Wacker Neuson WM 80 Repair Manual Download

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0162695en

003

0610

Repair Manual

Engine

WM 80

Summary of Contents for WM 80

Page 1: ...0162695en 003 0610 0 1 6 2 6 9 5 E N Repair Manual Engine WM 80...

Page 2: ...ten 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 pros...

Page 3: ...n 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...

Page 4: ...Foreword 4 wc_tx001528gb fm...

Page 5: ...etor 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 C...

Page 6: ...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 wi...

Page 7: ...5 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 mod...

Page 8: ...Table of Contents WM 80 8 wc_br0162695en_003TOC fm 10 21 Crankshaft Bearings 132 10 22 Bearing Installation 134...

Page 9: ...rsonal hazards f Obey all safety messages that follow this symbol DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury f To avoid death or serious...

Page 10: ...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 Prot...

Page 11: ...ngine 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 workin...

Page 12: ...sent 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 venti...

Page 13: ...rk 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 o...

Page 14: ...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...

Page 15: ...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 Ignitio...

Page 16: ...tson 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...

Page 17: ...18 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...

Page 18: ...pass 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...

Page 19: ...5Y 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 5...

Page 20: ...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 g...

Page 21: ...hrough 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 3 3 General Air Filter Maintenance Inspect the air filter daily Severe d...

Page 22: ...wet heavily soiled or torn 3 4 4 Inspect the condition of the rubber seals 4 on each end of the element Replace the element if the seals are damaged or deformed 3 4 5 The element can be cleaned by tap...

Page 23: ...inspect it Replace the screen if it is heavily soiled or damaged The screen can be cleaned by tapping it against a firm surface or by using low pressure 30 psi compressed air 3 5 3 Remove the retainer...

Page 24: ...pressure must not exceed 100 psi 3 6 3 Run fresh water through the grommet hole 1 until water runs clear NOTICE DO NOT use solvents fuel oil or gasoline to wash the filter 3 6 4 Plug or cover the hol...

Page 25: ...d with dirt that cannot be removed Clean elements using the following procedure 3 7 1 Remove air cleaner cover a Remove precleaner and paper element and inspect them for holes or tears Replace if dama...

Page 26: ...ocedure 3 8 1 Remove the air cleaner cover a Remove the main paper filter element b and the secondary prefilter c and inspect them for holes or tears Replace the elements if they are damaged 3 8 2 Mai...

Page 27: ...WM 80 Maintenance wc_tx000520gb fm 27 wc_gr001168 a b c d k i h...

Page 28: ...gine clean the immediate area around the spark plug to prevent any dirt from falling into the cylinder when the spark plug is removed NOTICE Do not remove the spark plug while the engine is hot The al...

Page 29: ...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 muffl...

Page 30: ...the style it is imperative the fuel filter be clean Check in line fuel filters often and replace at regular intervals Check in tank fuel filters yearly Clean the filter by back flushing with solvent R...

Page 31: ...Assembly Exploded View 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 Lock...

Page 32: ...turn spring if it is broken or appears distorted or twisted Check that the starter return spring ends are bent 180 a The starter return spring may be difficult to seat in the slots on the starter hous...

Page 33: ...on inside the pulley until it is completely wound Oil the spring lightly once it is wound 4 4 4 Lightly grease the center post of the housing and install the wear plate 4 and the rope reel pulley Rota...

Page 34: ...on 4 5 4 Thread the new rope through the rope reel pulley and then through the housing Install the handle and knot b each end of the rope as shown Be sure the end of the rope does not protrude from th...

Page 35: ...WM 80 repair Starting and Ignition wc_tx000521gb fm 35 wc_gr002882 a d e b c...

Page 36: ...Starting and Ignition WM 80 repair 36 wc_tx000521gb fm 4 6 Ignition System Diagram wc_gr002883 a f e aa aaa g c d b S N...

Page 37: ...ion module aaa with speed limiter is used This module cuts out ignition pulses at higher speeds to keep the engine from running away The two modules are not interchangeable Note the physical differenc...

Page 38: ...3 mm 1 8 inch from the engine cylinder and pull the rope on the rewind starter 4 8 4 If a strong blue spark is observed the ignition module is satisfactory and either the spark plug or the connection...

Page 39: ...gnition 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 Ground the other end of the teste...

Page 40: ...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 1 Loosen the three screws b holding the ignition module c to the cran...

Page 41: ...WM 80 repair Starting and Ignition wc_tx000521gb fm 41 wc_gr002885 S N d a c b...

Page 42: ...flywheel puller P N 46503 d completely onto the threaded shaft of the flywheel Turn the pusher screw portion of the puller until it engages with the crankshaft Continue turning the pusher screw until...

