OPERATOR`S SAFETY AND SERVICE MANUAL
Contents
1. NOISE PROTECTION Wear OSHA specified hearing protection devices 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 ei 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 Administration Act must be met when operated in areas that are under the jurisdiction of that United States Department Safety Decals Carefully read and follow all safety decals Keep them in good condition If decals become damaged replace as required If r2. CONVERSIONS inelbs x 0 083 ft lbs ft lbs x 12 in lbs ft los x 0 1383 kg m ft lbs x 1 3558 Nem 159 ft lbs 180 ft lbs 315 ft lbs 682 ft lbs 764 ft lbs 2371 ft lbs T ft lbs 18 ft lbs 30 ft lbs Engine Removal NOTE It is not necessary to remove the handle to take the engine off the machine Refer to Engine Assembly page 21 Follow steps 1 through 3 under Handle Removal For models with large air cleaner HA remove clamp from air tube and disconnect air tube from engine While supporting the engine remove the four hex flange nuts 12 holding the engine 11 and engine adapter plate 2 assembly to the studs 1 in gearbox Remove the engine assembly from the rammer Clutch Removal Refer to Engine Assembly page 21 1 Remove the jam 13 nut and slide the clutch off engine crank 2 Reinstall the clutch making sure key remains in place and aligned with keyway 3 Reinstall jam nut with medium strength thread locker and tighten to 60 ft Ibs Nem Gearbox Removal NOTE It is necessary to remove the Handle and the Engine to remove the Gearbox Refer to Gearbox and Lower Unit Assembly page 18 1 Drain the oil from the rammer following steps 1 through 3 under Changing Percussion System Oil on page 6 2 Replace the drain plug 3 Remove the four hex head flange screws 8 holding the cover 2 to the gearbox 4 A CAUTION A NOTE There may be oil in the gea
3. 5 16 18 x 7 8 ZP F0518FN NUT FLANGE 5 16 18 ZP REPLACEMENT AIR FILTER NOT SHOWN 20718 EJECTOR BOOT ALR CLEANER HOUSING NOT SHOWN Lae KIT TACHOMETER NOT SHOWN 20305 FUEL HOSE ASM Includes items 1 2 7 amp 8 ul 21 Lk b 0 ADAPTER ELBOW KIT pee FOR MODELS WITH OVER SIZE AIR CLEANER ONLY Engine Assembly 422 ITEM PARTNO DESCRIPTION 1 17164 STUD Mounted in gearbox 4 page 18 Install with red high strength loctite ADAPTER GX100 7 REDUCER BARBED Supplied with engine HF 4 CLIP FUEL LINE Supplied with engine 5 FUEL LINE 3 16 ID x 15 1 2 LG Supplied with engine 81 HEX HEAD FLANGE SCREW M8 1 25 X 40mm Supplied with engine PIN DOWEL 6mm 10mm 420H Not provided by MBW Inc 8 18053 KEY WOODRUFF METRIC 4X13 CLUTCH KIT Includes items 8 amp 13 10 18527 ENGINE GUARD HONDA 18530 ENGINE ASSEMBLY HONDA GX100 Includes items 2 thru 9 amp 13 21048 ENGINE ASSEMBLY HONDA GXR120 Includes items 2 thru 9 amp 13 20717 ENGINE ASSEMBLY HA MODEL ONLY Items not included are 1 amp 12 12 FO518FN FLANGE 5 16 18 ZP 13 M12CHJN NUT HEX JAM M12 X 1 25 ZP 14 M08CO025FWS FLANGE LOCK SCREW 8 1 25 X 25mm ZP gt A N 20539 20945 20946 20947 KIT ADAPTER ELBOW FOR HA MODELS ONLY Includes items 15 16 amp 17 ELBOW ADAPTER AIR C
4. Refer to Gearbox Assembly page 14 1 2 3 4 Press the small ball bearing 22 into the gearbox from the back Secure with a retaining ring 18 Press the large ball bearing 2 into the gearbox 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 21 Carefully press the pinion into the gearbox A CAUTION A Do not use excessive pressure to seat the pinion 5 Install a retaining ring 4 onto the pinion from inside the gearbox 20 21 22 Press the needle bearing 6 into the gearbox The bearing must be pressed in with the numbers and letters facing up Apply a light coat of oil see Fluid Levels page 5 for proper oil type to the needle bearing after installation Place a retaining ring 10 over the large shaft of the crank gear 20 Press the ball bearing 2 onto the crank gear Install a retaining ring 1 to secure the ball bearing to the crank gear shaft Press the bearing 3 into the connecting rod 5 and secure with a retaining ring 8 Press the connecting rod 5 onto the offset shaft of the crank gear 20 Install a retaining ring 9 to secure the connecting rod Press the crank gear assembly into the gearbox Install the snap ring 10 using a retaining ring pliers inserted throu
