MBW r440 User's Manual
Contents
1. 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 ea E REFERENCES For details on safety rules and regulations in the United States contact your local Occupational Safety and Health Administration 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 available2. Prior to assembly wash all parts in a suitable cleaner or solvent Check moving parts for wear and failure Refer to the Replacement section in this manual for tolerance and replacement cycles All shafts and housings should be oiled prior to pressing bearings Also ensure that the bearings are pressed square and are seated properly All bearings should be replaced when rebuilding any exciter or gearbox All gaskets and seals should be replaced after any disassembly Torque Chart 9 ft lbs 10 ft lbs 18 ft lbs 20 ft lbs 33 ft lbs 37 ft lbs 52 ft lbs 58 ft lbs 80 ft lbs 90 ft lbs 115 ft lbs 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7116 14 7116 20 1 2 13 1 2 20 9 16 12 49 in lbs 56 in lbs 8 ft lbs 9 ft lbs 15 ft lbs 17 ft lbs 24 ft lbs 27 ft lbs 37 ft lbs 41 ft lbs 53 ft lbs 76 in Ibs 87 in lbs 13 ft lbs 14 ft lbs 23 ft lbs 26 ft lbs 37 ft lbs 41 ft lbs 57 ft lbs 64 ft lbs 82 ft lbs 5 8 11 5 8 18 3 4 16 1 8 1 14 1 1 2 6 M 8 M 10 73 ft lbs 83 ft lbs 144 ft lbs 188 ft lbs 210 ft lbs 652 ft lbs 3 ft lbs 6 ft lbs 10 ft lbs 112 ft lbs 112 ft lbs 200 ft lbs 483 ft lbs 041 ft lbs 1462 ft lbs 4 ft lbs 10 ft lbs 20 ft lbs CONVERSIONS inelos x 0 083 ft lbs ft lbs x 12 in lbs ft los x 0 1383 kg m ft lbs x 1 3558 Nem 159 ft lbs 180 ft lbs 315 ft lbs 682 ft lbs 764 ft lbs 2371 ft lbs 7 ft lbs 18 ft lbs 30 ft lbs Service Tools Pa
3. 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 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 up
4. MO8CO25FWS FLANGE SCREW M8 1 25 x 25MM ZP THROTTLE FLANGE MOUNT FOR SERIAL NO 4400224 AND UP 1 32 F032402FSS FLAT HEAD SOCKET SCREW 10 24 X 1 4 ZP FOR SERIAL NO 4400224 AND UP _ NIO OJA OJIN EEE x cle lx aa Sa ux gt l I HONDA GX100 Engine Assembly 1 17164 STUD 17217 REDUCER BARBED 1 KEY WOODRUFF METRIC 4X13 18530 ENGINE HONDA GX100KR4 3HP Includes items 2 4 9 and 13 Also includes 1 x we 5 5 5 5 7 F0518FN NUT FLANGE 5 16 18 ZP 4 M12CHJN NUT HEX JAM M12 X 1 25 ZP BEBE HEX HEAD FLANGE SCREW M8 1 25 X 40mm Not provided by MBW Inc ET PIN DOWEL 6mm X 10mm Not provided by MBW Inc 11 FUEL LINE 3 16 ID X 5 5 LONG Not provided by MBW Inc 12 CLIP FUEL LINE Not provided by MBW Inc 2 OJN a NIA 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 defects 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 commen
5. remove the breather tube 16 CAUTION Do not disassemble the breather assembly Slide Bearing Removal 1 Remove the retaining ring 24 from the bottom of the gearbox guide tube 2 Slide the slide bearings 23 425 amp 27 out of the gearbox guide tube CAUTION Do not scratch or gouge the gearbox guide tube walls CAUTION The gearbox casting and screw in guide tube connection is permanant Do not attempt to unscrew guide tube or guide tube locking screw Bellows Removal 1 Loosen the four hex head flange screws page 18 13 securing the upper bellows ring page 16 6 to the gearbox 2 Slide the bellows upper bellows ring lower bellows ring and flange screws off the gearbox Gearbox Assembly Refer to Gearbox Assembly page 14 1 Press the small ball bearing 22 into the gearbox from the back Secure with a retaining ring 18 2 Press the large ball bearing 2 into the gearbox from the back Secure with a retaining ring 10 3 Press a new oil seal 11 into the gearbox Make sure the oil seal is pressed in straight 4 Lightly oil the lip of the oil seal and the shaft portion of the pinion 21 Carefully press the pinion into the gearbox CAUTION Do not use excessive pressure to seat the pinion 10 11 17 18 19 20 21 22 23 24 Install a retaining ring 4 onto the pinion from inside the gearbox Press
