Repair Manual Engine WM 80 0162695en 0 1 6 2 003 6 9 0610 5 E N
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.
Foreword Foreword Machine documentation Expectations for information in this manual 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.
Foreword 4 wc_tx001528gb.
WM 80 1 Foreword 3 Safety Information 9 1.1 1.2 1.3 1.4 2 14 Engine Specifications ......................................................................... 14 Tune-up Specifications ....................................................................... 15 Carburetor Specifications for Bing, and Tillotson (Standard**) .......... 16 Operating and Idle Speeds ................................................................. 19 Maintenance 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.
Table of Contents 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 5 46 Brands Used ........................................................................................46 Walbro Carburetor Operation ..............................................................47 Versions of Tillotson Carburetor ..........................................................54 Tillotson Carburetor Operation ............................................................55 Bing Carburetor Operation ......................................
WM 80 7.9 7.10 8 Bing Carburetor Exploded View ......................................................... 94 Bing Carburetor Components ............................................................. 95 Carburetor Inspection and Adjustment 8.1 8.2 8.3 9 Table of Contents Inspection ........................................................................................... 96 Adjusting the Inlet Control Lever ........................................................ 97 Carburetor Adjustments ..............
Table of Contents 10.21 10.22 WM 80 Crankshaft Bearings ..........................................................................132 Bearing Installation ............................................................................134 8 wc_br0162695en_003TOC.
WM 80 1 1.1 Safety Information Safety Information 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. This is the safety alert symbol. It is used to alert you to potential personal hazards. f Obey all safety messages that follow this symbol.
Safety Information 1.2 WM 80 Safety Guidelines for Operating the Machine Operator qualifications Only trained personnel are permitted to start, operate, and shut down the machine.
WM 80 wc_si000509gb.fm Safety Information 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.
Safety Information 1.3 WM 80 Operator Safety while Using Internal Combustion Engines WARNING Internal combustion engines present special hazards during operation and fueling. Failure to follow the warnings and safety standards could result in severe injury or death. f Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. DANGER Exhaust gas from the engine contains carbon monoxide, a deadly poison. Exposure to carbon monoxide can kill you in minutes.
WM 80 Safety Information • 1.4 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. 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. WARNING wc_si000509gb.fm 1.4.1 Do not attempt to clean or service the machine while it is running.
Technical Data 2 WM 80 Repair 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 Piston displacement 1 cc (cu.in.) 80 (4.9) Cylinder bore mm (in.) (45) 1.77 Stroke mm (in.) 50 (1.
WM 80 Repair 2.2 Technical Data Tune-up Specifications 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.
Technical Data 2.3 WM 80 Repair 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 #62 #71* 8 (0.315) 8 (0.315) #36 #70 8 (0.315) BS 50 Bing #40 #64 12 (0.472) BS 52Y •Bing •Tillotson •Tillotson w/ idle bypass #35 Adjustable #62 #71* 9 (0.354) 9 (0.354) #36 #70 9 (0.
WM 80 Repair Technical Data BS 500 7550 Rev. 111–121 #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) #36 #70 13 (0.512) BS 500 8049 Rev. >120 #36 #70 11 (0.433) BS 500 9074 High Altitude Rev.
Technical Data WM 80 Repair BS 600 8207 High Altitude Rev. > 104 #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) #36 #78 16 (0.630) BS 700 8052 Rev. 103–118 #36 #74 18 (0.709) BS 700 8052 Rev.
WM 80 Repair 2.
Maintenance 3 WM 80 Maintenance 3.1 Periodic Maintenance Schedule Daily After first 5 hours Every week or 25 Hours Check & tighten engine cylinder screws. • • Check & tighten external fasteners. • • Clean and check spark plug gap. • • Check fuel level. • Clean and/or inspect air filter (cartridge type). • Clean and oil foam precleaner where equipped. • Check condition of fuel lines. • Clean engine cooling fins.
WM 80 3.2 Maintenance Storage If storing the unit for a long period of time (more than 30 days) carry out the following: 3.3 3.2.1 Drain fuel from the tank. 3.2.2 Start the engine and run it until all the fuel in the carburetor is used. 3.2.3 Remove the spark plug and pour 30 ml (1 oz.) of clean SAE 30W engine oil into the cylinder through the spark plug opening. 3.2.4 Pull the starter rope slowly to distribute oil in the engine. 3.2.5 Reinstall the spark plug.
Maintenance 3.4 WM 80 Cartridge-Type Air Filter See Graphic: wc_gr002875 3.4.1 This type of air filter is found on rammers with Bing carburetors and on early rammers with Tillotson carburetors. To service: 3.4.2 Unsnap the spring clips (1) on the protective cover (2) and remove the filter element (3). 3.4.3 Inspect the paper filter element and replace it if it appears wet, heavily soiled, or torn. 3.4.4 Inspect the condition of the rubber seals (4) on each end of the element.
WM 80 3.5 Maintenance Disc-Type Air Filter See Graphic: wc_gr002876 The disc-type air filter with oil-wetted foam precleaner is used on BPS 1330, BPS 1350, BVPN 50, and the BHF 30S. To service the filter: 3.5.1 Close the carburetor choke. Loosen the clamp (1) around the carburetor and remove the precleaner housing (2). 3.5.2 Remove the metal screen (3) from the carburetor and inspect it. Replace the screen if it is heavily soiled or damaged.
Maintenance 3.6 WM 80 Low-Maintenance Air Filter See Graphic: wc_gr002877 This type of air filter is found on rammers. The air filter is self-cleaning and uses the movement of the machine to shake dust and dirt loose from the air filter element while the rammer is operating. Under normal operating conditions this element will not require cleaning and should not be removed from the machine. If the element does become plugged with dirt, the engine will begin to lose power.