5. of spring box 2 Insert the spring box tool MBW 20260 rods into the a box 13 up side down and install the spring box assembly as shown in Figure 3 upper springs 5 amp 6 4 Wrap slide bearing 16 around spring separator 15 and install into spring box 5 Apply high strength red thread locker to threads of new flange lock nut 19 and assemble to the ram shaft Torque to 60 ft Ibs 81 Nem Insert the lower springs 5 amp 6 Lightly grease the o ring groove in the cover 8 and install a new o ring 1 8 Insert the spring box tool MBW 20260 rods into the spring box as shown in Figure 4 Figure 3 Make sure the rods are 180 apart 4 Place the washers over the rods and run the nuts down so the washers are snug against the cover 8 5 Remove the flat head socket screws 21 holding the cover to the spring box 6 While holding the hex nuts from turning slowly and evenly back off the rods on the cover side of the spring box 7 After the tension is removed from the cover the spring box tools and the cover can be removed See Figure 4 Figure 4 8 Remove the o ring 1 from the cover 10 9 Slowly draw the cover down onto the spring box by alternately tightening each rod A WARNING A Keep the cover level with the spring box 10 11 12 13 14 15 16 Secure the cover with two flat head socket screws 21 torque to 8 ft Ibs 11 N
6. the external retaining ring 4 from the gear end of the pinion 21 on the inside of the gearbox If the retaining ring is pinched in its groove tap the pinion on the drum side This will relieve the pressure on the retaining ring Press out the pinion Pry out the oil seal 11 and discard Remove the retaining rings 10 amp 18 pa di om T9 Use a bearing puller to remove the ball bearings 2 amp 22 Breather Removal 1 2 3 Remove the hex head cap screw 28 from the top of the breather assembly 14 Remove the plain washer 29 cap 17 and filter 15 Use a pipe wrench to remove the breather tube 16 A A CAUTION Do not disassemble the breather assembly Slide Bearing Removal 1 2 If slide bearing is not damaged and appears to be in good shape do not remove If replacing slide bearing remove the retaining ring 23 if equipped from the bottom of the gearbox guide tube Pull ends of slide bearing 25 together until overlapping and slide out the bottom of the gear box guide tube A CAUTION Do not scratch or gouge the gearbox guide tube walls Bellows Removal Refer to Lower Unit Assembly page 16 1 Loosen the four hex head flange screws 20 securing the upper bellows ring 7 to the gearbox Slide the bellows assembly off the gearbox Remove upper amp lower bellows rings 7 amp 2 from bellows 4 Gearbox Assembly
7. 079 06079 U S PATENT 8 202 022 20425 RAMMER 01064 Compressed spring could cause severe injury See manual for disassembly instructions La resorte comprimida podria causar la herida severa Consulte el libro para ver el desmontaje correcto CHECK ENGINE OIL DAILY ENGINE MUST BE LEVEL 01326 OPERATING INSTRUCTIONS 1 Check fuel level 2 Open fuel valve 3 Set throttle at idle postion 4 Choke engine A warm engine may not need to be choked 5 Pull starter rope 6 After starting open choke gradually and let engine warm up at idle 7 To start compacting open throttle fully 8 To stop return throttle to idle and allow engine to run for a few minutes before turning off 9 Turn engine switch to off and close fuel valve 14773 Safety Decals Decal Set 17777 SPECIFICATIONS 422H 422H12 422HA 9 engine Honda Operating Noise Level dBa 93 dBA Travel Speed ft min m min 55 16 8 Compaction Area sqft hr sqm hr 2520 234 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 Compaction Force Ibf KN 3200 14 2 i No universal method or formula has been acce
