Manual / Parts Breakdown
Contents
1. Gearbox and Lower Unit Assembly ITEM PART NO DESCRIPTION QTY 1 14757 SPACER OIL SEAL 1 2 15667 GASKET COVER 1 3 19880 GEAR BOX ASSEMBLY 1 4 19885 LOWER UNIT ASSEMBLY R482 11 SHOE 1 19886 LOWER UNIT ASSEMBLY R483 13 SHOE 1 5 19894 COVER HOUSING R482 1 6 20045 PISTON CONNECTING PIN 1 7 20046 RETAINING RING INTERNAL 1 8 F042010HCS HEX HEAD CAP SCREW 1 4 20 x 1 1 4 GR5 ZP 4 9 FO4LW LOCKWASHER 1 4 ZP 4 10 F051807FWS FLANGE HEAD LOCK SCREW 5 16 18 x 7 8 ZP 6 19 SLIDE TACH WIRE THRU CLAMP Handle Assembly ITEM PART NO DESCRIPTION QTY 1 01045 FILTER FUEL 1 20387 FILTER DIAPHRAGM CARBURETOR HONDA 2 01052 CLAMP HOSE 1 2 4 3 01145 CLAMP CABLE 1 4 01034 HOSE FUEL 1 4 X 6 482H ONLY 1 02293 HOSE FUEL 1 4 X 13 482R ONLY 1 5 07351 TORSION MOUNT 2 6 07916 FERRULE THROTTLE LEVER 1 7 20476 CAP 2 1 4 1 20472 CAP 2 1 4 ROBIN EH12 ENGINE ONLY 8 14965 BRACKET MOUNTING HANDLE 2 9 15183 HOSE FUEL 1 4 X 1 1 2 1 10 20422 TANK FUEL WITH DECALS 1 11 16414 VALVE FUEL 1 12 20419 KIT ENGINE GUARD ROBIN ONLY Includes items 28 amp 29 1 13 16568 SLEEVING POLY x 14 ROBIN ONLY 1 17439 SLEEVING POLY x 7 HONDA ONLY 1 14 16566 GROMMET 1 2 12. de da eit Eats 9 Starting Engine 4 SPpriNgbOX 9 Operating 4 Assembly Instructions 9 Stopping Engine 4 Gearbox Assembly 9 Lifting and Transporting 4 Lower Unit Assembly 10 Maintenance ni 5 Gearbox amp Lower Unit Assembly 10 Parts Replacement Cycles and Tolerances 11 Maintenance Schedule 5 Fluid Levels chr ese REPRE RYE IAS UK 5 Replacement Parts 13 Engine Maintenance 5 Gearbox Assembly 14 Engine Speed 5 Lower Unit Assembly 16 Checking Percussion System Oil 5 Gearbox and Lower Unit Assembly 18 Changing Percussion System Oil 6 Handle Assembly 41 44 tit Wav 566 8 be 20 a a 7 Engine Assembly 22 Torque Chart card b30 dsc wish AA Aa A rae b dua Po Warranty seii Gi Wa 24 Service LO at ae oe ume ana 7 A WARNING A CALIFORNIA PROPOSITION 65 WARNING Engine exhaust and some of its constituents are known in the state of California to cause cancer birth defects and other reproductive harm SAFETY INFORMATION Introduction This Safety A
3. 15 16668 CABLE THROTTLE ROBIN ONLY 1 19899 CABLE THROTTLE HONDA ONLY 1 16 17602 TACHOMETER amp HOURMETER KIT 17 18527 GUARD ENGINE HONDA ONLY 1 18 18742 THROTTLE RACHET STYLE 1 19 18877 GUIDE HANDLE 4 20 20393 CLAMP SUPPORT 21 F032402FSS FLAT HEAD SCREW 10 24 X 1 4 ZP 2 22 F042004HCS HEX HEAD CAP SCREW 1 4 20 X 1 2 ZP 4 23 F051807FWS FLANGE SCREW 5 16 18 X 7 8 ZP 4 24 F051808FWS FLANGE SCREW 5 16 18 X 1 ZP 8 25 F051812FWS FLANGE SCREW 5 16 18 X 1 1 2 ZP 4 26 F0518FN NUT FLANGE 5 16 18 ZP 12 2T M08C025FWS FLANGE SCREW M8 1 25 X 25MM ZP 480H 481H ONLY PLATE STYLE GUARD 4 28 20417 ENGINE GUARD FORMED RAMMER 1 29 20418 HANDLE ENGINE GUARD 2 ITEMS NOT SHOWN 07592 TERMINAL SCOTCHLOK SPLICE NOT SHOWN 1 21 fx O m Q eon Ont BOT ob 3425 0 1 FDY Lor Zero LU E O Engine Assembly ITEM PART NO DESCRIPTION QTY 1 14872 ENGINE ROBIN EH12 Includes items 5 9 10 17 1 2 15068 HHCS M10 1 5 X 45MM 2 3 15184 NUT HEX M10 1 5 PITCH 2 4 15185 LOCKWASHER M10 4 5 15226 ADAPTER ENGINE ROBIN EH12 1 6 17217 REDUCER BARBED 1 7 17406 ADAPTER ENGINE HONDA 2100 1 8 17432 STUD HONDA ONLY 4 9 18055 CLUTCH KIT INCLUDES ITEMS 10 amp 17 1 10 18053 KEY WOODRUFF METRIC 4 X 13 1 11 18554 HONDA GX100 ENGINE DIAPHRAGM STYLE Includes item