WM 80 Maintenance 1 2 3 wc_gr002877 3.7 Dual-Element Air Cleaner See Graphic: wc_gr000046 NEVER use gasoline or other types of low flash-point solvents for cleaning the air cleaner. A fire or explosion could result. WARNING NOTICE: NEVER run engine without air cleaner. Severe engine damage will occur. The rammer is equipped with a dual-element air cleaner. Under normal operating conditions, elements should be cleaned once every week.
Maintenance 3.8 WM 80 Three-Stage Air Cleaners See Graphic: wc_gr001168 NEVER use gasoline or other types of low flash point solvents for cleaning the air filter. A fire or explosion could result. WARNING NOTICE: NEVER run engine without main paper filter element (b). Severe engine damage will occur. Filter Indicator The air intake system is equipped with a filter indicator (h), which indicates when a filter change is required.
WM 80 Maintenance a b c i d h k wc_tx000520gb.
Maintenance 3.9 WM 80 Engine Cleaning The WACKER WM 80 engine is air cooled and depends on the cylinder cooling fins to dissipate heat. Dirt and debris caught in the cooling fins can prevent them from dissipating heat causing the engine to overheat. For this reason, it is important to inspect and clean the fins as often as job conditions dictate. Clean debris from between the fins using a screwdriver or similar implement. 3.10 Spark Plug A well-maintained spark plug is essential to good combustion.
WM 80 wc_tx000520gb.fm Maintenance 3.11.3 Clean the exhaust port using a blunt scraper. Inspect the gasket (3, 4) and replace it if torn or cracked. 3.11.4 Soak the muffler in carburetor cleaner until the carbon deposits break up. Drain the muffler and blow dry it dry with compressed air.
Maintenance WM 80 3.12 Fuel Filter See Graphic: wc_gr002879 Dirt is the primary cause of carburetor problems. Unfiltered fuel can quickly plug the passages in the carburetor and cause poor performance. Two different styles of fuel filters are used with the WM 80 engine. One is an in-tank, self-cleaning style (h), the other is an inline replaceable filter (i). No matter the style, it is imperative the fuel filter be clean. Check in-line fuel filters often and replace at regular intervals.
WM 80 repair 4 Starting and Ignition Starting and Ignition 4.1 Starter Assembly Exploded View 1 4 5 6 13 9 7 10 8 3 11 2 12 wc_gr002880 See Graphic: wc_gr002880 Ref Description Ref Description 1 Starter assembly 8 Spring 2 Rope 9 Ratchet wheel 3 Handle 10 Cover 4 Wear plate 11 Lock washer 5 Return spring 12 Locknut 6 Starter pulley 13 Starter housing 7 Washer wc_tx000521gb.
Starting and Ignition 4.2 WM 80 repair Disassembling the Starter See Graphic: wc_gr002880 4.3 4.2.1 Remove the starter assembly from the fan cover and release the spring tension as described in section Replacing the Starter Rope. 4.2.2 Untie the rope (2) and remove the handle (3). 4.2.3 Remove the locknut (12), lock washer (11), and cover (10). 4.2.4 Remove the ratchet (9), spring (8), and washer (7). Note the position of the ratchet and the spring to ensure proper reassembly. 4.2.
WM 80 repair Starting and Ignition b a d e c f wc_gr002881 4.4 Assembling the Starter See Graphic: wc_gr002880 and wc_gr002881 4.4.1 Clean all the components of the starter before reassembling the starter. 4.4.2 Note: To reduce dirt and dust from collecting between the spring windings, avoid using grease to lubricate the tarter return spring or the inside of the reel where the spring seats. Use a light lubricating oil such as WD40 instead. 4.4.
Starting and Ignition 4.5 WM 80 repair Replacing the Starter Rope See Graphic: wc_gr002882 The starter rope can be replaced without removing the rope reel pulley from the starter assembly. Removal: 4.5.1 Remove the starter assembly from the flywheel housing. 4.5.2 Lift the rope through the notch (a) in the drum. Pull out as much of the rope as possible. Hold the rope and let the spring pull the drum around clockwise until all spring tension is released. 4.5.3 Untie the knot and remove the rope.
WM 80 repair Starting and Ignition a b c d e wc_gr002882 wc_tx000521gb.
Starting and Ignition 4.6 WM 80 repair Ignition System Diagram c d a S b N f e aa aaa g wc_gr002883 36 wc_tx000521gb.
WM 80 repair 4.7 Starting and Ignition Ignition System Operation See Graphic: wc_gr002883 The ignition system consists of the ignition module (a), flywheel (b), shutoff switch (c) or (d), and spark plug (e). During each engine revolution, a permanent magnet (f) embedded in the flywheel passes under the ignition module. As the magnet passes the module, it induces a current in the primary side of the coil. After it passes, the triggering circuit is activated and the current flow to the coil is interrupted.
Starting and Ignition 4.8 WM 80 repair Checking Spark Remove the spark plug and inspect the electrode and insulator for damage. Also check electrode for proper gap. See section Tune-up Specifications. Return the spark plug to the cylinder before checking for spark. WARNING WARNING Do not check for spark with the spark plug removed. Fuel could squirt out of the spark plug opening. Do not touch or lean against the engine when checking for spark.
WM 80 repair 4.9 Starting and Ignition • Poor wire connections • Defective stop switch • Incorrect air gap • Weak or dead flywheel magnet • Insufficient rpm (must have 500 min.) Using Ignition Tester See Graphic: wc_gr002884 A more accurate test of the ignition module can be made using ignition tester P/N 78836 (a). 4.9.1 Preset gap to 4.2 mm (0.166 in.) (b). 4.9.2 Attach the end of the ignition cable to one end of the tester.
