Mazda 8 Automobile User Manual
Contents
1. 7116 BASE PLATE COVER SEALANT APPLICATION 14 13 Install the 90 degree fitting 2 containing the roll pin 20 into the bearing cover 18 using LOCTITE 8565 sealant on the threads Make sure the port for the breather faces the top of the baseplate housing 14 Install the breather 3 into the 90 2 degree fitting 15 Install the exciter weights 17 on the idler shaft 8 and secure with four socket head cap screws 24 using LOCTITE 4243 thread locker sealant and torque the cap screws to 32 ft Ibs 16 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 17 Install the input gear 10 onto the input shaft 416 and slide to the end with the bearing inner race 18 Press the other bearing inner race onto the input shaft 16 19 Install the input shaft subassembly into the baseplate with the keyed end toward the left side pulley side of the base plate 20 Install the pulley side shaft cover 9 containing the shaft seal 5 over the input shaft on the pulley side of the baseplate See the figure 83 for LOCTITE 8515 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 the2. DESCRIPTION QTY 1 05559 CAPPLUG 2 2 16228 ROLLER BEARING 100 x 45 1 3 16230 BALL BEARING 2 4 16231 GUIDE RING 1 5 16237 EXTERNAL RETAINING RING METRIC 1 6 16238 HYDRAULIC SEAL 2 T 16239 WASHER SHIM 1 8 16240 INTERNAL RETAINING RING 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 27 HANDLE ASSEMBLY DESCRIPTION QTY 1 08355 FITTING STRAIGHT 1 2 16350 HYDRAULIC SEAL 1 3 16351 GUIDE RING HYDRAULIC 1 4 16352 O RING METRIC 52mm I D 3 5 1 5 16353 O RING METRIC 26mm I D x 2 5 1 6 16354 EXTERNAL RETAINING RING 52 1 0 x 3 1 T 16355 O RING METRIC 52mm I D x 1 8 16358 PIPE PLUG METRIC 1 9 16359 WASHER METRIC 1 10 16410 THREADED ROD 1 2 13 x 3 0 1 11 19533 SHOCKMOUNT 2 12 16493 SHOCKMOUNT HANDLE BUMPER 1 13 16629 CONTROL HOUSING 1 14 16632 SLIDE BUSHING 1 15 16633 RACK GEAR 1 16
3. 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 Oil Hydraulic Oil GPR99 8 oz 24 Liter Chevron AW 15032 or Rykon 32 GRP135 8 oz 24 Liter Chevron AW 15032 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 the governor setting The governor 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 Battery Charging 1 The state of charge in an Odyssey battery can be determined from the following chart Voltmeter Reading State of Charge 12 84 Volts 10096 12 50 Volts 7596 12 18 Volts 5096 11 88 Volts 2596 4 The engine idle speed must not exceed 1800 RPM If 2 get a long life from the Odyssey battery it is the idle speed is greater than 1800 RPM the clutch impor
4. 24 LOWER SHAFT ASSEMBLY 26 HANDLE ASSEMBLY 28 GASOLINE ENGINE ASSEMBLY 30 DIESEL ENGINE ASSEMBLY 32 Warranty 34 WARNING 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 A WARNING A 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 A 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 R LETHAL EXHAUST GAS An internal combustion engine discharges carbon monoxide a poisonous odorless invisible gas Death or serious illness may result if inhaled Opera
5. 775 Ib 352 kg 825 Ib 374 kg 882 Ib 400 kg ENGINE Honda GX390 20 6 in 5 389 cm3 Honda GX390 20 6 5 389 cm3 Hatz 1B40 28 2 5 462 cm5 FUEL Gas Gas Diesel ENGINE SPEED 3600 rpm 3600 rpm 3600 rpm STARTER SYSTEM Recoil Recoil Electric start with recoil PLATE EXTENSIONS 3 in 7 6 amp 6 in 15 2 cm 3 in 7 6 amp 6 in 15 2 cm 3 in 7 6 cm amp 6 in 15 2 cm Specifications subject to change without notice 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 soil types Recommended soil types include granular soils gravel sand mixtures and semi granular cohesive soils The MBW Reversible Plate Compactor is 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
6. 6 Lifting Transporting 6 7 Maintenance 7 Fluid Eevels 2 4 pee ELA REA 7 Engine 7 Cleaning Plate 7 Engine Speed 8 Battery 8 Battery Charging 8 Belt Adjustment 8 568716607 D nm 9 Torque Chart 9 Service ror IRR RP EGG UPS 9 Main Disassembly Procedure Diesel Engine 9 Main Disassembly Procedure Gasoline Engine 10 Exciter Oil Change Procedure 10 Lower Hydraulic Seal Replacement 11 Bleeding And Adjustment of Hydraulic Controls 11 Baseplate Disassembly Procedure 12 Handle Disassembly Procedure 13 Control Head Disassembly Procedure 13 Baseplate Assembly Procedure 14 Control Head Assembly Procedure 17 Handle Assembly Procedure 17 Final 8 17 Troubleshooting 18 Parts Replacement Cycles and 5 19 Replacement Parts 20 MAIN ASSEMBLY 22 BASEPLATE ASSEMBLY
