Operator`s Safety and Service Manual GPR135DE (DIESEL
Contents
1. 43 5 442. I oo BASEPLATE GPR99 CONTAINS ALL ABOVE ITEMS BASEPLATE GPR135 CONTAINS ALL ABOVE ITEMS 31 gt lt O 2 lt HANDLE ASSEMBLY PART DESCRIPTION 08355 FITTING ST PARKER 4F50X 16350 SEAL HYDRAULIC 16351 GUIDE RING HYDRAULIC 16352 O RING METRIC 52 ID x 3 5 16353 O RING METRIC 26 ID x 2 5 16354 RETAINING RING EXTERNAL METRIC 16355 O RING METRIC 52 1D x 3 16358 PIPE PLUG METRIC SPECIAL 16359 WASHER METRIC SPECIAL 16410 THREADED ROD 1 2 13 x 3 16460 SHOCKMOUNT 16493 SHOCKMOUNT BUMPER HANDLE 16629 HOUSING CONTROL 16632 BUSHING SLIDE 16633 GEAR RACK 16636 HOUSING GUIDE SHAFT 17058 CAP TUBE 17377 HANDLE CONTROL 17379 HANDLEBAR LEFT 17380 HANDLEBAR RIGHT 17402 MOUNT SPINDLE 17417 HANDLE TUBE 17445 FITTING ADAPTER HYDRAULIC 17509 GEAR PINION 17546 ANGLE MOUNT F051804HCS HHCS 5 16 18 x 1 2 GR5 ZP F051808FWS FWLS 5 16 18 x 1 ZP F051808SCS SHCS 5 16 18 x 1 F051812FWS FWLS 5 16 18 x 1 1 2 ZP F0518FN FLANGE WHIZ LOCK 5 16 18 ZP F05SW WASHER 5 16 x 3 4 x 15GA ZP F061607FWS FWLS 3 8 16 x 7 8 ZP F0813HN HEX 1 2 13 ZP MO8CO16FWS FWLS M8 1 25 x 16MM ZP MO8CO25FSS FHSS M8 x 1 25 x 25MM ZP o lt BR NIO o AIN Q N N Q aja Na aja aja aja aja CONTR
3. 11 Main Disassembly Procedure Diesel 11 Main Disassembly Procedure Gasoline Engine 13 Belt Adjustment a A eee he iii 13 Exciter Oil Change Procedure BOO 14 Lower Hydraulic Seal Replacement 15 Bleeding and Adjustment of Hydraulic Controls 16 Baseplate Disassembly Procedure 17 Handle Disassembly Procedures Eee ER I a E 18 Control Head Disassembly Procedure cece cece eee rennen 19 Baseplate Assembly Procedure ee hs 20 Control Head Assembly 23 Handle Assembly 24 Finak Assemblys2 oer poh des cance of Q Prin Su 24 Replacement ada ee A Sas ap Gow Ra 25 Torque Charts US AA i ee des AR Beg aqa 26 Main Assembly es sus ee Bu SN uu bs inched Watts 28 Assembly creta ee ee ale bel ata 30 Handle Assembly de 32 Lower Shift Assembly u ptas el ie bis a soe m Pte 972 8 ku de 34 Honda Engine Assembly 2 s Sede eke rap 36 Hatz Diesel
4. Engine Assembly eed uen ted eS il 38 Waranty t 40 Warehouse Locations z 23 35 Au Eo duce ERES esequi da bs pss 41 This page intentionally left blank SAFETY NOTICE 8 DECALS AIMPORTANT NOTICE SAFETY ALERT SYMBOL is used to attention to items operations that may be dangerous to those operating or working with this equipment The symbol can be found throughout the manual and on the unit itself Please read these warnings and cautions carefully READ SAFETY DECALS CAREFULLY Carefully read and follow all safety decals Keep them in good condition If decals become damaged replace as required Ifrepainting REPLACE ALL decals Decals are available from authorized MBW Distributors Decals are not shown to scale Decals on set 16031 Read the Operation Instructions before operating this piece of equipment Keep unauthorized and untrained people away from this equipment ROTATING amp MOVING PARTS Make sure all guardg and safety devices are in place DO NOT RUN this machine in an enclosed area The engine produces carbon monoxide a POISONOUS GAS Wear approved hearing protection foot protection eye protection and head protection SHUT OFF the engine before servicing cleaning or adding fuel Failure to comply could result in serious bodily injury 15867 15867 QTY 1 ROTATING PARTS hands 13484 QTY 1 Check engine oil l
5. Lubrication under the respective engine s Owner s Manual or the PERIODIC MAINTENANCE section of this manual 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 OPERATING ENGINE Refer to the engine manual for location of all controls and features STARTING ENGINE For detailed instructions refer to the Engine Manual 1 When starting engine THROTTLE MUST BE IN AN IDLE POSITION Open fuel valve Choke engine if necessary when starting a warm engine it may not be necessary to choke it 2 Pull starter rope After engine starts the choke lever can be moved back to the open position Let the engine warm up in the idle position 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 AN IDLE POSITION 2 Slowly pull the starter rope to its full extended length to open the decompression valve in the engine Let the starter rope recoil completely and pull the starter rope quickly to start the engine After the engine starts make sure the throttle lever is in the idle position Let the engine warm up in the idle position for one or two
6. 0 083 ft lbs ft lbs x 12 in lbs ft lbs x 0 1383 kg m ft lbs x 1 3558 N m 682 ft lbs 746 ft lbs 764 ft lbs 966 ft lbs 1083 ft lbs 1363 ft lbs 1509 ft lbs 1787 ft lbs 2034 ft lbs 2371 ft lbs 2668 ft lbs 7 ft lbs 18 ft lbs 30 ft lbs This page intentionally left blank 27 See HANDLE ASSEMBLY MAIN ASSEMBLY PART MAIN ASSEMBLY DESCRIPTION 2 lt 09642 10088 HOSE HYDRAULIC 16281 16442 DECK ENGINE BELLOWS 16543 16609 MOUNT HANDLE BASEPLATE GPR99 16607 16652 BASEPLATE GPR135 ROLLCAGE 16653 16654 MAT RUBBER PLATE MOUNT 17160 17419 SHOCKMOUNT GPR99 SHOCKMOUNT GPR135 17326 17333 PLATE EXTENSION GPR99 135 3 IN PLATE EXTENSION GPR99 135 6 IN 17335 17340 BUSHING WING MOUNT POP PIN 17403 17434 LEVER THROTTLE COVER SIDE 17435 17436 GUARD HYDRAULIC GUARD BELLOWS MOUNT 17438 16615 CABLE THROTTLE GPR99 CABLE THROTTLE GPR135 17462 F042004FWS RETAINER BELLOWS FWLS 1 4 20 x 1 2 ZP AN Bip PO BR Bla aja aja F042008FWS F0420ELN FWLS 1 4 20 x 1 ZP LOCKNUT ELASTIC 1 4 20 ZP F051808HCS F0518ELN HHCS 5 16 18 x 1 GR5 ZP LOCKNUT ELASTIC 5 16 18 ZP F061608FWS FO6SW FWLS 3 8 16 x 1 ZP WASHER 25 64 x 1 x 1 8 ZP F081314HCS F0813ELN HHCS 1 2 13 x 1 3 4 GR5 ZP LOCKNUT 1 2 1
7. 12 50 Volts 12 18 Volts 11 88 Volts To get long life from the Odyssey battery it is important that the battery is kept near full charge approximately 12 8 volts If there are electrical loads during storage then the negative battery cable should be disconnected or a Battery Tender trickle charger used Low power 1 25 amp Battery Tenders will keep a fully charged battery fully charged but cannot recharge if the battery becomes discharged If a standard automotive charger is used to boost charge a discharged battery it is important to make sure the charging voltage does not exceed 15 volts during charge A hand held voltmeter can be used to monitor this periodically The following chart provides recharge times under this type of boost charging to an 80 95 recharge ODYSSEY Charge time for 100 discharged battery 11 5 volts Model 10 amp charger 20 amp charger PC 925 275 hours 1 hours MAIN DISASSEMBLY PROCEDURE DIESEL ENGINE Separating the Engine Deck from the Exciter subassembly Reference the figure on page 28 1 Clean all visible debris from the machine before servicing 11 2 Remove the four hex head capscrews 29 securing the engine deck 3 to the baseplate 6 Use caution as the engine deck will drop down Reference the figure on page 38 for steps 3 amp 4 3 OB 9 10 11 Remove the four socket head capscrews 34 securing the belt guard 14 to the mount plate 22 o