4. 18 3 With the handle still on the ground remove the six hex head flange screws 10 holding the cover 5 to the gearbox 3 Remove the cover 5 and cover gasket 2 from the gearbox 3 Tip the unit forward and drain any oil into an oil pan After the oil has drained completely replace the drain plug Pour oil as specified from Fluid Level section of this manual into front of gear box Replace cover gasket and cover and secure with the six hex head flange Screws SERVICE Assembly and disassembly should be performed by a service technician who has been factory trained on MBW Service Tools 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 replacement cycles bearings square and are seated properly exciter or gearbox Check moving parts for wear and failure Refer to the Replacement section in this manual for tolerance and All shafts and housings should be oiled prior to pressing Also ensure that the bearings are pressed All bearings should be replaced when rebuilding any All gaskets and seals should be replaced after any disassembly Torque Chart SIZE GRADE 2 GRADE 5 GRADE 8 1 4 20 49 in lbs 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 1
5. bottom of the springbox cover tools should be 180 degrees apart Run the nuts that come with the tools down snug against the Cover Remove the flat head socket screws holding the cover to the springbox See Fig 3 SPRINGBOX TOOL AR HEAD SCREWS FIG 3 FIG 4 While holding the bottom of the tool 20260 from turning slowly and evenly back off the nuts on the cover 3 The tools and the cover can be removed when spring tension has been relieved See Fig 4 2 Refer to Lower Unit Assembly page 16 3 4 Remove the o ring 4 from the cover 3 The lower springs 1 amp 2 can be removed from the springbox Place a drift pin or steel rod through the piston hole in the ram head 12 Use this to hold the ram head from turning while removing the nut 5 Remove and discard the elastic nut Remove the spring separator 15 slide bearing 16 and upper springs 1 amp 2 Remove retaining ring 14 and ram shaft slide bearing 13 Assembly Instructions A CAUTION A Prior to assembly wash all parts in a suitable cleaner or solvent Check moving parts for wear and failure Refer to Parts Replacement and Tolerance Chart for toler ances and replacement cycles Replace all seals and gaskets at every overhaul or disassembly For torque settings other then those listed see torque chart All shafts and housings should be oiled prior to pressing bearings in Also ensure that bearing
6. the breather assembly 14 filter cap and plain washer Apply Loctite 242 to the threads of the hex head cap screw 28 and install Slide bearing support 24 into housing guide tube Align tabs on bearing support to fit sides of rib in guide tube on engine side of housing Push slide bearing 25 into bearing support Align hole on top of slide bearing with opening in gear box Lower Unit Assembly Refer to Lower Unit Assembly page 16 1 Install slide bearing 13 into top of spring box 11 and secure with retaining ring 14 Install the upper springs 1 2 into the springbox 11 Install the ram head 12 spring separator 15 and slide bearing 16 Secure with a new elastic stop nut 5 torqued to 100 ft Ibs 135 Nm Install the lower springs 1 2 Lightly grease the o ring groove in the cover 3 before installing a new o ring 4 Use the two springbox tools MBW 20260 to draw the cover down onto the springbox Install three flat head socket screws 18 and torque to 8 ft lbs 11Nm CAUTION A A The springbox WARNING DECAL should be clean and highly visible If it is not the old decal should be completely removed and replaced 10 Assemble shoe 10 to bottom of spring box with hex head cap screws 22 and lock washers 21 Orient the sight gauge 9 so it points to the back side of the machine Install the bellows 7 and clamping rings 6 amp 8