Starting and Ignition WM 80 repair 4.10 Setting Air Gap See Graphic: wc_gr002885 Newer engines use guide sleeve pins to automatically set the air gap; however, older models still require the proper air gap to be set manually. If the air gap is set incorrectly, the engine may be hard to start or it may run erratically. Check the air gap (a) with a feeler gauge and if the gap is not set at 0.4 mm (0.013–0.016 in.) the air gap needs to be reset. To set the air gap: 4.10.
WM 80 repair Starting and Ignition b c S N d a wc_gr002885 wc_tx000521gb.
Starting and Ignition WM 80 repair 4.11 Replacing the Ignition Module See Graphic: wc_gr002886 Removal: The engine does not have to be removed from the machine to replace the ignition module. 4.11.1 Disconnect the ignition wire from the spark plug. 4.11.2 Remove the seven M5 screws (a) which secure the flywheel housing to the crankcase. Note: The screws may require heat to loosen. Separate the flywheel housing from the crankcase. 4.11.
WM 80 repair Starting and Ignition b a d c f i h j g k e f wc_gr002886 wc_tx000521gb.
Starting and Ignition WM 80 repair See Graphic: wc_gr002887 Installation: 4.11.12 Apply a light coating of oil to the ground (a) and ignition wires (b) and slide them through the protective sleeve (c). 4.11.13 Slide the ignition wire through the boot (d) in the side of the crankcase. 4.11.14 Secure the ground wire to the stop switch (e). (Older models use a terminal flag (f).) Tuck the ground wire within the groove of the crankcase. 4.11.
WM 80 repair Starting and Ignition b j k c a d b e f h g i m l o n wc_gr002887 wc_tx000521gb.
Carburetor Basics 5 WM 80 Repair Carburetor Basics 5.1 Brands Used See Graphic: wc_gr005089 Three brands of carburetors are used on the WM 80 engine: Walbro (1), Tillotson (2), and Bing (3). The Walbro and Tillotson carburetors have internal fuel pumps while the Bing uses gravity feed to supply the fuel from the tank to the engine. With the Bing carburetor, the fuel tank must be located above the carburetor for the fuel feed to work properly.
WM 80 Repair 5.2 Carburetor Basics Walbro Carburetor Operation Fuel Pump The fuel pump is made up of a diaphragm (a) and a series of check valves (b & c). The power to operate the fuel pump comes from the crankcase impulse. As the engine’s piston moves up into the cylinder it creates a lowpressure area in the crankcase. The vacuum pulse travels through the impulse passage and draws up on the pump diaphragm creating a vacuum within the fuel chamber.
Carburetor Basics WM 80 Repair Fuel Metering There are four components of the fuel metering system: the metering diaphragm (a), the metering lever (b), the spring (c), and the inlet needle (d). The metering lever transfers the pressure of the spring to the inlet needle, holding the inlet needle closed and preventing fuel flow. When the metering diaphragm senses a vacuum pulse from the engine, it moves inward toward the carburetor.
WM 80 Repair Carburetor Basics Start up A rich fuel-to-air mixture is required at startup because of the lower cranking speed (compared to running) which causes less air flow, and the fact that the engine is usually cold. (A cold engine is not efficient at vaporizing fuel because heat is required to vaporize liquid.) The above two conditions can be overcome by closing the choke (a) and opening the throttle (b) slightly.
Carburetor Basics WM 80 Repair Idle Once the engine starts, the choke (a) is opened and the throttle (b) nearly closed. The engine is at the idle state. During idle, low pressure exists on the engine side of the throttle and atmosphere pressure (high) on the other. Atmosphere air enters the fuel nozzles (transition holes) and mixes with the fuel in the idle pocket (c). Fuel is drawn out of the idle pocket on the engine side of the throttle and into the engine.
WM 80 Repair Carburetor Basics Partial Throttle Operation At partial throttle, the choke (a) remains in the open position and the throttle (b) is partially opened. During partial throttle, low pressure exists on the engine side of the throttle plate. The low pressure draws fuel from the three progression fuel nozzles (d). As low pressure begins to fill the carburetor throat, the check valve starts to open and fuel begins to flow from the main nozzle (e). wc_tx000522gb.
Carburetor Basics WM 80 Repair Wide-Open Throttle Operation At wide-open throttle, the choke (a) remains in the open position and the throttle (b) is wide open. During this state, the throttle plate has little affect on high- and low-pressure areas within the carburetor throat. The venturi of the carburetor throat now takes over to create the lowpressure area. The low pressure created by the venturi draws fuel into the air stream.
WM 80 Repair Carburetor Basics Air Purge System The Walbro carburetor has an air purge system. The air purge system removes air from the fuel passages so that only fuel fills the carburetor and the fuel lines. The heart of the air purge system is the bulb. The bulb works in conjunction with a number of check valves. Pressing the bulb forces air (and fuel) through the discharge port back to the tank. Releasing the bulb creates a vacuum within the fuel passages and sucks air (and fuel) into the bulb.
Carburetor Basics 5.3 WM 80 Repair Versions of Tillotson Carburetor See Graphic: wc_gr002889 1) Dual Needle Dual needle carburetors have mixture needle valves that are adjustable. One of the valves (a) adjusts the high-speed jet (H) and the other valve (b) adjusts the low-speed jet (L). The needle valves operate by increasing or decreasing the size of the fuel passage to the discharge ports. 2) Single Needle Single needle carburetors use a fixed, high-speed fuel jet. No adjustment of this jet can be made.
WM 80 Repair 5.4 Carburetor Basics Tillotson Carburetor Operation See Graphic: wc_gr002891 Fuel Pump: The Tillotson carburetor uses a flexible diaphragm fuel pump (a) to operate an inlet valve (b) which controls fuel flow to the carburetor fuel reservoir (c). The fuel pump operates by reacting to pressure changes in the engine crankcase transmitted through an impulse line (d).