8. GPR135 99 25 TORQUE APPROXIMATE TIGHTENING TORQUE SIZE 10 24 10 32 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7116 14 7116 20 1 2 13 1 2 20 9 16 12 9 16 18 5 8 11 5 8 18 3 4 10 3 4 16 718 9 718 14 GRADE 2 GRADE 5 GRADE 8 21 in lbs 23 in lbs 49 in lbs 56 in lbs 8 ft lbs 9 ft lbs 15 ft lbs 17 ft lbs 24 ft lbs 27 ft lbs 37 ft lbs 41 ft lbs 53 ft lbs 59 ft lbs 73 ft lbs 83 ft lbs 129 ft lbs 144 ft lbs 125 ft lbs 138 ft lbs 32 in lbs 36 in lbs 76 in lbs 87 in lbs 13 ft lbs 14 ft lbs 23 ft lbs 26 ft lbs 37 ft lbs 41 ft lbs 57 ft lbs 64 ft lbs 82 ft lbs 82 ft lbs 112 ft lbs 112 ft lbs 223 ft lbs 200 ft lbs 322 ft lbs 355 ft lbs 45 in lbs 51 in lbs 9 ft lbs 10 ft lbs 18 ft lbs 20 ft lbs 33 ft lbs 37 ft lbs 52 ft lbs 58 ft lbs 80 ft lbs 90 ft lbs 115 ft lbs 129 ft lbs 159 ft lbs 180 ft lbs 282 ft lbs 315 ft lbs 454 ft lbs 501 ft lbs 26 APPROXIMATE TIGHTENING TORQUE GRADE 2 GRADE 5 GRADES SIZE 1 8 1 12 1 14 1 1 8 7 1 1 8 12 1 1 4 7 1 1 4 12 1 3 8 6 1 3 8 12 1 1 2 6 1 1 2 12 M6 M8 M 10 188 ft lbs 205 ft lbs 210 ft lbs 266 ft lbs 297 ft lbs 375 ft lbs 415 ft lbs 491 ft lbs 559 ft lbs 652 ft lbs 734 ft lbs 3 ft lbs 6 ft lbs 10 ft lbs 483 ft lbs 529 ft lbs 541 ft lbs 596 ft lbs 668 ft lbs 840 ft lbs 930 ft lbs 1102 ft lbs 1254 ft lbs 1462 ft lbs 1645 ft lbs 4 ft lbs 10 ft lbs 20 ft lbs CONVERSIONS in Ibs x
9. OIL CHANGE PROCEDURE Reference the drawing below 1 2 3 If installed remove the two 2 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 5 from the baseplate and drain the oil Examine the oil for metal chips as a precaution to future troubles Tip the plate opposite the drain hole and fill the baseplate subassembly through the pipe plug opening Use only MBW Ground Pounder Exciter Oil Oil can be purchased from your local MBW Distributor See page 8 for amount of oil to be used Reinstall the socket head pipe plug using sealant LOCTITE 565 If equipped reinstall the bushings and baseplate extension using antisieze lubricant LOCTITE 767 GPR135 99 EXCITER OIL DRAIN 14 LOWER HYDRAULIC SEAL REPLACEMENT Reference the figure on page 16 Ti Note The seals 12 guide ring 11 and gaskets 8 and 14 should be replaced as a set MBW recommends puchasing rebuild kit 17368 for ease of repairs Seals are pre assembled to the spool Position the handle in locked position and set the lock pin Remove the six flange screws securing the side cover to the recoil oil drain side of the baseplate Loosen hex head bolts page 28 29 on the oil drain side only Lift the engine deck
10. four hex head flange screws 21 Connect the hydraulic line 1 to the 90 degree fitting on the hydraulic housing Install the grommet 2 into the hydraulic guard 16 Guide the hydraulic line through the grommet in the hydraulic guard and secure the guard to the hydraulic side of the baseplate with the four hex head flange screws 20 Set the side cover off to the side until bleeding and final assembly is done The exciter is now ready for final assembly If required install the bushings 12 extension plates 11 and 1 socket head cap screws 34 to the sides of baseplate housing using LOCTITE 767 antiseize compound on the bushings and bolt threads CONTROL HEAD ASSEMBLY PROCEDURE Reference the figure on page 32 1 2 3 EUM 10 11 12 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 page 8 for type of hydraulic oil Assemble the hex head cap screw 26 and washer 31 to the rack gear using LOCTITE 243 threadlocker sealant on the threads Install the oring 7 onto the shaft guide housing Install the guide ring 3 onto the rack gear Lubricate the inside of the shaft guide housing and the rack gear subassembly with
11. in the grommet Loosen and rotate the hydraulic fitting 5 and rotate it as required Follow the steps for bleeding and adjusting the hydraulic controls on page 16 Follow the steps for changing the exciter oil on page 14 Reinstall the side cover removed in step 2 using LOCTITE 243 on the screw threads 15 BLEEDING AND ADJUSTMENT OF HYDRAULIC CONTROLS Reference the figure on page 16 1 Remove the six flange screws securing the side cover to the recoil oil drain side of the baseplate Loosen hex head bolts page 28 29 on the oil drain side only Lift the engine deck up to allow the hydraulic guard to be removed Check the hydraulic line 4 for loose fittings and tighten as needed Position the handle in the locked position and set the lock pin 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 see page 8 for fluid type and amount Place a drip pan or shop rag below the bleeder to catch any excess oil Slowly operate the control handle 3 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 9 After the air bubbles have be
12. must be ordered through your local MBW Inc distributor If you cannot locate an MBW Inc distributor in your area refer to page 41 of this manual to locate the MBW Inc Sales Branch nearest you and call for assistance ALWAYS INCLUDE Model and Serial Number of machine when ordering MBW Inc Parts Model and Serial Number of engine when ordering Engine Parts Item Part Number Description and Quantity Company Name Address Zip Code and Purchase Order Number Preferred method of shipping UI Po cS REMEMBER you own the best If repairs are needed use only MBW Inc parts purchased from Authorized MBW Inc distributors ASAFETY PRECAUTIONSA READ AND STUDY THE FOLLOWING SAFETY INFORMATION BEFORE ATTEMPTING TO OPERATE THIS EQUIPMENT IN ADDITION ENSURE THAT EVERY INDIVIDUAL WHO OPERATES OR WORKS WITH THIS EQUIPMENT IS FAMILIAR WITH THESE SAFETY PRECAUTIONS WARNING 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 good ventilation NEVER IN A CONFINED AREA WARNING DANGEROUS FUELS Use extreme caution when storing handling and using fuels 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 ALL GUARDS AND SHIELDS are in p
13. up to allow the side cover to be removed Remove the pipe plug 2 from the control head housing Remove the hydraulic line 4 from the 90 degree fitting 5 on the hydraulic housing Be careful to use a drain pan to catch the hydraulic oil Remove the 90 degree fitting 5 from the hydraulic housing Remove the four flange screws 13 securing the hydraulic housing and cylinder mount plate 6 to the input shaft cover 7 and remove the hydraulic housing Remove the shift spool 10 from the shift shaft 9 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 If you purchased the rebuild kit MBW Part Number 17368 go to step 12 Remove the seal guide ring 11 from the shift spool Remove the damaged or worn seals 12 from the shift spool 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 16 the cylinder cover 15 and the cylinder gasket 14 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 1 from its port on the hydraulic housing Thoroughly clean and inpect the bleeder screw for damage Replace if needed Clean and inspect the shift spool and the hydra