7. the clutch 4 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 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 2 After the engine warms up open the throttle fully for normal operation 3 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 Move throttle to idle position Let engine idle for one or two minutes 1 2 3 Turn switch on engine to STOP position 4 Turn off fuel valve A WARNING A 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 2 The unit should be transported laying face down 3 Secure it in place by the handle and shoe DO NOT lay the unit on its sides or face up during transport MAINTENANCE A WARNING A Always exercise the stopping procedure before servicing or lubricatin
8. 15 8 40 15 8 40 Length in cm 27 68 6 27 68 6 27 68 6 27 68 6 Engine Honda GX100 Robin EH12 Honda GX100 Robin EH12 Shoe W x L in cm 11 x 13 28 x 33 11 x 13 28 x 33 13 x 15 33 x 38 13 x 15 33 x 38 Operating Noise Level dBA 85 103 85 103 85 103 85 103 Compaction Force Ibf kN blow 4550 20 24 4550 20 24 4550 20 24 4550 20 24 Percussion Rate blows minute 600 650 600 650 600 650 600 650 Travel Speed ft min m min 60 18 3 60 18 3 60 18 3 60 18 3 Compaction Depth in cm 24 60 9 24 60 9 24 60 9 24 60 9 Compaction Area sqft sqm 3300 307 3300 307 3900 362 3900 362 Engine Speed rpm 3200 3200 3200 3200 Fuel Capacity gal L 1 1 4 3 1 1 4 3 1 1 4 3 1 1 4 3 Gearbox Oil Capacity oz L 12 4 12 4 162 4 12 4 Engine Crank Case Capacity oz L 10 3 10 3 10 3 10 3 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 Noise level is operating on loose gravel surface Hearing protection may be required 3 Not all product variations shown No universal method or formula has been accepted for determining Compaction Force All manufactures employ their own method or formula OPERATION Introduction MBW equipment is intended for use in very severe applications They are powered by f
9. 6 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 lbs 57 ft lbs 80 ft lbs 1 2 20 41 ft lbs 64 ft lbs 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 lbs x 0 083 ft lbs ft lbs x 12 in lbs ft lbs x 0 1383 kg m ft lbs x 1 3558 Nem Part No Description 01629 Rubber Test Mat 20260 Springbox Tool 07205 Bellows Installation Tool 07552 Blind Hole Bearing Puller Tool 19950 Service Kit Robin 20194 Service Kit Honda Handle Removal Refer to Handle Assembly page 20 Turn fuel valve 11 to the off position 2 Loosen the hose clamp closest to the carburetor and disconnect the fuel line 9 from the carburetor 3 Remove the hardware 20 holding the throttle 18 to the handle 4 Disconnect the tachometer 16 wire running from the engine 5 Remove four hex head flange screws 23 and lift the handle free from the rammer Engine Removal Note It is not necessary to remove the handle to take the engine off the machine Re
10. EARING Includes items 25 amp slide bearings in lower unit 15 ITEM PART NO DESCRIPTION R482 R483 1 03167 SPRING COMP 2 188 OD 2 2 2 03168 SPRING COMP 2 875 OD 2 2 3 06173 COVER 1 1 4 06237 O RING 4 33 ID X 103 1 1 5 06257 NUT HEX 7 8 14 ELASTIC LOCK ZP 1 1 6 07154 RING CLAMPING 1 1 7 11694 BELLOWS 4 PLY 1 1 8 14493 RING CLAMPING 1 1 9 18276 PLUG OIL LEVEL 1 1 10 20344 SHOE KIT CAST IRON 11 Includes item 21 1 20340 SHOE KIT ALUMINUM 13 Includes item 21 1 11 19763 SPRING BOX MACHINING 1 1 12 20337 KIT RAM SHAFT Includes items 5 amp 7 from page 18 1 1 13 19889 SLIDE BEARING FORMED 1 1 14 19890 RETAINING RING INTERNAL 1 5 1 1 15 19891 SPRING SEPERATOR 480 1 1 16 19893 SLIDE BEARING FORMED 1 1 17 F0227SHPP SQ HD PIPE PLUG 1 8 27 1 1 18 F042005FSS FSS 1 4 20 X 5 8 3 3 19 F042008HCS HEX HEAD CAP SCREW 1 4 20 X 1 285 ZP 6 6 20 FO4LW LOCKWASHER 1 4 6 6 21 F071412HCS HEX HEAD CAP SCREW 7 16 14 X 1 1 2 GR5 ZP 6 F071414HCS HEX HEAD CAP SCREW 7 16 14 X 1 3 4 GR5 ZP 6 22 FO7LW LOCKWASHER 7 16 ZP 6 6 KITS 20178 KIT SLIDE BEARING Includes items 13 14 16 amp slide bearing in gear box 20175 SPRING BOX ASM Includes Items 1 2 3 4 5 9 11 thru 18 17