Carburetor Basics WM 80 Repair See Graphic: wc_gr002892 Inlet Needle Valve: The inlet needle valve (e) controls fuel flow into the fuel chamber. This valve is operated by a second diaphragm called the control diaphragm (f). The control diaphragm is activated by the vacuum created when air moves past the venturi (g) of the carburetor throat. A vent (h) to the atmosphere provides the air pressure differential needed to create the vacuum.
WM 80 Repair Carburetor Basics See Graphic: wc_gr002893 Start-up mode (choke): During cold start-up, the choke shutter (butterfly) (k) is closed and the throttle shutter (l) is partially open. As the engine is turned over, engine suction draws fuel from the primary (m), secondary (n), and main fuel (o) discharge ports. Since the choke is closed, the amount of air flowing through the carburetor is very restricted.
Carburetor Basics WM 80 Repair In single-needle versions (2), the throttle shutter does not open and there is no idle speed screw; instead, a small hole (q) in the shutter regulates the air flow. The idle speed is also regulated by the slow speed mixture needle valve (t). By turning the valve, the fuel/air mixture can be made richer or leaner, affecting the engine’s speed (rpm).
WM 80 Repair Carburetor Basics See Graphic: wc_gr002895 Partial Throttle: At partial throttle, the throttle shutter is partially opened, allowing a greater amount of air through the carburetor. The throttle has opened wide enough to expose the secondary idle discharge port (a) which provides more fuel to mix with the air. In dual-needle versions, engine suction draws fuel from both the primary (b) and secondary idle discharge ports.
Carburetor Basics WM 80 Repair See Graphic: wc_gr002896 Full Throttle: The wider the throttle shutter opens, the more air that will flow through the carburetor. As the air reaches the venturi (c), it is forced to flow faster to keep the same volume of air flowing. The faster the air flows through the venturi, the lower the air pressure in the venturi becomes.
WM 80 Repair 5.5 Carburetor Basics Bing Carburetor Operation g e f b c h d a wc_gr002897 See Graphic: wc_gr002897 Fuel Feed: The Bing carburetor does not use a fuel pump; instead, the fuel supply is gravity fed. A priming button (a) is used during the initial start-up to manually open the inlet needle valve (b) which primes the fuel chamber (c). Inlet Needle Valve: While the engine is running, fuel flow into the fuel chamber is controlled by the inlet needle valve.
Carburetor Basics WM 80 Repair Partial Throttle: At partial throttle, the throttle shutter is partially opened allowing a greater amount of air through the carburetor. The throttle has opened wide enough to expose the secondary-idle discharge port and the engine suction draws fuel from both the primary-idle and secondaryidle discharge ports. Idle and Low Speed: The amount of air flowing through the carburetor is regulated by the throttle and choke shutters. At idle, only a small amount air flow is needed.
WM 80 Repair Carburetor Basics Notes wc_tx000522gb.
Carburetor Basics 5.6 WM 80 Repair Carburetor Adapters See Graphic: wc_gr007414 The function of the carburetor adapter is to control the amount of fuel/ air mixture that can reach the engine. When used in combination with the carburetor fuel jets, the power and speed of the engine is controlled. This allows the WM 80 engine to adapt to the power and speed requirements of different machine models. No matter the style, all adapters control the fuel/air mixture through bore diameter (d) size.
WM 80 Repair Carburetor Basics d 1 d 2 d d 3 f 4 e d 5 h g 6 wc_gr007414 wc_tx000522gb.
Carburetor Replacement 6 6.1 WM 80 Repair Carburetor Replacement Replacing the Walbro Carburetor (auto-release choke models) Removal 6.1.1 Stop the machine and allow it to cool. 6.1.2 Remove the carburetor guard (a). 6.1.3 Loosen the hose clamp and remove the air duct (b). 6.1.4 Disconnect the ignition wire (c) from the spark plug. 6.1.5 Loosen the clamp (d) and remove the throttle cable (e) from the carburetor adapter (f). 6.1.
WM 80 Repair Carburetor Replacement Continued from the previous page. 6.1.7 Have a container ready, then remove the oil hose (h) and drain it. 6.1.8 Make sure the throttle is in the OFF position. This position also closes the fuel valve. Then, remove the fuel hose (n) and drain it. 6.1.9 Remove the gasket (m). 6.1.10 Disassemble the carburetor (i) from the adapter (j), flange (k), and gaskets (l and o). Result The removal procedure is now complete. wc_tx000522gb.
Carburetor Replacement WM 80 Repair Installation Perform the procedure below to install the carburetor 6.1.1 Assemble the adapter (j), lower gasket (l), flange (k), and upper gasket (o) to the carburetor (i). Note: The gaskets are not interchangeable. 6.1.2 Connect the oil hose (h), and the fuel hose (n), to the carburetor. 6.1.3 Install the carburetor assembly to the engine. 68 wc_tx000522gb.
WM 80 Repair 6.1.4 Carburetor Replacement Slide the throttle cable (e) through the adapter (f) and reconnect it to the clamp (d). d wc_gr007456 6.1.5 Install the air duct (b) with the hose clamp. 6.1.6 Using Loctite® 243 on the screws, install the carburetor guard (a). Result The installation procedure is now complete. wc_tx000522gb.
Carburetor Replacement 6.2 WM 80 Repair Removing Walbro Carburetor (standard choke models) 6.2.1 Stop the machine and allow it to cool. 6.2.2 Place the throttle in the OFF position. 6.2.3 Disconnect the ignition wire (a) from the spark plug. 6.2.4 Remove the carburetor guard (b). 6.2.5 Loosen the hose clamp (c) and remove the air duct (d). 6.2.6 Remove the two screws and remove the flange (e) and the carburetor from the machine. 6.2.7 Remove the screws (f) and remove the adapter (g). 6.2.