14. 3 NYLOC ZP FO8SW F101110HCS WASHER 9 16 x 1 3 8 x 12GA 2 HHCS 5 8 11 x 1 1 4 GR5 ZP F1011HN F10LW NUT 5 8 11 ZP LOCKWASHER 5 8 ZP F10PW F160816SCS WASHER 5 8 x 1 1 4 x 12GA ZP SHCS 1 8 x 2 GR8 ZP F160836SCS SHCS 1 8 x 4 1 2 GR8 ZP AIA O AJO Oj O 17337 KIT 3 EXTENSION GPR135 99 CONTAINS ITEMS 11 12 AND 35 17338 KIT 6 EXTENSION GPR135 99 CONTAINS ITEMS 11 12 AND 35 LOWERSHIFT ASSEMBLY page 34 BASEPLATE ASSEMBLY PART DESCRIPTION 05559 CAPLUG 09748 FITTING PIPE 90 DEGREE 09749 PLUG BREATHER 16228 BEARING ROLLER 100 x 45 16232 SEAL SHAFT 16259 KEY METRIC 8x 7 x 28 ROUND ENDS 16262 COVER BEARING EXCITER 16263 SHAFT EXCITER 16264 COVER BEARING EXCITER 16265 GEAR INPUT 16266 GEAR IDLER 16321 KEY METRIC 16 x 10 x 45 ROUND ENDS 16322 COVER EXCITER 16328 WASHER 11 32 x 1 3 4 x 3 16 ZP 16331 BASEPLATE MACHINED 16599 SHAFT INPUT 16608 WEIGHT EXCITER GPR99 16260 WEIGHT EXCITER GPR135 17104 COVER BREATHER 17502 PULLEY EXCITER F0410SP SPIROL 1 4 x 1 1 4 F051804FWS FWLS 5 16 18 1 2 ZP F051806FWS FWLS 5 16 18 x 3 4 2 F051808FWS FWLS 5 16 18 x 1 ZP F061612SCS SHCS 3 8 16 x 1 1 2 GR8 ZP F0618SPP _IPLUG PIPE 3 8 16 1608165 5 SHCS 1 8 x 2 GR8 ZP 2 lt Co ala 14 bla aja aja aja Na aja al BR aja O N
15. C020FSS FHSS M10 x 1 5 x 20 ZP BATTERY BOLT METRIC Not Provided by MBW Inc N Bio a T BIB BiB NIN O T N a aja aj aja aja aja aja N Na aja WARRANTY MBW Inc Slinger Wisconsin warrants each new machine against defects in material and workmanship under normal use and service for a period of six 6 months This warranty commences the first day the machine is sold assigned to a rental fleet or otherwise put to first use The obligation under this warranty is limited to the replacement or repair of parts and or machine at MBW Inc factory branches or at authorized MBW Inc Distributors Machines altered or modified without MBW Inc written consent voids this warranty Misuse negligence accidents or the operation of machines in any way other than recommended by MBW Inc will void this warranty This warranty shall not apply to machines repaired by other MBW Inc factory branches or authorized MBW Inc Distributors This warranty includes labor on all MBW Inc products Labor must be performed at an authorized MBW Inc Distributor The cost of transportation and other expenses connected therewith are not covered by this warranty Written authorization for the return of merchandise under warranty must be obtained from MBW Inc Slinger Wisconsin In England MBW UK LIMITED Bradley Fold Trading Estate Unit 6 Radcliffe Moor Road Bolton BL2 6RT MBW Inc reserves the rig
16. MBOL is used to call attention to items or operations that may be dangerous to those operating or working with this equipment The symbol can be found throughout the manual and on the unit itself Please read these warnings and cautions carefully READ SAFETY DECALS CAREFULLY Carefully read and follow all safety decals Keep them in good condition If decals become damaged replace as required Ifrepainting REPLACE ALL decals Decals are available from authorized MBW Distributors Decals are not shown to scale Decals on set 16031 FORWARD UNLEADED GASOLINE 13481 13481 QTY 1 GPR99H ONLY IDLE STOP m THROTTLE 10843 14665 14665 QTY 1 15843 QTY 1 GPR135DE ONLY ENGINE RUN IDLE OIL DRAIN THROTTLE 17449 17449 QTY 1 GPR99H ONLY 15845 15845 QTY 1 HYDRAULIC OIL 15844 15844 QTY 1 SAFETY NOTICE 8 DECALS AIMPORTANT NOTICE The SAFETY ALERT SYMBOL is used to attention to items or operations that may dangerous to those operating or working with this equipment The symbol can be found throughout the manual and on the unit itself Please read these warnings and cautions carefully READ SAFETY DECALS CAREFULLY Carefully read and follow all safety decals Keep them in good condition If decals become damaged replace as required Ifrepainting REPLACE ALL decals Decals are available from authorized MBW Distributor
17. N T 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 four hex head flange screws 27 using LOCTITE 243 threadlocker 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 threadlocker sealant on the threads Thread one hex nut 32 onto the threaded rod 10 Install the threaded rod into the handle and thread on the other jam nut Thread the handle bumper shockmount 12 onto the threaded rod and secure it with the hex nut Connect the shockmounts 11 to the handle from inside the tube with four 8mm hex head flange screws 33 using LOCTITE 243 threadlocker sealant on the threads Secure the spindle mounts 21 to the shockmounts with four 8mm flat head socket screws 34 using LOCTITE 243 threadlocker sealant on the threads Reference the figure on page 28 8 9 Install the handle mounts 5 onto the handle assembly Route the hydraulic line 1 through the handle tube 10 Secure the handle assembly to the engine deck with four hex head flange screws 24 11 Secure the hydraulic line to the hydraulic control head fitting 12 Bleed the hydraulics according to the procedures on page 16 FINAL ASSEMBLY Reference the figure on page 28 1 2 3 Lower engine assembly onto baseplate Use care to route hydraulic h
18. OL HEAD INCLUDES ITEMS 1 9 13 16 23 24 26 29 31 LOWER SHIFT ASSEMBLY 34 LOWER SHIFT ASSEMBLY PART DESCRIPTION 2 lt 05559 16228 CAPLUG BEARING ROLLER 100 x 45 16230 16231 BEARING BALL GUIDE RING 16237 16238 RETAINING RING EXTERNAL METRIC SEAL HYDRAULIC 16239 16240 WASHER SHIM RETAINING RING INTERNAL 16241 16242 CARRIER HELIX PIN SHAFT SHIFT 16254 16264 PIN DOWEL M10 x 70 COVER BEARING EXCITER 16446 17023 FITTING 90 PARKER BLEEDER SCREW KIT 17275 17276 SPOOL SHIFT HOUSING HYDRAULIC 17277 17278 GASKET MOUNT GASKET CYLINDER 17279 17280 COVER CYLINDER PLATE MOUNT CYLINDER F042004FWS FO51808FWS FWLS 1 4 20 x 1 2 ZP FWLS 5 16 18 x 1 ZP CO ala aja aja aja aja aja gt N al a Na N gt m lt 2 lt 2 I HONDA ASSEMBLY PART DESCRIPTION 2 lt 00808 07767 KEY 1 4 SQ x 1 3 4 ENGINE HONDA 11HP 09375 16576 V BELT 44 CLUTCH 16580 16665 SPACER CLUTCH WASHER MOUNT 16676 16974 BELT GUARD LINE OIL DRAIN 17467 F052408FSS MOUNT BELTGUARD FHSS 5 16 24 x 1 ZP F061618HCS F061636SCS HHCS 3 8 16 x 2 1 4 GR5 ZP SHCS 3 8 16 x 4 1 2 GR8 2 F062408FSS FO6LW FHSS 3 8 24 x 1 2 LOCK WA
19. Operator s Safety and Service Manual GPR135DE DIESEL GPR99H GASOLINE lt is the OWNER S RESPONSIBILITY to communicate information on the SAFE USE and OPERATION of this machine to the operators MBW INC 250 HARTFORD ROAD BOX 440 SLINGER WI 53086 0440 pz PHONE 262 644 5234 e FAX 262 644 5169 MBW CORPORATE INTERNET ADDRESS E MAIL mbw mbw com WEB SITE www mbw com IN ENGLAND MBW UK LIMITED o Bradley Fold Trading Estate Unit 6 117433 04 03 D Radcliffe Moor Road MBW Inc 2003 Bolton BL2 6RT Printed in U S A Phone 01204 387784 Fax 01204 387797 SERIAL NUMBER LOCATION 1 Serial number decal location for MBW reversible plate compactors 2 Serialnumber is also stamped on the baseplate housing top edge near right rear shockmount and engine deck back edge near handle STAMPED SERIAL NUMBER The units year of Manufacture can be LOCATIONS determined by the serial number Contact your nearest Sales Branch or MBW Inc for this information PARTS ORDERING PROCEDURE The Warranty is stated in this book on page 40 Failure to return Warranty Registration Card renders the Warranty null and void An Owner s Manual for the engine is also furnished Engine parts may be ordered from any authorized dealer Refer to the engine Owner s Manual for exploded views and part identifications PARTS ORDERING MBW Inc parts are available worldwide and
