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Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement

Introdução

Use this guide to remove or replace the clutch drum on a Wacker BS50-4AS REV 101 (2019) Vibrator/Rammer.

This model requires up to 0.7 liters of SAE 10W-40 oil to replace drained oil.

O que você precisa

  1. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Disconnect the spark plug wire: passo 1, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Disconnect the spark plug wire: passo 1, imagem 2 %32

    • Ensure the device is powered down and cool to the touch before starting your repair.

    • Firmly grip the base of the spark plug wire's connector and pull it away from the spark plug to disconnect it.

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  2. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Loosen the sight gauge: passo 2, imagem 1 %32

    • Use a 1-1/16 inch socket to break loose the oil sight gauge near the bottom of the device.

    • Do not fully remove the oil sight gauge yet with the device in this upright position.

    • The oil sight gauge doubles as the oil drain and fill plug.

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  3. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Prepare a drain pan: passo 3, imagem 1 %32

    • Lay the device down horizontally with the oil sight gauge facing down.

    • Position a shallow oil drain pan underneath the sight gauge.

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  4. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Drain the oil: passo 4, imagem 1 %32

    • Remove the oil sight gauge.

    • Let the oil drain until drips are infrequent.

    • Replace and retighten the oil sight gauge.

    • This model requires 0.7 liters of SAE 10W-40 oil.

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  5. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Support the device: passo 5, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Support the device: passo 5, imagem 2 %32

    • Flip the device onto the work surface such that the motor and handles face up.

    • Place two separate blocks of wood underneath the seam between the leg assembly and crankcase.

    • Once the two halves separate, each side will need to be supported.

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  6. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the leg assembly bolts: passo 6, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the leg assembly bolts: passo 6, imagem 2 %32

    • Use an 8 mm hex key socket to remove the four bolts securing the leg's guiding cylinder to the crankcase.

    • You may need to use an impact driver or breaker bar to break these bolts loose.

    • During reassembly, ensure each bolt has its accompanying lock washer.

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  7. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Begin to separate the halves: passo 7, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Begin to separate the halves: passo 7, imagem 2 %32

    • Pull the leg assembly away from the rest of the device.

    • Ensure each half stays adequately supported.

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  8. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Reveal the pin: passo 8, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Reveal the pin: passo 8, imagem 2 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Reveal the pin: passo 8, imagem 3 %32

    • Continue to separate the two halves by compressing the bellows until the nylon plug covering the piston pin is visible.

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  9. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Procedure tip: passo 9, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Procedure tip: passo 9, imagem 2 %32

    • Tip: To compress the bellows, insert a block of wood between the two halves and pivot the leg assembly off of the crankcase to compress the guide cylinder, revealing the pin.

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  10. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the pin: passo 10, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the pin: passo 10, imagem 2 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the pin: passo 10, imagem 3 %32

    • Use an appropriately-sized punch and a ball-peen hammer to tap the pin out of its hole on the guide piston until it is no longer securing the connecting rod.

    • Once the piston and connecting rod are separated, the two halves become completely disconnected and will need to be adequately supported.

    • During reassembly, ensure that both nylon plugs are reinstalled and are flush with the surface of the guide piston.

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  12. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the leg assembly: passo 11, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the leg assembly: passo 11, imagem 2 %32

    • Remove the leg assembly from the crankcase.

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  13. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Completely remove the pin: passo 12, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Completely remove the pin: passo 12, imagem 2 %32

    • Use a punch and hammer to tap the pin out of the guide piston.

    • Once the pin is removed, the guide cylinder may spring up due to the compression of the bellows.

    • During reassembly, the bellows will need to be compressed to uncover the pin hole on the guide piston.

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  14. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Support the device in an upright position: passo 13, imagem 1 %32

    • Use wood blocks to support the device on the work surface, motor facing up.

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  15. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the engine guard: passo 14, imagem 1 %32

    • Use a 6 mm hex socket to remove the engine guard bolt securing the cable guide.

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  16. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement: passo 15, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement: passo 15, imagem 2 %32

    • Pull the cable guide away from the engine guard.

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  17. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement: passo 16, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement: passo 16, imagem 2 %32

    • Use a 6 mm hex socket to remove the three remaining bolts securing the engine guard: two on the outer edge and one near the crankcase.

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  18. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement: passo 17, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement: passo 17, imagem 2 %32

    • Remove the engine guard.

