GPR99/GPR135 Manual
Contents
1. 1 9 16241 HELIX PIN CARRIER 1 10 16242 SHIFT SHAFT 1 11 16254 DOWEL PIN M10 x 70 1 12 16264 BEARING COVER EXCITER 1 13 16446 FITTING 90DEGREE PARKER 1 14 17023 KIT BLEEDER SCREW 1 15 17275 SHIFT SPOOL 1 16 17276 HOUSING HYDRAULIC 1 17 17277 GASKET HOUSING 1 18 17278 GASKET CYLINGER 1 19 17279 CYLINDER COVER 1 20 17280 CYLINDER PLATE MOUNT 1 21 F042004FWS FWS 1 4 20 x 1 2 ZP 4 22 F051508FWS FWS 5 16 18 x 1 ZP 8 17368 REBUILD KIT LOWER HYDRAULIC INCLUDES ITEMS 4 6 15 17 amp 18 27 DESCRIPTION QTY 1 11162 SCREW 1 4 x 1 00 TEKS 2 2 16410 THREADED ROD 1 2 13 x 3 00 PLATED 1 3 16493 HANDLE BUMPER 1 4 16543 HANDLE MOUNT 2 5 17058 TUBE CAP ROUND 3 6 17177 RETAINING RING EXTERNAL 1 00 2 7 19268 THROTTLE LEVER 1 8 19411 TUBE HANDLE 1 9 19412 HYDRAULIC CONTROL HEAD COMPLETE 1 10 19414 BRACKET SHIFT HANDLE 1 11 19415 HANDLE BAR LEFT 1 12 19416 HANDLE BAR RIGHT 1 13 19417 TUBE CAP SQUARE 3 1 2 1 14 19418 PLAIN BEARING 1 00 I D 2 15 19419 BRACKET BUMPER MOUNT 1 16 19420 SHIFT LINKAGE ASSEMBLY 1 17 19422 CONTROL HANDLE 1 18 19442 SHOULDER BOLT 5 16 x 3 4 1 4 20 2 19 19519 HANDLE GRIP 1 00 I D x 4 1 2 3 20 19526 SHAFT CONTROL 1 21 FO23204FSS SOCKET HEAD SREW 88 32 x 1 2 PLATED 2 22 F0232HN2. 3 TheMBW Reversible Plate Compactor is designed to slowly move forward without application of the control lever The number of passes needed to reach the compaction level desired will depend on soil type and moisture Maximum compaction of the soil has been reached when excessive kickback is noticed in the compactor Stopping Engine 1 To stop the compactor from traveling forward return the engine throttle to idle position 2 Whenever possible it is recommended to let the engine idle for one or two minutes before stopping 3 Gas engines Turn the switch on the engine to STOP position Diesel engines Move the throttle control to the STOP position 4 Turn off the fuel valve where applicable Lifting Transporting 1 Lift unit by center lifting eye on rollcage 2 unit must be transported in the upright position DO NOT lay machine on its side 3 Secure ortiedown unit using lift eye or roll cage when transporting WARNING 4 Always stop the engine before Adding fuel Leaving the equipment unattended even if only for a minute Before making any repairs or adjustments to the machine LIFT 8 SECURE HERE MAINTENANCE A Always exercise the stopping procedure before WARNING A servicing or lubricating the unit After servicing the unit replace and fasten all guards shields and covers to their original positions before resuming operation Maintenance Schedule A
3. Follow the steps for Bleeding And Adjustment Of Hydraulic Controls section of this manual Reinstall the side cover removed in step 2 using LOCTITE 2243 on the screw threads Lower engine deck to level position and tighten hex head bolts 32 Bleeding And Adjustment of Hydraulic Controls Refer to figure 2 on next page 1 11 Remove the six flange screws 2 securing the side cover 3 to the recoil oil drain side of the baseplate Loosen hex head bolts 1 on the oil drain side only Lift the engine deck up to allow the side cover to be removed Position the handle in the operation position as shown 10 11 12 13 Check the hydraulic line 4 for loose fittings and tighten as needed Remove the socket head plug 7 from the control head Loosen the bleeder screw 5 located at the hydraulic control housing of the exciter Fill the control head with hydraulic fluid as shown in the Maintenance Checking Hydraulic fluid section of this manual Place a drip pan or shop rag below the bleeder to catch any excess oil Slowly operate the control handle 46 from the forward to the reverse position while watching the bleeder screw hole for air bubbles If no air bubbles are seen hold the control handle in the reverse position and tighten the bleeder If air bubbles are still present at the end of the stroke refill the control head with hydraulic oil and repeat this procedure After the air b
4. Always verify fluid levels and check for leaks after changing fluids CAUTION A Do not drain oil onto ground into open streams or down sewage drains SYSTEM MAINTENANCE 11 11 01 loue an PEAR Engine Refer to engine operator owner manual X Clean cooling fins X X Belts Check for wear and retighten X Exciter Check oil level X Check for oil leaks X Change oil X X Tighten Bolts X X Hydraulics Check level and refill X Hardware Check and tighten as needed X X Shockmounts Check for cracks or tears X X 1 Check all hardware after the first 5 hours of use then follow the maintenance schedule Fluid Levels SYSTEM FLUID VOLUME RECOMMENDED OIL Exciter GPR99 32 oz 0 95 Liter MBW Ground Pounder Exciter Oil GPR135 32 oz 0 95 Liter MBW Ground Pounder Exciter Hydraulic Oil GPR99 5 oz 24 Liter Chevron AW ISO32 or Rykon 32 GRP135 5 oz 24 Liter Chevron AW ISO32 or Rykon 32 Engine Refer to engine operator owner manual 1 MBW 01058 6 Pack 8 oz bottles MBW 17320 1 quart 32 oz Engine Maintenance Refer to the engine owner s manual for maintenance intervals and procedures Cleaning Plate Remove any excess debris which may get into the housing of the unit Engine Speed 1 Engine speed is factory set according to the speeds listed in the Specifications section of this manual Do not tamper with
5. 12887 HONDA ENGINE 13 HP GX390 1 1 4 09375 V BELT B 44 1 1 5 16576 CLUTCH 1 1 6 16580 SPACER CLUTCH 1 1 7 16665 WASHER MOUNT 1 1 8 16676 BELT GUARD 1 1 9 16974 HOSE OIL DRAIN 1 1 10 17467 BELT GUARD MOUNT 1 1 11 F052408FSS FSS 5 16 24 x 1 ZP 4 4 12 F061618HCS HCS 3 8 16 x 2 1 4 GR 5 ZP 4 4 13 0616365 5 1 5 5 3 8 16 x 4 1 2 GR 8 ZP 4 4 14 F062408FSS FSS 3 8 24 x 1 ZP 1 1 15 FO6LW LOCKWASHER 3 8 ZP 4 4 16 FO6PW WASHER 3 8 ZP 8 8 Q2893907 AIR CLEANER HONDA 11 amp 13 HP NOT SHOWN 33 2 ih A om 4 Ss CL 8 EE LAS BA Y EA EJ Diesel Engine Assembly DESCRIPTION QTY 1 00808 SQUARE KEY 1 4 x 1 3 4 1 2 01428 CABLE CLAMP BATTERY 2 3 09275 HHCS M6 x 1 0 x 20 ZP 3 4 09375 V BELT B 44 1 5 16523 FITTING PLUG HYDRAULIC 1 6 16556 J BOLT 1 4 20 x 6 1 2 2 7 16576 CLUTCH 1 8 16578 FITTING ADAPTER HYDRAULIC 1 9 16580 SPACER CLUTCH 1 10 16600 BATTERY CABLE BLACK 4 GA x 19 1 11 16604 BATTERY CABLE RED 4 GA x 48 1 12 16621 BELT GUARD 1 13 16665 WASHER MOUNT 1 14 16969 MOUNTING IGNITION BOX 1 15 17144 ENGINE HATZ DIESEL 1B40 1 16 17170 SHOCK MOUNT 30 DUROMETER 4 17 17468 MOUNT BELT GUARD 1 18 19483 BRACKET
6. Retighten the four hex head capscrews Reinstall the beltguard Checking Hydraulic Fluid 1 To avoid contaminating the hydraulic oil clean all dirt amp debris from around the fill plug on handle Remove fill plug With handle in operating position oil level to be at bottom edge of inside hole as shown FILL PLUG FLUID LEVEL TO BE UP TO BOTTOM EDGE OF INSIDE HOLE SERVICE Assembly and disassembly should be preformed by a Service Tools service technician who has been factory trained on MBW equipment the unit should be clean and free of debris Part No Description Pressure washing before disassembly is recommended 16129 Rubber Test Mat Prior to assembly wash all parts in a suitable cleaner or solvent 16031 Decal Set Check moving parts for wear and failure Refer to the 17368 Kit Rebuild Lower Hydraulic Replacement Section of this manual for tolerances and 19606 Kit Rebuild Upper Hydraulic replacement cycles All shafts and housings should be oiled prior to pressing Main Disassembly Procedure Diesel Engine bearings Also ensure that bearings are pressed square and are seated properly Refer to Main Assembly page 22 for disassembly 1 Clean all visible debris from the machine before servicing All bearings should be replaced when rebuilding any exciter or gearbox
7. THROTTLE ENGINE 1 19 19540 BATTERY BOX 1 20 19545 COVER BATTERY BOX 1 21 19547 MOUNT BATTERY BOX 2 22 19549 BRACKET BATTERY HOLD DOWN 1 23 19551 BATTERY 12 VOLT SIZE U1 300CCA BUY LOCALLY HAZARDOUS TO SHIP 1 24 19624 HYDRAULIC HOSE OIL DRAIN 1 2 x 22 1 25 F042006FWS FWS 1 4 20 x 1 ZP 6 26 F0420ELN LOCKNUT 1 4 20 NYLOC 8 2T F04LW LOCKWASHER 1 4 ZP 3 28 F04PW WASHER 1 4 ZP 6 29 FO51804FWS FWS 5 16 18 x 1 2 ZP 4 30 FO51806FWS FWS 5 16 18 x 3 4 ZP 4 31 F051810HCS HCS 5 16 18 x 1 1 4 GR 5 ZP 4 32 FOSLW LOCKWASHER 5 16 ZP 4 33 FOSSW WASHER 5 16 ZP 4 34 0616365 5 SCS 3 8 161 x 4 1 2 GR 8 ZP 4 35 F062408FSS FSS 3 8 24 x 1 ZP 1 36 F081305HCS HHCS 1 2 13 x 5 8 GR 5 ZP 8 37 M10CO20FSS FSS M10 x 1 5 x 20 ZP 4 38 M12ETLW LOCKWASHER M12 EXTERNAL TOOTH 8 H50484100 AIR FILTER HATZ DIESEL 1B40 Not Shown H01635210 FUEL FILTER INSIDE TANK HATZ DIESEL H50404900 KEY STARTER HATZ 17751 CONTROL BOX HATZ 35 WARRANTY WHAT DOES THIS WARRANTY COVER MBW Incorporated MBW warrants each New Machine against defects in material and workmanship for a period of twelve 12 months New Machine means a machine shipped directly from MBW or authorized MBW dealer to the end user This warranty commences on the first day the machine is sold assigned to a rental fleet or otherwise put to first use MBW warrants each Demonstration Machine against de