8. 12 ft Ibs 16 Nem Tip the assembly back and place a new gasket 3 over the gearbox face Insert the dowel pins 1 into the gearbox through the holes in the gasket Align the holes in the cover 2 with the dowel pins and place the cover on the gasket 11 secure the cover to the gearbox using four flange head screws 8 Tighten the flange screws equally and torque to 12 ft Ibs 16 The gasket will tightening minutes If the lifting bracket amp handle brackets page 20 12 13 amp 19 were removed reinstall with flange head cap screws page 20 22 amp 23 Torque to 35 ft Ibs 47 Nem Fill the unit with oil according to the Changing Percussion System Oil section on page 6 compress slightly after initial re torque the flange screws after 5 Parts Replacement Cycles and Tolerances Replace anytime a bearing is rough binding discolored or removed from housing or Bearings shaft Replace when they are worn cracked or to the point of leaking Replace clutch if shoes and or springs show signs of heat damage or if it does not Clutch disengage below 2000 rpm Replace if teeth are cracked or if they become sharp Engine Components Refer to your engine manufacturer s Owner s Manual Guide Bushings Replace if a 0 025 0 635 mm feeler gauge can be slid between the spring box and the guide tube Replace any worn or damaged hardware as needed Replacement hardware should Hardware ee be grad
9. 3 1 2 20 9 16 12 49 in lbs 56 in lbs 8 ft lbs 9 ft lbs 15 ft lbs 17 ft lbs 24 ft lbs 27 ft lbs 37 ft lbs 41 ft lbs 53 ft lbs Service Tools 01629 Rubber Test Mat 07205 Bellows Installation Tool 07552 Blind Hole Bearing Puller Tool 20260 Spring box Tool General The disassembly and assembly procedures given on the next few pages are intended for a complete dismantling of the rammer Read the following sections carefully It is not necessary to follow the complete disassembly procedure when only partial disassembly is required If repairs have to be made to the Lower Assembly only it is recommended that the drive unit engine gearbox and handle be removed from the lower unit See Lower Unit Disassembly Handle Removal Refer to Handle Assembly page 20 Turn the fuel valve 10 to the off position 2 Loosen the hose clamp 2 at the engine end of the fuel line 8 Disconnect the fuel line 3 Remove the flat head screws 19 holding the throttle 15 to the handle 16 4 Remove the four flange head cap screws 22 and flange nuts 23 securing the handle to the torsion mounts 4 5 Lift the handle 16 from the rammer 5 8 11 5 8 18 3 4 16 1 8 1 14 1 1 2 6 M6 M8 M 10 73 ft lbs 83 ft lbs 144 ft lbs 188 ft lbs 210 ft lbs 652 ft lbs 3 ft lbs 6 ft lbs 10 ft lbs 112 ft lbs 112 ft lbs 200 ft lbs 483 ft lbs 541 ft lbs 1462 ft lbs 4 ft lbs 10 ft lbs 20 ft lbs
10. 4 Remove the cover the cover gasket page 18 3 and the dowel pins page 18 1 from the gearbox Tip the unit forward and drain any oil into an oil pan After the oil has drained out replace the dowel pins gasket and cover and secure with the four hex head flange screws Tip the rammer onto it s face and fill according to the Fluid Levels section in this manual Replace the drain plug 4 SERVICE Assembly and disassembly should be performed by a service technician who has been factory trained on MBW equipment The unit should be clean and free of debris Pressure washing before disassembly is recommended Prior to assembly wash all parts in a suitable cleaner or solvent Check moving parts for wear and failure Refer to the Replacement section in this manual for tolerance and replacement cycles All shafts and housings should be oiled prior to pressing bearings Also ensure that the bearings are pressed square and are seated properly All bearings should be replaced when rebuilding any exciter or gearbox All gaskets and seals should be replaced after any disassembly Torque Chart GRADES GRADES 76 in lbs 9 ft lbs 87 in lbs 10 ft lbs 13 ft lbs 18 ft lbs 14 ft lbs 20 ft lbs 23 ft lbs 33 ft lbs 26 ft lbs 37 ft lbs 37 ft lbs 52 ft lbs 41 ft lbs 58 ft lbs 57 ft lbs 80 ft lbs 64 ft lbs 90 ft lbs 82 ft lbs 115 ft lbs 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 7 16 20 1 2 1