Page 43: ...WM 80 repair Starting and Ignition wc_tx000521gb fm 43 wc_gr002886 a d f f e k c g i h j b...

Page 44: ...ean the area of the crankcase around the ground wire and apply a new white label h to the crankcase 4 11 17 Attach the spark plug cap i to the ignition wire 4 11 18 Apply Loctite 243 or equivalent to...

Page 45: ...WM 80 repair Starting and Ignition wc_tx000521gb fm 45 wc_gr002887 k e a b j f n o l h g m d c i b...

Page 46: ...operate on differences in air pressure between the atmosphere and the crankcase No matter the design the carburetors can be used at different angles and are very tolerant of high vibration As of the...

Page 47: ...reating a vacuum within the fuel chamber Atmosphere pressure in the fuel tank pushes the fuel through the fuel filter and fuel line The vacuum opens the inlet check valve b and allows fuel to fill the...

Page 48: ...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 pul...

Page 49: ...low 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 c...

Page 50: ...ere 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 throt...

Page 51: ...sition 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...

Page 52: ...essure areas within the carburetor throat The venturi of the carburetor throat now takes over to create the low pressure area The low pressure created by the venturi draws fuel into the air stream It...

Page 53: ...r 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 Th...

Page 54: ...Single Needle Single needle carburetors use a fixed high speed fuel jet No adjustment of this jet can be made A low speed mixture needle valve c is used to adjust the low speed jet L which controls t...

Page 55: ...e carburetor connected through an orifice drilled in the carburetor adapter depending on carburetor version During the compression stroke the vacuum created in the crankcase is transmitted to the carb...

Page 56: ...The vacuum draws the control diaphragm towards the carburetor throat and in turn opens the inlet needle valve allowing fuel into the fuel chamber i Suction at the engine intake draws fuel out of the f...

Page 57: ...air is delivered to the engine which allows the engine to start more readily than a lean mixture See Graphic wc_gr002894 Idle Speed At idle speed only a small amount of air flow through the carburetor...

Page 58: ...turning the valve the fuel air mixture can be made richer or leaner affecting the engine s speed rpm In fixed jet primary idle bypass versions 3 a separate port r leads from the fuel chamber through...

Page 59: ...d mixture needle valve regulates the engine speed By turning the valve the fuel air mixture can be made richer or leaner affecting the engine s speed rpm In single needle versions engine suction also...

Page 60: ...in discharge port e into the throat of the carburetor The fuel mixes with the air stream flows through the carburetor adapter and into the engine crankcase In summary the wider the throttle is open th...

Page 61: ...pressure differential needed to create the vacuum This vacuum draws the control diaphragm towards the carburetor throat and in turn opens the inlet needle valve allowing fuel into the fuel chamber Su...

Page 62: ...discharge ports Because the choke is closed the amount of air flowing through the carburetor is very restricted As a result a rich fuel mixture fuel mixed with a relatively small amount of air is del...

Page 63: ...WM 80 Repair Carburetor Basics wc_tx000522gb fm 63 Notes...

Page 64: ...d with Tillotson carburetors that have single or dual mixture needle valves This adapter is used on rammers 3 This straight through style adapter is used with both Bing and Tillotson carburetors that...

Page 65: ...WM 80 Repair Carburetor Basics wc_tx000522gb fm 65 d d d d d 1 2 3 e 4 f g 5 6 h wc_gr007414...

Page 66: ...ow 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...

Page 67: ...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 1...

Page 68: ...ure 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 an...

Page 69: ...Slide the throttle cable e through the adapter f and reconnect it to the clamp d 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 R...

Page 70: ...ottle 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 scre...

Page 71: ...WM 80 Repair Carburetor Replacement wc_tx000522gb fm 71 Notes...

Page 72: ...retor 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 6 Remove the two socket head cap screws e holding the flange f to the car...

Page 73: ...WM 80 Repair Carburetor Replacement wc_tx000522gb fm 73 d e f g wc_gr002929 i m c a b e d f g h m j k l i...

Page 74: ...4 5 Protect the cylinder from dirt by cranking the engine until the piston is covering the intake port 6 5 Tillotson with Elbow Adapters See Graphic wc_gr002899 6 5 1 Turn off the fuel valve at the t...

Page 75: ...e 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 carburet...

Page 76: ...Carburetor Overhaul WM 80 Repair 76 wc_tx000522gb fm 7 Carburetor Overhaul 7 1 Walbro Carburetor Exploded View auto release choke models...

Page 77: ...iaphragm 24 Bulb 5 Screen 25 Valve 6 Washer 26 Air purge body assembly 7 Spring 27 Diaphragm 8 Choke shaft 28 Gasket 9 Spacer 29 Nozzle 10 Throttle lever 30 Spring 11 Screw 31 Needle 12 Swivel 32 Need...

