Wacker Neuson WM 80 User manual

Category
Engine
Type
User manual
0162695en 003 0610
0162695EN
Repair Manual
Engine
WM 80
Copyright
notice
© Copyright 2010 by Wacker Neuson Corporation.
All rights, including copying and distribution rights, are reserved.
This publication may be photocopied by the original purchaser of the machine. Any
other type of reproduction is prohibited without express written permission from
Wacker Neuson Corporation.
Any type of reproduction or distribution not authorized by 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.
Manufacturers
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.)
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.)
mm (in.)
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)
8 (0.315)
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)
9 (0.354)
9 (0.354)
BS 60Y •Bing
•Tillotson
•Tillotson w/
idle bypass
#35
Adjustable
#36
#62
#71*
#70
12 (0.472)
11 (0.433)
11 (0.433)
BS 62Y •Bing
•Tillotson
•Tillotson w/
idle bypass
#35
Adjustable
#36
#62
#71*
#70
12 (0.472)
14 (0.551)
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.
1 / 1

Wacker Neuson WM 80 User manual

Category
Engine
Type
User manual

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