WM 80 Repair Carburetor Replacement Notes wc_tx000522gb.
Carburetor Replacement 6.3 WM 80 Repair Removal, Tillotson with composite adapter See Graphic: wc_gr002929 6.3.1 Stop the machine and allow it to cool. 6.3.2 Close the fuel valve (a) (if equipped). 6.3.3 Disconnect the ignition wire (b) at the spark plug. 6.3.4 Remove the carburetor guard (c). 6.3.5 Loosen the clamps holding the air duct (d) to the carburetor and remove the air duct from the carburetor. 6.3.
WM 80 Repair Carburetor Replacement m i g f e d b a d c e l h j m i f g k wc_gr002929 wc_tx000522gb.
Carburetor Replacement 6.4 WM 80 Repair Tillotson with Straight-Through Adapters See Graphic: wc_gr002898 6.4.1 Turn off the fuel valve at the tank and disconnect the spark plug lead wire. 6.4.2 Remove the air filter pipe (loosen both clamps). 6.4.3 Disconnect the throttle cable. 6.4.4 Loosen the clamp which secures the carburetor to the adapter and slide the carburetor off. 6.4.5 Protect the cylinder from dirt by cranking the engine until the piston is covering the intake port. wc_gr002898 6.
WM 80 Repair Carburetor Replacement wc_gr002899 6.6 wc_gr002900 Bing See Graphic: wc_gr002900 wc_tx000522gb.fm 6.6.1 Turn off the fuel valve at the tank and disconnect the spark plug lead wire. 6.6.2 Remove the air filter pipe (loosen both clamps). 6.6.3 Disconnect the throttle cable. 6.6.4 Loosen the clamp which secures the carburetor to the adapter and slide the carburetor off the adapter. 6.6.
Carburetor Overhaul 7 WM 80 Repair Carburetor Overhaul 7.1 Walbro Carburetor Exploded View (auto-release choke models) 76 wc_tx000522gb.
WM 80 Repair 7.
Carburetor Overhaul 7.3 WM 80 Repair Rebuilding the Walbro Carburetor (auto-release choke models) Disassembly 7.3.1 Remove the cover (a) from the fuel-pump side of the carburetor. 7.3.2 Remove the fuel pump diaphragm and gasket (b). 7.3.3 Remove the bracket and the air purge bulb (c). Separate the bulb from the bracket. 7.3.4 Remove the air purge body assembly (d). Remove the combination valve (e). 7.3.5 Remove the metering diaphragm (f). wc_gr007436 7.3.
WM 80 Repair Carburetor Overhaul 7.3.7 Remove the shutter (l) (butterfly). 7.3.8 Remove the screw (m), lever (n), washer (o), and spacer (p). 7.3.9 Remove the retaining ring (q), then remove the choke shaft (r). 7.3.10 Remove the shutter (t) (butterfly) from the throttle shaft. 7.3.11 Remove the throttle lever (u), spacer (v), and washer (w). 7.3.12 Remove the throttle shaft (aa) and the spring (bb). wc_tx000522gb.
Carburetor Overhaul WM 80 Repair 7.3.13 Non-EPA regulated countries only. Remove the high- and low-speed needle valves (x and y). x y wc_gr005125 7.3.14 Using a punch, remove the Welch plug (z). 7.3.15 Non-EPA regulated countries only. Press out the main nozzle (zz). 7.3.16 Remove the screen(s) (dd). Result The disassembly procedure is now complete. 80 wc_tx000522gb.
WM 80 Repair Carburetor Overhaul Reassembly 7.3.1 Align the hole in the main nozzle (zz) with the passage of the highspeed needle. Press the main nozzle into the carburetor body until the top of the main nozzle is flush with the carburetor body. 7.3.2 Install the Welch plug (z). Tap it in with a flat punch. 7.3.3 Install the high- and low-speed needles (x and y). Note: The high-speed needle is shorter than the low-speed needle. 7.3.4 Install the screen(s) (dd). 7.3.
Carburetor Overhaul WM 80 Repair Continued from the previous page. 7.3.7 Install the shutter (t) (butterfly). 7.3.8 Install the spring and washer on the choke shaft, then install the choke shaft (r) into the carburetor body. 7.3.9 Align the spring (ee) as shown, then secure the choke shaft with retaining ring (q). 7.3.10 Install the spacer (p), washer (o), lever (n), with screw (m). 7.3.11 Install the shutter (l) (butterfly). This procedure continues on the next page. 82 wc_tx000522gb.
WM 80 Repair Carburetor Overhaul Continued from the previous page. 7.3.12 Install the screw (j), metering lever (h), pin (k), spring (g), and inlet needle (i). 7.3.13 Install the metering diaphragm (f). 7.3.14 Install the combination valve (e) into the air purge body assembly (d), then install the air purge body assembly. 7.3.15 Install the air purge bulb (c) and bracket. 7.3.16 Install the fuel pump diaphragm (b). 7.3.17 Install the cover (a). Result The reassembly procedure is now complete.
Carburetor Overhaul 7.4 WM 80 Repair Walbro Carburetor Exploded View (standard choke models) wc_gr005118 84 wc_tx000522gb.
WM 80 Repair 7.
Carburetor Overhaul 7.6 WM 80 Repair Rebuilding the Walbro Carburetor (standard choke models) Disassembly 7.6.1 Remove the cover (a) from the fuel-pump side. 7.6.2 Remove the fuel pump diaphragm and gasket (b). 7.6.3 Remove the bracket and the air purge bulb (c). Separate the bulb from the bracket. 7.6.4 Remove the air purge body assembly (d). Remove the combination valve (e). 7.6.5 Remove the metering diaphragm (f). 7.6.