11. AR BOX ASSEMBLY 20045 PISTON CONNECTING RETAINING RING F051807FWS SCREW 5 16 18 x 7 8 ZP OJIN O1 EXTENSION TRENCH SHOE 6 16934 KIT 4 TRENCH SHOE 1 4 19 SUPPLIED WITH ENGINE INSTALL TACH WIRE THRU CLAMP amp ASSEMBLE CLAMP TO ENGINE TACH MODELS ONLY 1 e Sr as x N R lt 9 AIR INTAKE TO POINT DOWN amp FORWARD SEE ENGINE PAGE FOR ADAPTER ELBOW KIT Handle Assembly 1 01045 FILTER FUEL IN LIN FLOAT CARBURETOR ONLY 1 oer FUELFLTER NLINOAPHRAM CARBURETOR _ 01145 CLAMP SPRING 1 07916 FERRULE THROTTLE LEVER 1 15183 HOSE FUEL 1 1 2 LONG HOSE FUEL 3 16 I D SEE ENGINE ASSEMBLY PAGE 20422 KIT TANK FUEL INCLUDES ITEM 6 11 16586 GROMMET 1 2 13 18511 BRACKET HANDLE LEFT 15 18742 THROTTLE RATCHET STYLE 17 14946 CLAMP TACH WIRE 19 22 24 26 27 28 29 30 31 AJO N N O BRACKET LIFTING 20719 HANDLE COATED HANDLE COATED For serial number 4220899 and lower HL F032402FSS FLAT HEAD SCREW 10 24x1 4 FLANGE SCREW 1 4 20 x 1 2 ZP F051807FWS FLANGE SCREW 5 16 18 x 7 8 ZP FLANGE SCREW 5 167 18 x 1 ZP F0518FN NUT FLANGE 5 16 18 ZP AIR CLEANER COMPONENTS FOR HA MODELS ONY MEME 20714 AIR CLEANER CLAMP WORM DRIVE 2 1 4 20716 CLAMP WORM DRIVE 2 EJE FLANGE SCREW
12. LEANER GASKET AIR CLEANER BREATHER TUBE 90 AIR CLEANER Kits 20194 RAMMER SERVICE KIT NOT FOR HA MODELS 01045 IN LINE FUEL FILTER 15667 COVER GASKET 16414 FUEL VALVE 16586 GROMMET FUEL VALVE 19951 OIL 10W30 ONE QUART 017211218023 AIR CLEANER ELEMENT Q9805655777 SPARK PLUG 20305 FUEL HOSE ASSEMBLY COMPLETE SEE HANDLE ASSEMBLY PAGE 20539 KIT ELBOW AIRFILTER HA MODELS ONLY Includes items 15 thru 17 gt NO 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 machine is sold assigned to a rental fleet or otherwise put to first use MBW warrants each Demonstration Machine against defects in material and workmanship for a period of six 6 months Demonstration Machine means a machine used by MBW or its agents for promotional purposes This warranty commences on the first day the machine is sold assigned to a rental fleet or otherwise put to first use This warranty covers the labor cost for replacement or repair of parts components or equipment on New Machines or Demonstration Machines and MBW shall pay labor costs at MBW s prevailing rate to affect the warranted repair or replacement MBW reserves t
13. OPERATOR S SAFETY AND SERVICE MANUAL R422 This manual covers the following serial numbers and higher for each model listed I 4220900 SMART RAMMERS MBW Inc 250 Hartford Rd PO Box 440 Slinger WI 53086 0440 Phone 262 644 5234 Fax 262 644 5169 Email mow mbw com Website www mbw com MBW UK Ltd Units 2 amp 3 CochraneStreet Bolton BL3 6BN England UK Phone 44 0 01204 387784 Fax 44 0 01204 387797 E mail mowuk btinternet com MBW FRANCE S A R L Phone 33 0 3 44 07 15 96 Fax 33 0 3 44 07 41 28 L19903 09 15 P MBW Inc 2015 Printed in the USA TABLE OF CONTENTS Safety Information T SerVI6O ars usan RE QN Ned eee ees 7 1 Torque Chart xus ER usss hinaia 7 Safety Precautions 1 Service ToolS sursis rte duree dur CECE LAM 7 Safety 5 1 General 7 S ificati 3 Mande TREIMOVAl ss ce n 7 Engine 7 Operation 4 Clutch 8 Gearbox Removal 8 PERCHE 4 Gearbox Disassembly 8 Before Starting amp Operating 4 Gearbox 9 Starti
14. decision on each warranty case and MBW s repair or replacement is solely within the discretion of MBW IT IS EXPRESSLY AGREED THAT THIS SHALL BE THE SOLE AND EXCLUSIVE REMEDY UNDER THIS WARRANTY UNDER NO CIRCUMSTANCES SHALL MBW BE LIABLE FOR ANY COSTS LOSS EXPENSE DAMAGES SPECIAL DAMAGES INCIDENTAL DAMAGES OR PUNITIVE DAMAGES ARISING DIRECTLY OR INDIRECTLY FROM THE USE OF THE NEW MACHINE OR DEMONSTRATION MACHINE WHETHER BASED UPON WARRANTY CONTRACT NEGLIGENCE STRICT LIABILITY OR ANY OTHER LEGAL THEORY THE FOREGOING WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY FITNESS FOR USE AND FITNESS FOR A PARTICULAR PURPOSE AND ALL OTHER OBLIGATIONS OR LIABILITY ON MBW S PART MBW NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME ON BEHALF OF MBW ANY OTHER LIABILITY OR WARRANTY IN CONNECTION WITH THE SALE OR SERVICE OF ANY NEW MACHINE DEMONSTRATION MACHINE OR ANY OTHER MBW PRODUCT 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 war