8. 13 Control Head Disassembly Procedure 14 Operation 5 Baseplate Assembly Procedure 14 Introduction 5 Control Head Assembly Procedure 17 Before Operation 5 Handle Assembly Procedure 17 i 5 Final Assembly 17 Starting Gasoline Engine 5 Diesel Engine Throttle Adjustment 18 Starting Diesel Engine 5 19 Running Engine 5 Stopping e Replacement 21 Lifting Transporting 6 Main Assembly 22 Baseplate 24 7 Maintenance 7 Lower Shaft Assembly 26 Fl id Eevels AL te wzi PEPPER 27 Engine 7 Handle Assembly 28 Cleaning Plate 29 Engine 8 Control Head Assembly 30 Battery N a A
9. CN SA NS a 31 Battery Charging 8 Gasoline Engine Assembly 32 Belt Adjustment AAA OT TE RER TE 33 Checking Hydraulic Fluid 8 Diesel Engine Assembly 34 C o IS res 35 Torque ait sati ebbe ped 9 ee needs EE 36 WARNING A CALIFORNIA PROPOSITION 65 WARNING Engine exhaust and some of its constituents are known in the state of California to cause cancer birth defects and other reproductive harm SAFETY INFORMATION Introduction This Safety Alert Symbol is used to call attention to items or operations which may be dangerous to those operating or working with this equipment The symbol can be found throughout this manual and on the unit Please read these warnings and cautions along with all decals carefully before attempting to operate the unit Make sure every individual who operates or works with this equipment is familiar with all safety precautions WARNING GENERAL WARNING Indicates information important to the proper operation of the equipment Failure to observe may result in damage to the equipment and or severe bodily injury or death CAUTION A GENERAL CAUTION Indicates information important to the proper operation of the equipment Failure to observe may result in damage to the equipment Safety Precautions a n L
10. DEMONSTRATION MACHINE OR ANY OTHER MBW PRODUCT EXTENDED RAMMER WARRANTY MODELS R422 R442 R482 amp 483 This extended warranty commences on the last day of MBW s standard one year limited warranty and runs for an additional four years 48 months This extended warranty is limited to part replacement and shipping costs of rammer bellows and non metallic slide bearings only This extended warranty does not cover labor down time or any other cost beyond that of component replacement and freight This extended warranty is subject to all limitations set fourth in MBW s limited warranty above 36 NOTES 27 NOTES 38
11. FIRE PREVENTION ES BOTH SIDES 15846 01554 U S PATENT 7 165 469 19326 n 742500 801554 SPECIFICATIONS GPR135 GPR99H GPR135H GPR135DE CENTRIFUGAL FORCE 9900 Ibf 44 kN 13500 Ibf 60kN 13500 Ibf 60kN EXCITER VPM 3840 vpm 3840 vpm 3840 vpm TRAVEL SPEED 80 ft min 24 m min 78 ft min 24 m min 76 ft min 23 m min COMPACTION DEPTH 28 in 71 cm 28 in 71 cm 28 in 71 cm WIDTH x LENGTH 19 7 x 37 3 in 50 x 95 cm 19 7 x 37 3 in 50 x 95 cm 19 7 x 37 3 in 50 x 95 OPERATING WEIGHT 775 lb 352 kg 792 Ib 359 kg 854 Ib 387 kg ENGINE Honda GX390 389 cm S Honda GX390 389 cm Hatz 1B40 462 cm FUEL Gas Gas Diesel ENGINE SPEED 3600 rpm 3600 rpm 3600 rpm STARTER SYSTEM Recoil Recoil Electric start with recoil OPTIONAL PLATE EXTENSIONS 3 in 7 6 cm amp 6 in 15 2 cm 3 in 7 6 cm amp 6 in 15 2 cm 3 in 7 6 cm 6 in 15 2 cm Specifications subject to change without notice No universal method or formula has been accepted for determining Compaction Force own method or formula All manufactures employ their OPERATION Introduction MBW Inc equipment is intended for use in very severe applications They are powered by four cycle engines and are available in different sizes and a selection of engines The MBW Reversible Plate Compactor is intended to compact various
12. HEX NUT 88 32 PLATED 2 23 FO2LW LOCKWASHER 8 PLATED 2 24 F042004FWS FLANGE LOCK SCREW 1 4 20 x 1 2 PLATED 2 25 F0420ELN LOCK NUT 1 4 20 PLATED 2 26 F04PW WASER 1 4 PLATED 2 27 F051804FWS FLANGE LOCK SCREW 5 16 18 x 1 2 PLATED 4 28 F051807FWS FLANGE LOCK SCREW 5 16 18 x 7 8 PLATED 2 29 06125 SPIROL PIN 1 30 F061606FWS FLANGE LOCK SCREW 3 8 16 x 3 4 PLATED 4 31 FO61608FWS FLANGE LOCK SCREW 3 8 16 x 1 0 PLATED 4 32 F0813HN HEX NUT 1 2 13 PLATED 2 29 Control Head Assembly DESCRIPTION QTY 1 08355 HYDRAULIC FITTING 1 2 16359 WASHER SEALING METRIC 1 3 16404 O RING METRIC 30mm I D x 2 mm 1 4 16468 SLIDE BUSHING 1 5 16519 HYDRAULIC SEAL 1 6 17250 FITTING SOCKET HEAD PLUG 1 T 19427 HOUSING CONTROL HEAD 1 8 19430 SHAFT WIPER SEAL 1 9 19431 HYDRAULIC SHAFT SEAL 1 10 19433 BEARING GUIDE RING 1 11 19434 BEARING GUIDE RING 1 12 19527 PISTON SHAFT 1 13 19528 SEAL CAP FITTING 1 14 19529 ADAPTER FITTING 1 15 F0227SPP SOCKET PIPE PLUG 1 16 F1214SPP PIPE PLUG 3 4 14 NPTF 1 KITS 19606 REBUILD KIT UPPER INCLUDES ITEMS 2 3 5 amp 8 THRU 11 31 DESCRIPTION GPR99 GPR135 1 00259 SHIM 1 1 4 O D x 005 THK 2 00808 KEY SQUARE 1 4 x 1 3 4 1 1 3
13. MBW Inc 250 Hartford PO Box 440 Slinger WI 53086 0440 Phone 262 644 5234 Fax 262 644 5169 Email mbw mbw com Website www mbw com MBW UK Ltd Units 2 amp 3 Cochrane Street Bolton BL3 6BN England Phone 01204 387784 Fax 01204 387797 MBW FRANCE S A R L Z A d Outreville 11 rue Jean Baptiste N ron 60540 BORNEL FRANCE Phone 33 0 3 44 07 15 96 Fax 33 0 3 44 07 41 28 Email mbwfrance free fr 21 PART DESCRIPTION 99H 135H 135DE 1 05477 SWIVEL THROTTLE CABLE 1 1 2 10088 GROMMET 1 1 1 3 16442 BELLOWS 1 1 1 4 16607 BASEPLATE ASSEMBLY GPR135 1 1 16609 BASEPLATE ASSEMBLY GPR99 1 20311 BASE PLATE ASSEMBLY GPR160 5 16653 RUBBER MAT 1 1 1 6 16654 MOUNTING PLATE RUBBER MAT 1 1 1 T 17160 SHOCKMOUNT GPR99 4 17419 SHOCKMOUNT GPR135 4 4 20320 SHOCKMOUNT GPR160 8 17326 EXTENSION PLATE 3 WIDE OPTIONAL SEE KIT 17337 2 2 2 17333 EXTENSION PLATE 6 WIDE OPTIONAL SEE KIT 17338 2 2 2 9 17335 BUSHING USED WITH EXTENSION PLATES OPTIONAL 4 4 4 10 17340 POP PIN 1 1 1 11 17402 SPINDLE HANDLE MOUNT 2 2 2 12 17434 COVER SIDE 2 2 2 13 17435 GUARD HYDRAULIC COVER 1 1 1 14 17436 GUARD BELLOWS MOUNT 2 2 2 15 17462 RETAINER BELLOWS 1 1 1 16 17997 SHIM SHOCKMOUNT AS REQUIRED 17 19445 HANDLE COMPLETE 1 1 1 18 19479 THROTTLE CABLE 1 1 1 19 19533 SHOCK MO
14. MBW FRANCE SARL and written authorization for the return of merchandise or parts under the warranty must be obtained before shipment to MBW WHAT WILL MBW DO MBW s obligation under this warranty is limited to the replacement or repair of parts for a New Machine or Demonstration Machine at MBW factory branches or at authorized MBW distributors and such replacement or repair is the exclusive remedy provided hereunder Labor must be performed at an authorized MBW distributor MBW reserves the right to inspect and render a final decision on each warranty case and MBW s repair or replacement is solely within the discretion of MBW IT IS EXPRESSLY AGREED THAT THIS SHALL BE THE SOLE AND EXCLUSIVE REMEDY UNDER THIS WARRANTY UNDER NO CIRCUMSTANCES SHALL MBW BE LIABLE FOR ANY COSTS LOSS EXPENSE DAMAGES SPECIAL DAMAGES INCIDENTAL DAMAGES OR PUNITIVE DAMAGES ARISING DIRECTLY OR INDIRECTLY FROM THE USE OF THE NEW MACHINE OR DEMONSTRATION MACHINE WHETHER BASED UPON WARRANTY CONTRACT NEGLIGENCE STRICT LIABILITY OR ANY OTHER LEGAL THEORY THE FOREGOING WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY FITNESS FOR USE AND FITNESS FOR A PARTICULAR PURPOSE AND ALL OTHER OBLIGATIONS OR LIABILITY ON MBW S PART MBW NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME ON BEHALF OF MBW ANY OTHER LIABILITY OR WARRANTY IN CONNECTION WITH THE SALE OR SERVICE OF ANY NEW MACHINE
15. hydraulic system bleed system per Bleeding and Adjustment of Hydraulic Controls section of this manual Improper adjustment of hydraulic control system requires authorized MBW service repair Incorrect engine rpm reset engine rpm per Specifications section of this manual Material build up on bottom of plate remove all debris from bottom of plate Mechanical failure requires authorized MBW service repair Loss of hydraulic oil m Leaking hydraulic connections tighten connections Leaking hydraulic line replace hydraulic hose Worn or damaged piston seals requires authorized MBW service repair 19 Parts Replacement Cycles and Tolerances Bearings Replace anytime a bearing is rough binding discolored or removed from housing or shaft Clutch Replace clutch if it does not disengage below 1800 rpm Engine Components Refer to your engine manufacturer s Owner s Manual Replace any worn or damaged hardware as needed Replacement hardware should Hardware m be grade 5 and zinc plated unless otherwise specified Safety Decals Replace if they become damaged or illegible Seals amp Gaskets Replace if a leak is detected and at every overhaul or tear down V Belts Replace if cracked torn or stretched to the point the belt won t tension properly Exciter Oil Replace once every season or every 250 hours 20 REPLACEMENT PARTS The warranty is stated in this book