7. 16636 HOUSING SHAFT GUIDE 1 17 17058 TUBE CAP 4 18 17377 CONTROL HANDLE 2 19 17379 HANDLEBAR LEFT 1 20 17380 HANDLEBAR RIGHT 1 21 17402 SPINDLE MOUNT 2 22 17417 HANDLE TUBE 1 23 17445 FITTING ADAPTER HYDRAULIC 1 24 17509 PINION GEAR 1 25 17546 ANGLE MOUNT 1 26 F051804HCS HCS 5 16 18 x 1 2 GR 5 ZP 1 2T F051808FWS FWS 5 16 18 x 1 ZP 3 28 F051808SCS SCS 5 16 18 x 1 2 29 F051812FWS FWS 5 16 18 x 1 1 2 ZP 4 30 F0518FN FLANGE WHIZ LOCKNUT 5 16 18 ZP 3 31 FOSSW WASHER 5 16 x 3 4 x 15 GA 1 32 1607 FWS 3 8 16 x 7 8 ZP 6 33 F0813HN HEX NUT 1 2 13 ZP 2 34 M08C016FWS FWS M8 x 1 25 x 16mm ZP 4 35 MO8C025FSS FSS M8 x 1 25 x 25mm ZP 4 16638 CONTROL HEAD ASSEMBLY INCLUDES ITEMS 1 9 13 16 23 24 26 29 8 31 17369 REBUILD KIT UPPER HYDRULIC 29 GASOLINE ENGINE ASSEMBLY 30 DESCRIPTION GPR99 GPR135 1 00808 KEY SQUARE 1 4 x 1 3 4 1 1 2 07767 HONDA ENGINE 11 HP GX340 1 12887 HONDA ENGINE 13 HP GX390 1 3 09375 V BELT B 44 1 1 4 16576 CLUTCH 1 1 5 16580 SPACER CLUTCH 1 1 6 16665 WASHER MOUNT 1 1 E 16676 BELT GUARD 1 1 8 16974 HOSE OIL DRAIN 1 1 9 17467 BELT GUARD MOUNT 1 1 10 F052408FSS FSS 5 16 24 x 1 ZP 4 4 11 1618165 HCS 3 8 16 x 2 1 4 GR 5 ZP 4 4 12 FO61636SCS SCS 3 8 16 x 4 1 2 GR 8 ZP 4 4 13 F062408FSS FSS 3 8 24 x 1 ZP
8. 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 817 to the shafts and remove the exciter weights Refer to LOWER SHAFT ASSEMBLY page 26 11 12 14 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 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 816 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 24 15 16 17 18 19 20 21 22 23 24 25 26 2T Remove the plastic plugs 1 from
9. head bolts 821 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 26 28 29 30 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 Remove the e clip retaining ring 5 securing the bearings to the shift shaft 31 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 2 from the fitting 1 in control head of the handle Use a drain pan to catch the hydraulic oil Disconnect the throttle cable 819 from the engine Remove the two hex head flange screws 24 securing the throttle lever 15 to the handle and remove the throttle lever with bracket and throttle cable as a subassembly from the handle Remove the four hex head flange screws 29 securing the handle mount to the engine deck 4 Remove the handle assembly from the main assembly Refer to HANDLE ASSEMBLY page 28
10. 1 1 14 FO6LW LOCKWASHER 3 8 ZP 4 4 15 FO6PW WASHER 3 8 ZP 8 8 Q2893907 AIR CLEANER HONDA 11 amp 13 HP NOT SHOWN 31 DIESEL ENGINE ASSEMBLY DESCRIPTION QTY 1 00808 SQUARE KEY 1 4 x 1 3 4 1 2 01428 CABLE CLAMP BATTERY 2 3 08505 HYDRAULIC HOSE OIL DRAIN 1 2 x 22 1 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 T 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 BRACKET IGNITION BOX 1 15 17144 ENGINE HATZ DIESEL 1B40 1 16 17468 MOUNT BELT GUARD 1 17 19483 BRACKET THROTTLE ENGINE 1 18 19534 SHOCK MOUNT 60 DUROMETER 4 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 1 24 F042006FWS FWS 1 4 20 x 1 ZP 6 25 F0420ELN LOCKNUT 1 4 20 NYLOC 8 26 F04PW WASHER 1 4 ZP 6 27 F051804FWS FWS 5 16 18 x 1 2 ZP 4 28 F051806HCS HCS 5 16 18 x 3 4 ZP 4 29 F051808HCS HCS 5 16 18 x 1 GR 5 ZP 4 30 FOSLW LOCKWASHER 5 16 ZP 4 31 FOSSW WASHER 5 16 ZP 4 32 F0
11. 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 34
12. Secure the hydraulic line 2 to the hydraulic control head fitting Final Assembly Refer to engine pages Gasoline or Diesel 1 17 Lower engine assembly onto baseplate Use care to route hydraulic hose through engine deck and up handle tube Install four bolts lock washers and washers 11 14 amp 15 or 28 3229 amp 30 through the engine block into engine deck Install four bolts 34 lockwashers 36 and washers 37 through engine deck into shockmounts on bottom plate Refer to the Belt Adjustment section of this manual to complete assembly Bleed the hydraulics according to the Bleeding and Adjustment of Hydraulic Controls section of this Manual Troubleshooting SYMTOM REPAIR Engine does not start or stalls Fuel valve is closed open valve gasoline engine Engine switch is in 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 motor Defective or worn ignition switch replace ignition switch Engine does not accelerate is hard to start or runs erratically PLN O O R w 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 gaso
13. 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 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 C
14. torque the cap screws to 76 in lbs 41 42 43 44 45 46 4T 48 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 4565 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 8515 gasket maker on the lip of the mounting surface and secure with twenty hex head flange screws 22 using LOCTITE 243 on the threads See the figure 84 for LOCTITE 4515 gasket maker application Install the key 86 into the input shaft 816 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 4243 thread locker sealant on the threads Refer to engine pages Gasoline or Diesel 49 Install the v belt 3 to the pulley of the baseplate assembly Refer to MAIN ASSEMBLY page 22 50 51 52 53 54 55 16 Install the side cover 16 on the pulley side of the baseplate housing and secure with six hex head flange screws 24 using LOCTITE 243 thread locker sealant Install the bellows