6. 5 SPRING INNER 18693 SPRING OUTER SPRINGBOX ASSEMBLY 440 includes 1 2 7 8 9 10 11 16 17 18 20 21 22 23 24 OR OJN EE E EN rN N NIN 19621 1 1 1 3 1 2 2 17 Gearbox and Lower Unit Assembly 1 07203 PIN DOWEL 1 4 x 1 2 ws cOVERRAMMEROEARBOK O a 16361 GASKET COVER 21 E NEM EE 19585 RAMMER SHOE CAST IRON 11 13 DEG INCLUDES ITEMS 11 amp 12 F051807FWS FWLS 5 16 18 X 7 8 ZP 4 10 F0518HN 5 16 18 ZP SCS 7 16 14 X 2 1 4 12 FO7LW LOCKWASHER 7 16 ZP NIO OJA OJIN ns E om EN af un C5 jn MAX TA lt Handle Assembly 20 1 17720 HOSE FUEL 7 1 2 LONG FILTER FUEL IN LINE 01145 CLAMP SPRING LOCKWASHER 5 16 HIGH COLLAR 07351 TORSION MOUNT 2 14715 THROTTLE RATCHET STYLE FUEL 1 1 2 LONG 10 16303 TANK FUEL HH 12 16415 HOURMETER AND TACHOMETER m 13 16572 CASING 30 THROTTLE WIRE 16 14714 CAP 1 3 4 18 18511 HANDLE SUPPORT LEFT 20 18527 ENGINE GUARD HONDA 440 ONLY 2 ae ee 22 18553 RAMMER HANDLE m g RAMMER HANDLE FOR SERIAL 4400224 AND UP 23 F033206PMS PAN HEAD MACHINE SCREW 10 32 x 3 4 LG ZP E 25 F042004FWS FLANGE SCREW 1 4 20 x 1 2 ZP 4 26 F051808FWS SCREW 5 16 18 1 ZP 8 NUT FLANGE 5 16 18 ZP 8 30
7. 6 16 in the lower unit so the threaded hole on top is positioned toward the front of the shoe 6 olide the gearbox assembly onto the lower unit Align the connecting rod page 14 5 with the ram head and install the piston pin 3 with the groove in the pin facing out Align the groove in the piston pin with the hole for the setscrew 9 Install the setscrew into the ram head finger tight then back off 1 4 turn Lock the setscrew in place with the hex nut 10 Make sure setscrew is in groove 11 CAUTION The piston pin must be able to rotate Rotate the gearbox assembly so the front of the gearbox is aligned with the front of the lower unit Secure the lower bellows mount to the springbox guard using six hex head flange screws page 16 19 Torque to 12 ft Ibs 16 Nem Apply a light coat of oil to all of the bearings in the gearbox assembly Tip the assembly back and place a new gasket 4 over the gearbox face Insert the dowel pins 1 into the gearbox through the holes in the gasket Align the holes in the cover 2 with the dowel pins and place the cover on the gasket Secure the cover to the gearbox using four hex head flange screws 8 with medium strength thread locker Tighten the flange screws equally and torque to 12 ft lbs 16 Nem The gasket will compress slightly after initial tightening re torque the flange screws after 5 minutes If the handle brackets pag
8. 8 Nem Insert the lower springs 13 amp 14 Lightly grease the o ring groove in the cover 1 and install a new o ring 2 6 Insert the springbox tool MBW 06468 rods into the springbox as shown in Figure 4 Figure 4 7 Slowly draw the cover down onto the springbox by alternately tightening each rod WARNING Keep the cover level with the springbox 8 Secure the cover with three flat head socket screws 18 torqued to 8 ft lbs 11 Nem 10 11 12 13 14 Remove the springbox tool rods from the assembly The springbox warning decal page 2 01326 should be clean and highly visible If not the old decal should be completely removed and replaced with a new decal Lightly oil a new o ring Z9 and place it into the groove in the springbox guard 12 Slide the springbox guard over the ram head onto the springbox Be careful not to damage the o ring during installation Place the springbox assembly onto the shoe page 18 13 with the fill plug 4 pointing toward the back of the shoe Install six hex head cap screws and lockwashers 18 11 amp 12 with medium strength lock tite Torque the cap screws to 40 ft lbs 56 Nem Gearbox and Lower Unit Assembly NOTE If replacing gearbox housing install engine studs with high strength red Loctite Refer to Gearbox and Lower Unit Assembly page 18 1 Rotate the ram head page 1
9. CRUSHED REPLACE IT WARNING DO NOT OPERATE ENGINE WITHOUT AIR CLEANER ELEMENT INTERNAL DAMAGE WILL RESULT 06079 Compressed spring could cause severe injury See manual for disassembly instructions La primavera comprimida podria causar la herida severa Consulte el libro para ver el desmontaje correcto Safety Decals Decal Set 17777 EN CHECK ENGINE OIL DAILY ENGINE MUST BE LEVEL 15137 SPECIFICATIONS engine _ 3800 Ibf 16 9 kN per blow Specifications subject to change without notice 1 Noise levels are taken at the operating position and are based on operating conditions Background noise will increase noise levels 2 First level is operating on loose gravel surface The second level is operating in highly compacted gravel surface Hearing protection may be needed OPERATION Introduction MBW 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 This parts manual contains only standard parts Variations of these parts as well as other special parts are not included Contact your local MBW distributor for assistance in identifying parts not included in this manual Before Starting amp Operating e REMEMBER It is the owners responsibility to communicate information on the safe use and proper operation of this unit to the operators Re