16. shaft covers 7 on the pulley side and 418 on the hydraulic side Secure each cover with four hex head flange screws 823 using LOCTITE 243 on the bolt threads and torque the flange screws to 13 ft Ibs See the figure 3 for LOCTITE 515 gasket maker application Check idler shaft for minimum of 020 end play after covers are installed and the bolts are torqued Install the 90 degree fitting 2 containing the roll pin 20 into the bearing cover 18 using LOCTITE 565 sealant on the threads Make sure the port for the breather faces the top of the baseplate housing Install the breather 3 into the 90 2 degree fitting Install the exciter weights 17 on the idler shaft 88 and secure with four socket head cap screws 24 using LOCTITE 243 thread locker sealant and torque the cap screws to 32 ft Ibs Press one bearing inner race onto one end of the input shaft 16 Note Make sure the bearings and their inner races are kept as a matched set The flange on the inner race goes toward the shoulder of the shaft Install the input gear 10 onto the input shaft 16 and slide to the end with the bearing inner race Press the other bearing inner race onto the input shaft 16 Install the input shaft subassembly into the baseplate with the keyed end toward the left side pulley side of the base plate Install the pulley side shaft cover 9 containing the shaft seal 5 over the input shaft on the pulle
17. to Main Assembly page 22 49 50 51 52 53 16 Install the side cover 12 on the pulley side of the baseplate housing and secure with six hex head flange screws 823 using LOCTITE 243 thread locker sealant Install the bellows into the bellows mount plate 814 and secure it to the baseplate with four hex head flange screws 24 Note spacer washers 29 between plates 14 Connect the hydraulic line 22 to the 90 degree fitting on the hydraulic housing Install the grommet 2 into the hydraulic guard 13 Guide the hydraulic line 22 through the grommet 82 the hydraulic guard 13 and secure the guard to the hydraulic side of the baseplate with the four hex head flange screws 23 Set the side cover 12 off to the side until bleeding and final assembly is done The exciter is now ready for final assembly 54 If required install the bushings 9 extension plates 48 and 1 socket head cap screws 37 to the sides of baseplate housing using LOCTITE 767 antisieze compound on the bushings and bolt threads Control Head Assembly Procedure Refer to Control Head Assembly page 30 1 Clean and dry all parts to be assembled 2 f required press the slide bushing 4 into the control housing 7 3 Press the hydraulic seal 85 onto the piston shaft 412 Be careful to orient the seal lip to face away from the guide ring groove Tip Use approved hydraulic oil
18. 2 Remove the four hex head capscrews 32 securing All gaskets and seals should be replaced after any the engine deck 20 to the baseplate 5 Use disassembly caution as the engine deck will drop down Refer to DIESEL ENGINE ASSEMBLY page 38 Sections Torque Chart of this manual for belt guard amp belt removal 3 Remove the four socket head capscrews 32 SIZE GRADE 2 GRADE 5 GRADE 8 securing the belt guard 12 to the mount plate 16 1 4 20 49 in lbs 76 in lbs 9 ft lbs on the engine 15 and remove the beltguard 1 4 28 56 in lbs 87 in lbs 10 ft lbs 4 Slide the belt 4 off the clutch 7 5 16 18 8 ft lbs 13 ft lbs 18 ft lbs 5 Remove the two flange screws 23 securing the 5 16 24 9 ft lbs 14 ft lbs 20 ft lbs bellows retainer 15 and remove the retainer 3 8 16 15 ft lbs 23 ft Ibs 33 ft lbs 6 Push the lip of the bellows 3 through the hole in the 3 8 24 17 ft lbs 26 ft lbs 37 ft lbs engine deck 1116 14 PDS 37 ft lbs 52 ft lbs 7 Disconnect the hydraulic line 21 from the control 7 16 20 27 ft lbs 41 ft lbs 58 ft lbs head in the handle assembly Keep the end of the 1 2 13 37 ft lbs 57 ft lbs 80 ft lbs hydraulic line and control head fitting free of dirt and 1 2 20 41 ft lbs 64 ft lbs 90 ft lbs debris by using tape Be careful to use a drain pan 9 16 12 53 ft lbs 82 ft lbs 115 ft lbs to catch the hydraulic oil 5 8 11 73 ft lbs 112 ft lbs 159 ft lbs 8 Use the main lift hook on the rollcage 19 to 5 8 18 83
19. 28 6 Remove the hex head flange screw 22 and washer 14 securing the pulley 19 to the input shaft 16 and remove the pulley Remove the twenty hex head flange screws 22 securing the baseplate cover 13 to the baseplate 15 and remove the baseplate cover Remove the oil drain plug 25 and completely drain the exciter oil into a drain pan Examine the oil for metal chips as a precaution to future troubles Note the position of the gear timing marks Remove the socket head capscrews 24 securing the exciter weights 17 to the shafts and remove the exciter weights Refer to LOWER SHAFT ASSEMBLY page 30 11 14 12 Place a shop rag under the hydraulic housing 16 to catch the oil and remove the four flange screws 22 securing the cylinder mount plate 20 to the input shaft cover 12 and remove the hydraulic housing 16 from the baseplate Remove the 90 degree hydraulic fitting 13 Remove the four hex head flange screws 21 securing the cylinder cover 19 to the hydraulic housing 16 and remove the cylinder cover and gasket 18 Remove the shift spool 15 from the shift shaft 10 by sliding the shift spool out of the baseplate and holding it secure while unthreading the shift spool NOTE This connection is left hand thread Refer to BASEPLATE ASSEMBLY page 28 15 16 17 18 19 20 21 22 23 24 25 26 27 Remove the plasti
20. 5846 15847 iz U S PATENT 7 165 469 ROTATING PARTS can crush and cut 813483 Keep hands away 12573 15832 ENGINE 801554 DRAIN 1584 15845 Machine may fall and cause injury or damage if lifted improperly Lift only by lift hook Weight 781 355kg 16026 GPR99 15853 GRR135 15847 ENGINE OIL DRAIN 15845 UNLEADED GASOLINE 13481 13481 ie ROTATING PARTS can crush and cut Keep hands away 12573 GPR99 15856 GPR135 15855 GASOLINE MODELS ROT rn ly could result in serious bodily injury en 13483 GPR99 15856 GPR135 15855 Check engine oil level Open fuel valve Choke engine A warm engine may not need to be choked Open throttle part way Pull starter rope After starting open choke return throttle to idle position During operation when excessive kickback is noticed maximum compaction has been reached To stop return throttle to the idle position use engine stop switch close fuel valve Safety Decals GPR99 135 Decal Set 16031 19492 HYDRAULIC OIL 15844 15844 lA WZ c 2 gt gt LS OPERATION OF THIS EQUIPMENT MAY ICREATE SPARKS THAT CAN START FIRES AROUND DRY VEGETATION A SPARK JARRESTER MAY BE REQUIRED THE OPERATOR SHOULD CONTACT LOCAL FIRE FOR LAWS OR REGULATIONS RELATING TO
21. AIR CLEANER Check to ensure element is in good condition and properly installed FUEL SUPPLY The engines on MBW Inc Compaction equipment require an automotive grade of clean fresh diesel fuel or unleaded gasoline dependent on engine type See Engine Owner s Manual FUEL FILTER If clogged or damaged replace Engine Refer to the engine manual for location of all controls and features Starting Gasoline Engine Open fuel valve Turn engine switch to on position Set throttle to idle position R Choke engine if necessary you may not need to choke a warm engine e Pull starter rope repeatedly until engine starts Move choke to the off or open position 7 Allow engine to warm up for one or two minutes Starting Diesel Engine For detailed instructions refer to the engine Manual 1 When starting the engine the throttle lever on the handle must be in the idle position 2 The engine has an automatic decompression System however it is recommended to slowly pull the starter rope until you feel a slight resistance Let the starter rope recoil completely and pull the starter rope quickly do not jerk the starter handle until the engine starts 3 Letthe engine warm up in the idle position for one or two minutes Running Engine After the engine warms up fully open throttle 2 The compactor will begin vibrating and moving in a forward direction Never leave compactor idling unattended