11. ERSON 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 EXTENDED RAMMER WARRANTY MODELS R422 R442 R482 amp R483 This extended warranty commences on the last day of MBW s standard one year limited warranty and runs for an additional four years 48 months This extended warranty is limited to part replacement and shipping costs of rammer bellows and non metallic slide bearings only This extended warranty does not cover labor down time or any other cost beyond that of component replacement and freight This extended warranty is subject to all limitations set fourth in MBW s limited warranty above 24 NOTES 25 NOTES 26
12. Failure to return the Warranty Registration Card renders the warranty null and void MBW has established a network of reputable distributors dealers with trained mechanics and full facilities for maintenance and rebuilding and to carry an adequate parts stock in all areas of the country Their sales engineers are available for professional consultation If you cannot locate an MBW distributor in your area contact MBW or one of our Sales Branches listed below When ordering replacement parts be sure to have the following information available Model and Serial Number of machine when ordering MBW parts Model and Serial Number of engine when ordering engine parts Part Number Description and Quantity Company Name Address Zip Code and Purchase Order Number Preferred method of shipping REMEMBER You own the best If repairs are needed use only MBW parts purchased from authorized MBW distributors Write Model Number here Write Serial Number here Contact Information STAMPED DECAL The unit s serial number can be found in the following 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 MBW Inc 250 Hartford Rd PO Box 440 Slinger WI 53086 0440 Phone 262 644 5234 Fax 262 644 5169 Email mbw mbw com Website www mbw com MBW UK Ltd Unit 6 Bradley Fold Trading Estate Rad
13. OPERATOR S SAFETY AND SERVICE MANUAL N lt A RON 482 483 Mi POUNDER This manual covers the following serial numbers and higher for each model listed RA482 RA83 ii id 4820350 SMART RAMMERS MBW Inc MBW UK Ltd MBW FRANCE S A R L 250 Hartford Rd PO Box 440 Units 283 CochraneStreet Z A d Outreville Slinger WI 53086 0440 Bolton BL3 6BN 11 Rue Jean Baptiste N ron Phone 262 644 5234 England UK 60540 BORNEL Fax 262 644 5169 Phone 44 0 01204 387784 France L19905 10 14 F Email mbw mbw com Fax 44 0 01204 387797 Email mbwfrance free fr MBW Inc 2004 Website www mbw com E mail mbwuk btinternet com Phone 33 0 3 44 07 15 96 Printed in the USA Fax 33 0 3 44 07 41 28 TABLE OF CONTENTS Safety Information 1 Handle Removal 7 Introduction etere s eaa mme EE 1 Engine Removal s f Safety Precautions 1 Centrifugal Clutch 8 Safety DeCalS ee 0 0 ped duct et bo 1 Gearbox Removal case 8 Crank Gear Removal 8 Specifications ss iar Fear A EAS 3 Pinion Removal GL A perd 8 Breather Assembly 8 Operation ters tee Sete 063 4 Slide Bearing Removal 8 Introduction 22 33 sat sans 4 Lower Unit NN 9 Before Starting amp Operating 4 Bellows and Shoe
14. cliffe Moor Road Bolton BL2 6RT 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 Tel fono 33 0 3 44 07 15 96 Fax 33 0 3 44 07 41 28 Correo electr nico mbwfrance free fr 13 Gearbox Assembly ITEM PART NO DESCRIPTION QTY 1 01001 RETAINING RING EXT 5100 137 1 2 01103 BEARING BALL 2 3 01105 BEARING BALL 1 4 01244 RETAINING RING EXT 5160 112 1 5 06161 CONNECTING ROD ASM includes item 7 1 6 06259 BEARING NEEDLE 1 7 06262 BUSHING CONNECTIONG ROD 1 8 06264 RETAINING RING INT N5000 187 1 9 06265 RETAINING RING EXT 5100 78 1 10 06266 RETAINING RING INT N5000 281 2 11 06274 SEAL 1 12 06413 VALVE 1 13 06423 COMPRESSION SPRING 1 14 06904 BREATHER SUB ASM includes items 11 12 14 15 16 25 27 amp 28 1 15 06905 BREATHER FILTER 1 16 06908 BREATHER TUBE 1 17 06910 COVER 1 18 09476 RETAINING RING INT N5000 244 1 19 09618 FITTING PLUG PARKER 4HP50N 1 20 13733 GEAR CRANK LOW RATIO 1 21 15959 PINION GROUND LR 1 22 16021 BEARING BALL 6206 1 23 19881 HOUSING GEAR BOX 480 1 24 19882 BEARING SUPPORT FORMED 1 25 19883 SLIDE BEARING FORMED 480 1 26 FO1PW FLAT WASHER 1 27 F0618SPP PLUG PIPE 3 8 18 1 28 F081305HCS HEX HEAD CAP SCREW 1 2 13 x 5 8 1 29 FO8SW WASHER 1 2 1 20178 KIT SLIDE B