WM 80 Repair Carburetor Overhaul 7.6.7 Remove the shutter (l) (butterfly). 7.6.8 Remove the choke shaft (m) and spacer (n). Also remove the ball (o) and the spring (p) from the carburetor body. 7.6.9 Remove the throttle lever (q), spacer (r), and washer (s). 7.6.10 Remove the shutter (t) (butterfly), then pull the throttle shaft (u) from the carburetor body. Remove the spring (v) and nipple (w). 7.6.11 Non-EPA regulated countries only. Remove the high- and low-speed needle valves (x and y).
Carburetor Overhaul 7.6.13 WM 80 Repair Non-EPA regulated countries only. Press out the main nozzle (zz). The procedure is now complete. Reassembly 7.6.1 Align the hole in the main nozzle (zz) with the passage of the highspeed needle. Press the main nozzle into the carburetor body until the top of the main nozzle is flush with the carburetor body. 7.6.2 Install the Welsh plug (z). Tap it in with a flat punch. 7.6.3 Install the high- and low-speed needles (x and y).
WM 80 Repair Carburetor Overhaul x y wc_gr005128 7.6.4 Install the spring (v) to the throttle shaft (u). Install the throttle shaft into the carburetor body and install the shutter (t) (butterfly). This procedure continues on the next page. wc_tx000522gb.
Carburetor Overhaul WM 80 Repair Continued from the previous page. 7.6.5 Install the washer (s), spacer (r), and the throttle lever (q). Note the positioning of the throttle lever (q) compared to the throttle shaft (u). u wc_gr005130 7.6.6 Install the spring (p) and ball (o). Install the spacer (n) and choke shaft (m). wc_gr005131 7.6.7 Install the shutter (l) (butterfly). 7.6.8 Install the inlet needle (i), spring (g), pin (k), and metering lever (h) with the screw (j). 7.6.
WM 80 Repair Carburetor Overhaul Continued from the previous page. 7.6.10 Install the combination valve (e). Install the air purge body assembly (d), bracket, and air purge bulb (c). 7.6.11 Install the new fuel pump diaphragm then the new gasket (b). Be sure to align each with the positioning pins. 7.6.12 Install the cover (a). wc_tx000522gb.
Carburetor Overhaul 7.7 WM 80 Repair Tillotson Carburetor Exploded View 44 1 2 3 4 34 7 6 35 5 40 35 33 8 28 28 9 31 32 30 28 29 27 10 38 37 13 26 25 24 12 11 7 23 14 15 43 41 16 42 17 43 41 22 20 21 18 21 19 39 20 20 21 22 wc_gr002901 92 wc_tx000522gb.
WM 80 Repair 7.
Carburetor Overhaul 7.9 WM 80 Repair Bing Carburetor Exploded View 45 46 1 44 2 3 43 40 41 42 41 40 39 4 5 6 5 34 7 35 8 36 33 9 10 32 13 38 11 30 31 27 29 28 14 17 26 25 37 12 16 15 18 20 19 24 23 21 21 22 22 wc_gr002902 94 wc_tx000522gb.
WM 80 Repair Carburetor Overhaul 7.
Carburetor Inspection and Adjustment 8 WM 80 Repair Carburetor Inspection and Adjustment 8.1 Inspection Diaphragms: • Check for tears, punctures, and distortion in the elastic material. Replace the diaphragm if it appears stretched or puckered. • Be certain diaphragms are installed correctly. See appropriate exploded view. On Walbro and Tillotson carburetors, be sure that the control diaphragm is connected to the inlet lever.
WM 80 Repair 8.2 Carburetor Inspection and Ad- Adjusting the Inlet Control Lever See Graphic: wc_gr002903 Walbro: Use the special tool (e) to set height of metering lever. Tillotson: Set the inlet control lever (a) so that it is flush with the floor of the fuel chamber (b). Bend the end of the control lever up or down as required. Bing: Set the inlet control lever so that it is 1.4 mm (0.055 in.) below the surface of the carburetor casting by bending the tab up or down as required.
Carburetor Inspection and Adjustment 8.3 WM 80 Repair Carburetor Adjustments Walbro: Procedures apply in only non-EPA regulated applications. Both high- and low-speed mixture adjustment is possible. A special tool is required. See section Operating & Idle Speeds for correct operating and idle speed settings. For best accuracy use a tachometer when making carburetor adjustments. For initial carburetor set-up after rebuilding, complete the following procedures: 8.3.
WM 80 Repair Carburetor Inspection and Ad- See Graphic: wc_gr002904 Tillotson Dual Needle: Both high- and low-speed mixture adjustment is required on dual needle models. See section Operating & Idle Speeds for correct operating and idle speed settings. For best accuracy use a tachometer when making carburetor adjustments. For initial carburetor set-up after rebuilding, complete the following procedures: 8.3.6 Turn in (clockwise) high- (H) and low-speed mixture needle valve (L) by hand until tight.
Carburetor Inspection and Adjustment WM 80 Repair H L L wc_gr002905 wc_gr002904 See Graphic: wc_gr002905 Tillotson Single Needle: On single-needle Tillotson carburetors the high-speed fuel jet is fixed; only the low-speed jet can be adjusted. See section Operating & Idle Speeds for correct operating and idle speed settings. For initial carburetor set-up after rebuilding, complete the following procedures: 8.3.13 Turn in (clockwise) the low-speed mixture valve (L) by hand until tight.