22. ENDS 1 1 7 16262 BEARING COVER EXCITER 1 1 8 16263 EXCITER SHAFT 1 1 9 16264 BEARING COVER EXCITER 2 2 10 16265 IN PUT GEAR 1 1 11 16266 IDLER GEAR 1 1 12 16321 KEY METRIC 16 x 10 x 45 ROUND ENDS 1 1 13 16322 COVER PLATE EXCITER 1 1 14 16328 WASHER 11 32 x 1 3 4 x 3 16 ZP 1 1 15 16331 BASEPLATE MACHINED 1 1 16 16599 INPUT SHAFT 1 1 17 16608 EXCITER WEIGHT GPR99 4 16260 EXCITER WEIGHT GPR135 4 20312 EXCITER WEIGHT GPR160 18 17104 BEARING COVER EXCITER BREATHER 1 1 19 17502 EXCITER PULLEY 1 1 20 F0410SP SPIROL PIN 1 4 x 1 1 4 1 1 21 F051804FWS FWS 5 16 18 x 1 2 ZP 8 8 22 F051806FWS FWS 5 16 18 x 3 4 ZP 21 21 23 F051808FWS FWS 5 16 18 x 1 0 ZP 12 12 24 0616125 5 SOCKET HEAD CAP SCREW 3 8 16 x 1 1 2 GR8 8 8 25 F0618SPP PIPE PLUG 3 8 16 NPT 1 1 26 F160816SCS SOCKET HEAD CAP SCREW 1 8 x 2 0 GR 8 ZP 4 4 16609 BASEPLATE COMPLETE GPR99 CONTAINS ITEMS ABOVE 16607 BASEPLATE COMPLETE GPR135 CONTAINS ITEMS ABOVE 20311 BASEPLATE COMPLETE GPR160 CONTAINS ITEMS ABOVE 25 Lower Shaft Assembly DESCRIPTION QTY 1 05559 CAPPLUG 2 2 16228 ROLLER BEARING 100 x 45 1 3 16230 BALL BEARING 2 4 19434 GUIDE RING 1 5 16237 EXTERNAL RETAINING RING METRIC 1 6 16238 HYDRAULIC SEAL 2 7 16239 WASHER SHIM 1 8 16240
23. ETHAL EXHAUST GAS An internal combustion engine discharges carbon monoxide a poisonous odorless invisible gas Death or serious illness may result if inhaled Operate only in an area with proper ventilation NEVER OPERATE IN A CONFINED AREA DANGEROUS FUELS Use extreme caution when storing handling and using fuels as they are highly volatile and explosive in vapor state Do not add fuel while engine is running Stop and cool the engine before adding fuel DO NOT SMOKE SAFETY GUARDS t is the owners responsibility to ensure that all guards and shields are in place and in working order IGNITION SYSTEMS Breakerless magneto and battery ignition systems can cause severe electrical shocks Avoid contacting these units or their wiring SAFE DRESS Do not wear loose clothing e n gt rings wristwatches etc near machinery 8 ar NOISE PROTECTION Wear OSHA specified hearing protection devices BS EYE PROTECTION Wear OSHA specified eye shields safety glasses and sweat bands FOOT PROTECTION Wear OSHA specified steel tipped safety shoes HEAD PROTECTION Wear OSHA specified safety helmets DUST PROTECTION Wear OSHA specified dust mask or respirator OPERATOR Keep children and bystanders off and away from the equipment I ut REFERENCES For details on safety rules and regulations in the United States contact your local Occupational Safety and Health Administratio
24. OPERATOR S SAFETY AND SERVICE MANUAL GPR99 6 GPR135 This manual covers the following serial numbers and higher for each model listed GPR99 3090230 GPR135 2900280 REVERSIBLE MBW Inc MBW UK Ltd 250 Hartford Rd PO Box 440 Slinger WI 53086 0440 Phone 262 644 5234 Fax 262 644 5169 Email mbw mbw com Website www mbw com Units 2 amp 3 Cochrane Street Bolton BL3 6BN England Phone 01204 387784 Fax 01204 387797 MBW FRANCE S A R L Z A d Outreville 11 rue Jean Baptiste N ron 60540 BORNEL FRANCE L17433 06 14 5 33 0 3 44 07 15 96 MBW Inc 2011 Fax 33 0 3 44 07 41 28 Email mbwfrance free fr printed Abe MS TABLE OF CONTENTS Safety Information 1 Service 9 Introduction Re ade mme EE 1 Main Disassembly Procedure Diesel Engine a 9 Safety 5 1 Main Disassembly Procedure Gasoline Engine 10 Safety Decals ima epe ates 1 Exciter Qil Change Procedure e esque 10 Safety Decals GPR135 Decal Set 4416031 2 Lower Hydraulic Seal Replacement 11 Safety Decals GPR99 135 Decal Set 16031 3 Bleeding And Adjustment of Hydraulic Controls 11 Baseplate Disassembly Procedure 12 Specifications 4 Handle Disassembly Procedure
25. UNT HANDLE 2 2 2 20 19535 ROLLCAGE 1 1 1 21 19537 ENGINE DECK 1 19538 ENGINE DECK 1 1 20317 ENGINE DECK 22 19790 HOSE HYDRAULIC 1 1 1 23 F042004FWS FWS 1 4 20 x 1 2 ZP 16 16 16 24 F042008FWS FWS 1 4 20 x 1 0 ZP 9 9 9 25 F0420ELN LOCKNUT 1 4 20 NYLOC ZP 1 1 1 26 F051805HCS HHCS 5 16 18 x 1 0 GRD 5 ZP 3 3 3 27 F0518ELN LOCKNUT 5 16 18 NYLOC ZP 3 3 3 28 FO6SW WASHER 25 64 x 1 0 x 1 4 ZP 5 5 5 29 081314 5 5 1 2 13 x 1 3 4 GRD 5 ZP 4 4 4 30 F0813ELN LOCKNUT 1 2 13 NYLOC ZP 4 4 4 31 FO8SW WASHER 9 16 x 1 3 8 x 12 GA ZP 4 4 4 32 F101110HCS HHCS 5 8 11 x 1 1 4 GRD 5 ZP 4 4 4 33 F1011HN NUT 5 8 11 ZP 4 4 4 34 F10LW LOCKWASHER 5 8 ZP 8 8 8 35 F10PW WASHER 5 8 x 1 1 4 x 12 GA ZP 8 8 8 36 F160816SCS SOCKET HEAD CAP SCREW 1 8 x 2 0 GR 8 ZP 4 4 4 37 F160836SCS SOCKET HEAD CAP SCREW 1 8 x 4 1 2 GR 8 ZP 4 4 4 38 MO8C020FWS FWS 8 x 20 PLATED 4 4 4 39 08 025 55 FLAT HEAD SOCKET SCREW M8x25 PLATED 4 4 4 17337 KIT 3 EXTENSION CONTAINS ITEMS 12 13 amp 37 17338 KIT 6 EXTENSION CONTAINS ITEMS 12 13 8 37 23 Baseplate Assembly PART DESCRIPTION GPR99 GPR135 1 05559 CAP PLUG 6 6 2 09748 FITTING PIPE 90 DEGREE 1 1 3 09749 PLUG BREATHER 1 1 4 16228 ROLLER BEARING 100 x 45 4 4 5 16232 SHAFT SEAL 1 1 6 16259 KEY METRIC 8 x 7 x 28 ROUND
26. c plugs 1 from the threaded holes in the shaft covers 7 9 12 8 18 This can be done using a 72 phillips screwdriver lightly tapped into the center of the plug and unthreading it as a screw Clean all dirt from the threaded holes in the shaft covers which were not plugged and chase the threads with a 5 16 18 UNC thread tap Remove the covers from the idler shaft 8 ends of the baseplate by removing the flange screws 23 and using two 5 16 18 x 2 long screws to press off the covers by installing them into the threaded holes cleaned in the previous steps Turn both screws evenly to prevent binding of the cover in the bore Note Make sure the bearings and their inner races are kept as a matched set Remove the idler shaft 8 and idler gear 11 from the baseplate Press the inner bearing races from the ends of the idler shaft 8 Press the idler gear 11 off the idler shaft 88 and remove the key 12 Repeat steps 16 and 17 for the input shaft covers Remove the input shaft 16 as an assembly from the baseplate Slide the input gear 10 to one end of the input shaft and remove the helix 11 from the input shaft and slide out the helix pin carrier 9 as subassembly Press the inner bearing races from the ends of the input shaft 16 Slide the input gear 10 off of the input shaft 16 Remove the roller bearings 4 from the shaft covers 7 9 18 8 12 by removing tw
27. cover the cost of transportation and other expenses which may be connected with warranty service but not specifically mentioned herein 6 This warranty does not cover any updates to any New Machine Demonstration Machine or any other MBW product MBW reserves the right to improve or make product changes without incurring any obligation to update refit or install the same on New Machines or Demonstration Machines previously sold WHAT MUST YOU DO TO OBTAIN WARRANTY COVERAGE Each New Machine or Demonstration Machine is accompanied by a Warranty Registration Card You must sign date and return the Warranty Registration Card to the place of origin of the New Machine or Demonstration Machine either to MBW Inc at P O Box 440 Slinger Wisconsin 53086 MBW UK Ltd at Units 2 amp 3 Cochrane Street Bolton BL3 6BN United Kingdom or MBW FRANCE SARL at ZA D Outreville 5 Rue Jean Baptiste Neron Bornel 60540 France within ten 10 days after purchase assignment to a rental fleet or first use This signed warranty card is the buyer s affirmation that he has read understood and accepted the warranty at the time of purchase Failure to return the warranty card as specified herein renders the warranty null and void In order to receive warranty coverage consideration warranty claims must be submitted within thirty 30 days after the New Machine or Demonstration Machine fails Warranty claims must be submitted to MBW Inc MBW UK Ltd or
28. d the four flanged capscrews 21 Remove all mount gasket material from the input shaft cover 12 Be careful to keep debris and gasket pieces from entering the exciter assembly when cleaning the cover If you purchased the rebuild kit MBW Part Number 17368 go to step 20 Assemble the new seals 6 to the shift spool 15 Note the orientation of the seal lips Hint use hydraulic oil to lubricate the seal inner diameter before pressing onto the spool Beware the slot cut on the shift spool it may be sharp Press the seal on WITH the slot and NOT ACROSS the slot Assemble the new guide ring 4 to the shift spool 15 Thread the shift spool 15 onto the shift shaft 10 Note the left hand thread Install a new mount gasket 17 on the hydraulic housing 16 Guide the hydraulic housing over the shift spool seals and guide ring and secure the cylinder mount plate 420 to the input shaft cover 12 using the four flange screws 22 removed in step 5 using LOCTITE 243 on the screw threads Note Tighten the screws in a criss cross pattern tighten evenly to prevent cocking the cylinder mount plate Reinstall the 90 degree fitting 13 into the hydraulic housing 16 Clean and reattach the hydraulic line 21 to the 90 degree fitting 13 on the hydraulic housing Be sure the hydraulic line does not bind in the grommet Loosen and rotate the hydraulic fitting 13 and rotate it as required