15. 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 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 P
16. eakerless magneto and battery ignition systems can cause severe electrical shocks Avoid contacting these units or their wiring SAFE DRESS Do not wear loose clothing e n gt x rings wristwatches etc near machinery 5 ar NOISE PROTECTION Wear OSHA specified hearing protection devices DA w EYE PROTECTION Wear OSHA specified eye shields safety glasses and sweat bands FOOT PROTECTION Wear OSHA specified steel tipped safety shoes HEAD PROTECTION Wear OSHA specified safety helmets DUST PROTECTION Wear OSHA specified dust mask or respirator OPERATOR Keep children and bystanders off and away from the equipment I ut REFERENCES For details on safety rules and regulations in the United States contact your local Occupational Safety and Health 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 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 Administrati
17. fer to Engine Assembly page 22 Robin EH12 Engine Follow steps1 through 4 under Handle Removal 2 Remove the two hex head cap screws 2 and lock washers 4 that secure the bottom of the engine to the spacer plate Then while supporting the engine remove the two hex nuts 3 and lock washers 4 securing the top of the engine to the spacer plate 3 Remove the engine from the spacer plate Honda GX100 Engine 1 Follow steps 1 through 4 under Handle Removal 2 Support the engine and remove the four flange nuts 13 securing the engine to the gearbox 3 Remove the engine from the machine Centrifugal Clutch Refer to Engine Assembly page 22 1 Remove jam nut 17 and key 10 Slide clutch 9 off engine crank 2 Carefully insert woodruff key 10 making sure key remains aligned with keyway 3 Apply anti seize to engine shaft and slide clutch onto shaft 4 Reinstall jam nut with medium strength thread locker and tighten to 60 ft Ibs Gearbox Removal Note It is necessary to remove the Handle and the Engine to remove the Gearbox It is easier to reassemble the gearbox if the handle and engine are removed 1 If removing handle amp engine refer to Handle Removal and Engine Removal sections of this manual Refer to the Gearbox and Lower Unit Assembly page 18 2 Remove the hex flange screws 10 holding the cover to the gearbox A CAUTION A NOTE There may be oil in the gearbox T
18. g the unit After servicing the unit replace and fasten all guards shields and covers to their original positions before resuming operation Maintenance Schedule A CAUTION A Always verify fluid levels and check for leaks after changing fluids Do not drain oil onto ground into open streams or down sewage drains SYSTEM MAINTENANCE DAILY p ae YEARLY Air Cleaner Check and clean X Engine Refer to engine operator owner manual X Hardware Check and tighten as needed X X In Line Fuel Filter Replace X X Percussion System Check oil level X Change oil X X Shockmounts Check for cracks or deterioration X Spark Plug Replace X X 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 12 oz 35 L SF SAE 10W 30 Motor Oil Engine Refer to engine operator owner manual Engine Maintenance Refer to the engine owner s 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 dipstic
19. ine 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 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 com