20. SHER 3 8 ZP FO6PW WASHER 3 8 ZP Co HATZ DIESEL ENGINE ASSEMBLY 38 HATZ DIESEL ENGINE ASSEMBLY PART DESCRIPTION 2 lt 00808 08505 KEY 1 4 SQ x 1 3 4 HOSE HYDRAULIC 1 2 x 22 09375 16332 V BELT B 44 BAR MOUNT 16360 16523 BATTERY 12V ODYSSEY FITTING PLUG HYDRAULIC 16537 16556 L BRACKET TERMINAL BATTERY J BOLT 1 4 20 x 6 1 2 16576 16578 CLUTCH FITTING ADAPTER HYDRAULIC 16580 16600 SPACER CLUTCH CABLE BATTERY 4GA BLACK 19 16604 16621 CABLE BATTERY 4GA RED 48 BELT GUARD 16659 16660 HOLD DOWN BATTERY BOX BATTERY 16665 16969 WASHER MOUNT MOUNT IGNITION BOX 17144 17415 ENGINE HATZ DIESEL CUSHION CONTROL BOX 17426 17468 COVER BATTERY MOUNT BELTGUARD F042006HCS F042008FWS HHCS 1 4 20 x 3 4 GR5 ZP FWLS 1 4 20 x 1 ZP FO420ELN FO420HN LOCKNUT 1 4 20 NYLOC NUT HEX 1 4 20 ZP FO4LW F04PW LOCKWASHER 1 4 ZP WASHER 1 4 ZP F051804FWS F051808HCS FWLS 5 16 18 x 1 2 ZP HHCS 5 16 18 x 1 GR5 ZP F051814FWS FOSLW FWLS 5 16 18 x 1 3 4 GR5 ZP LOCKWASHER 5 16 ZP FOSSW F061636SCS WASHER 5 16 ZP SHCS 3 8 16 4 1 2 GR8 ZP F062408FSS MO6CO12FWS FHSS 3 8 24 x 1 ZP FWLS M6 x 1 0 x 12 ZP M10
21. aft through the oil seal in the cover to prevent tearing the seal Secure the input shaft cover with the four flange head screws 23 using LOCTITE 243 threadlocker sealant on the bolt threads and torque the capscrews to 13 ft lbs See the figure on page 20 for LOCTITE 515 gasket maker application Install the other input shaft cover page 34 12 and secure with the four flange head screws page 34 22 using LOCTITE 243 threadlocker sealant and torque the screws to 13 ft lbs See the figure on page 20 for LOCTITE 515 gasket maker application Check input shaft for minimum of 020 endlpay after covers are installed and the bolts are torqued to specifications 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 threadlocker sealant and torque the cap screws to 30 ft lbs Be careful to use a small amount of threadlocker to avoid dripping it into the helix pin carrier bearings at installation TIMING MARK LOCATION HYDRAULIC HOUSING SIDE OF BASEPLATE HUB OF IDLER GEAR OPPOSITE SHAFT SHOULDER ROTATED AS SHOWN HELIX PIN ORIENTED HORIZONTALLY GPR135 BASEPLATE GEAR TIMING 21 24 25 26 27 28 29 30 31 32 33 34 47 48 Slide the input gear 10 toward the pulley side of the input shaft 16 The gears should not be meshing at this time Install the ball bearings page 34 3 and the spac
22. and torque the flange screws to 13 ft Ibs See the figure on page 20 for LOCTITE 515 gasket maker application Check idler shaft for minimum of 020 endlpay after covers are installed and the bolts are torqued to specifications 20 13 14 15 16 17 Press the other bearing inner race onto the input shaft 19 20 21 22 23 Install the 90 degree fitting 2 containing the roll pin 20 into the bearing cover 18 using LOCTITE 565 sealant on the threads Make sure the port for the breather faces the top of the baseplate housing Install the breather 3 into the 90 degree fitting Install the exciter weights 17 on the idler shaft and secure with four socket head cap screws 24 using LOCTITE 243 threadlocker sealant and torque the cap screws to 32 ft lbs Press one bearing inner race onto one end of the input shaft 16 Note Make sure the bearings and their inner races are kept as a matched set The flange on the inner race goes toward the shoulder of the shaft Install the input gear 10 onto the input shaft and slide to the end with the bearing inner race Install the input shaft subassembly into the baseplate with the keyed end toward the left side pulley side of the baseplate Install the pulley side shaft cover 9 containing the shaft seal 5 over the input shaft on the pulley side of the baseplate Lubricate the input shaft seal and bearing with exciter oil before inserting the input sh
23. anufactures and used on MBW Inc products but such items shall have such warranties as may be provided by the manufacturer thereof lt 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 Radcliffe Moor Road Bolton BL2 6RT England Phone 01204 387784 Fax 01204 387797 WAREHOUSE LOCATIONS MBW Inc has established a network of reputable distributors 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 M B W distributor in your area contact one of our Sales Branches or MBW Inc The locations and phone numbers of the Sales Branches are listed below REMEMBER You own the best If repairs are needed use only M B W parts purchased from authorized M B W distributors Sales Branches 1 MBW INC 2 MBW UK LIMITED 250 Hartford Rd Bradley Fold Trading Estate Unit 6 P O Box 440 Radcliffe Moor Rd Slinger WI 53086 0440 Bolton BL2 6RT Phone 262 644 5234 Phone 01204 387784 Fax 262 644 5169 Fax 01204 387797 Email mbw mbw com Website www mbw com Great Britain C 5 42 5
24. d a selection of engines The MBW Reversible Plate Compactor is intended to compact various 5015 types Recommended soil types include granular soils gravel sand mixtures and semi granular cohesive soils The MBW Reversible Plate Compactor is not recommended for use in cohesive soils nor for very hard surfaces such as concrete or asphalt This parts manual contains only standard or standard option parts Variations of these parts as well as other special parts are not included Contact your local MBW Inc Distributor for assistance in identifying parts not included in this manual BEFORE OPERATION After receiving your new MBW Inc Reversible Plate Compactor inspect it for any visible damage done during shipment Make sure the engine throttle works properly Contact your nearest MBW Inc Distributor if there are any problems Your new MBW Inc Reversible Plate Compactor is shipped complete and ready for use REMEMBER It is the owner s responsibility for communicating information on the safe use and proper operation of this unit to the operators Before operating review related SAFETY PRECAUTIONS listed on page ii of this manual Familiarize yourself with the operation of the equipment BEFORE starting the engine Know how to STOP the equipment Make sure hands feet and clothing are at a safe distance from any moveable parts prior to starting OIL LEVEL Check the oil level in the engine For more information see
25. de the pinion shaft out of the control housing Note the size and location of the o rings for assembly Remove the o rings 4 and 5 from the pinion shaft 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 of the rack gear Use a 1 4 pin punch to drive the slide bushing 14 out of the control head housing 19 BASEPLATE ASSEMBLY PROCEDURE the figure on 30 1 2 3 a 10 11 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 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 Press the roller bearings 4 and page 34 2 into all four of the covers 7 9 18 and page 34 12 Note Make sure the bearings and their inner races are kept as a matched set Install the h