29. e end of the helix to the other Refer to LOWER SHAFT ASSEMBLY page 30 for steps 32 thru 42 Note and 18 should be replaced as a set The seals 6 guide ring 4 and gaskets 17 MBW recommends purchasing rebuild kit 17368 for ease of repairs Seals are pre assembled to the spool 31 32 33 34 35 36 37 38 If rebuild kit 17368 was purchased skip to step 34 Assemble the new seals 6 to the shift spool 15 Note the orientation of the seal lips Hint use hydraulic oil to lubricate the seal inner diameter before pressing onto the spool Beware the slot cut on the shift spool It may be sharp Press the seal on WITH the slot and NOT ACROSS the slot Thread the shift spool with seals onto the shift shaft 410 Note the left had thread Assemble the new guide ring 4 to the shift spool Install a new mount gasket 17 onto the hydraulic housing 16 Lubricate the inside of the hydraulic housing 16 and the seal lips with hydraulic oil See Maintenance section for hydraulic fluid type Install the hydraulic housing over the hydraulic seals and guide ring Be careful not to damage the guide ring and hydraulic seals during installation Secure the mount plate 820 over the hydraulic housing 16 to the input shaft cover 12 with the four flanged cap screws 22 using LOCTITE 243 thread locker sealant on the threads and torque the cap screws evenly in sta
30. e handle tube 8 with four flange lock screws 27 4 Install plain bearings 14 into each side of handle tube 8 5 Install control shaft 20 into handle tube 8 and secure with retaining rings 86 Note Control shaft can be install for either right or left hand operation 6 Install control handle 17 to control shaft 20 and secure by driving spiral 429 thorough handle hub amp control shaft 7 Assemble shift bracket 10 to control shaft 20 with flange lock screws 24 8 Install throttle lever 7 to handle tube 8 with flat head screw 21 lock washers 23 and hex nuts 422 9 Install handle bars 11 amp 12 to handle tube 8 using flange lock screws 30 10 Install tube cap 13 to handle tube 8 with self tapping screws 41 11 Install bumper bracket 15 to handle tube 8 using flange lock screws 28 12 Assemble threaded rod 2 hex nuts 432 and handle bumper 3 to bumper bracket 15 13 Assemble handle mounts 4 to handle tube 8 with flange lock screws 31 Refer to Main Assembly page 22 14 Assemble spindle mounts 11 to shock mounts 19 with flat head screws 39 15 Install shock mounts spindle assemblies onto handle 16 Secure handle assembly to engine deck with four hex head flange screws 28 Final Assembly Refer to Main Assembly page 22 1 Place engine 2 or 15 on engine deck 20 and align with
31. e the main lift hook on the roll cage 19 to separate the engine deck from the baseplate Be careful to guide the hydraulic line through the handle assembly and engine deck as the subassemblies are separated to prevent damage to components and personal injury If further 11 12 disassembly of the engine deck is required proceed to step 9 If baseplate service is required refer to Baseplate Disassembly Procedure section of this manual Disconnect the throttle cable 18 from the engine Remove the handle assembly by removing the four flange screws 428 securing the handle shock mount 19 to the engine deck Remove the four hex head capscrews 33 securing the rollcage 20 to the engine deck 21 and remove the rollcage Remove the four hex head capscrews 12 securing the engine 3 to the engine deck 21 and remove the engine Exciter Oil Change Procedure Refer to Figure 1 1 GPR 99 135 EXCITER OIL DRAIN 10 If possible run unit for approximately 5 minutes to warm oil before draining Clean all dirt and debris from baseplate before disassembly to prevent contamination of exciter oil If installed remove the two 1 socket head capscrews 1 and bushings 3 securing the baseplate extensions 2 to the baseplate 4 from the recoil oil drain side of the baseplate Tilt the plate toward a drain pan to aid in the removal of all used oil and particles Remove the socket head pipe
32. engine mounting holes Refer to engine pages Gasoline or Diesel 2 Install four bolts lock washers and washers 11 14 amp 15 or 29 30 amp 31 through the engine block into engine deck Note If engine does not sit flat on engine deck shim as needed Refer to DIESEL ENGINE ASSEMBLY page 38 3 Secure battery box mounting brackets 21 to engine deck using four hex head flange screws 28 4 Assemble battery box 19 to shockmounts 18 with four hex head cap screws 34 and lockwashers 37 17 5 Remove electrical tape from positive battery cable 11 and assemble to engine starter 6 Remove electrical tape from negative battery cable 10 and assemble under head of engine mounting bolt 29 7 Secure engine ignition box to mounting bracket 14 using three 6mm bolts 35 Refer to Main Assembly page 22 8 Assemble rollcage 20 to engine deck 21 with four hex head cap screws 30 washers 35 and lock nuts 31 9 Using main lift hook on roll cage lower engine deck assembly onto baseplate Use care to route hydraulic hose through engine deck and up handle tube 10 Install four bolts 33 lockwashers 35 and washers 36 through engine deck into shockmounts on bottom plate Refer to engine pages Gasoline or Diesel 11 Slide belt 3 or 4 onto clutch 4 of 7 12 Refer to the Belt Adjustment section of this manual to complete assembly 13 Secure hydrau
33. fects in material and workmanship for a period of six 6 months Demonstration Machine means a machine used by MBW or its agents for promotional purposes This warranty commences on the first day the machine is sold assigned to a rental fleet or otherwise put to first use This warranty covers the labor cost for replacement or repair of parts components or equipment on New Machines or Demonstration Machines and MBW shall pay labor costs at MBW s prevailing rate to affect the warranted repair or replacement MBW reserves the right to adjust labor claims on a claim by claim basis This warranty covers the shipping cost of replacement parts components or equipment via common ground carriers from MBW to an authorized MBW dealer Air freight is considered only in cases where ground transportation is not practical MAY THIS WARRANTY BE TRANSFERRED This warranty is non transferable and only applies to the original end user of a new machine or demonstration machine WHAT DOES THIS WARRANTY NOT COVER 1 This warranty does not cover any Used Equipment Used Equipment means any MBW machine or equipment that is not a New Machine or a Demonstration Machine All Used Equipment is sold AS IS WHERE IS WITH ALL FAULTS 2 This warranty does not cover any New Machine Demonstration Machine or their equipment parts or components altered or modified in any way without MBW s prior written consent This warranty does not cover the use of parts no
34. ft lbs 112 ft lbs 180 ft lbs separate the engine deck from the baseplate Be 3 4 16 144 ft lbs 200 ft lbs 315 ft lbs to eo e 2 iie 1 8 188 ftlbs 4831458 682 ft lbs en subassemblies are separated to prevent damage 1 14 210 ft lbs 541 ft lbs 764 ft lbs to components If further disassembly of the engine 1 1 2 6 652 ft lbs 1462 ft lbs 2371 ft lbs deck is required proceed to step 9 If baseplate 6 3 ft lbs 4 ft lbs 7 ft lbs service is required refer to the Baseplate M8 6 ft lbs 10 ft lbs 18 ft lbs Disassembly Procedure section of this manual M 10 10 ft lbs 20 ft lbs 30 ft lbs 9 Disconnect the throttle cable 18 from the engine CONVERSIONS 10 Remove the handle assembly by removing the four in Ibs x 0 083 ft lbs flange screws 28 securing the handle shock mount ft lbs x 12 in Ibs 19 to the engine deck 21 ft lbs x 0 1383 kg m 11 Remove the four hex head capscrews 33 securing ft lbs x 1 3558 Nem the rollcage to the engine deck and remove the rollcage Refer to DIESEL ENGINE ASSEMBLY page 38 12 13 14 15 16 17 18 Disconnect the negative black battery cable 410 from the engine mount bolt 29 Use electrical tape to enclose the terminal of the negative black battery cable to prevent accidental discharge of the battery Disconnect the positive red battery cable 11 from the starter of the engine Use the electrical tape to enclose the terminal of the posi