20. ip the unit back when removing the cover from the gearbox Tip the unit forward and drain any oil into an oil pan 4 Remove the retaining ring 7 from piston Thread a 5 16 18 screw into the piston pin 6 and remove the piston pin See Fig 1 5 Remove the hex head cap screws and lock washers 8 amp 9 holding the gearbox to the lower system 6 Remove the gearbox assembly 3 from the lower system See Fig 2 Crank Gear Removal Refer to Gearbox Assembly page 14 1 Slip a retaining ring pliers through the slot opening in the crank gear 20 and remove the retaining ring 10 2 Remove the SAE plug 19 from the rear of the gearbox Use a 3 8 in 10mm dia steel rod to press the crank gear out of the gearbox 3 Remove the small retaining ring 9 from the front of the crank gear 20 and remove the connecting rod 5 4 Remove the retaining ring 1 from the back of the crank gear Remove the ball bearing 2 using a bearing puller Pinion Removal 1 Remove the retaining ring 4 from inside of the gearbox and press out the pinion 21 2 Ifthe retaining ring is pinched in its groove tap on the drum side of the pinion This will relieve the pressure on the retaining ring 3 Pry out the oil seal 11 and discard Remove the retaining rings 10 amp 18 Use a bearing puller to remove the ball bearings 2 amp 22 Breather Assembly 1 Remove the hex head cap scre
21. k See the Check Engine Oil section of the engine Owner s Manual for information See the Change Engine Oil section of the engine Owner s Manual 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 place the rammer on a flat surface and check the oil level in the sight gauge 9 on the back side of lower unit 11 If the oil is not visible in the sight gauge add oil through fill plug on top of gear box page 14 27 as required See Fluid Levels section of this manual for recommended type of oil Wait several minutes for oil to run down into lower unit and check oil level in sight gauge again Be sure not to over fill unit Changing Percussion System Oil Refer to Lower Unit Assembly page 16 1 Remove the drain plug 17 below the sight gauge 9 on the back of the springbox 11 Place an oil drain pan behind the shoe and tip the rammer back so the handle is on the ground Refer to Gearbox and Lower Unit Assembly page
22. lert 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 a n 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 A CONFINED AREA DANGEROUS FUELS Use extreme caution when storing handling and using fuels as they are highly volatile and explosive in vapor state Do not add fuel while engine is running Stop and cool the engine before adding fuel DO NOT SMOKE SAFETY GUARDS It is the owner s responsibility to ensure that all guards and shields are in place and in working order IGNITION SYSTEMS Br
23. on Act must be met when operated in areas that are under the jurisdiction of that United States Department Safety Decals Carefully read and follow all safety decals Keep them in good condition If decals become damaged replace as required If repainting the unit replace all decals Decals are available from authorized MBW distributors Order the decal set listed on the following page s Ib 68 kg R482 483 177 lb 80 89 u UNLEADED GASOLINE 44781 OPERATION OF THIS EQUIPMENT MAY ICREATE SPARKS THAT CAN START FIRES AROUND DRY VEGETATION A SPARK ARRESTER MAY BE REQUIRED THE OPERATOR SHOULD CONTACT LOCAL FIRE AGENCIES FOR LAWS OR REGULATIONS RELATING TO FIRE PREVENTION 19791 19791 U S PATENT 8 057 125 19895 U S PATENT 8 202 022 20425 Compressed spring could cause severe injury See manual for disassembly instructions La resorte comprimida podr a causar la herida severa Consulte el libro para ver el desmontaje correcto h j CHECK ENGINE OIL DAILY ae h ENGINE MUST BE LEVEL 1 Check fuel level 2 Open fuel valve 3 Set throttle at idle postion Chok to be SPECIFICATIONS R482 R483 482H 482R 483H 483R Operating Weight 158 Ib 71 6 kg 170 Ib 77 kg 165 Ib 75 kg 177 Ib 80 kg Height in cm 40 101 6 40 101 6 40 101 6 40 101 6 Width in cm 15 8 40 15 8 40