10. OPERATOR S SAFETY AND SERVICE R440 This manual covers the following serial numbers and higher for each model listed AO nn ee 4400004 SMART RAMMER MBW Inc MBW UK Ltd 250 Hartford Rd PO Box 440 Units 2 amp 3 CochraneStreet Slinger WI 53086 0440 Bolton BL3 6BN Phone 262 644 5234 Phone 01204 387784 Fax 262 644 5169 Fax 01204 387797 L18428 04 08 G MBW Inc 2008 Email mow mbw com Printed in the USA Website www mbw com TABLE CONTENTS Safety Information 1 SCNVICC es 7 e Sen breed RT 1 Torque Cha aed e E SERA ome a ee 7 Safety Precautions 1 Service 4 44 eese 4 ipae e 4 7 Safety Decals 1 7 S f 3 Handle Removal 7 Engine Removal 7 Operation 4 Clutch Removal 8 Gearbox Removal 8 MOGUCOM POR HDD 4 Gearbox Disassembly 8 Before Starting amp Operating 4 Gearbox Assembly 9 ENGNG ss codi Pc wee ae 4 Lower Unit Disassembly 10 eres bdo Stee di days dy iii d mos E 4 Low
11. acks or deterioration oo ane 1 2 Fluid Levels Check all hardware after the first 5 hours of use then follow the maintenance schedule Change oil in lower unit after the first 50 hours of operation then follow the maintenance schedule SYSTEM FLUID VOLUME RECOMMENDED OIL Percussion System SF SAE 10W 30 Motor Oil Engine Refer to engine operator owner manual Engine Maintenance Refer to the engine owners manual for maintenance intervals and procedures Check and clean the air cleaner element at least once daily The air cleaner has a foam pre cleaner that can be washed Check the engine oil level by removing the dipstick the engine must be level The oil level should be between the marks on the dipstick See the Check Engine Oil section of the engine Owner s Manual for information oee the Change Engine Oil section of the engine Owner s for information on the oil change intervals Engine Speed Engine speed is factory set according to the speed listed in the Specifications section of this manual Refer to the engine owners manual for procedure on setting operating speed if necessary Checking Percussion System Oil Refer to Lower Unit Assembly page 16 The rammer percussion system and gearbox are lubricated by an oil mist which is formed and carried throughout the rammer by a pumping action in the machine s lower system 1 Before daily operation tilt the ram
12. al operation On uneven terrain pushing down on the handle will aid climbing ability A WARNING A Do not bear down body weight of operator on the machine 4 After 3 passes the rammer may have more kick back this is an indication that ideal compaction is being reached Stopping Engine 1 2 3 4 Move throttle to idle position Let engine idle for one or two minutes Turn switch on engine to STOP position Turn off fuel valve WARNING Always stop the engine before Adding fuel Leaving the equipment unattended for any amount of time Before making any repairs or adjustments to the machine Lifting and Transporting 1 The unit may be lifted by the handle and engine guard The unit should be transported laying face down oecure it in place by the handle and shoe DO NOT lay the unit on its sides or face up during transport MAINTENANCE WARNING Always exercise the stopping procedure before 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 CAUTION Always verify fluid levels and check for leaks after changing fluids Do not drain oil onto ground into open streams or down sewage drains EVERY 25 EVERY 300 SYSTEM MAINTENANCE DAILY HOURS HOURS YEARLY Check oil level System Shockmounts Check for cr
13. ces 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 not 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