15. e 5 and zinc plated unless otherwise specified Replace if teeth are cracked or if they become sharp Replace if the drum is scored or gouged deeper than 0 03 0 76 mm Replace if a 0 025 0 635 mm feeler gauge can be slid between the spring box and the piston Piston Pin Replace if the outside diameter is less than 0 620 15 75 mm Safety Decals Replace if they become damaged or illegible Seals amp Gaskets Replace if a leak is detected and at every overhaul or tear down Replace if a flat spot on the side of a spring is greater than 0 09 2 mm Replace if the free length is less than 6 75 171 mm Replace ALL springs at the same time Piston Spring box 12 REPLACEMENT PARTS The warranty is stated in this book on page 24 Failure to return the Warranty Registration Card renders the warranty null and void MBW has established a network of reputable distributors dealers with trained mechanics and full facilities for maintenance and rebuilding and to carry an adequate parts stock in all areas of the country Their sales engineers are available for professional consultation If you cannot locate an MBW distributor in your area contact MBW or one of our 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 e Model and Serial Number of engine when ordering engine parts e Part Numbe
16. em Remove the spring box tool rods from the assembly The spring box warning decal page 2 01326 should be clean and highly visible If not the old decal should be completely removed and replaced with a new decal Lightly oil a new o ring 9 and place it into the groove in the spring box guard 12 Slide the spring box guard over the ram head onto the spring box Be careful not to damage the o ring during installation Place the spring box assembly onto the shoe 11 with the fill plug 3 pointing toward the back of the shoe Install socket head cap screws 24 amp 25 handle 20 and lock washers 26 Torque cap screws to 40 ft Ibs 56 Nem Gearbox and Lower Unit Assembly Refer to Gearbox and Lower Unit Assembly page 18 1 Rotate the ram head page 16 14 in the lower unit so the larger hole on top is positioned toward the front of the shoe 11 Slide the gearbox assembly onto the lower unit Align the connecting rod page 14 5 with the ram head and install the piston connecting pin 6 with the threaded hole in the pin facing out Install retaining ring 8 into ram head Be sure retaining ring is completely seated into groove in ram head Rotate the gearbox assembly so the front of the gearbox is aligned with the front of the lower unit Secure the lower bellows mount page 16 4 to the spring box guard page 16 12 using six hex head flange screws page 16 21 Torque to
17. epainting the unit replace all decals Decals are available from authorized MBW distributors Order the decal set listed on the following page s OPERATION OF THIS EQUIPMENT MAY CREATE 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 UNLEADED Read the Operating Instructions before operating this piece of equipment Keep unauthorized and untrained people away from this equipment ROTATING amp MOVING PARTS Make sure all guards and safety devices are in place Wear approved hearing protection foot protection eye protection and head protection RELATING TO FIRE PREVENTION GASOLINE 14781 SHUT OFF the motor before servic ing or cleaning DO NOTRUNin an enclosed area The engine produces carbon monoxide a POISONOUS GAS Machine is top heavy and Failure to comply could result in serious bodily injury 13483 119 54kg 440 270 450 143 65kg NT 13483 460 470 480 160 73kg 2 c 2 U S PATENT 8 057 125 19895 RAMMER 19895 9 AIR CLEANER INSTRUCTIONS CLEAN ELEMENT DAILY MORE OFTEN UNDER DUSTY CONDITIONS S TAP ELEMENT LIGHTLY ON A FLAT SURFACE IF DUST DOES NOT DROP b OFF EASILY OR IF ELEMENT IS BENT OR CRUSHED y REPLACE IT WARNING DO NOT OPERATE ENGINE WITHOUT AIR CLEANER ELEMENT INTERNAL DAMAGE WILL RESULT 06