24. our 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 REMEMBER It is the owner s responsibility to communicate information on the safe use and proper operation of this unit to the operators Review 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 Know how to STOP the machine 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 Owners 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 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 2 3 Open fuel valve Turn engine switch to ON Set throttle to idle A CAUTION A The engine speed must NOT be high enough to engage
25. ponents 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 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 seal
26. s 7 9 10 17 20 amp 21 1 12 20172 SPACER CLUTCH ROBIN ONLY 1 13 FO61614HCS HHCS 3 8 16 X 1 3 4 285 ZP 4 14 F0616FN NUT FLANGE 3 8 16 ZP 4 15 FO6LW LOCKWASHER 3 8 ZP 4 16 J0176060030 NUT SELF LOCKING 2 17 J2523260207 ELEMENT AIR CLEANER ROBIN EH12 1 Q17211ZL8023 ELEMENT AIR CLEANER HONDA GX100 18 M12CHJN JAMNUT HEX 12MM 1 25 ZP 1 19 CLIP FUEL LINE Not provided by MBW Inc 2 20 FUEL LINE 3 16 ID X 1 LONG Not provided by MBW Inc 1 21 HEX HEAD FLANGE SCREW M8 1 25 X 40MM Not provided by MBW Inc 4 22 PIN DOWEL 6MM X 10MM Not provided by MBW Inc 2 KITS 20194 SERVICE KIT HONDA RAMMER 20387 IN LINE FUEL FILTER Diaphragm Carburetor Only 15667 HOUSING COVER GASKET 16414 FUEL VALVE 16586 GROMMET FUEL VALVE 19951 OIL 1 QUART Q17211ZL8023 AIR CLEANER ELEMENT ITEM 16 Q9805655777 SPARK PLUG CR5HSB 19950 SERVICE KIT ROBIN RAMMER 01045 IN LINE FUEL FILTER 15667 HOUSING COVER GASKET 16414 FUEL VALVE 16586 GROMMET FUEL VALVE 19951 OIL 1 QUART J2523260207 AIR CLEANER ELEMENT ITEM 16 J0650140100 SPARK PLUG NGK B 6ES 23 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 mach
27. s press in square and seat properly Gearbox Assembly Refer to Gearbox Assembly page 14 1 Press the small ball bearing 22 into the housing from the back Secure with a retaining ring 18 Press the large ball bearing 2 into the housing from the back Secure with a retaining ring 10 Press a new oil seal 11 into the gearbox Make sure the oil seal is pressed in straight Lightly oil the lip of the oil seal and the shaft portion of the pinion carefully press the pinion 21 into the gearbox Do not use excessive pressure to seat the pinion Install retaining ring 4 into the pinion from inside the gearbox Press in the needle bearing 6 inside the gearbox Bearing must be pressed in with the numbers and letters facing up Place the retaining ring 10 over the large shaft of the crank gear 20 Press the ball bearing 2 onto the crank gear Install retaining ring 1 to secure the ball bearing Press bushing 7 into connecting rod 5 10 11 12 13 14 15 16 Press the ball bearing 3 into connection rod 5 and secure with internal snap ring 8 Insert connecting rod assembly 5 onto crank gear 20 and secure with external retaining ring 9 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 19 plug Do not over tighten Replace
28. s 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 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