15. 3 amp 37 17338 KIT 6 EXTENSION CONTAINS ITEMS 12 13 amp 37 23 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 ENDS 1 1 T 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 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 FO51806FWS FWS 5 16 18 x 3 4 ZP 21 21 23 F051808FWS FWS 5 16 18 x 1 0 ZP 12 12 24 F0616128CS SOCKET HEAD SCREW 3 8 16 x 1 1 2 GR 8 8 8 25 F0618SPP PIPE PLUG 3 8 16 NPT 1 1 26 F160816SCS SOCKET HEAD CAP SCREW 18 x 2 0 GR 8 ZP 4 4 16609 BASEPLATE COMPLETE GPR99 CONTAINS ITEMS ABOVE 16607 BASEPLATE COMPLETE GPR135 CONTAINS ITEMS ABOVE 25
16. 5 into the bellows mount plate 18 and secure it to the baseplate with four hex head flange screws 25 Connect the hydraulic line 2 to the 90 degree fitting on the hydraulic housing Install the grommet 43 into the hydraulic guard 17 Guide the hydraulic line 2 through the grommet 3 in the hydraulic guard 17 and secure the guard to the hydraulic side of the baseplate with the four hex head flange screws 24 Set the side cover 16 off to the side until bleeding and final assembly is done The exciter is now ready for final assembly If required install the bushings 13 extension plates 12 and 1 socket head cap screws 39 to the sides of baseplate housing using LOCTITE 767 antisieze compound on the bushings and bolt threads Control Head Assembly Procedure Refer to HANDLE ASSEMBLY page 28 10 11 12 13 14 15 16 17 Clean and dry all parts to be assembled Press the slide bushing 14 into the control housing 13 Press the hydraulic seal 2 onto the rack gear 15 Be careful to orient the seal lip to face the shaft guide housing 16 Tip Use approved hydraulic oil to lubricate the seal inside diameter to ease assembly See Maintenance Section for type of hydraulic oil Assembly the hex head cap screw 826 and washer 31 to the rack gear using LOCTITE 243 thread locker sealant on the threads Install the O ring 7 onto housing 16 I
17. 6 10 Remove the four flat head socket screws 835 securing the spindle mounts 421 to the shockmounts 11 Remove the four hex head flange screws 834 securing the shockmounts to the handle 22 from inside the tube Remove the two jam nuts 433 securing the threaded rod 810 to the handle and remove the handle bumper shockmount 412 and threaded rod Remove the two socket head cap screws 28 from the control handles 18 and separate the control handles from the control head 13 Remove the six hex head flange screws 432 securing the handle bars 419 and 420 to the handle and remove the handlebars and the control head from the handle Control Head Disassembly Procedure Refer to HANDLE ASSEMBLY page 28 1 13 Note the position of the threaded holes in the pinion shaft 24 Remove the hydraulic fitting 1 and the adapter fitting 23 from the shaft guide housing 16 Remove the four hex head flange screws 29 securing the shaft guide housing 16 to the control head housing 813 Be sure to note the locations of the O rings for the assembly Remove O ring 7 from the shaft guide housing Remove the pipe plug 8 and seal washer 9 from the control head housing 10 11 12 Remove the external snap ring 6 from the pinion shaft 24 Slide the pinion shaft 824 out of the control housing 13 Note the size and location of the O rings 4 amp 5 for assem
18. 61636SCS SCS 3 8 161 x 4 1 2 GR 8 ZP 4 33 F062408FSS FSS 3 8 24 x 1 ZP 1 34 F081305HCS HHCS 1 2 13 x 5 8 GR 5 ZP 8 35 M06C012FWS FWS M6 x 1 0 x 12 ZP 3 36 M10C020FSS FSS M10 x 1 5 x 20 ZP 4 37 M12ETLW LOCKWASHER M12 EXTERNAL TOOTH 8 H50484100 AIR FILTER HATZ DIESEL 1B40 Not Shown H50404900 KEY STARTER HATZ 17751 CONTROL BOX 2 KITS 19608 KIT 4 FOAM STRIPS BATTERY BOX 33 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 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 cl
19. 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 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 1 Open fuel valve 2 Turn engine switch to on position 3 Setthrottle to idle position 4 Choke engine if necessary you may not need to choke a warm engine 5 Pull starter rope repeatedly until engine starts Move choke to the off or op
20. OPERATOR S SAFETY AND SERVICE MANUAL GPR99 6 GPR135 This manual covers the following serial numbers and higher for each model listed a 3090201 5 een 2900253 CR cee eee 2910050 VIBRATOY PLATES MBW Inc MBW UK Ltd MBW FRANCE S A R L 250 Hartford Rd PO Box 440 Units 2 amp 3 Cochrane Street Z A d Outreville Slinger WI 53086 0440 Bolton BL3 6BN England 11 rue Jean Baptiste N ron Phone 262 644 5234 Phone 01204 387784 60540 BORNEL Fax 262 644 5169 Fax 01204 387797 FRANCE TET L17433 02 08 M Email mbw mbw com E 300194 ay gt MBW Inc 2004 Printed in the USA Website www mbw com Email mbwfranceQfree fr TABLE OF CONTENTS Safety Information 1 Introduction sns mee 1 Safety Precautions 1 Safety Decals en sr adie al 1 Safety Decals GPR135 Decal Set 16031 2 Safety Decals GPR99 135 Decal Set 16031 3 Specifieati ns 4 Operation 5 5 Before Operation 5 EnGI EG cs ete eM e aA Tq e ea pas 5 Starting Gasoline Engine 5 Starting Diesel Engine 5 Running Engine 5 Stopping