18. gh the slot in the crank gear Install the SAE plug 2219 into the gearbox Do not over tighten Replace the breather tube sub assembly 16 filter 15 cap 17 and plain washer 29 Apply medium strength thread locking liquid to the threads of the hex head cap screw 28 and install Squeeze slide bearing 25 until ends overlap with the holes up slide into the gearbox tube and align the hole in the bearing with the access hole in the gearbox amp guide tube Replace retaining ring 23 if equipped to secure slide bearing in place Assemble the lower bellows ring page 16 3 to one side of the bellows page 16 5 Assemble the upper bellows ring page 16 8 to the other side of the bellows Insert four hex head flange screws page 16 20 through the upper bellows mount so the head of the screw is wedged between the bellows and the upper bellows mount olide the bellows assembly over the gearbox guide tube page 18 4 with the upper bellows ring toward the gearbox Thread the hex head flange screws into the gearbox to secure the bellows Apply a light coat of oil see Fluid Levels page 5 for proper oil type to all bearings after installation is complete Lower Unit Disassembly 9 The lower springs 5 amp 6 can be removed from the spring box 13 NOTE The lower unit can be separated from the drive unit engine gearbox and handle without completely disassembling the rammer If the lo
19. gine For detailed instructions refer to the engine Owner s Manual 1 Open fuel valve 2 Turn engine switch to ON 3 Set throttle to idle A CAUTION A The engine speed must NOT be high enough to engage the clutch Choke engine if necessary you may not need to choke a warm engine Pull starter rope repeatedly until engine starts Move choke lever to open position Allow engine to warm up for one or two minutes Operating 1 2 3 Familiarize yourself with the balance of the rammer before using it in job conditions Due to the inherent design the machine is top heavy and could tip over After the engine warms up open the throttle fully for normal operation On uneven terrain pushing down on the handle will aid climbing ability A WARNING A Do not bear down body weight of operator on the machine 4 After 3 passes the rammer may have more kick back this is an indication that ideal compaction is being reached Stopping Engine 1 2 3 4 Move throttle to idle position Let engine idle for one or two minutes Turn switch on engine to STOP position Turn off fuel valve 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 lifting bracket and engine guard The unit should be
20. he right to adjust labor claims on a claim by claim basis This warranty covers the shipping cost of replacement parts components or equipment via common ground carriers from MBW to an authorized MBW dealer Air freight is considered only in cases where ground transportation is not practical MAY THIS WARRANTY BE TRANSFERRED This warranty is non transferable and only applies to the original end user of a new machine or demonstration machine WHAT DOES THIS WARRANTY NOT COVER 1 This warranty does not cover any Used Equipment Used Equipment means any MBW machine or equipment that is not a New Machine or a Demonstration Machine All Used Equipment is sold AS IS WHERE IS WITH ALL FAULTS 2 This warranty does not cover any New Machine Demonstration Machine or their equipment parts or components altered or modified in any way without MBW s prior written consent This warranty does not cover the use of parts not specifically approved by MBW for use on MBW products This warranty does not cover misuse neglect shipping damage accidents acts of God the operation of any New Machine or 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 affirmativel
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 glass sight 2 on the spring box guard 9 2 Ifthe oil is not visible in the sight gauge add oil as required See Fluid Levels for recommended type of oil Changing Percussion System Oil Refer to Lower Unit Assembly page 16 1 Remove the drain plug 4 above the sight glass 2 on the back of the spring box guard 9 2 Place an oil drain pan behind the shoe and tip the rammer back so the handle is on the ground 3 Elevate the shoe until the lower assembly is horizontal Hold this position until the oil is completely drained With the handle still on the ground remove the four hex head flange screws page 18 8 holding the cover page 18 2 to the gearbox page 18