26. en removed tighten the bleeder screw 1 and adjust the hydraulic oil level in the control head by pushing the shift handle to the forward position and then pulling it into the reverse position until it stops Repeat this procedure two times 10 With the shift lever in the forward position and the handle in the locked position as shown oil level should be about 1 1 4 to 1 1 2 from top of control head 11 Reinstall the pipe plug 2 12 Reinstall the side cover removed in step 1 using LOCTITE 243 on the screw threads ey Oil Level _ 10 qo O n 0 GPR135DE 99H HYDRAULICS 16 BASEPLATE DISASSEMBLY PROCEDURE Reference the Disassembly Procedure on page 11 diesel or page 13 gasoline to separate the engine deck from the exciter subassembly Reference the main assembly figure on page 28 1 2 3 4 5 Remove the four socket head capscrews 34 extension plates 11 and bushings 12 if equipped from the sides of baseplate 6 Remove the twelve hex head flange screws 20 securing the side covers 15 to the baseplate Remove the four hex head flange screws 21 securing the bellows mounts 17 to the baseplate and remove the bellows mounts and bellows 4 Disconnect the hydraulic line 1 from the hydraulic fitting Remove the four hex head flange screws 20 securing the hydraulic guard 16 to the baseplate and remove the hydrau
27. er washer page 34 7 onto the shift shaft page 34 10 and secure with the e clip page 34 5 Press the shift shaft and ball bearing assembly into the helix pin carrier page 34 9 and secure with the internal snapring page 34 8 Lubricate the helix pin carrier shift shaft assembly with exciter oil and slide it into the input shaft and install the dowel pin page 34 11 Slide the helix pin carrier to the middle of the helix and orient the dowel pin parallel with the bottom of the baseplate housing 15 Align the timing marks on both gears and slide the input gear over the helix pin carrier and into mesh with the gear on the idler shaft See the illustration on page 21 for setting the gear timing Install the other exciter weight 17 to the input shaft with two socket head cap screws 24 using LOCTITE 243 threadlocker sealant on the threads and torque the cap screws to 30 ft Ibs Be careful to use a small amount of threadlocker 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 Note The seals page 34 6 guide ring page 34 4 and gaskets page 34 17 and 18 should be replaced as a set MBW recommends puchasing rebuild kit 17368 for ease of repairs Seals are pre assembled to the spool If rebuild kit 17368 wa
28. evel Open fuel valve Choke engine A warm engine may not need to be choked Open throttle part way Pull starter rope After starting open choke return throttle to idle position During operation when excessive kickback is noticed maximum compaction has been reached To stop return throttle to the idle position use engine stop switch close fuel valve 15866 QTY 1 GPR99H ONLY LIFT ONLY BY IAPPROXIMATE WEIGHT 924 LBS 420 KG 15853 15853 QTY 1 GPR135DE ONLY LIFT ONLY BY LIFTHOOK IAPPROXIMATE WEIGHT 781 LBS 355 KG 16026 16026 QTY 1 GPR99H ONLY engine level E Check fuel level Set engine speed control in the middle position Move decompression lever if equipped to the up position Located on top of the engine Use key if equipped or starting handle to start engine Refer to engine instruction book for proper Manual Starting procedure After starting return engine speed control to the idle position and allow engine to reach operation temperature During operation run engine at full throttle when excessive kickback is noticed maximum compaction has been reached To stop return throttle to the idle position and allow engine to idle for one minute then move control to stop position 15832 15832 QTY 1 GPR135DE ONLY SAFETY NOTICE amp DECALS AIMPORTANT NOTICE A The SAFETY ALERT SY
29. ex head flange screws 21 into the shaft bearing covers using LOCTITE 243 thread locker sealant Install the plastic plugs 1 in the threaded holes used to press the covers out of the baseplate Install the key 12 into the idler shaft 8 Align the idler gear 11 with the key and idler shaft and press the idler gear onto the idler shaft using exciter oil as a lubricant Reference the figure on page 21 for 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 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 3 16 BEAD LOCTITE 515 HOUSING SIDE MAN HOUSING GASKET MAKER COVER 18 BEAD 2 LOCTITE 515 GASKET MAKER SHAFT BEARING COVER 7 16 GPR135 BASEPLATE COVER SEALANT APPLICATION 12 Install the idler shaft covers 7 on the pulley side and 18 on the hydraulic side Secure each cover with four hex head flange screws 23 using LOCTITE 243 on the bolt threads
30. gs 4 and page 34 2 from the shaft covers 7 9 18 and page 34 12 by removing two 5 16 flange head bolts 21 from the covers and use a 1 4 x 2 long pin punch to the bearings out of the covers Alternate between the access holes evenly to prevent binding of the bearings in the covers Note performance of the following steps will require replacement of the ball bearings page 34 3 M B W recommends replacement of these bearings as a set at every complete disassembly or rebuild Remove the internal retaining ring page 34 8 from the helix pin carrier page 34 9 and remove the shift shaft page 34 10 and bearings page 34 3 as a subassembly from the carrier Remove the e clip retaining ring page 34 5 securing the bearings to the shift shaft Secure the bearings in a vice and press out the shift shaft Note the position of spacer washer page 34 7 HANDLE DISASSEMBLY PROCEDURE Reference the main assembly figure on page 28 1 2 3 4 5 Disconnect the hydraulic line 1 from the fitting page 32 1 in control head of the handle Use a drain pan to catch the hydraulic oil Disconnect the throttle cable 18 from the engine Remove the two hex head flange screws 21 securing the throttle lever 14 to the handle and remove the throttle lever and throttle cable as subassembly from the handle Remove the four hex head flange screws 24 securing the handle mount to the engine dec
31. ht to inspect and render final decision on each warranty case MBW Inc reserves the right to improve or make product changes without incurring any obligation to up date refit or install the same on machines previously sold MBW Inc is not responsible for any liability or damage or injury directly or indirectly from design material or operation of its products Warranty card must be returned to MBW Inc P O Box 440 Slinger Wisconsin 53086 0440 within 10 days after purchase assignment to a rental fleet or first use In England MBW UK LIMITED Bradley Fold Trading Estate Unit 6 Radcliffe Moor Road Bolton BL2 6RT Failure to return warranty card as spec ified renders the warranty null and void Requests for warranty must be submitted in writing within 30 days after machine failure to MBW Inc P O Box 440 Slinger Wisconsin 53086 0440 In England MBW UK LIMITED Bradley Fold Trading Estate Unit 6 Radcliffe Moor Road Bolton BL2 6RT The foregoing warranty is expressly in lieu of all other warranties expressed or implied including the war ranties of merchantability and fitness for use and of all other obligation or liabilities on our part and we neither assume nor authorize any other person to assume for us any other liability or warranty in connec tion with the sale or service of any of our products Likewise this warranty shall not apply with respect to engines motors and other component parts produced by other m