WM 80 Repair 9 Carburetor Troubleshooting Carburetor Troubleshooting 9.1 Troubleshooting Walbro Carburetors Problem Probable Cause Remedy Engine floods. Worn inlet needle body or tip. Replace the inlet needle. Inlet needle sticking Check spring tension and metering lever. Dirt or gum formations preventing the inlet needle from sealing Remove and clean the carburetor. Metering lever set incorrectly. Adjust metering lever. Diaphragm installed incorrectly Correct diaphragm installation.
Carburetor Troubleshooting 9.2 WM 80 Repair Troubleshooting Tillotson and Bing Carburetors Problem Probable Cause Remedy Engine floods. Defective or missing fuel filter allowing dirt to enter carburetor Install a new fuel filter. Inlet needle sticking Check spring tension and axle point. Dirt or gum formations preventing the inlet needle from sealing Remove and clean the carburetor. Inlet control lever set Adjust inlet control lever.
WM 80 Repair Engine runs rich. wc_tx000522gb.fm Carburetor Troubleshooting High-speed adjustment incorrect Readjust the high speed. High-speed mixture needle valve damaged Replace the high-speed mixture needle valve. The size of the fixed jet is incorrect. Replace the fixed jet with correct size. Plug covering main discharge port is leaking. Install new plug.
Disassembly and Assembly WM 80 Repair 10 Disassembly and Assembly 10.1 Tools Because all possible problems encountered while repairing the machine cannot be anticipated, it is up to the mechanic to use common sense and good judgement in tool selection. The use of any special tools is recommended only for those operations where the use of conventional tools proves inadequate.
WM 80 Repair Disassembly and Assembly 10.3 Ordering Parts The repair procedures contained in this manual do not include part numbers. For parts replacement information, refer to the Parts Book originally supplied with the machine. If the original Parts Book has been lost, a replacement may be ordered from Wacker Neuson Corporation. When ordering a replacement Parts Book, please list the model number, item number, revision level, and serial number of the machine.
Disassembly and Assembly WM 80 Repair 10.6 Removing the WM 80 Engine from BS Rammers (auto-release choke models) Requirements • Engine cool • Carburetor removed Removal Perform the procedure below to remove the engine. 10.6.1 Remove the carburetor. See topic Removing the Carburetor. 10.6.2 Remove the muffler (a). 10.6.3 Remove the bracket (b). 10.6.4 Disconnect the wiring to the switches (c). 10.6.5 Remove the screws that hold the engine and remove the engine (d) from the machine.
WM 80 Repair Disassembly and Assembly Installation Perform the procedure below to install the engine. 10.6.6 Install the engine (d) to the machine with three screws. Torque the screws to 28 Nm (20 ft.lbs.). 10.6.7 Reconnect the wiring (c) to the switches. 10.6.8 Install the bracket (b). 10.6.9 Install the muffler (a). Torque screws (x) to 18 Nm (13 ft.lbs.). Torque screw (y) to 23 Nm (16 ft.lbs.). 10.6.10 Install the carburetor. Result The engine has now been installed. wc_tx000523gb.
Disassembly and Assembly WM 80 Repair 10.7 Removing Engine From BS Model Rammers (standard choke models) See Graphic:wc_gr002935 Removal: 10.7.1 Stop the machine and allow it to cool. 10.7.2 Remove the carburetor. See section Removing Carburetor. 10.7.3 Remove the muffler guard (a) (if equipped) and the muffler (b). 10.7.4 Disconnect the connector (c) from the stop switch. 10.7.5 Remove the three socket head cap screws (d) that hold the engine to the crankcase. 10.7.
WM 80 Repair Disassembly and Assembly d b e a c d wc_gr002935 wc_tx000523gb.
Disassembly and Assembly WM 80 Repair 10.8 Removing Engine From BH 23 Breakers See Graphic: wc_gr002937 Removal: 10.8.1 Stop the machine and allow it to cool. 10.8.2 Remove the screws (a) and lock washers which secure the two shells together. 10.8.3 Remove the shell (b) opposite the throttle. 10.8.4 Remove the cover of the air cleaner, the air filter (c), and the base of the air cleaner (d). 10.8.5 Remove the carburetor (e). 10.8.
WM 80 Repair Disassembly and Assembly a b d e c f wc_gr002937 wc_tx000523gb.
Disassembly and Assembly WM 80 Repair 10.9 Removing Clutch See Graphic: wc_gr002941 This procedure requires special tool P/N 0117972, puller. WARNING DO NOT run the engine while it is off the machine unless the clutch has been removed. Running the engine with the clutch attached to the crankshaft will cause the clutch shoes to separate and fly off. Removal: 10.9.1 Stop the machine and allow it to cool. 10.9.2 Remove the engine from the machine. See section Removing Engine. 10.9.
WM 80 Repair Disassembly and Assembly c a b wc_tx000523gb.
Disassembly and Assembly WM 80 Repair 10.10 WM 80 Exploded View 11 9 10 12 2 3 1 8 28 4 5 29 26 7 6 27 7 30 31 40 15 25 33 32 24 34 35 23 21 36 22 41 19 17 13 39 20 37 38 14 19 15 18 17 16 wc_gr002906 114 wc_tx000523gb.
WM 80 Repair Disassembly and Assembly 10.11 WM 80 Components See Graphic: wc_gr002906 Ref Description Ref Description 1 Set-cylinder 21 Needle bearing 2 Stud M6x18 22 Screw M5x55 3 Stud M5x20 23 Ignition module 4 Piston 24 Sleeve 5 Piston ring 25 Screw M5x20 6 Wrist pin 26 Nut M12x1.
Disassembly and Assembly WM 80 Repair 10.12 WM 80 Cross Section 7 8 6 9 10 11 5 12 13 4 14 15 16 1 3 2 wc_gr002920 116 wc_tx000523gb.