14. chrane Street Slinger WI 53086 0440 Bolton BL3 6BN England Phone 262 644 5234 Phone 01204 387784 Fax 262 644 5169 Fax 01204 387797 Email mbow mbw com Website www mbw com 13 Gearbox Assembly A 1 01001 RETAINING RING EXT 5100 137 01244 RETIANING RING EXT 5160 112 06259 BEARING NEEDLE EH 06264 RETAINING RING INT 5000 187 10 06266 RETINAING RING INT N5000 281 12 06413 VALVE SPRING COMPRESSION 0 420 OD 14 06904 BREATHER ASSEMBLY Includes items 12 13 15 16 17 28 29 30 16 06908 TUBE BREATHER 18 09476 RETAINING RING INT N500 244 20 13733 GEAR 22 16021 BEARING BALL BEARING SLIDE CUT 24 16451 RETAINING RING INTERNAL 3 0 26 18522 HOUSING GEARBOX 28 WASHER 5 32 X 3 8 18 ZP 30 OR OJN CO N F081304HCS HEAD CAP SCREW 1 2 13 X 1 2 GR5 ZP FO8SW WASHER 9 16 X 1 3 8 X 12 GA ZP INCLUDES GEARBOX TUBE GEARBOX TUBE NOT AVAILABLE SEPARATELY 15 Lower Unit Assembly 16 1 06173 COVER bancais 1 09618 FITTING PLUG PARKER 4HP 50N H 16311 RING CLAMPING BELLOWS 16324 PISTON 16423 SPACER 18136 GUARD SPRINGBOX 18276 PLUG OIL LEVEL 1 18462 RAM 17 18475 BUSHING 18 F042005FSS 55 1 4 20 X 5 8 20 F081318HCS HHCS 1 2 13 X 2 1 4 GR5 ZP 1869
15. dates 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 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 obliga
16. e 20 17 and 18 were removed apply medium strength thread locker to the four socket head cap screws page 20 27 before assembly Torque to 35 ft Ibs 47 Nem the unit with oil according to the Changing Percussion System Oil section on page 6 Parts Replacement Cycles and Tolerances Replace anytime a bearing is rough binding discolored or removed from housing or Bearings shaft Replace when they are worn cracked or to the point of leaking Replace clutch if shoes and or springs show signs of heat damage or if it does not Clutch disengage below 2000 rpm Replace if teeth are cracked or if they become sharp Engine Components Refer to your engine manufacturer s Owner s Manual Guide Bushings Replace if a 0 025 0 635 mm feeler gauge can be slid between the springbox and the guide tube or damaged hardware as needed Replacement hardware should be grade 5 and zinc plated unless otherwise specified Replace if teeth are cracked or if they become sharp Replace if the drum is scored or gouged deeper than 0 03 0 76 mm Piston Springbox 0 025 0 635 mm feeler gauge can slid between the springbox and Replace if the outside diameter is less than 0 620 15 75 mm springs 1 Replace if a flat spot on the side of a spring is greater than 0 09 2 mm Replace if the free length is less than 7 27 184 mm Replace ALL springs at the same time S
17. e upper bellows ring page 16 6 to the other side of the bellows Insert four hex head flange screws page 18 13 through the upper bellows mount so the head of the screw is wedged between the bellows and the upper bellows mount Slide the bellows bellows rings and hex head flange screws over the gearbox guide tube with the upper bellows ring toward the gearbox Thread the hex head flange screws into the gearbox to secure the bellows Apply a light coat of oil see Fluid Levels page 5 for proper oil type to all bearings after installation is complete Lower Unit Disassembly NOTE The lower unit can be separated from the drive unit engine gearbox and handle without completely disassembling the rammer If the lower unit has not already been separated follow the Gearbox Removal instructions Refer to Lower Unit Assembly page 16 Shoe and Springbox Guard Removal 1 Remove the six socket head cap screws and lockwashers page 18 11 amp 12 that secure the lower unit assembly page 18 5 to the shoe page 18 6 2 Remove the shoe Lift the springbox guard off the springbox and ram head assembly 4 Remove the o ring 9 from the springbox guard Springbox Disassembly WARNING Working with compressed springs Failure to follow the next set of steps very carefully could result in injury or death 1 Flip the springbox assembly upside down 2 Insert the springbox tool MBW 06468
18. er Unit Assembly 10 Stopping Engine 4 Gearbox and Lower Unit Assembly 11 Lifting and Transporting 4 Parts Replacement Cycles and Tolerances 12 Maintenance 5 Replacement Parts 13 Maintenance Schedule 5 Gearbox Assembly 14 Deere Bund EP Coh af d en oce 9 Lower Unit Assembly 16 Engine Maintenance 5 Gearbox and Lower Unit Assembly 18 Engine 5 5 Handle Assembly 20 Checking Percussion System Oil 5 Engine Assembly 22 Changing Percussion System Oil 6 Warranty ea v yews 24 WARNING CALIFORNIA PROPOSITION 65 WARNING Engine exhaust and some ofits 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