32. hydraulic oil See page 8 for hydraulic fluid type Slide the rack gear subassembly into the shaft guide housing until the guide ring is fully inserted into the shaft guide housing Slide the shaft guide housing rack gear subassembly into the control housing while guiding the rack gear into the slide bushing Secure the shaft guide housing to the control housing with the four hex head flange screws 29 using LOCTITE 243 threadlocker sealant on the threads and torque the cap screws to 13 ft lbs Push the rack gear toward the pipe plug end of the control housing until it is approximately 0 90 from the end of the control housing Note this measurement is approximate Install the orings 4 and 5 on the pinion gear 24 Tip Use hydraulic oil to lubricate the o rings to ease assembly Slide the pinion gear with seals into the control housing 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 Install the hydraulic adapter 23 into the shaft guide housing using hydraulic oil as a seal lubricant Install the hydraulic fitting 1 into the hydraulic adapter using hydraulic oil as a seal lubricant Install the pipe plug 8 and the sealing washer 9 into the control housing all the way but do not tighten 23 HANDLE ASSEMBLY PROCEDURE figure on 32 1 N E
33. ic Measurements Specifications are subject to change without notice TROUBLESHOOTING Engine does not start or stalls 1 No fuel in the tank The fuel valve is closed gasoline engines On gasoline engines the stop switch is not in the ON position Fouled spark plugs gasoline engines Electric Start battery charge low recharge Starter Motor defective or worn replace Defective ignition switch replace Engine does not accelerate is hard to start Improper fuel or runs erratically Spark plug or injection nozzle fouled clean Fuel filter clogged replace Air cleaner dirty or clogged replace Engine overheats or runs hot Cooling fins and blower are dirty clean Engine runs at full speed but machine Check the belt for excessive wear replace does not move Centrifugal clutch worn replace Engine runs but machine operates Retension the belt replace if needed erratically Centrifugal clutch worn replace Forward speed too slow much oil in the hydraulic head reduce Improper adjustment of the control system requires authorized MBW service Reverse speed too slow Not enough oil in the hydraulic head fill Air in control system bleed Improper adjustment of ofthe control system requires authorized MBW service Plate vibrates but has no forward or Mechanical failure requires authorized reverse movement MBW service Leaking hydrau
34. k 3 Remove the handle assembly from the main assembly Reference the handle assembly figure on page 32 6 7 8 9 10 Remove the four flat head socket screws 30 securing the spindle mounts 21 to the shockmounts 11 Remove the four hex head flange screws 33 securing the shockmounts to the handle 22 from inside the tube Remove the two jam nuts 32 securing the threaded rod 10 to the handle and remove the handle bumper shockmount 12 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 27 securing the handle bars 19 and 20 to the handle and remove the handlebars and the control head from the handle 18 CONTROL HEAD DISASSEMBLY PROCEDURE Reference the figure on page 32 1 2 3 DUE om 10 11 12 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 to the control head housing 13 Be sure to note the locations of the o rings for assembly Remove o ring 7 from the shaft guide housing Remove the pipe plug 8 and seal washer 9 from the control head housing Remove the external snap ring 6 from the pinion shaft 24 Sli
35. l Safety and Healthy Administration Act must be met when operated in areas that are under the jurisdiction of that United States Department ii TABLE OF 5 Serial Number Location 4 Parts Ordering Procedure u a a me tee Eau deca ex i Precautloris u l poi a the ed XII Ie ios bab ES ii Safety Notice Decals l dx dei aou eet euet eii c He acis edd Eua 1 Decal Locations 1 5 A Se Sr is tee d 4 Decal kocatigns OPROSF Regg ge efe dE e q ee 5 Operaling Instruclionses st e pe A MU SEAS 6 neis 6 Before Operations 5 23 2 te DS 6 e See e io is AO 7 ENGINE d 5 6652 Sh om ate s sag S sm De 7 ls O A A 7 staring pete eo Me eot 7 R nning ENGINE 4 3 a D a A AA E ANA A Me 7 Stopping Engien ey re terae ee ee is de E A oe 7 Maintenance Schedule 8 AS E 8 Pesca tons 9 IN Er 1 a ans ay S a De llo DA O Le o O de 10 ree 11 Engine MaIDEeDsriGe s 11 Engine SDBBU sr aan a few ui REITER a 11 Battery Maintenance 11 Battery Charging
36. l head fitting free of dirt and debris by using tape Be careful to use a drain pan to catch the hydraulic oil 8 Use the main lift hook on the rollcage 7 to separate the engine deck from the baseplate If further disassembly of the engine deck is required proceed to step 9 If baseplate service is required refer to page 17 9 Disconnect the throttle cable 18 from the engine 10 Remove the handle assembly by removing the four flange screws 24 securing the handle mount 5 to the engine deck Be careful to guide the hydraulic line through the handle assembly and engine deck as the subassemblies are separated to prevent damage to components and personal injury 11 Remove the four hex head capscrews 26 securing the rollcage to the engine deck and remove the rollcage 12 Remove the four hex head capscrews page 36 11 securing the engine to the engine deck and remove the engine BELT ADJUSTMENT Reference the figure on page 28 1 2 3 Remove the belt guard for gas engine referto page 36 7 for diesel engine refer to page 38 14 Loosen do not remove the four hex head capscrews 29 securing the engine deck 3 to the baseplate 6 Retension the belt by lifting the engine deck to provide 3 8 3 4 inch of play on one side of the belt Be sure to keep the engine deck level with the baseplate when retensioning the belt Retighten the four hex head capscrews Reinstall the beltguard 13
37. lace 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 WEAR loose clothing rings wristwatches etc near machinery NOISE PROTECTION Wear 5 specified hearing protection devices FOOT PROTECTION Wear 5 specified steel tip safety shoes HEAD PROTECTION Wear 5 specified safety helmets EYE PROTECTION Wear 5 specified eye shields safety glasses and sweat bands DUST PROTECTION Wear 5 specified dust mask or respitator OPERATOR Keep children and bystanders off and away from the equipment REFERENCES For details on safety rules and regulations in the United States contact your local Occupational Safety and Health Administration 5 office Equipment operated in other countries must 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 Inc 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 Inc 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 Occupationa