35. ges to 13 ft Ibs Make sure the bleeder screw port 14 is in the vertical position 39 40 42 43 44 45 46 4T Install the gasket 18 and cover 19 to the hydraulic housing 16 with four hex head flange screws 21 using LOCTITE 2243 thread locker sealant on the threads and torque the cap screws to 76 in lbs Install the 90 degree fitting 13 into the port on the hydraulic housing 16 Install the bleeder screw 14 loosely into the port fitting of the hydraulic housing Install the socket head pipe plug 25 into the oil drain port using LOCTITE 565 pipe sealant Pour in the exciter oil Use only MBW Ground Pounder Exciter Oil The amount of exciter oil required is shown in the FLUID LEVELS section of this manual Install the baseplate cover 13 using LOCTITE 515 gasket maker on the lip of the mounting surface and secure with twenty hex head flange screws 422 using LOCTITE 243 on the threads See the figure 4 for LOCTITE 515 gasket maker application Install the key 6 into the input shaft 16 Install the pulley 19 with the longer hub shoulder toward the baseplate housing Install the pulley mount washer 14 and secure it to the input shaft with the hex head flange screw 22 using LOCTITE 243 thread locker sealant on the threads Refer to engine pages Gasoline or Diesel 48 Install the v belt 3 or 4 to the pulley of the baseplate assembly Refer
36. he ball bearings 3 and the spacer washer 7 onto the shift shaft 10 and secure with the e clip 5 Press the shift shaft and ball bearing assembly into the helix pin carrier 9 and secure with the internal retaining ring 8 FIGURE 5 HYDRAULIC HOUSING SIDE OF BASEPLATE HELIX PIN ORIENTED HORIZONTALLY BASEPLATE GEAR TIMING 15 26 Note 27 28 29 30 Lubricate the helix pin carrier shift shaft assembly with exciter oil and slide into the input shaft and install the dowel pin 11 Helix pin carrier MUST slide freely in input shaft Slide the helix pin carrier to the middle of the helix and orient the dowel pin parallel with the bottom of the baseplate housing 15 Align the timing marks on both gears and slide the input gear over the helix pin carrier and into mesh with the gear on the idler shaft Note position of exciter weights both weights in the down position See the figure 5 for setting the gear timing Install the other exciter weight 17 to the input shaft 16 with two socket head cap screws 24 using LOCTITE 243 thread locker sealant on the threads and torque the cap screws to 30 ft lbs Be careful to use a small amount of thread locker to avoid dripping it into the helix pin carrier bearings at installation Check the gear timing to assure free motion of the shift shaft helix pin carrier within the helix of the input shaft for the full range of motion from on
37. lic line 21 to control head fitting 14 Bleed the hydraulics according to the Bleeding and Adjustment of Hydraulic Controls section of this Manual Diesel Engine Throttle Adjustment 1 Check to make sure the throttle control lever 1 is in the full stop position and the engine throttle arm 4 is rotated to the full counter clockwise position If not adjust as needed using the threaded portion of the throttle cable in bracket 5 then tighten jam nuts 6 after final adjustment 18 Push throttle control lever 1 forward to full throttle position do not force While holding lever in this po sition screw in throttle stop set screw 2 until you can feel it touch or start moving the throttle control le ver Assemble and tighten jam nut 3 to lock this po sition Start unit up and test for full throttle operation and shut down Re adjust as needed full throttle RPM for diesel engine is 3600 to 3700 this is not adjustable FIGURE 6 ENGINE VIEW Troubleshooting SYMPTOM REPAIR Engine does not start or stalls Fuel valve is closed open valve gasoline engine Engine switch is STOP position turn switch to ON position gasoline engine Fouled spark plug clean or replace spark plug gasoline engine Dirty or pugged injection nozzle clean or replace if damaged Electric start low battery charge recharge battery Starter motor defective or worn replace starter m
38. n OSHA office Equipment operated in other countries must be operated and serviced in accordance and compliance with any and all safety requirements of that country The publication of these safety precautions is done for your information MBW does not by the publication of these precautions imply or in any way represent that these are the sum of all dangers present near MBW equipment If you are operating MBW equipment it is your responsibility to insure that such operation is in full accordance with all applicable safety requirements and codes All requirements of the United States Federal Occupational Safety and Health Administration Act must be met when operated in areas that are under the jurisdiction of that United States Department Safety Decals Carefully read and follow all safety decals Keep them in good condition If decals become damaged replace as required If repainting the unit replace all decals Decals are available from authorized MBW distributors Order the decal set listed on the following page s oo e D 5 L M O D E L THROTTLE 19493 a ZH ARRESTER MAY BE REQUII TI RELATING TO FIRE PREVENTION Cp 19493 OPERATION OF THIS EQUIPMENT IRED THE SHOULD CONTACT LOCAL FIRE 19791 U 9 Y CREATE SPARKS THAT CAN START FIRES AROUND DRY VEGETATION A SPARK JAGENCIES REGULATIONS HYDRAULIC OIL 15844 15853 GRP135 BOTH SIDES 1
39. o 5 16 flange head bolts 21 from the covers and use a 1 4 x 2 long pin punch to tap the bearings out of the covers Alternate between the access holes evenly to prevent binding of the bearings in the covers Refer to LOWER SHAFT ASSEMBLY page 30 28 29 Note performance of the following steps will require replacement of the ball bearings 3 M B W recommends replacement of these bearings as a set at every complete disassembly or rebuild Remove the internal retaining ring 8 from the helix pin carrier 9 and remove the shift shaft 10 and bearings 3 as a subassembly from the carrier 30 31 Remove the e clip retaining ring 5 securing the bearings to the shift shaft Secure the bearings in a vice and press out the shift shaft 10 Note the position of the spacer washer 7 Handle Disassembly Procedure Refer to Main Assembly page 22 1 Disconnect the hydraulic line 22 from the fitting in control head 9 of the handle Use a drain pan to catch the hydraulic oil Remove the four hex head flange screws 828 securing the handle shock mount 19 to the engine deck 21 Remove the handle assembly from the main assembly Disconnect the throttle cable 18 from the engine Remove the four flat head socket screws 439 securing the spindle mounts 11 to the shockmounts 19 Refer to Handle Assembly page 28 6 10 11 13 14 15 13 Remove the
40. on page36 Failure to return the Warranty Registration Card renders the warranty null and void MBW has established a network of reputable distributors dealers with trained mechanics and full facilities for maintenance and rebuilding and to carry an adequate parts stock in all areas of the country Their sales engineers are available for professional consultation If you cannot locate an MBW distributor in your area contact MBW or one of our Sales Branches listed below When ordering replacement parts be sure to have the following information available Model and Serial Number of machine when ordering MBW parts Model and Serial Number of engine when ordering engine parts Part Number Description and Quantity Company Name Address Zip Code and Purchase Order Number Preferred method of shipping REMEMBER You own the best If repairs are needed use only MBW parts purchased from authorized MBW distributors Write Model Number here Write Serial Number here Contact Information This page intentional AE SERIAL NUMBER DECAL SERIAL NUMBER The units serial number can be found in the following locations The model serial number decal is located on the engine deck side plate behind the engine as shown above The serial number is stamped on the back edge of the bottom plate and the back end of the engine deck as shown above