21. PLATE RUBBER MAT 1 1 1 11 17160 SHOCKMOUNT GPR99 4 17419 SHOCKMOUNT GPR135 4 4 12 17326 EXTENSION PLATE 3 WIDE OPTIONAL SEE KIT 817337 2 2 2 17333 EXTENSION PLATE 6 WIDE OPTIONAL SEE KIT 817338 2 2 2 13 17335 BUSHING USED WITH EXTENSION PLATES OPTIONAL 4 4 4 14 17340 POP PIN 1 1 1 15 19268 THROTTLE LEVER 1 1 1 16 17434 COVER SIDE 2 2 2 17 17435 GUARD HYDRAULIC COVER 1 1 1 18 17436 GUARD BELLOWS MOUNT 2 2 2 19 19479 THROTTLE CABLE 1 1 1 20 17462 RETAINER BELLOWS 1 1 1 21 17997 SHIM SHOCKMOUNT AS REQUIRED 22 19481 BRACKET THROTTLE 1 1 1 23 F032403FSS FSS 10 24 x 3 8 ZP 2 2 2 24 F042004FWS FWS 1 4 20 x 1 2 ZP 18 18 18 25 F042008FWS FWS 1 4 20 x 1 0 ZP 9 9 9 26 F0420ELN LOCKNUT 1 4 20 NYLOC ZP 1 1 1 2T F051805HCS HHCS 5 16 18 x 1 0 GRD 5 ZP 3 3 3 28 F0518ELN LOCKNUT 5 16 18 NYLOC ZP 3 3 3 29 FO61608FWS FWS 3 8 16 x 1 0 ZP 4 4 4 30 FO6SW WASHER 25 64 x 1 0 x 1 4 5 5 5 31 F081314HCS 5 1 2 13 x 1 3 4 GRD 5 ZP 4 4 4 32 FO813ELN LOCKNUT 1 2 13 NYLOC ZP 4 4 4 33 FO8SW WASHER 8 16 x 1 3 8 x 12 GA ZP 4 4 4 34 F101110HCS 5 5 8 11 x 1 1 4 GRD 5 ZP 4 4 4 35 1011 HEX NUT 5 8 11 ZP 4 4 4 36 F10LW LOCKWASHER 5 8 ZP 8 8 8 37 F10PW WASHER 5 8 x 1 1 4 x 12 GA ZP 8 8 8 38 F1608165CS SOCKET HEAD CAP SCREW 1 8 x 2 0 GR 8 ZP 4 4 4 39 F1608365CS SOCKET HEAD CAP SCREW 1 8 x 4 1 2 GR 8 ZP 4 4 4 17337 KIT 3 EXTENSION CONTAINS ITEMS 12 1
22. 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 20 This page intentionally left blank Contact Information MBW Inc MBW UK Ltd MBW FRANCE S A R L 250 Hartford Rd PO Box 440 Units 2 amp 3 Cochrane Street Z A d Outreville Slinger WI 53086 0440 Bolton BL3 6BN England 11 rue Jean Baptiste N ron Phone 262 644 5234 Phone 01204 387784 AN NE Fax 262 644 5169 Fax 01204 387797 Phone 33 0 3 44 07 15 96 Fax 33 0 3 44 07 41 28 Email mbwfrance free fr Email mbw mbw com Website www mbw com 21 ASSEMBLY PAGE LLI 0 2 lt I LLI LLI n MAIN ASSEMBLY DESCRIPTION 99H 135H 135D 1 05477 SWIVEL THROTTLE CABLE 1 1 2 09642 HOSE HYDRAULIC 1 1 1 3 10088 GROMMET 1 1 1 4 16281 ENGINE DECK 1 17284 ENGINE DECK 1 1 5 16442 BELLOWS 1 1 1 6 16543 HANDLE MOUNT 2 2 2 7 16607 BASEPLATE ASSEMBLY 135 1 1 16609 BASEPLATE ASSEMBLY GPR99 1 8 16652 ROLLCAGE 1 1 1 9 16653 RUBBER MAT 1 1 1 10 16654 MOUNTING
23. 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 8565 FIGURE 1 T If equipped reinstall the bushings and baseplate extension using antisieze lubricant LOCTITE 4767 Lower Hydraulic Seal Replacement Refer to LOWER SHAFT ASSEMBLY page 26 Note The seals 6 guide ring 4 and gaskets 17 and 18 should be replaced as a 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 24 securing the side cover 16 to the recoil oil drain side of the baseplate Loosen hex head bolts 34 on the oil drain side only Lift the engine deck up to allow the side cover to be removed Refer to HANDLE ASSEMBLY page 28 3 11 12 Remove the pipe plug 8 from the control head housing Remove the hydraulic line 2 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 the hydraulic housing Remove the four flange screws 22 securing the hydr
24. aim 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 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
25. ained 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 e HL e 2 7 STAMPED SERIAL NUMBER DECAL SERIAL NUMBER E ep 25 CS Sal The unit s 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 MBW Inc 250 Hartford Rd PO Box 440 Slinger
26. ard 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 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
27. are pre assembled to the spool 32 33 MBW 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 84 to the shift spool Install a new mount gasket 17 onto the hydraulic housing 16 Lubricate the inside of the hydraulic housing 416 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 20 over the hydraulic housing 16 to the input shaft cover 12 with the four flanged cap screws 22 with the four flanged cap screws page 34 822 using LOCTITE 4243 thread locker sealant on the threads and torque the cap screws evenly in stages to 13 ft Ibs Make sure the bleeder screw port 14 is in the vertical position Install the gasket 18 and cover 19 to the hydraulic housing 16 with four hex head flange screws 21 using LOCTITE 243 thread locker sealant on the threads and