19. from authorized MBW distributors Order the decal set listed on the following page s Read the Operating Instructions before operating this piece of f equipment Keep unauthorized and untrained people away from this equipment ROTATING amp MOVING PARTS Make sure all guards and safety devices are in place Wear approved hearing protection foot protection eye protection and head protection SHUT OFF the motor before servic ing or cleaning DO NOT RUN an enclosed area The engine produces carbon monoxide a POISONOUS GAS Failure to comply could result in serious bodily injury 13483 Machine is top heavy and could fall if not lifted from this bar 420 119 54kg 440 270 450 143 65kg 460 470 480 160 73kg AIR CLEANER INSTRUCTIONS UNLEADED GASOLINE 14781 OPERATING INSTRUCTIONS 1 Check fuel level 2 Open fuel valve 3 Set throttle at idle postion 4 Choke engine A warm engine may not need to be choked 5 Pull starter rope 6 After starting open choke gradually and let engine warm up at idle 7 To start compacting open throttle fully 8 To stop return throttle to idle and allow engine to run for a few minutes before turning off 9 Turn engine switch to off and close fuel valve 14773 MT 4 4 QO X r4 CLEAN ELEMENT DAILY MORE OFTEN UNDER DUSTY CONDITIONS TAP ELEMENT LIGHTLY ON A FLAT SURFACE IF DUST DOES NOT DROP OFF EASILY OR IF ELEMENT IS BENT OR
20. gure 2 Gearbox Disassembly Refer to Gearbox Assembly page 14 Crank Gear Removal 1 Slip a retaining ring pliers through the slot opening in the crank gear 20 and remove the retaining ring 10 from the housing The retaining ring will remain between the crank gear and the bearing Remove the SAE plug 19 from the rear of the gearbox Use a 3 8 in 10mm diameter steel rod to press the crank gear out of the gearbox Remove the ball bearing 2 from the crank gear using a bearing puller Remove the large retaining ring 10 from the back of the crank gear Remove the small retaining ring 9 from the front of the offset shaft on the crank gear and remove the connecting rod 5 Remove the needle bearing 6 from the gearbox with a blind hole bearing puller tool MBW 07552 Pinion Removal 1 Remove the external retaining ring 4 from the gear end of the pinion 21 on the inside of the gearbox If the retaining ring is pinched in its groove tap the pinion on the drum side This will relieve the pressure on the retaining ring Press out the pinion Pry out the oil seal 11 and discard Remove the retaining rings 10 amp 18 Sm T9 Use a bearing puller to remove the ball bearings 22 amp 2 Breather Removal 1 Remove the hex head cap screw 29 from the top of the breather assembly 14 2 Remove the plain washer 30 cap 17 and filter 15 3 Use a pipe wrench to
21. mer back until the lower unit is plumb vertical and check the oil level in the glass sight 15 on the springbox guard 12 If the oil is not visible in the sight gauge add oil as required See Fluid Levels for recommeneded type of oil DO NOT OVERFILL THE PERCUSSION UNIT Changing Percussion System Oil Refer to Lower Unit Assembly page 16 1 Remove the drain plug 4 below the sight glass 15 on the back of the springbox guard 12 Place an oil drain pan behind the shoe and tip the rammer back so the handle is on the ground Elevate the shoe until the lower assembly is horizontal Hold this position until the oil is completely drained With the handle still on the ground remove the four hex head flange screws page 18 8 holding the cover page 18 2 to the gearbox page 18 7 Remove the cover the cover gasket page 18 4 and the dowel pins page 18 1 from the gearbox Tip the unit forward and drain any oil into an oil pan After the oil has drained out replace the dowel pins gasket and cover and secure with the four hex head flange screws Tip the rammer onto it s face and fill according to the Fluid Levels section in this manual Replace the drain plug SERVICE Assembly and disassembly should be performed by a service technician who has been factory trained on MBW equipment The unit should be clean and free of debris Pressure washing before disassembly is recommended