38. lic guard and hydraulic line from the baseplate Reference the baseplate assembly figure on page 30 6 11 12 13 14 15 16 we Remove the hex head flange screw 22 and washer 14 securing the pulley 19 to the input shaft 16 and remove the pulley Remove the twenty hex head flange screws 22 securing the baseplate cover 13 to the baseplate 15 and remove the baseplate cover Remove the oil drain plug 25 and completely drain the exciter oil into a drain pan Examine the oil for metal chips as a precaution to future troubles Note the position of the gear timing marks Remove the socket head capscrews 24 securing the exciter weights 17 to the shafts and remove the exciter weights Place a shop rag under the hydraulic housing page 34 16 to catch the oil and remove the four flange screws page 34 22 securing the cylinder mount plate page 34 20 to the input shaft cover page 34 12 and remove the hydraulic housing from the baseplate Remove the 90 degree hydraulic port fitting page 34 13 Remove the four hex head flange screws page 34 21 securing the cylinder cover page 34 19 to the hydraulic housing and remove the cylinder cover and gasket page 34 18 Remove the shift spool page 34 15 from the shift shaft page 34 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 th
39. lic line connections tighten replace Damaged hydraulic hose replace Seal on the piston in gearbox is worn damaged requires authorized MBW service Loss of hydraulic oil NOTE If the engine performance is poor or erratic check clean and replace the air filter and or the fuel filter as needed 10 SERVICE ENGINE MAINTENANCE Refer to the engine owner s manual for maintenance schedule ENGINE SPEED 1 The engine should be set at an operating speed of 3600 rpm Check the engine owner s manual for the procedure on setting the operating speed 2 The idle speed of the engine must not exceed 1800 rpm If the idle speed is greater the clutch may not disengage Check the engine owner s manual for the procedure on setting the idle speed BATTERY MAINTENANCE The Odyssey battery is very different from standard liquid acid batteries that are openly vented The battery is and operates as a sealed battery recycling all gases internally There is no corrosion to the surrounding area The battery is shipped fully charged from the factory but prior to installation check the battery s voltage to see if it is 12 65 volts or greater If not recharge it using the procedure below Caution Never attempt to remove the top decal cover as it will cause the battery to fail BATTERY CHARGING The state of charge in an Odyssey battery can be determined from the following chart Voltmeter Reading State of Charge 12 84 Volts
40. minutes RUNNING ENGINE 1 After the engine warms up fully open throttle The compactor will begin vibrating and moving in a forward direction Never leave compactor idling unattended The MBW 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 stop the compactor from traveling forward return the engine throttle to idle position 2 Whenever possible it is recommended to let the engine idle before stopping 3 Gas engines Turn the switch on the engine to STOP position Diesel engines Move the throttle control to the STOP position 4 Turn off the fuel valve where applicable STOP THE ENGINE BEFORE ADDING FUEL LEAVING EQUIPMENT UNATTENDED EVEN IF ONLY FOR A MINUTE MAKING ANY REPAIRS OR ADJUSTMENTS TO UNIT MAINTENANCE SCHEDULE Every Every Maintenance 100 Hours 250 Hours Refer to engine operator owner manual Clean cooling fins Check for wear and retighten Belt Exciter Check for oil leaks Change oil Tighten bolts Hydraulics Check level and refill Check and tighten as Hardware needed Shock Check for cracks or tears Mounts 1 be done after the fir
41. n the engine 19 and remove the beltguard Slide the belt 3 off the clutch 9 Remove the two flange screws 21 securing the bellows retainer 19 and remove the retainer Push the lip of the bellows 4 through the hole in the engine deck Disconnect the hydraulic line 1 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 7 to separate the engine deck from the baseplate If further disassembly of the engine deck is required proceed to step 9 If baseplate service is required refer to page 17 Disconnect the throttle cable 18 from the engine Remove the handle assembly by removing the four flange screws 24 securing the handle mount 5 to the engine deck Be careful to guide the hydraulic line through the handle assembly and engine deck as the subassemblies are separated to prevent damage to components Remove the four hex head capscrews 26 securing the rollcage to the engine deck and remove the rollcage Reference the figure on page 38 for steps 12 thru 18 12 13 14 15 16 17 18 Disconnect the negative black battery cable 12 from the engine mount bolt 30 Use electrical tape to enclose the terminal of the negative black battery cable to prevent accidental discharge of the battery Di
42. o 76 in lbs Install the 90 degree fitting page 34 13 into the port on the hydraulic housing Install the bleeder screw page 34 14 loosely into the port fitting of the hydraulic housing Install the socket head pipe plug 25 into the oil drain port using LOCTITE 565 pipe sealant Pour in the exciter oil Use only MBW Ground Pounder Exciter Oil The amount of exciter oil required is shown in the FLUID LEVELS section of this manual on page 8 Install the baseplate cover 13 using LOCTITE 515 gasket maker on the lip of the mounting surface and secure with twenty hex head flange screws 22 using LOCTITE 243 on the threads See the figure on page 20 for LOCTITE 515 gasket maker application Install the key 6 into the input shaft 16 Install the pulley 19 with the longer hub shoulder toward the baseplate housing 22 49 Install the pulley mount washer 14 and secure it to the input shaft with the hex head flange screw 22 using LOCTITE 243 threadlocker sealant on the threads Reference the figure on page 28 for further assembly 50 51 52 56 Install the v belt page 36 3 or page 38 3 to the pulley of the baseplate assembly Install the side cover 15 on the pulley side ofthe baseplate housing and secure with six hex head flange screws 20 using LOCTITE 243 thread locker sealant Install the bellows 4 into the bellows mount plate 17 and secure it to the baseplate with
43. ose through engine deck and up handle tube Install four bolts 29 lockwashers 31 and washers 32 through the engine deck into the shockmounts on the baseplate Refer to Belt Adjustment on page 13 and to Bleeding and Adjustment of Hydraulic Controls on page 16 to complete assembly 24 Engine Components Bearings Clutch Exciter Hardware Safety Decals Seals and Gaskets Special MBW Tools and Kits REPLACEMENT Tolerance Replacement Cycle Refer to your authorized engine dealer Replace anytime a bearing is rough binding or discolored Replace clutch if it does not disengage the exciter below 1800 rpm or engage above 1800 rpm The clutch is not serviceable so it must be replaced as assembly Replace once every season or every 250 hours Use Only MBW Ground Pounder Exciter Oil Re torque all bolts after the first eight hours of operation and check every 50 hours All hardware is zinc plate grade 5 unless otherwise specified Replace if they become damaged or illegible Replace at every overhaul or teardown 01058 6 Pack 8 oz bottles Ground Pounder Exciter Oil 17320 1 quart 32 Ground Pounder Exciter Oil 01469 1 gallon U S Ground Pounder Exciter Oil 16031 DECAL SET HYD REV PLATE 17337 EXT PLATES GPR135 99 2X3 2X76mm 17338 EXT PLATES GPR135 99 2X6 2X152mm 17368 KIT REBUILD HYD LOWER GPR135 99 17369 KIT REBUILD HYD UPPER