28. aulic adapter 23 using hydraulic oil as a seal lubricant Install the pipe plug 8 and the sealing washer 9 into the control housing 13 all the way but do not tighten Handle Assembly Procedure Refer to HANDLE ASSEMBLY page 28 1 Install the control head assembly into the handle tube 22 and secure the handlebars 19 and 20 to the handle and control head with the six hex head flange screws 32 using LOCTITE 243 thread locker sealant on the threads Slide the two control handles 18 onto the control head and secure them with the two socket head cap screws 28 using LOCTITE 243 thread locker sealant on the threads Thread one hex nut 33 onto the threaded rod 10 Install the threaded rod 10 into the handle angle mount 25 and thread on the other jam nut 33 Thread the handle bumper shockmount 12 onto the threaded rod Connect the shock mounts 11 to the handle from inside the tube with four 8mm hex head flange screws 34 using LOCTITE 243 thread locker sealant on the threads Secure the spindle mounts 21 to the shockmounts with four 8mm flat head socket screws 435 using LOCTITE 4243 thread locker sealant on the threads Refer to MAIN ASSEMBLY page 22 8 11 Install the handle mounts 46 onto the handle assembly Route the hydraulic line 222 through the handle tube Secure the handle assembly to the engine deck with four hex head flange screws 29
29. aulic housing 16 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 84 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 421 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 16 17 18 19 20 21 22 23 24 25 26 27 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 Install the new cylinder gasket 18 the cylinder cover 19 and the four flanged capscrews 21 Remove all mount gasket material from the input s
30. blication 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 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 DIESEL MODEL D RUN OP E Ee THROTTLE 15847 15855 U S PATENT 7 165 469 15832 19326 12573 HYDRAULIC OIL 15844 2 ZAR 815844 9X Y K EE 2227 0 EN OF ENGINE OIL DRAIN 15845 GASOLINE MODELS IDLE RUN ick engine orf Tevel t 2 Check fuel level THROTTLE 19492 3 Set engine speed control in the middle position 4 Move decompression lever if equipped to the up position Located on top of the engine 3119492 5 Use key if equipped or starting handle to start engine Refer to engine instructi
31. bly Remove the O rings 4 amp 5 from the pinion shaft 24 Slide the rack gear 15 seal 2 and guide ring 3 out of the control head housing Note the orientation of the seal lip Remove the hex head cap screw 26 and washer 31 from the rack gear 15 Remove the hydraulic seal 2 from the rack gear Be careful to prevent scratching the seal mounting area ofthe rack gear Use a 1 4 pin punch to drive the slide bushing 14 out of the control head housing Baseplate Assembly Procedure Refer to BASEPLATE ASSEMBLY page 24 Clean all baseplate components Note Make sure the bearings and their inner races are kept as a matched set 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 inspection Install the input shaft cover seal 5 into cover 9 FIGURE 3 3 16 BEAD LOCTITE 515 GASKET MAKER r HOUSING SIDE OF COVER 1 8 BEAD LOCTITE 515 GASKET MAKER SHAFT BEARING COVER 10 11 12 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
32. bs 57 ft lbs 80 ft lbs 1 2 20 41 ft lbs 64 ft Ibs 90 ft lbs 9 16 12 53 ft lbs 82 ft lbs 115 ft lbs 5 8 11 73 ft lbs 112 ft lbs 159 ft lbs 5 8 18 83 ft lbs 112 ft lbs 180 ft lbs 3 4 16 144 ft lbs 200 ft lbs 315 ft lbs 1 8 188 ft lbs 483 ft lbs 682 ft lbs 1 14 210 ft lbs 541 ft lbs 764 ft lbs 1 1 2 6 652 ft lbs 1462 ft lbs 2371 ft lbs M6 3 ft lbs 4 ft lbs 7 ft lbs M8 6 ft lbs 10 ft lbs 18 ft lbs M 10 10 ft lbs 20 ft lbs 30 ft lbs CONVERSIONS in Ibs x 0 083 ft lbs ft lbs x 12 in lbs ft lbs x 0 1383 kg m ft lbs x 1 3558 Nem Service Tools Part No Description 17320 Ground Pounder Exciter Oil 016129 Rubber Test Mat 16031 Decal Set 17368 Kit Rebuild Lower Hydraulic 17369 Kit Rebuild Upper Hydraulic Main Disassembly Procedure Diesel 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 32 securing the engine deck 4 to the baseplate 7 Use caution as the engine deck will drop down Refer to DIESEL ENGINE ASSEMBLY page 32 Sections of this manual for belt guard amp belt removal Remove the four socket head capscrews 31 securing the belt guard 11 to the mount plate 15 on the engine 14 and remove the beltguard Slide the belt 3 off the clutch 6 Remove the two flange screws 23 securing the bellows retainer 820 and remove the retaine
33. e Use the electrical tape to enclose the terminal of the positive red battery cable to prevent accidental discharge of the battery Remove the three 6mm bolts 34 securing the ignition box to the mount 13 Remove the four hex head screws 433 securing the battery box 818 to shockmounts remove battery box and cables Then remove four hex head flange screws 827 and mounting brackets 20 Remove the four hex head capscrews 28 securing the engine to the engine deck and remove the engine 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 32 securing the engine deck Z4 to the baseplate 87 Use caution as the engine deck will drop down Refer to GASOLINE ENGINE ASSEMBLY page 30 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 820 and remove the retainer Push the lip of the bellows 5 through the hole in the engine deck Disconnect the hydraulic line 82 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