22. pringbox Bushing Bronze Replace if inner diameter is larger than 0 890 22 7 12 REPLACEMENT PARTS The warranty is stated in this book on page 24 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 oales Branches listed below When ordering replacement parts be sure to have the following information available e Model and Serial Number of machine when ordering MBW parts e Model and Serial Number of engine when ordering engine parts e 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 The units serial number can be found in the following MBW distributors locations The serial number decal is located on the top of the gearbox The serial number is also stamped on the top of the gearbox Write Model Number here Write Serial Number here Contact Information MBW Inc MBW UK Ltd 250 Hartford Rd PO Box 440 Units 2 amp 3 Co
23. rods into the springbox assembly as shown in Figure 3 Figure 3 Make sure the rods are 180 apart 4 Place the washers over the rods and run the nuts down so the washers are snug against the cover 1 5 Remove the flat head socket screws 18 holding the cover to the springbox 6 While holding the bottom of the rods from turning slowly and evenly back off the nuts on the cover side 7 After the tension is removed from the cover the springbox tools and the cover can be removed 8 Remove the o ring 2 from the cover 9 The lower springs 13 amp 14 can be removed from the springbox 11 10 Place a drift pin or steel rod through the piston hole in the ram head 16 Use this to hold the ram head from turning while removing the hex head cap screw and lockwasher 20 amp 21 11 Remove the washers 7 piston 8 spacer 10 and upper springs 13 amp 14 Lower Unit Assembly A WARNING A Working with compressed springs Failure to follow the next set of steps very carefully could result in injury or death Refer to Lower Unit Assembly page 16 1 Turn springbox 11 up side down and insert the upper springs 13 amp 14 2 Install the ram head 16 and add the washers 7 the piston 8 and the spacer 10 3 Apply medium strength thread locker to the hex head cap screw 20 and install it along with a lockwasher 21 into the ram head Torque to 50 ft Ibs 6
24. rt No Description 01629 Rubber Test Mat 06468 Springbox Tool 07205 Bellows Installation Tool 07353 Clutch Removal Tool Blind Hole Bearing Puller Tool General The disassembly and assembly procedures given on the next few pages are intended for a complete dismantling of the rammer Read the following sections carefully It is not necessary to follow the complete disassembly procedure when only partial disassembly is required If repairs have to be made to the Lower Assembly only it is recommended that the drive unit engine gearbox and handle be removed from the lower unit See Lower Unit Disassembly Handle Removal Refer to Handle Assembly page 20 1 Turn the fuel valve 11 to the off position 2 Loosen the hose clamp 3 at the engine end of the fuel line 9 Disconnect the fuel line 3 Remove the hardware holding the throttle 8 to the handle 22 4 Remove the four cap screws securing the handle to the gearbox 5 the handle from the rammer Engine Removal NOTE is not necessary to remove the handle to take the engine off the machine Refer to Engine Assembly page 24 1 Follow steps 1 through 3 under Handle Removal 2 Remove the four metric hex head flange screws 20 30 securing the engine guard page 20 20 to the engine 6 3 While supporting the engine remove the four hex flange nuts 7 holding the engine and engine adapter plate 2 to the st