41. otor Defective or worn ignition switch replace ignition switch Engine does not accelerate is hard to start or runs erratically E e Improper or old fuel remove all fuel from tank amp engine and replace with the proper fresh fuel Fouled spark plug clean or replace spark plug gasoline engine Dirty or pugged fuel filter replace with new fuel filter Dirty or pugged injection nozzle clean or replace if damaged Dirty or clogged air cleaner clean or replace Engine over heats or runs hot Cooling fins are dirty or plugged remove debris and clean Engine runs at full speed but machine does not move Dr Belt tension too loose tighten belt per Belt Adjustment section of this Manual Worn belt replace belt Clutch malfunction replace clutch Slow or no forward travel speed Too much hydraulic fluid in control head set fluid level per Bleeding and Adjustment of Hydraulic Controls section of this manual Belt is slipping tighten belt per Belt Adjustment section of this Manual Incorrect engine rpm reset engine rpm per Specifications section of this manual Material build up on bottom of plate remove all debris from bottom of plate Mechanical failure requires authorized MBW service repair Slow or no reverse travel speed Not enough hydraulic fluid in control head set fluid level per Bleeding and Adjustment of Hydraulic Controls section of this manual Air in the
42. plug 5 from the baseplate and drain the oil Examine the oil for metal chips as a precaution to future troubles Tip the plate opposite the drain hole and fill the baseplate through the pipe plug opening with exciter oil to level specified in the Fluid Levels section of this manual Use only MBW Ground Pounder Exciter Oil Reinstall the socket head pipe plug using sealant LOCTITE 565 If equipped reinstall the bushings and baseplate extension using antisieze lubricant LOCTITE 767 FIGURE 1 Lower Hydraulic Seal Replacement Refer to LOWER SHAFT ASSEMBLY page 30 Note The seals 6 guide ring 4 and gaskets 17 and 18 should be replaced as set recommends purchasing rebuild kit 17368 for ease of repairs Seals are pre assembled to the spool MBW Position the handle in locked position and set the lock pin Refer to Main Assembly page 22 for side cover removal Remove the six flange screws 22 securing the side cover 12 to the recoil oil drain side of the baseplate Loosen hex head bolts 32 on the oil drain side only Lift the engine deck up to allow the side cover to be removed Refer to Control Head Assembly page 30 11 12 13 14 Remove plug 6 from the control head housing Remove the hydraulic line 21 from the 90 degree fitting 13 on the hydraulic housing Be careful to use a drain pan to catch the hydraulic oil Remove the 90 degree fitting 13 from
43. sed end being careful not to damage the shaft Note the orientation of hydraulic seal 5 lip direction 3 Remove seal 5 and guide bearing 10 from shaft 12 Remove seal 13 and washer seal 2 from control head 7 Note When removing seals be careful not to scratch or damage seal mounting surfaces Remove hydraulic seal 9 guide ring 811 and wiper seal 8 from seal cap 13 Remove socket pipe plugs 415 amp 16 and hydraulic fitting 6 from control head 7 If Required use a 1 4 pin punch to drive the slide bushing 4 out of the control head 7 Clean the control head 7 to remove any dirt or debris making sure all ports amp passages are open Baseplate Assembly Procedure Refer to BASEPLATE ASSEMBLY page 28 1 Clean all baseplate components Note Make sure the bearings and their inner races are kept as a matched set FIGURE 3 3 16 BEAD LOCTITE 515 GASKET MAKER r HOUSING SIDE OF COVER 1 8 BEAD SHAFT BEARING COVER LOCTITE 515 GASKET MAKER 10 Inspect all bearings shafts helix pin carrier and gears for wear debris and discoloration from heat Replace as needed Replace the roller bearings and the inner races on each shaft as a set both bearings on the shaft as needed Replace the helix carrier ball bearings as a set at each complete disassembly or rebuild Replace all seals and gaskets removed at each disassembly or inspec
44. soil types Recommended soil types include granular soils gravel sand mixtures and semi granular cohesive soils MBW Reversible Plate Compactor is not recommended for use in cohesive soils nor for very hard surfaces such as concrete or asphalt This parts manual contains only standard parts Variations of these parts as well as other special parts are not included Contact your local MBW Inc Distributor for assistance in identifying parts not included in this manual Before Operation After receiving your new MBW Inc Reversible Plate Compactor inspect it for any visible damage done during shipment Make sure the engine throttle works properly Contact your nearest MBW Inc Distributor if there are any problems Your new MBW Inc Reversible Plate Compactor is shipped complete and ready for use REMEMBER It is the owners responsibility to communicate information on the safe use and proper operation of this unit to all operators Review All of the Safety Precautions listed on page 1 of this manual Familiarize yourself with the operation of the equipment and confirm that all controls function properly Know how to STOP the equipment in case of an emergency Make sure hands feet and clothing are at a safe distance from any moving parts OIL LEVEL Check the oil level in the engine For more information see Lubrication under the respective engine s Owner s Manual or the MAINTENANCE section of this manual
45. t specifically approved by MBW for use on MBW products This warranty does not cover misuse neglect shipping damage accidents acts of God the operation of any New Machine or Demonstration Machine in any way other than recommended by MBW in accordance with its specifications or any other circumstances beyond MBW s control This warranty does not cover any New Machine or Demonstration Machine repaired by anyone other than MBW factory branches or authorized MBW distributors 3 This warranty does not cover and MBW affirmatively disclaims liability for any damage or injury resulting directly or indirectly from design materials or operation of a New Machine or Demonstration Machine or any other MBW product MBW s liability with respect to any breach of warranty shall be limited to the provisions of this document and in no event shall exceed an amount equal to the purchase price of the New Machine or Demonstration Machine purchased from MBW 4 This warranty does not cover engines motors and other assemblies or components produced by other manufacturers and used on a New Machine or Demonstration Machine as said engines motors and other assemblies or components may have warranties provided by the manufacturer thereof This warranty does not apply to consumable items such as v belts filters trowel and screed blades seals shock mounts batteries and the like all of which are sold AS IS WHERE IS WITH ALL FAULTS 5 This warranty does not
46. the governor setting The establishes safe operating limits which must not be exceeded 2 Refer to the engine Owner s Manual for procedure on setting operating and idle speeds 3 engine operating speed should be set to 3600 RPM 4 The engine idle speed must not exceed 1800 RPM If the idle speed is greater than 1800 RPM the clutch may not disengage Battery Maintenance 1 Loose or corroded battery terminals will lead to weak starts and poor charging Clean posts and connectors with a wire brush for best connection Remove dirt from case using a solution of 2 teaspoons baking soda and 1 pint of water Dry completely 2 Always recycle old battery when replacing Improper disposal of batteries can lead to contamination of soil and ground water Battery Charging 1 Ifunitis not routinely used charging your battery may be necessary An unused battery will self discharge over time Under charged batteries may suffer permanent damage and premature failure Belt Adjustment If any belt stretch develops follow these steps Refer to Main Assembly page 22 Remove the belt guard refer to engine assembly pages Loosen do not remove the four hex head capscrews 32 securing the engine deck to the baseplate Tighten the belt by lifting the engine deck to provide 3 8 3 4 inch of play on one side of the belt Be sure to keep the engine deck level with the baseplate when adjusting the belt
47. the hydraulic housing Remove the four flange screws 22 securing the hydraulic housing 816 and cylinder mount plate 20 to the input shaft cover 12 and remove the hydraulic housing Remove the shift spool 15 from the shift shaft 10 by sliding the shift spool out of the baseplate and holding it secure while un threading the shift spool NOTE This connection is left hand thread If you purchased the rebuild kit MBW Part Number 17368 go to step 12 Remove the seal guide ring 4 from the shift spool Remove the damaged or worn seals 6 from the shift spool 15 Note the orientation of the sealing lips of the seals to be replaced Be careful not to scratch the inner diameter sealing surface of the shift spool when removing the seals Remove the four flanged capscrews 21 the cylinder cover 19 and the cylinder gasket 18 Be sure to remove all of the gasket pieces from the hydraulic housing to provide a good seal surface for the new gasket Remove the bleeder screw 14 from its port on the hydraulic housing 16 Thoroughly clean and inspect the bleeder screw for damage Replace if needed Clean and inspect the shift spool 15 and the hydraulic housing 16 Reinstall the bleeder screw 14 into its port in the hydraulic housing 16 15 16 17 18 19 20 21 22 23 24 25 26 27 Install the new cylinder gasket 18 the cylinder cover 19 an