34. e fuel valve where applicable Lifting Transporting 1 Lift unit by center lifting eye on rollcage 2 The unit must be transported in the upright position DO NOT lay machine on its side 3 Secure or tiedown unit using lift eye or roll cage when transporting WARNING A 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 Always exercise the stopping procedure before WARNING 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 Always verify fluid levels and check for leaks after changing fluids CAUTION Do not drain oil onto ground into open streams or down sewage drains SYSTEM MAINTENANCE 11 11 12 icine 2201 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 Shockmounts Check for cracks or tears X X 1 Check all hardware after the first 5 hours of use then follow the maintenance schedule
35. e the helix pin carrier shift shaft assembly with exciter oil and slide into the input shaft and install the dowel pin 11 Note Helix pin carrier MUST slide freely in input shaft 28 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 FIGURE 5 HYDRAULIC HOUSING EN SIDE OF BASEPLATE NY 1 HELIX PIN ORIENTED HORIZONTALLY BASEPLATE GEAR TIMING 15 29 30 31 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 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 Ibs 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 one end of the helix to the other Refer to LOWER SHAFT ASSEMBLY page 26 for steps 32 thru 42 Note The seals 6 guide ring 4 and gaskets 17 34 35 36 37 38 39 40 and 18 should be replaced as a set recommends purchasing rebuild kit 17368 for ease of repairs Seals
36. en 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 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 th
37. 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 o co Leaking hydraulic connections tighten connections Leaking hydraulic line replace hydraulic hose Worn or damaged piston seals requires authorized MBW service repair 18 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 Hardware Replace any worn or damaged hardware as needed Replacement hardware should 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 19 REPLACEMENT PARTS The warranty is stated in this book on page 34 Failure to return the Warranty Registration Card renders the warranty null and void MBW has established a network of reputable distributors dealers with tr
38. haft 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 86 to the shift spool 815 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 20 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 2 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 Follow the steps for Bleeding And Adjustment Of Hydraulic Controls section of this manua
39. 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 and the handle in the locked position oil level should be about 1 1 4 to 1 1 2 from top of control head Reinstall the pipe plug 2 Reinstall the side cover removed in stop 1 using LOCTITE 243 on the screw threads Lower engine deck to level position and tighten hex head bolts 32 FIGURE 2 50 25 OIL LEVEL 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 39 extension plates 12 and bushings 13 from the sides of baseplate 7 Remove the twelve hex head flange screws 24 securing the side covers 16 to the baseplate Remove the four hex head flange screws 25 securing the bellows mounts 18 to the baseplate and remove the bellows mounts and bellows 5 Disconnect the hydraulic line 2 from the hydraulic fitting Remove the four hex head flange screws 24 securing the hydraulic guard 17 to the baseplate and remove the hydraulic guard and hydraulic line from the baseplate Refer to BASEPLATE ASSEMBLY page 24 6
40. l Reinstall the side cover removed in step 2 using LOCTITE 243 on the screw threads Lower engine deck to level position and tighten hex head bolts 32 Bleeding And Adjustment of Hydraulic Controls Refer to MAIN ASSEMBLY page 22 for side cover 1 11 removal Remove the six flange screws 23 securing the side cover 16 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 hydraulic guard to be removed Refer to figure 2 2 10 11 12 13 Position the handle in the locked position and set the lock pin Check the hydraulic line 84 for loose fittings and tighten as needed Remove the pipe plug 2 from the control head Loosen the bleeder screw 1 located at the hydraulic control housing of the exciter Fill the control head with hydraulic fluid as shown Place a drip pan or shop rag below the bleeder to catch any excess oil Slowly operate the control handle 43 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 bubbles have been removed tighten the bleeder screw 1 and adjust the hydraulic oil level