Page 78: ...l 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 ass...

Page 79: ...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 th...

Page 80: ...countries only Remove the high and low speed needle valves x and y 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...

Page 81: ...uretor 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 Instal...

Page 82: ...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 In...

Page 83: ...g 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...

Page 84: ...Carburetor Overhaul WM 80 Repair 84 wc_tx000522gb fm 7 4 Walbro Carburetor Exploded View standard choke models wc_gr005118...

Page 85: ...asket 22 Air purge body assembly 4 Diaphragm 23 Diaphragm 5 Screen 24 Gasket 6 Washer 25 Nozzle 7 Spacer 26 Idle needle 8 Lever 27 Power needle 9 Screw 28 Spring 10 Inlet needle 29 Screw 11 Metering l...

Page 86: ...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...

Page 87: ...ring 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...

Page 88: ...Align the hole in the main nozzle zz with the passage of the high speed 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 I...

Page 89: ...verhaul wc_tx000522gb fm 89 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 n...

Page 90: ...d to the throttle shaft u 7 6 6 Install the spring p and ball o Install the spacer n and choke shaft m 7 6 7 Install the shutter l butterfly 7 6 8 Install the inlet needle i spring g pin k and meterin...

Page 91: ...m 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 t...

Page 92: ...pair 92 wc_tx000522gb fm 7 7 Tillotson Carburetor Exploded View wc_gr002901 1 2 3 4 6 5 40 8 9 10 38 37 11 7 13 12 14 27 26 25 24 23 15 16 17 18 19 22 21 20 39 21 20 20 21 22 43 41 42 43 41 29 28 30 3...

Page 93: ...ug 6 Elbow fitting 28 Bushing 7 Screw w lock washer 29 Bushing 8 Clip 30 Choke shaft 9 Spring 31 Throttle shaft 10 Ball 32 O Ring 11 Choke shutter 33 Spring 12 Needle fuel inlet 34 Gasket 13 Spring 35...

Page 94: ...M 80 Repair 94 wc_tx000522gb fm 7 9 Bing Carburetor Exploded View wc_gr002902 1 2 3 4 5 6 7 8 9 11 19 38 18 20 10 14 12 13 23 15 17 21 24 22 22 21 25 26 28 29 27 30 31 32 33 34 35 36 39 41 40 42 41 40...

Page 95: ...ver 6 Throttle control lever 29 Spring 7 Carburetor body 30 Needle 8 Choke 31 Clamp 9 Spring 32 Nut 10 Idle stop screw 33 Screw 11 Choke lever 34 Sealing ring 12 Nut 35 Cover 13 Main jet 62 36 Fuel fi...

Page 96: ...or the engine may flood or run rich The elastic tip must be in good condition Replace the needle if the tip becomes hard or brittle Keep the seating area clean and free from dirt Clean it using compr...

Page 97: ...ever 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 Check the distance with...

Page 98: ...to the valve seats may result Preset the fuel jets as follows 8 3 2 Open the low speed needle valve 1 1 2 revolutions counterclockwise 8 3 3 Open the high speed needle valve 3 1 2 revolutions counterc...

Page 99: ...djustments are necessary continue with step 5 Note After full throttle operation allow engine to idle one minute before making any adjustments 8 3 10 When making carburetor adjustments turn the valve...

Page 100: ...t 1 revolution turn counterclockwise 8 3 15 Start the engine and allow it to warm up to operating temperature by running it at high speed for 3 6 minutes 8 3 16 Set the engine idle speed with the engi...

Page 101: ...Clean metering lever Loose mounting bolts Tighten mounting bolts Main nozzle plugged Replace the main nozzle Fuel hose plugged Replace the fuel hose Engine will not idle Idle speed incorrectly adjuste...

Page 102: ...ne will not accelerate Idle mixture is too lean Adjust idle mixture Diaphragm cover plate loose air leak Check and tighten the cover plate Inlet control lever is set incor rectly Correct the lever adj...

Page 103: ...h speed adjustment incor rect Readjust the high speed High speed mixture needle valve damaged Replace the high speed mixture needle valve The size of the fixed jet is incor rect Replace the fixed jet...

Page 104: ...d that neither personal injury nor damage to the component will result 10 2 Special Tools The following list of special tools will be needed when disassembling and assembling the machine Tool Part Num...

Page 105: ...enclosed in parentheses These numbers refer to the item numbers shown on the assembly drawings and other detailed drawings They are included to aid the mechanic in identifying parts and assembling com...

Page 106: ...retor 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 Dis...

Page 107: ...tall 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 s...

Page 108: ...ase 10 7 6 Tilt the engine down and away to remove it from the crankcase NOTICE The rammer tips easily when the engine is removed DO NOT run the engine while it is off the machine unless the clutch e...