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  19. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the motor nuts: passo 18, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the motor nuts: passo 18, imagem 2 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the motor nuts: passo 18, imagem 3 %32

    • Use a 13 mm wrench to remove the four nuts securing the motor to the crankcase, two on each side.

    • When removing the nuts, the crankcase bolts may also become unthreaded, preventing its accompanying nut from being removed. This is fine.

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  20. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Move the muffler shroud: passo 19, imagem 1 %32

    • Use a 10 mm socket to remove the bolt securing the muffler shroud.

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  21. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement: passo 20, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement: passo 20, imagem 2 %32

    • Lower the muffler shroud away from the motor, down onto the crankcase.

    • Do not fully remove the muffler shroud.

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  22. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Separate the motor from the crankcase: passo 21, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Separate the motor from the crankcase: passo 21, imagem 2 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Separate the motor from the crankcase: passo 21, imagem 3 %32

    • Tilt the device down onto its side, supporting both the crankcase and motor with blocks of wood.

    • The motor is loose from the crankcase, so support the motor as you lower the device down.

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  23. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement: passo 22, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement: passo 22, imagem 2 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement: passo 22, imagem 3 %32

    • Hold the crankcase steady and pull the motor directly away from it.

    • Ensure each half stays adequately supported.

    • The motor is still attached to the rest of the device via various hoses and cables, so don't attempt to completely remove it.

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  24. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the crankcase cover bolts: passo 23, imagem 1 %32

    • Use an 8 mm hex socket to remove the four bolts securing the crankcase cover.

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  25. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Separate the crankcase cover from the crankcase: passo 24, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Separate the crankcase cover from the crankcase: passo 24, imagem 2 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Separate the crankcase cover from the crankcase: passo 24, imagem 3 %32

    • Any excess oil that did not drain out of the drain plug may leak out here. Be prepared with a shop rag or shop towel to catch any drips.

    • Insert a flathead screwdriver into one of the side gaps between the crankcase cover and the crankcase.

    • Twist the screwdriver to begin to pull the crankcase cover away from the crankcase.

    • Repeat for the opposite side gap, and repeat until the crankcase cover comes loose from the crankcase.

    • During reassembly, check that the crankcase cover O-ring is in good condition, and replace it if it is cracked or deformed.

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  26. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the crankcase cover: passo 25, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the crankcase cover: passo 25, imagem 2 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the crankcase cover: passo 25, imagem 3 %32

    • Use your fingers to pull the crankcase cover off of the crankcase.

    • Feed the connecting rod around the clutch drum shaft and out through the crankcase cover hole.

    • During reassembly, feed the connecting rod around the clutch drum shaft and ensure the helical gears fully mesh.

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  27. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the clutch drum snap ring: passo 26, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the clutch drum snap ring: passo 26, imagem 2 %32

    • Use a pair of snap ring pliers to remove the snap ring securing the clutch drum to the crankcase bearing assembly.

    • During reassembly, ensure the clutch drum shaft is fully seated in the bearing assembly before attempting to reinstall the snap ring.

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  28. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Tap out the clutch drum: passo 27, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Tap out the clutch drum: passo 27, imagem 2 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Tap out the clutch drum: passo 27, imagem 3 %32

    • Use a rubber mallet to tap the end of the clutch drum shaft through its hole on the top of the crankcase until it becomes loose enough to be moved by hand.

    • During reassembly, reseat the clutch drum into the bearing assembly by tapping it by the drum end.

    • Oil the new clutch drum shaft to ease installation.

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  29. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the clutch drum: passo 28, imagem 1 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the clutch drum: passo 28, imagem 2 %32 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Clutch Drum Replacement, Remove the clutch drum: passo 28, imagem 3 %32

    • Push the clutch drum shaft with your fingers until it can be gripped from the top of the crankcase.

    • Since the motor is still connected to the crankcase, you may need to shift the motor's position on the wood blocks in order to fully remove the clutch drum.

    • Remove the clutch drum.

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Conclusão

To reassemble your device, follow these instructions in reverse order.

After reassembly, tilt the device upright and check the oil level through the sight glass. The oil should cover 1/2 to 3/4 of the sight glass to be considered full. This model requires up to 0.7 liters of SAE 10W-40 oil.

Autor(a)

com 1 outro contribuidor

Carsten Frauenheim

Membro desde: 03/10/20

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