41. line 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 ll m 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 Improper adjustment of hydraulic control system requires authorized MBW service repair 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 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
42. llow these steps baseplate Refer to MAIN ASSEMBLY page 22 3 Tighten the belt by lifting the engine deck to provide 3 8 3 4 inch of play on one side of the belt Be 1 Remove the belt guard refer to engine assembly sure to keep the engine deck level with the pages baseplate when adjusting the belt 4 Retighten the four hex head capscrews Reinstall the beltguard SERVICE Assembly and disassembly should be preformed 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 Prior to assembly wash all parts in a suitable cleaner or solvent Check moving parts for wear and failure Refer to the Replacement Section of this manual for tolerances and replacement cycles All shafts and housings should be oiled prior to pressing bearings Also ensure that 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 SIZE GRADE 2 GRADE 5 GRADE 8 1 4 20 49 in Ibs 76 in lbs 9 ft lbs 1 4 28 56 in lbs 87 in lbs 10 ft lbs 5 16 18 8 ft lbs 13 ft lbs 18 ft lbs 5 16 24 9 ft lbs 14 ft lbs 20 ft lbs 3 8 16 15 ft lbs 23 ft lbs 33 ft lbs 3 8 24 17 ft lbs 26 ft lbs 37 ft lbs 7 16 14 24 ft lbs 37 ft lbs 52 ft lbs 7 16 20 27 ft lbs 41 ft lbs 58 ft lbs 1 2 13 37 ft l
43. nstall the guide ring 3 onto the rack gear 15 the shaft guide Lubricate the inside of the shaft guide housing 16 and the rack gear subassembly with hydraulic oil See Maintenance Section for type of hydraulic oil Slide the rack gear subassembly into the shaft guide housing 16 until the guide ring 3 is fully inserted into the shaft guide housing 16 Slide the shaft guide housing rack gear subassembly into the control housing 13 while guiding the rack gear 15 into the slide bushing 14 Secure the shaft guide housing 16 to the control housing 13 with the four hex head flange screws 829 using LOCTITE 4243 thread locker sealant on the threads and torque the cap screws to 13 ft Ibs Push the rack gear 15 toward the pipe plug end of the control housing 13 until it is approximately 0 90 from the end of the control housing Note this measurement is approximate Install the O rings 84 and 85 on the pinion gear 424 Tip Use hydraulic oil to lubricate the O rings to ease assembly Slide the pinion gear 24 with seals into the control housing 13 Note the positions of the rack gear and the pinion gear and align as shown use care when meshing the gears Install the external snap ring 6 onto the pinion gear shaft 24 Install the hydraulic adapter 23 into the shaft guide housing 16 using hydraulic oil as a seal lubricant Install the hydraulic fitting 1 into the hydr
44. on book for proper Manual Starting procedure 6 After starting return engine speed control to the idle position and allow engine to reach operation temperature 7 During operation run engine at full throttle when excessive kickback is noticed maximum compaction has been reached 8 To stop return throttle to the idle position and allow engine to idle for one minute then move control to Failure to comply could result in serious engine t bodily injury stop position 13483 15866 ZS Machine may fall and cause 4 injury or damage if lifted improperly 4 Lift only by lift hook Weight 781 855kg 16026 15847 ENGINE OIL DRAIN 15845 15845 UNLEADED GASOLINE 13481 813481 ic ROTATING PARTS can crush and cut Keep hands away 812573 GPR99 15856 GPR135 15855 Safety Decals GPR99 135 Decal Set 16031 01554 FORWARD 01554 GPR99 15856 GPR135 15855 15844 SPECIFICATIONS GRP135 GPR99H GPR135H GPR135DE CENTRIFUGAL FORCE 9900161 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 cm OPERATING WEIGHT
45. r Push the lip of the bellows 5 through the hole in the engine deck Disconnect the hydraulic line 2 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 Use the main lift hook on the rollcage 8 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 If further disassembly of the engine deck is required proceed to step 9 If baseplate service is required refer to If baseplate service is required refer to the Baseplate Disassembly Procedure section of this manual Disconnect the throttle cable 819 from the engine Remove the handle assembly by removing the four flange screws 27 securing the handle mount 6 to the engine deck 11 Remove the four hex head capscrews 29 securing the rollcage to the engine deck and remove the rollcage Refer to DIESEL ENGINE ASSEMBLY page 32 12 13 14 15 16 17 18 Disconnect the negative black battery cable 9 from the engine mount bolt 28 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 10 from the starter of the engin
