Description

Wacker Neuson BS 50, BS 500, BS 60, BS 600, BS 700 2010 Repair Manual

If you’re wrenching on a Wacker Neuson rammer and you don’t have the factory repair manual in front of you, you’re working blind. I’ve seen guys try to pull a clutch bell housing with a pickle fork and a prayer because they guessed the bolt pattern. That costs time and parts. This manual—148 pages of OEM-sourced procedures—gives you the exact specs for Wacker Neuson BS 50, BS 500, BS 60, BS 600, BS 700 2010 Repair Manual models. It covers BS 65, BS 650, DS 70, and DS 720 as well, but the core lineup is what most shops see. The copyright is 2010 from Wacker Neuson Corporation, Menomonee Falls, WI. No third-party reprints. This is the original factory document, scanned clean and searchable.

I’ve been turning wrenches for 28 years, and I can tell you that the difference between a job that goes smooth and one that turns into a two-day headache is having the right torque value on page 73 instead of guessing. This manual has them—every fastener torque for the BS 500 crankcase, the BS 60 shock mounts, the clutch drum on the BS 700. You name it.

Safety Information: Why It’s More Than a Liability Page

Section 1 starts on page 9 with signal words and machine description. Wacker Neuson doesn’t mess around. They spell out operating safety, operator safety around internal combustion engines, and service safety. If you’ve ever had a rammer kick back because you skipped the spring system lockout, you’ll appreciate the detail. Page 11 covers the specific hazards of working on a machine that stores energy in heavy springs. Read it.

Tools and Maintenance Schedules: What You Need Before You Start

Section 2 lists recommended special tools and repair tools on pages 17-18. You don’t need a full Snap-on box, but you’ll need a flywheel puller and a clutch holding tool for the BS 600 and BS 700. Maintenance schedules start on page 19. There are separate schedules for each model family: BS 50/60/70-2, BS 65, BS 500/600/700/650, and the DS series. The BS 50-2i and BS 500-oi each get their own schedule too. Hours-based intervals, not calendar. If you’re serious about fleet maintenance, this is your baseline.

Wacker Neuson BS 50, BS 500, BS 60, BS 600, BS 700: Engine and Upper Machine Components

Section 4 (page 25) dives into engine and upper machine components. You’ll find procedures for removing the silencing cover, replacing throttle controls (2010 and later 2-stroke and 4-stroke models separately), guide handles, stop switches, shock mounts, the Tillotson carburetor on the BS 500/600/700/650, fuel lines, fuel tank, muffler, and engine cooling fins. Pages 58-64 cover replacing the WM 80 carburetor and the WM 80 engine for both pre-2010 and 2010+ models. Clutch work is on pages 78-82, with separate subsections for 2- and 4-stroke models, DS 720 only, and DS 70 only. Don’t mix them up.

Ramming System: Bellows, Springs, and Lubrication

Section 5 (page 84) is where the real work happens. Bellows replacement, spring system cover removal and installation (page 90), spring system inspection (page 98), protective pipe, and ramming system lubrication. Lubrication differs between the BS 500/600/700/650/DS 720 and the BS 50/60/70/BS 65/DS 70. Get that wrong and you’ll be buying a new bellows in 50 hours. Also note the spring system cover torque spec on page 93—it’s in inch-pounds, not foot-pounds.

Troubleshooting: When the Rammer Jumps Erratically

Section 9 (page 124) has six troubleshooting charts: engine hard to start, engine doesn’t start, engine doesn’t accelerate or runs poorly, engine overheats, rammer doesn’t tamp, rammer jumps erratically. The last one is a common complaint—usually a broken spring or incorrect lubrication. The manual walks you through it without guesswork. I’ve used this section to fix a BS 600 that had been sitting in a rental yard for months.

Technical Data: Torque Specs and Fluid Capacities

Section 10 (page 128) gives you full technical data for each model: BS 50-2, BS 50-4, BS 500, BS 500S, BS 50-2i, BS 500-oi, BS 60/70-2, BS 60-4, BS 600/700, BS 600S, BS 60/70-2i, BS 600/700-oi, BS 600/700 High Altitude, BS 65-V, BS 650, DS 70, and DS 720. You get bore and stroke, displacement, compression ratio, fuel and oil capacities, spark plug gap, and all fastener torques. For example, the BS 50-2i uses a WM 80 engine with a bore of 50 mm. The BS 700 high altitude version has different jetting specs—all listed.

If you work on other Wacker gear, check out the Wacker Vibratory Rammers BS/DS Series Repair Manual for additional models. The Wacker Roller RD 27 Repair Manual – Section: Lubricating Articulated Steeri is useful if you service rollers too, and the Wacker PT, PG, PD Pumps Repair Manual covers pumps. For understanding the mechanical principles behind the ramming action, think of it like a Manual Transmission—gears and clutches need precise timing. Broader industry context can be found in the Automotive Industry Overview.

FAQ

Does this manual cover the BS 70 models?

Yes, but those are listed separately under DS 70 and DS 720 in the manual.

Can I use this manual for older models like pre-2010?

Partially. The manual includes procedures for pre-2010 models in several sections, such as replacing the WM 80 engine (pre-2010) on page 64 and throttle control for pre-2010 models in section 4.4. However, the primary focus is 2010 and later. If you have a machine with serial numbers listed in the foreword, you’re covered. For earlier machines, cross-reference with the machine’s serial number and the specific component sections. The maintenance schedules also differentiate between BS 50/60/70-2 and BS 500/600/700 variants. So you can use it, but pay attention to the model-specific callouts. I’d still recommend getting the correct year-specific manual if available.

Get the factory spec data you need. Don’t trust aftermarket documentation that skips torque values. This manual has every page scanned from the original Wacker Neuson 2010 binder. Access the Factory Manual now and start your job with the right numbers.