WM 80 Repair Disassembly and Assembly 10.13 WM 80 Cross Section Components See Graphic: wc_gr002920 Ref Description Ref Description 1 Crankcase 9 Piston 2 Crankcase gasket 10 Piston rings 3 Recoil starter 11 Cylinder 4 Flywheel key 12 Connecting rod 5 Flywheel fan 13 Cylinder gasket 6 Fan hood 14 Crankshaft 7 Retaining ring 15 Shaft seal 8 Piston wrist pin 16 Crankshaft bearing wc_tx000523gb.
Disassembly and Assembly WM 80 Repair 10.14 Vacuum Testing Cylinder See Graphic: wc_gr002940 This procedure requires the use of test kit P/N 0155268, an 1/8 NPT hose barb, new gaskets, and a vacuum pump. Note: For clarity, the engine is shown removed from the machine. 10.14.1 Remove the air cleaner or air cleaner duct. 10.14.2 Remove the carburetor. See section Removing Carburetor. 10.14.3 Remove the muffler. 10.14.
WM 80 Repair Disassembly and Assembly c e a d b f wc_gr002940 wc_tx000523gb.
Disassembly and Assembly WM 80 Repair 10.15 Cylinder and Piston Removal See Graphic: wc_gr002907 The cylinder and cylinder head is of a one-piece design providing easy access to the cylinder and piston and eliminating the need for a head gasket. The cylinder bore is coated with a wear-resistant metal alloy. This allows heat to dissipate faster than using a cast iron cylinder sleeve.
WM 80 Repair Disassembly and Assembly b f c e d c g wc_gr002907 wc_tx000523gb.
Disassembly and Assembly WM 80 Repair 10.16 Cylinder and Piston Inspection See Graphic: wc_gr002908 Ring Gap: Remove the cylinder from the crankcase. Check the ring gap at the lower part of the cylinder by placing the ring (h) in the cylinder and measuring the gap between the ends of the ring. If the ring gap is greater than 1.2 mm (0.047 in.) the rings need to be replaced. Ring gaps should measure as follows: New: 0.2 – 0.4 mm (0.008 – 0.016 in.) Maximum: 1.0 – 1.2 mm (0.040 – 0.047 in.
WM 80 Repair Disassembly and Assembly h wc_gr002908 wc_tx000523gb.
Disassembly and Assembly WM 80 Repair 10.17 Cylinder and Piston Installation See Graphic: wc_gr002909 This procedure requires the use of special tool P/N 0031986, ring compressor. It also requires the use of new retaining rings, P/N 0012257. 10.17.1 Remove all old gasket material from the cylinder and crankcase. Inspect the mating surfaces of the cylinder and crankcase for any deep scratches or defects which could prevent a good seal.
WM 80 Repair Disassembly and Assembly c a f b e g h i d 2 4 3 1 wc_gr002909 wc_tx000523gb.
Disassembly and Assembly WM 80 Repair 10.18 Inspecting Connecting Rod and Crankshaft See Graphic: wc_gr002910 10.18.1 With the cylinder removed, check the needle bearing (a) for damage or wear. Replace it if necessary. 10.18.2 Insert the wrist pin into the needle bearing and check for excessive play. Replay the needle bearing and/or the wrist pin if necessary. 10.18.3 Check the connecting rod (b) for any vertical play—there should be none. Side play is allowable.
WM 80 Repair Disassembly and Assembly a OK OK b wc_gr002910 wc_tx000523gb.
Disassembly and Assembly WM 80 Repair 10.19 Disassembling Crankcase See Graphic: wc_gr002911 10.19.1 Remove the clutch, starter, flywheel, cylinder, and piston. Place the nut back on the shaft to protect shaft threads. 10.19.2 Remove eight M5 screws (a) which secure the crankcase halves together. 10.19.3 Secure the crankcase in vice or equivalent. Note: It is suggested that M8 cap screws (b) be screwed into clutch end of crankcase. Then secure crankcase in vise (c) using the capscrews. 10.19.
WM 80 Repair Disassembly and Assembly a c b e d f g h wc_gr002911 wc_tx000523gb.
Disassembly and Assembly WM 80 Repair 10.20 Assembling Crankcase See Graphic: wc_gr002912 This procedure requires a propane torch or equivalent heat source. 10.20.1 Lubricate the shaft seals (a) using 2-cycle engine oil. Position one of the seals over the bore in the crankcase shell (b) with the open side of the seal facing in. Make sure the seal is laying straight and press it into the bore, from the outer side, using pusher P/N 0048585.
WM 80 Repair Disassembly and Assembly a a g f c e d e a f b h wc_gr002912 wc_tx000523gb.
Disassembly and Assembly WM 80 Repair 10.21 Crankshaft Bearings See Graphic: wc_gr002913 Press Method Removal: This procedure requires special tools P/N 0023338, split ring puller (a); and P/N 0023339, crank support tube (b). It also requires the use of an Arbor press or equivalent. 10.21.1 Place the two halves of the split ring puller around the bearing on the crankshaft. If necessary, tap gently on the ring halves to seat them under the bearing. 10.21.
WM 80 Repair Disassembly and Assembly c a e d b wc_gr002913 wc_tx000523gb.
Disassembly and Assembly WM 80 Repair 10.22 Bearing Installation See Graphic: wc_gr002914 This procedure requires special tools P/N 0048585, pusher tube (f); P/N 0032028, crank support plate (g); and P/N 0023339 crank support tube (h). 10.22.1 Slide the support plate between the counterweights at the center of the crankshaft as far as possible, then place it on the support tube so that the counterweight on the crankshaft is fully supported. 10.22.
Wacker Neuson SE · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02-0 · Fax: +49 - (0)89-3 54 02-390 Wacker Neuson Corporation · N92W15000 Anthony Ave. · Menomonee Falls, WI 53051 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 ·Tel. : (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