46. seal 21 Secure the input shaft cover with the four flange head crews 23 using LOCTITE 243 thread locker sealant on the bolt threads and torque the capscrews to 13 ft Ibs Refer to LOWER SHAFT ASSEMBLY page 26 TIMING MARK LOCATION HUB OF IDLER GEAR OPPOSITE SHAFT SHOULDER EXCITER WEIGHTS m dd ROTATED AS SHOWN 22 Install the other input shaft cover 12 and secure with the four flange head screws 22 using LOCTITE 4243 thread locker sealant and torque the screws to 13 ft lbs See the figure 3 for LOCTITE 8515 gasket maker application Check input shaft for minimum of 020 end play after covers are installed and the bolts are torqued 23 Install one exciter weight 17 to the input shaft on the hydraulic housing side of the baseplate with two socket head cap screws 24 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 24 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 26 25 Install the ball bearings 3 and the spacer washer 7 onto the shift shaft 10 and secure with the e clip 85 26 Press the shift shaft and ball bearing assembly into the helix pin carrier 9 and secure with the internal retaining ring 8 27 Lubricat
47. set Install the hex head flange screws 821 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 8 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 shaft with the hole goes toward the front right side of the machine with the breather cover 18 Install the idler 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 lbs See the figure 3 for LOCTITE 8515 gasket maker application Check idler shaft for minimum of 020 end play after covers are installed and the bolts are torqued FIGURE 4 MAIN HOUSING COVER LPR
48. tant that the battery is kept near full charge may not disengage approximately 12 8 volts 3 If there are electrical loads during storage then the Battery Maintenance negative battery cable should be disconnected or a Battery Tender trickle charge used Low power 1 25 1 The Odyssey battery is very different from standard batteries amp Battery Tenders will keep a fully charged battery PSP a peny 1 fully charged but cannot recharge if the battery 2 The battery is and operates as a sealed battery becomes discharged CO 06 4 f a standard automotive charger is used to boost TS garga charge a discharged battery it is important to make 3 The battery is shipped fully charged from the factory sure the charging voltage does not exceed 15 volts but prior to installation check the battery s voltage to during charge A hand held voltmeter can be used to see if it is 12 65 volts or greater If not recharge it monitor this periodically The following chart provides using the procedure below Caution Never attempt recharge times under this type of boost charging to to remove the top decal cover as it will cause the an 80 9596 recharge battery to fail ODYSSEY Charge time for 100 discharged battery 11 5 volts Model 10 amp charger 20 amp charger PC 925 2 1 2 hours 1 1 4 hours Belt Adjustment 2 Loosen do not remove the four hex head capscrews securing the engine deck to the If any belt stretch develops fo
49. te 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 5 SAFETY GUARDS It is the owner s 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 f rings wristwatches etc near machinery 8 ar NOISE PROTECTION Wear OSHA specified hearing protection devices 2024 Ly 27 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 221171 REFERENCES For details on safety rules and regulations in the United States contact your local Occupational Safety and Health Administration 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 pu
50. the threaded holes in the shaft covers 7 9 12 amp 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 823 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 8 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 pin 11 from the input shaft and slide out the helix pin carrier 49 as a 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 amp 12 by removing two 5 16 flange
51. to use a drain pan to catch the hydraulic oil Use the main lift hook on the roll cage 8 to separate the engine deck from the baseplate Be 11 12 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 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 819 from the engine Remove the handle assembly by removing the four flange screws 27 securing the handle mount 6 to the engine deck Remove the four hex head capscrews 29 securing the rollcage to the engine deck and remove the rollcage Remove the four hex head capscrews 11 securing the engine to the engine deck and remove the engine Exciter Oil Change Procedure 1 GPR 99 135 EXCITER OIL DRAIN 10 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 plug 85 from the baseplate and drain the oil Examine the oil for metal chips as
Download Pdf Manuals
Related Search