7.5 Walbro Carburetor Components (standard choke models) .................85

7.6 Rebuilding the Walbro Carburetor (standard choke models) ..............86

7.7 Tillotson Carburetor Exploded View ..................................................92

7.8 Tillotson Components ..........................................................................93

WM 80 Table of Contents

wc_br0162695en_003TOC.fm 7

7.9 Bing Carburetor Exploded View ......................................................... 94

7.10 Bing Carburetor Components ............................................................. 95

8 Carburetor Inspection and Adjustment 96

8.1 Inspection ........................................................................................... 96

8.2 Adjusting the Inlet Control Lever ........................................................ 97

8.3 Carburetor Adjustments ..................................................................... 98

9 Carburetor Troubleshooting 101

9.1 Troubleshooting Walbro Carburetors ............................................... 101

9.2 Troubleshooting Tillotson and Bing Carburetors .............................. 102

10 Disassembly and Assembly 104

10.1 Tools ................................................................................................. 104

10.2 Special Tools .................................................................................... 104

10.3 Ordering Parts .................................................................................. 105

10.4 Reference Numbers ( ) ..................................................................... 105

10.5 Threadlocking Compounds .............................................................. 105

10.6 Removing the WM 80 Engine from BS Rammers (auto-release

choke models) .................................................................................. 106

10.7 Removing Engine From BS Model Rammers

(standard choke models) .................................................................. 108

10.8 Removing Engine From BH 23 Breakers ......................................... 110

10.9 Removing Clutch .............................................................................. 112

10.10 WM 80 Exploded View .................................................................... 114

10.11 WM 80 Components ......................................................................... 115

10.12 WM 80 Cross Section ..................................................................... 116

10.13 WM 80 Cross Section Components ................................................. 117

10.14 Vacuum Testing Cylinder ................................................................. 118

10.15 Cylinder and Piston Removal ........................................................... 120

10.16 Cylinder and Piston Inspection ......................................................... 122

10.17 Cylinder and Piston Installation ........................................................ 124

10.18 Inspecting Connecting Rod and Crankshaft ..................................... 126

10.19 Disassembling Crankcase ................................................................ 128

10.20 Assembling Crankcase ..................................................................... 130

Table of Contents WM 80

8 wc_br0162695en_003TOC.fm

10.21 Crankshaft Bearings ..........................................................................132

10.22 Bearing Installation ............................................................................134

WM 80 Safety Information

wc_si000509gb.fm 9

1 Safety Information

1.1 Signal Words Used in this Manual

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

NOTE signal words which must be followed to reduce the possibility

of personal injury, damage to the equipment, or improper service.

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

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

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

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

fObey all safety messages that follow this symbol.

DANGER

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

or serious injury.

fTo avoid death or serious injury from this type of hazard, obey all safety messages that

follow this signal word.

WARNING

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

death or serious injury.

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

sages that follow this signal word.

CAUTION!

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

minor or moderate injury.

fTo avoid possible minor or moderate injury from this type of hazard, obey all safety mes-

sages that follow this signal word.

Safety Information WM 80

10 wc_si000509gb.fm

1.2 Safety Guidelines for Operating the Machine

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

1.2.1 Never operate this machine in applications for which it is not intended.

1.2.2 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.

1.2.3 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.

1.2.4 Do not operate the machine with unapproved accessories or

attachments.

1.2.5 Never leave the machine running unattended.

WM 80 Safety Information

wc_si000509gb.fm 11

1.2.6 Never tamper with or disable the function of operating controls.

1.2.7 Never use the choke to stop the engine.

1.2.8 Never operate the machine in areas where explosions may occur.

1.2.9 Read, understand, and follow procedures in the Operator’s Manual

before attempting to operate the machine.

1.2.10 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.

1.2.11 Be sure operator is familiar with proper safety precautions and

operation techniques before using machine.

1.2.12 Always keep hands, feet, and loose clothing away from moving parts

of the machine.

1.2.13 Always use common sense and caution when operating the machine.

1.2.14 Always be sure the rammer will not tip over, roll, slide, or fall when not

being operated.

1.2.15 Always turn the engine OFF when the rammer is not being operated.

1.2.16 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.

1.2.17 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.

1.2.18 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.

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

being operated.

1.2.20 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.

1.2.21 Do not transport the machine while it is running.

1.2.22 Do not tip the machine for cleaning or for any other reason.

Safety Information WM 80

12 wc_si000509gb.fm

1.3 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.

fRead 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. Expo-

sure to carbon monoxide can kill you in minutes.

fNEVER operate the machine inside an enclosed area, such as a tunnel, unless

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

WM 80 Safety Information

wc_si000509gb.fm 13

• 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.