48. tion Install the input shaft cover seal 5 into cover 9 Press the roller bearings 4 into all four of the covers 7 9 12 amp 18 Note Make sure the bearings and their inner races are kept as a matched set Install the hex head flange screws 21 into the shaft bearing covers using LOCTITE 243 thread locker sealant Install the plastic plugs 1 in the threaded holes used to press the covers out of the baseplate Install the key 12 into the idler shaft 8 Align the idler gear 11 with the key 12 and idler shaft 88 and press the idler gear onto the idler shaft using exciter oil as a lubricant Reference the figure 5 for the idler gear and shaft orientation Press the bearing inner races onto the idler shaft gear assembly The flanged end of the inner race goes toward the shoulder on the shaft Place the idler shaft and gear assembly into the baseplate housing in the forward location Note The housing is not symmetric The input pulley side of the housing has a pocket machined for the belt bellows This pocket is to be oriented toward the front left side of the machine The end of the idler FIGURE 4 MAIN HOUSING 1 COVER 7 16 BASE PLATE COVER SEALANT APPLICATION 14 11 12 13 14 15 16 17 18 19 shaft with the hole goes toward the front right side of the machine with the breather cover 18 Install the idler
49. tive red battery cable to prevent accidental discharge of the battery Remove the three 6mm bolts 35 securing the ignition box to the mount 14 Remove the four hex head screws 434 securing the battery box 19 to shockmounts 818 remove battery box and cables Then remove four hex head flange screws 28 and mounting brackets 21 Remove the four hex head capscrews 29 securing the engine to the engine deck and remove the engine 15 Main Disassembly Procedure Gasoline Engine Refer to Main Assembly page 22 for disassembly 1 Clean all visible debris from the machine before servicing Remove the four hex head capscrews 33 securing the engine deck 21 to the baseplate 4 Use caution as the engine deck will drop down Refer to GASOLINE ENGINE ASSEMBLY page 36 Sections of this manual for belt guard amp belt removal Remove the four socket head capscrews 12 securing the belt guard 7 to the mount plate 9 and remove the beltguard Slide the belt 3 off the clutch 4 Remove the two flange screws 23 securing the bellows retainer 15 and remove the retainer Push the lip of the bellows 3 through the hole in the engine deck Disconnect the hydraulic line 21 from the control head in the handle assembly Keep the end of the hydraulic line and control head fitting free of dirt and debris by using tape Be careful to use a drain pan to catch the hydraulic oil Us
50. to lubricate the seal inside diameter to ease assembly See Maintenance Section for type of hydraulic oil 4 Assembly the bearing guide ring 10 to piston shaft 412 groove behind the hydraulic seal 5 Note Use hydraulic oil to lubricate guide ring amp hydraulic seal before assembling into control housing 5 Slide the piston shaft assembly 12 into the control head housing 7 being careful not to damage guide ring or hydraulic seal when entering control housing 6 Install O ring 3 and hydraulic fitting 1 to adapter nut 14 7 Install adapter nut assembly 14 into control head housing 7 Note Use hydraulic oil to lubricate guide ring amp hydraulic seals before assembling into seal cap 8 Assemble guide ring 11 hydraulic seal 9 and shaft wiper seal 8 into seal cap 13 9 Install washer seal 2 and seal cap assembly 13 over piston shaft 12 and into control head housing HT 10 Assemble socket pipe plugs 15 16 into control head housing 7 using LOCTITE 4565 pipe sealant 11 Install hydraulic fitting 6 into control head housing Handle Assembly Procedure Refer to Handle Assembly page 28 1 Install shift linkage 16 to control head 9 with shoulder bolt 18 washer 426 and lock nut 25 2 Assemble shift bracket 10 to shift linkage 16 with shoulder bolt 18 washer 26 and lock nut 25 3 Install the control head assembly 9 into th
51. two flat head socket screws 21 securing the throttle lever 7 to the handle and remove the throttle lever and throttle cable as a subassembly from the handle Remove the four hex head flange screws 31 securing the handle mounts 4 to the handle 8 from inside the tube Remove the two jam nuts 432 securing the threaded rod 2 to the handle and remove the handle bumper shockmount 43 and threaded rod Drive the spirol 29 from the control handle 17 and separate the control handle from the control shaft 20 Remove the four hex head flange screws 30 securing the handle bars 11 and 12 to the handle 88 and remove the handlebars from the handle Remove two self tapping screws 41 from handle tube 8 and remove tube 13 Remove retaining rings 6 from control shaft 20 and two flange lock screws 24 from shift bracket 10 and slide control shaft 20 out of handle tube Remove bearings 14 from handle tube 8 Remove four flange lock screws 27 from control head 9 and slide control head out end of handle tube 8 Remove shoulder bolts 818 washer 26 and locknuts 22 from shift linkage 16 Control Head Disassembly Procedure Refer to Control Head Assembly page 30 1 Remove the hydraulic fitting 1 adapter fitting 14 and O ring 3 from the control head housing 7 Push piston shaft 12 out of control head by lightly tapping the expo
52. ubbles have been removed tighten the bleeder screw 45 and adjust the hydraulic oil level in the control head by pushing the shift handle to the forward position and then pulling it into the reverse position until it stops Repeat this procedure two times With the shift lever in the forward position fill the control head with hydraulic oil as shown in step 6 Reinstall the socket head plug 7 Reinstall the side cover 3 removed in step 1 using LOCTITE 243 on the screw threads 2 Lower engine deck to level position and tighten hex head bolts 1 Baseplate Disassembly Procedure Reference the Main Disassembly Procedure diesel or gasoline Engine listed earlier in this section to separate the engine deck from the baseplate Refer to Main Assembly page 22 1 If installed remove the four socked head capscrews 38 extension plates 8 and bushings 9 from the sides of baseplate 4 Remove the twelve hex head flange screws 23 securing the side covers 12 to the baseplate Remove the four hex head flange screws 24 securing the bellows mounts 14 to the baseplate and remove the bellows mounts and bellows 3 Disconnect the hydraulic line 22 from the hydraulic fitting Remove the four hex head flange screws 23 securing the hydraulic guard 13 to the baseplate and remove the hydraulic guard and hydraulic line from the baseplate Refer to BASEPLATE ASSEMBLY page
53. y side TIMING MARK LOCATION HUB OF IDLER GEAR OPPOSITE SHAFT SHOULDER EXCITER WEIGHTS m dd ROTATED AS SHOWN 20 22 23 24 25 of the baseplate See the figure 3 for LOCTITE 515 gasket maker application Lubricate the input shaft seal and bearing with exciter oil before inserting the input shaft through the oil seal in the cover to prevent tearing the seal Secure the input shaft cover with the four flange head crews 823 using LOCTITE 4243 thread locker sealant on the bolt threads and torque the capscrews to 13 ft Ibs Refer to LOWER SHAFT ASSEMBLY page 30 21 Install the other input shaft cover 12 and secure with the four flange head screws 22 using LOCTITE 243 thread locker sealant and torque the screws to 13 ft lbs See the figure 3 for LOCTITE 515 gasket maker application Check input shaft for minimum of 020 end play after covers are installed and the bolts are torqued Install one exciter weight 17 to the input shaft on the hydraulic housing side of the baseplate with two Socket head cap screws 424 using LOCTITE 243 thread locker sealant and torque the cap screws to 30 ft Ibs Be careful to use a small amount of thread locker to avoid dripping it into the helix pin carrier bearings at installation Slide the input gear 10 toward the pulley side of the input shaft 416 The gears should not be meshing at this time Refer to LOWER SHAFT ASSEMBLY page 30 Install t
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