Page 109: ...WM 80 Repair Disassembly and Assembly wc_tx000523gb fm 109 wc_gr002935 d a b e c d...

Page 110: ...over 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 6 Remove the three socket head cap screws f that hold the engine to the crankcase and rem...

Page 111: ...WM 80 Repair Disassembly and Assembly wc_tx000523gb fm 111 wc_gr002937 a b d e c f...

Page 112: ...impact wrench is not available rap the wrench handle sharply to help break the nut loose Note Loosen the nut but do not completely remove it from the engine crankshaft This will protect the crankshaf...

Page 113: ...WM 80 Repair Disassembly and Assembly wc_tx000523gb fm 113 wc_gr002941 a b c...

Page 114: ...and Assembly WM 80 Repair 114 wc_tx000523gb fm 10 10 WM 80 Exploded View 9 10 11 12 3 2 1 4 8 7 5 6 7 41 14 13 15 16 17 18 19 20 21 36 19 35 34 32 33 40 31 17 22 37 38 39 23 24 25 26 27 28 29 30 15 w...

Page 115: ...ton ring 25 Screw M5x20 6 Wrist pin 26 Nut M12x1 5 7 Retaining ring 27 Washer 8 Gasket 28 Screw M5x20 9 Screw M6x60 29 Flywheel housing 10 Spark plug 30 Flywheel 11 Spark plug cap 31 Locknut M3 12 Ign...

Page 116: ...Disassembly and Assembly WM 80 Repair 116 wc_tx000523gb fm 10 12 WM 80 Cross Section wc_gr002920 6 7 10 9 11 12 13 15 16 1 2 3 4 5 8 14...

Page 117: ...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 gas...

Page 118: ...the existing nuts attach a new intake gasket c and the intake cover d over the intake port Attach an 1 8 inch NPT hose barb e to the intake cover 10 14 6 Be sure that the spark plug and all the hardw...

Page 119: ...WM 80 Repair Disassembly and Assembly wc_tx000523gb fm 119 wc_gr002940 a c d e f b...

Page 120: ...e the cylinder and piston carry out the following procedure 10 15 1 Disconnect and remove the spark plug from the engine 10 15 2 Disconnect the fuel line and the throttle cable from the engine 10 15 3...

Page 121: ...WM 80 Repair Disassembly and Assembly wc_tx000523gb fm 121 b c f e g d c wc_gr002907...

Page 122: ...f rings before requiring replacement Cylinder Wear Remove the cylinder from the crankcase Carefully remove any carbon deposits from the cylinder head exhaust port and piston head Inspect the piston an...

Page 123: ...WM 80 Repair Disassembly and Assembly wc_tx000523gb fm 123 h wc_gr002908...

Page 124: ...the notch in rings facing up and around the pins c that are located in each groove of the piston 10 17 3 Install the needle bearing d in the connecting rod e Position the piston over the connecting r...

Page 125: ...WM 80 Repair Disassembly and Assembly wc_tx000523gb fm 125 1 2 3 4 wc_gr002909 c a b e d g f h i...

Page 126: ...necting rod b for any vertical play there should be none Side play is allowable If any vertical play is present the complete crankshaft assembly must be replaced 10 18 4 Turn the crankshaft by hand an...

Page 127: ...WM 80 Repair Disassembly and Assembly wc_tx000523gb fm 127 a wc_gr002910 b OK OK...

Page 128: ...f the crankcase around the bearing using a propane torch 10 19 5 While the crankcase is hot tap firmly on the end of the crankshaft with a plastic mallet to remove the crankcase from the shaft Support...

Page 129: ...WM 80 Repair Disassembly and Assembly wc_tx000523gb fm 129 wc_gr002911 a b c e f d g h...

Page 130: ...heating Install the crankshaft into the warm crankcase shell Note The crankshaft should slide easily into the crankcase shell if heated sufficiently 10 20 4 Lightly oil gasket e with 2 cycle engine o...

Page 131: ...WM 80 Repair Disassembly and Assembly wc_tx000523gb fm 131 wc_gr002912 f e a h g d a b c a f e...

Page 132: ...the ring halves to seat them under the bearing 10 21 2 Secure the complete assembly in the crank support tube 10 21 3 Using an Arbor press press on the end of the crankshaft until the bearing breaks...

Page 133: ...WM 80 Repair Disassembly and Assembly wc_tx000523gb fm 133 a c d wc_gr002913 e b...

Page 134: ...place it on the support tube so that the counterweight on the crankshaft is fully supported 10 22 2 Lubricate the inner bearing race and the crankshaft using 2 cycle engine oil 10 22 3 Using the pushe...

Page 135: ......

Page 136: ...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 Pl...

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