1.4 Service Safety

A poorly maintained machine can become a safety hazard! In order

for the machine to operate safely and properly over a long period of

time, periodic maintenance and occasional repairs are necessary.

1.4.1 Do not attempt to clean or service the machine while it is running.

Rotating parts can cause severe injury.

1.4.2 DO NOT operate the machine without an air cleaner.

1.4.3 DO NOT remove air cleaner cover, paper element, or precleaner while

engine is running.

1.4.4 DO NOT alter engine speeds. Run the engine only at speeds specified

in the Technical Data Section.

1.4.5 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.

1.4.6 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.

1.4.7 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.

1.4.8 ALWAYS replace the safety devices and guards after repairs and

maintenance.

1.4.9 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.

1.4.10 ALWAYS do periodic maintenance as recommended in the Operator’s

Manual.

1.4.11 ALWAYS clean debris from engine cooling fins.

1.4.12 Replace worn or damaged components with spare parts designed and

recommended by Wacker Neuson Corporation.

1.4.13 Disconnect the spark plug on machines equipped with gasoline

engines, before servicing, to avoid accidental start-up.

1.4.14 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.

WARNING

Technical Data WM 80 Repair

14 wc_td000166gb.fm

2 Technical Data

2.1 Engine Specifications

Engine Model WM 80

Type 2-cycle

Maximum rated power (kW) hp 3.0 (4.0)

Number of cylinders 1

Piston displacement cc

(cu.in.)

80 (4.9)

Cylinder bore mm (in.) (45) 1.77

Stroke mm (in.) 50 (1.96)

Compression ratio 9:1

Operating speed range rpm 3,000–5,000

Starter Pull-type, recoil starter

Ignition Transistor-controlled electronic (TCI)

Carburetor Diaphragm

Fuel Gas/oil mixture

Fuel:oil ratio between 120–50:1 (first tank 25:1)

Cooling Forced air

Weight kg (lbs.) 7.8 (17)

Direction of rotation Counterclockwise when viewed from drive end

WM 80 Repair Technical Data

wc_td000166gb.fm 15

2.2 Tune-up Specifications

* On models with adjustable air gap

** Must be used on models with oil injection

Engine Model WM 80

Ring gap:

New

Maximum

mm (in.)

0.2–0.4 (0.008–0.016)

1.0–1.2 (0.039–0.047)

Cylinder wear:

Maximum bore taper mm (in.) 0.2 (0.008)

Cylinder head

compression kg/cc (psi) 8.0–9.7 (120–140)

Ignition module air gap* mm (in.) 0.4 (0.016)

Spark plug gap:

Champion RL86C

Champion UJ11G

Champion RL95YC**

mm (in.)

0.5 (0.020)

1.0–1.1 (0.040–0.045)

0.5 (0.020)

Technical Data WM 80 Repair

16 wc_td000166gb.fm

2.3 Carburetor Specifications for Bing, and Tillotson (Standard**)

Machine Carburetor

Make

Low-speed jet

size (x 0.01)

High-speed jet

size (x 0.01)

Carburetor

adapter bore

diameter

mm (in.)

BS 45Y •Bing

•Tillotson

•Tillotson w/

idle bypass

#35

Adjustable

#36

#62

#71*

#70

8 (0.315)

BS 50 Bing #40 #64 12 (0.472)

BS 52Y •Bing

•Tillotson

•Tillotson w/

idle bypass

#35

Adjustable

#36

#62

#71*

#70

9 (0.354)

BS 60Y •Bing

•Tillotson

•Tillotson w/

idle bypass

#35

Adjustable

#36

#62

#71*

#70

12 (0.472)

11 (0.433)

BS 62Y •Bing

•Tillotson

•Tillotson w/

idle bypass

#35

Adjustable

#36

#62

#71*

#70

12 (0.472)

14 (0.551)

BS 65Y

Bing

#35 #62 16 (0.630)

BS 100Y #40 #64 16 (0.630)

BPS 1330 #40 #58 10 (0.394)

BPS 1350 #40 #58 10 (0.394)

BVNPN #40 #64 12 (0.472)

BHF 30S #40 #58 16 (0.630)

BH 23 Tillotson w/ idle

bypass

#42 #74 10 (0.394)

BS 500 7550

Rev. 100–102 Tillotson w/ idle

bypass

#36 #78 13 (0.512)

BS 500 7550

Rev. 103–110

#36 #66 13 (0.512)

WM 80 Repair Technical Data

wc_td000166gb.fm 17

BS 500 7550

Rev. 111–121

Tillotson w/ idle

bypass

#36 #70 13 (0.512)

BS 500 7550

Rev. >121

#36 #70 11 (0.433)

BS 500 8048

Rev. 100–102

#36 #78 13 (0.512)