25. the needle bearing 6 into the gearbox The bearing must be pressed in with the numbers and letters facing outward Apply a light coat of oil see Fluid Levels page 5 for proper oil type to the needle bearing after installation Install a retaining ring 1 to secure the needle bearing Place a retaining ring 10 over the large shaft of the crank gear 20 Press the ball bearing 2 onto the crank gear Press the bearing 3 into the connecting rod 5 and secure with a retaining ring 8 Press bearing 7 into the connecting rod 5 Press the connecting rod onto the offset shaft of the crank gear Install a retaining ring 9 to secure the connecting rod Press the crank gear assembly into the gearbox Install the snap ring 10 using a retaining ring pliers inserted through the slot in the crank gear Install the SAE plug 19 into the gearbox Do not over tighten Replace the breather sub assembly 14 filter 15 cap 17 and plain washer 30 Apply medium strength thread locking liquid to the threads of the hex head cap screw 29 and install Slide the slide bearing with the hole 23 into the gearbox tube and align the hole and slot in the bearing with the access hole screw in the gearbox Insert the other slide bearings 25 amp 27 oecure with the internal retaining ring 24 Assemble the lower bellows ring page 16 3 to one side of the bellows page 16 5 Assemble th
26. 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 GENERAL CAUTION Indicates information important to the proper operation of the equipment Failure to observe may result in damage to the equipment Safety Precautions aJ LETHAL 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 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 It is the owner s responsibility to ensure that all guards and shields are in place and in working order S C9 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 rings wristwatches etc near machinery NOISE PROTECTION Wear OSHA specified hearing protection devices
27. tion 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 DEMONSTRATION MACHINE OR ANY OTHER MBW PRODUCT 24
28. uds 1 4 Remove the engine engine adapter plate and engine guard from the rammer Clutch Removal Refer to Engine Assembly page 22 1 Remove the jam nut 8 and key 5 clutch off engine crank Slide the 2 Reinstall the clutch Carefully insert woodruff key 5 making sure key remains aligned with keyway 3 Reinstall jam nut Z8 with medium strength thread locker Gearbox Removal NOTE It is necessary to remove the Handle and the Engine to remove the Gearbox Refer to Gearbox and Lower Unit Assembly page 18 1 Drain the oil from the rammer following steps 1 through 3 under Changing Percussion System Oil on page 6 2 Replace the drain plug 3 Remove the four hex head flange screws 8 holding the cover 2 to the gearbox 7 CAUTION NOTE There may be oil in the gearbox Tip the unit back when removing the cover from the gearbox Remove the cover the cover gasket 4 and the dowel pins 1 from the gearbox Tip the unit forward and drain any oil into an oil pan Loosen the hex nut 10 on top of the ram head and remove the setscrew 9 Insert the setscrew into the piston pin 3 and remove the piston pin See Figure 1 Figure 1 Remove the six hex head flange screws page 16 19 holding the springbox guard page 16 12 to the bottom bellows ring page 16 3 Remove the gearbox assembly from the lower unit assembly See Figure 2 Fi
29. view ALL of the Safety Precautions listed on page 1 of this manual Familiarize yourself with the operation of the machine and confirm that all controls function properly e Know how to STOP the machine in case of emergency e 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 Owners Manual or the Maintenance section of this manual AIR CLEANER Check to ensure element is in good condition and properly installed e FUEL SUPPLY The engines on MBW equipment require an automotive grade of clean fresh unleaded gasoline FUEL FILTER If clogged or damaged replace Starting Engine For detailed instructions refer to the engine Owner s Manual 1 Open fuel valve 2 Turn engine switch to ON 3 Set throttle to idle A CAUTION A The engine speed must NOT be high enough to engage the clutch Choke engine if necessary you may not need to choke a warm engine Pull starter rope repeatedly until engine starts Move choke lever to open position Allow engine to warm up for one or two minutes Operating 1 2 3 Familiarize yourself with the balance of the rammer before using it in job conditions Due to the inherent design the machine is top heavy and could tip over After the engine warms up open the throttle fully for norm
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