44. read Remove the plastic plugs 1 from the threaded holes in the shaft covers 7 9 18 and page 34 12 This can be done using a 2 phillips screwdriver lightly tapped into the center of the plug and unthreading it as a screw Clean all dirt from the threaded holes in the shaft covers which were not plugged and chase the threads with a 5 16 18 UNC thread tap Remove the covers from the idler shaft 8 ends of the baseplate by removing the flange screws 23 and using two 5 16 18 x 2 long screws to press off the covers by installing them into the threaded holes cleaned in the previous steps Turn both screws evenly to prevent binding of the cover in the bore Note Make sure the bearings and their inner races are kept as a matched set Remove the idler shaft 8 and idler gear 11 from the baseplate Press the inner bearing races from the ends of the idler shaft Press the idler gear off of the idler shaft 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 page 34 11 from the input shaft and slide out the helix pin carrier page 34 9 as a subassembly Press the inner bearing races from the ends of the input shaft 17 26 27 28 29 30 31 Slide the input gear of the input shaft Remove the roller bearin
45. s Decals are not shown to scale 15847 01554 15856 SS Em E 15856 15855 DECAL LOCATIONS GPR135DE 15844 RUN D OP THROTTLE 15843 15843 01554 2 s 15832 ENGINE OIL DRAIN 15845 15845 15855 FORWARD LIFT ONLY BY LIFT HOOK APPROXIMATE WEIGHT 880 LBS 400 KG 16028 15853 REVERSE 14665 14665 as ROTATING PARTS Keep hands away 15855 01554 DECAL LOCATIONS GPR99H 13481 UNLEADED GASOLINE E RUN TDLE THROTTLE HYDRAULIC OIL 17449 15844 15847 E hs 15856 r b 21 A FORWARD eed 14665 LIFT ONLY BY LIFT HOOK arman 16026 E REVERSE 13484 15867 16026 ENGINE OIL DRAIN 15845 15845 ON ENGINE DECK 15866 801554 5 OPERATING INSTRUCTIONS INTRODUCTION MBW Inc Compaction Equipment is intended for use in very severe applications They are powered by four stroke engines and are available in different sizes an
46. s purchased skip to step 35 Assemble the new seals page 34 6 to the shift spool page 34 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 page 34 10 Note the left hand thread Assemble the new guide ring page 34 4 to the shift spool Install a new mount gasket page 34 17 onto the hydraulic housing page 34 16 Lubricate the inside of the hydraulic housing and the seal lips with hydraulic oil See page 8 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 page 34 20 over the hydraulic housing page 34 16 to the input shaft cover page 34 12 with the four flanged cap screws page 34 22 using LOCTITE 243 threadlocker sealant on the threads and torque the cap screws evenly in stages to 13 ft lbs Make sure the bleeder screw port page 34 14 is in the vertical position Install the gasket page 34 18 and cover page 34 19 to the hydraulic housing with four hex head flange screws page 34 21 using LOCTITE 243 threadlocker sealant on the threads and torque the cap screws t
47. sconnect the positive red battery cable 13 from the starter ofthe engine Use electrical tape to enclose the terminal of the positive red battery cable to prevent accidental discharge of the battery Remove the three 6mm bolts 36 securing the ignition box to the mount 18 Remove the four hex head flange screws 31 securing the battery box 16 to the engine deck and remove the battery box mount bars 4 and battery cables Remove the four hex head capscrews 30 securing the engine to the engine deck and remove the engine 12 MAIN DISASSEMBLY PROCEDURE GASOLINE ENGINE Separating the Engine Deck from the Exciter subassembly Reference the figure on page 28 1 2 Clean visible debris from the machine before servicing Remove the four hex head capscrews 29 securing the engine deck 3 to the baseplate 6 Use caution as the engine deck will drop down Reference the figure on page 36 for steps 3 amp 4 3 Remove the four socket head capscrews 12 securing the belt guard 7 to the mount plate 9 on the engine 2 and remove the beltguard 4 Slide the belt 3 off the clutch 4 5 Remove the two flange screws 21 securing the bellows retainer 19 and remove the retainer 6 Push the of the bellows 4 through the hole in the engine deck 7 Disconnect the hydraulic line 1 from the control head in the handle assembly Keep the end of the hydraulic line and contro
48. st 5 hours then do as shown in the maintenance schedule FLUID LEVELS Fluid Volume Recommended Brand Refer to engine operator Refer to engine operator owner Engine Oil g owner manual manual Exciter Oil MBW Inc Ground Pounder GPR99 48 oz 0 95 Liter Exciter MBW Inc Ground Pounder GPR135 48 oz 0 95 Liter Exciter Hydraulic Oil CHEVRON AW ISO32 OR RYKON 32 CHEVRON AW ISO32 OR RYKON 32 GPR99 8 oz 24 Liter GPR135 8 oz 24 Liter SPECIFICATIONS Specifications achine Data Operating Weight GPR99H 814 Ib 369 kg GPR135DE 925 420 kg Drive System Mechanical w V belt Mechanical w V belt Starter System Recoil Electric w Recoil Fuel Capacity 1 72 gal 6 5 liters 1 32 gal 5 liters Base Plate Width 19 7 in 480 mm 19 7 in 480 mm Base Plate Length Overall 37 2 in 945mm 37 2 945 Extensions 2 x 3 6 in 2 x 75 150 mm 2 x 3 6 in 2 x 75 150 mm erformance Centrifugal Force 9900 Ibf 44 kN blow 13500 Ibf 60 kN blow Exciter Speed 3840 vpm 3840 vpm Travel Speed 78 ft min 24m min 76 ft min 23 m min ngine Data Engine Speed 3600 rpm 3600 rpm Make Honda Hatz Model GX340 1B40 Fuel Gas Diesel Power 11 0 HP 9 9 HP Data in parenthesis are Metr
49. ulic housing Reinstall the bleeder screw into its port in the hydraulic housing 6 Install the new cylinder gasket 14 the cylinder cover 15 and the four flanged capscrews 16 Remove all mount gasket material 8 from the input shaft cover 7 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 12 to the shift spool 10 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 11 to the shift spool 10 Thread the shift spool 10 onto the shift shaft 9 Note the left hand thread Install a new mount gasket 8 on the hydraulic housing 6 Guide the hydraulic housing over the shift spool seals and guide ring and secure the cylinder mount plate to the input shaft cover using the four flange screws removed in step 5 using LOCTITE 243 on the screw threads Note Tighten the screws in a criss cross pattern tighten evenly Reinstall the 90 degree fitting 5 into the hydraulic housing Clean and reattach the hydraulic line 4 to the 90 degree fitting 5 on the hydraulic housing Be sure the hydraulic line does not bind
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