29. they are worn cracked or to the point of leaking Replace clutch if the shoe and springs show signs of heat damage or if the clutch Clutch engages below 2000 rpm Crank Gear Replace if teeth are cracked or if they become sharp Engine Components Refer to your engine manufacturer s Owner s Manual Slide Bearings Gear Box Replace if a 0 025 0 635mm feeler gauge can be slid between the spring box and guide tube Hardware Replace any worn or damaged hardware as needed Replacement hardware should be grade 5 and zinc plated unless otherwise specified Pinion Replace if teeth are cracked or if they become sharp Replace if the drum is scored or gouged deeper than 0 03 76mm Slide Bearing Spring Separator Replace if a 0 025 0 635mm feeler gauge can be slid between the springbox and the piston Piston Pin Replace if the outside diameter is less than 0 620 15 75mm Slide Bearing Ram Shaft Replace if less than 100 thick or visibly damaged Safety Decals Replace if they become damaged or illegible Seals amp Gaskets Replace if a leak is detected and at every overhaul or teardown Springs If a flat spot on the side of a spring is greater then 0 09 in 2 mm or the free length is less than 6 75 in 171 mm replace all 11 This page intentionally left blank 12 REPLACEMENT PARTS The warranty is stated in this book on page 24
30. to the spring box and secure with six hex head cap screws 19 and lock washers 20 Torque to 9 ft los 12 Nm Gearbox amp Lower Unit Assembly Refer to Gearbox and Lower Unit Assembly page 18 1 10 Before installing the gearbox to the lower assembly apply Loctite 598 or equivalent silicone to the bottom of the gearbox 3 Press the oil seal spacer 1 onto the bottom of the gearbox Slide the gearbox assembly 3 onto the lower assembly 4 Secure using four hex head cap screws 8 with lock washers 9 torqued to 12 ft los 16Nm Align the connecting rod with the piston and install the wrist pin 6 Install the retaining ring 7 to secure wrist pin in place Place a new gasket 2 over the face of the gearbox Secure the cover to the gearbox using the hex flange head screws from the previous step Be sure the bolts pass through the holes in the gasket Tighten the flange screws equally and torque to 8 ft 55 11Nm The gasket will compress slightly after initial tightening Retorque the bolts after 5 minutes If the handle mounting brackets were removed apply Loctite 242 to the four hex head flange screws and assemble handle bracket see page 20 Refill percussion unit with oil per procedure in Maintenance section Parts Replacement Cycles and Tolerances Replace anytime a bearing is rough binding discolored or removed from housing Bearings or shaft Bellows Replace when
31. w 28 from the top of the breather assembly Remove the plain washer cap and filter 29 17 15 2 Use a pipe wrench to remove the breather tube 16 A CAUTION A Do not disassemble the breather assembly Slide Bearing Removal 1 Remove the slide bearings support amp slide bearing 24 25 by pulling them out of the housing guide tube A CAUTION A Do not scratch or gouge the housing guide tube walls Lower Unit Note The lower unit can be separated from the drive unit engine gearbox and handle without going through the complete disassembly procedure If the lower system has not already been separated follow the Gearbox Removal instruction Bellows and Shoe Refer to Lower Unit Assembly page 16 Shoe and Springbox Removal 1 Drain the oil by removing the drain plug 17 Tilt the lower unit to the side until all of the oil is drained out Remove the six hex head cap screws 19 and lock washers 20 from the top flange of the spring box 11 Remove the bellows and clamping rings 6 7 amp 8 Remove the six hex head cap screws 20 and lock washers 21 from the bottom flange of the spring box Remove the shoe 10 Springbox A CAUTION A Observe the warning label on the Springbox Cov er Springbox contains springs under high com pression Follow the next steps very carefully Flip Springbox Assembly upside down Insert two springbox tools MBW 20260 into the
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