BS 500 8048

Rev. 103–110

#36 #66 13 (0.512)

BS 500 8048

Rev. 111–118

#36 #70 13 (0.512)

BS 500 8048

Rev. >118

#36 #70 11 (0.433)

BS 500 8049

Rev. 100–102

#36 #78 13 (0.512)

BS 500 8049

Rev. 103–110

#36 #66 13 (0.512)

BS 500 8049

Rev. 111–119

#36 #70 13 (0.512)

BS 500 8049

Rev. >120

#36 #70 11 (0.433)

BS 500 9074

High Altitude

Rev. 116

#36 #70 16 (0.630)

BS 500oi 9166 #36 #72 11 (0.433)

BS 600 7551

Rev. 100–103

#36 #78 14 (0.551)

BS 600 7551

Rev. 105–120

#36 #66 13 (0.512)

BS 600 7551

Rev. >121

#36 #72 13 (0.512)

BS 600 8207

High Altitude

Rev. <104

#36 #78 16 (0.630)

Technical Data WM 80 Repair

18 wc_td000166gb.fm

* Single-needle Tillotson carburetors only. Dual-needle Tillotson carburetors use an adjustable needle

for high-speed adjustment.

** Standard sizes listed. Operation at altitudes above 3000 m (5000 feet) may require different jet and

carburetor adapter sizes. Contact Wacker Neuson Neuson Service for the modifications required.

BS 600 8207

High Altitude

Rev. > 104

Tillotson w/ idle

bypass

#36 #74 18 (0.709)

BS 600oi 9166 #36 #72 18 (0.709)

BS 600oi 9262

High Altitude

#36 #74 18 (0.709)

BS 700 7552

Rev. <104

#36 #78 16 (0.630)

BS 700 7552

Rev. 104–118

#36 #74 18 (0.709)

BS 700 7552

Rev. >118

#36 #74 18 (0.709)

BS 700 8051

Rev. 100–120

#36 #78 16 (0.630)

BS 700 8051

Rev. >120

#36 #74 16 (0.630)

BS 700 8052

Rev. 100–102

#36 #78 16 (0.630)

BS 700 8052

Rev. 103–118

#36 #74 18 (0.709)

BS 700 8052

Rev. >118

#36 #74 18 (0.709)

BS 700oi 9167 #36 #74 18 (0.709)

BS 50-2 9384 #36 #72 19 (0.748)

BS 50-2i 9338 #36 #72 19 (0.748)

BS 50-2i 9383 #36 #72 19 (0.748)

BS 60-2i 9339 #36 #72 19 (0.748)

BS 60-2i 9393 #36 #72 19 (0.748)

BS 70-2i 9341 #36 #72 19 (0.748)

BS 70-2i 9401 #36 #72 19 (0.748)

WM 80 Repair Technical Data

wc_td000166gb.fm 19

2.4 Operating and Idle Speeds

Machine Idle speed ±100 rpm Full speed ±100 rpm

BS 45Y 1800 4300

BS 52Y 1800 4300

BS 60Y 1800 4600

BS 62Y 1800 4500

BS 65Y 1500 4400

BS 100Y 1500 4300

BS 105Y/92Y 1500 4400

BPS 1330 1500 4800

BPS 1350 1500 4800

BVNPN 1700 4500

BHF 30S 1500 4300

BH 23 1500 4250

BS 500 1800 4400

BS 500-oi 1800 4400

BS 50-2 1800 4400

BS 50-2i 1800 4400

BS 600 1800 4350

BS 600-oi 1800 4350

BS 60-2 1800 4350

BS 60-2i 1800 4350

BS 650 1800 4350

BS 65V 1800 4350

BS 700 1800 4350

BS 700-oi 1800 4350

BS 70-2 1800 4350

BS 70-2i 1800 4350

Maintenance WM 80

20 wc_tx000520gb.fm

3 Maintenance

3.1 Periodic Maintenance Schedule

Daily After first

5 hours

Every

week or

25 Hours

Every

month or

100 Hours

Every 3

months or

300 hours

Check fuel level. •

Clean and/or inspect air filter (cartridge type). •

Clean and oil foam precleaner where equipped. •

Check condition of fuel lines. •

Check & tighten engine cylinder screws. ••

Check & tighten external fasteners. ••

Clean and check spark plug gap. ••

Clean engine cooling fins. •

Replace cartridge style air filter element. •

Replace spark plug. •

Clean recoil starter. •

Remove carbon deposits from muffler & cylinder

exhaust port.

•

Replace in-line fuel filter. •

Inspect in-tank fuel filter. •

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Wacker Neuson WM 80 User manual

Wacker Neuson WM 80 User manual

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