22. ng 4 Lower Unit Disassembly 10 Operan 4 Lower Unit Assembly 10 Stopping 4 Gearbox and Lower Unit Assembly 11 Lifting and Transporting 4 Parts Replacement Cycles and Tolerances 12 Maintenance 5 Replacement Parts 13 Maintenance Schedule 5 Gearbox Assembly 14 FUQ EA 5 Lower Unit Assembly 16 Engine Maintenance 5 Gearbox and Lower Unit Assembly 18 Engine 5 Handle Assembly 20 Checking Percussion System Oil 5 Engine Assembly 22 Changing Percussion System Oil 6 Warranty oa E E yews 24 A WARNING A CALIFORNIA PROPOSITION 65 WARNING Engine exhaust and some of its constituents are known the state of California to cause cancer birth defects and other reproductive harm SAFETY INFORMATION Introduction This Safety Alert Symbol is used to call attention to items or operations which may be dangerous to those operating or working with this equipment The symbol can be found throughout this manual and on the unit Please read
23. panied by a Warranty Registration Card You must sign date and return the Warranty Registration Card to the place of origin of the New Machine or Demonstration Machine either to MBW Inc at P O Box 440 Slinger Wisconsin 53086 MBW UK Ltd at Units 2 amp 3 Cochrane Street Bolton BL3 6BN United Kingdom or MBW FRANCE SARL at ZA D Outreville 5 Rue Jean Baptiste Neron Bornel 60540 France within ten 10 days after purchase assignment to a rental fleet or first use This signed warranty card is the buyer s affirmation that he has read understood and accepted the warranty at the time of purchase Failure to return the warranty card as specified herein renders the warranty null and void In order to receive warranty coverage consideration warranty claims must be submitted within thirty 30 days after the New Machine or Demonstration Machine fails Warranty claims must be submitted to MBW Inc MBW UK Ltd or MBW FRANCE SARL and written authorization for the return of merchandise or parts under the warranty must be obtained before shipment to MBW WHAT WILL MBW DO MBW s 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
24. pted 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 four cycle engines and are available in different sizes and a selection of engines This parts manual contains only standard parts Variations of these parts as well as other special parts are not included Contact your local MBW distributor for assistance in identifying parts not included in this manual Before Starting amp Operating e REMEMBER It is the owners responsibility to communicate information on the safe use and proper operation of this unit to the operators 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 e Know how to STOP the machine in case of emergency e Make sure hands feet and clothing are at a safe distance from any moving parts OIL LEVEL Check the oil level in the engine For more information see Lubrication under the respective engine s Owners Manual or the Maintenance section of this manual AIR CLEANER Check to ensure element is in good condition and properly installed e FUEL SUPPLY The engines on MBW equipment require an automotive grade of clean fresh unleaded gasoline FUEL FILTER If clogged or damaged replace Starting En
25. r 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 KC The units 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 mow 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 MBW FRANCE S A R L Tel fono 33 0 3 44 07 15 96 Fax 33 0 3 44 07 41 28 13 Gearbox Assembly 14 1 01001 RETAINING RING EXT 5100 137 01244 RETIANING RING EXT 5160 112 ROD ASSEMBLY CONNECTING includes item 7 06259 BEARING NEEDLE 06264 RETAINING RING INT 5000 187 10 06266 RETINAING RING INT N5000 281 12 06413 VALVE SPRING COMPRESSION 0 420 OD 14 06904 BREATHER ASSEMBLY Includes items 12 13 15 16 17 26 28 29 16 06908 TUBE BREATHER 18 09476 RETAINING RING INT N500 244 20 13733 GEAR 22 16021 BEARING BALL RETAINING RING INTERNAL 3 0 For Serial N
26. ranty is subject to all limitations set fourth in MBW s limited warranty above 24 NOTES 25 NOTES 26
27. rbox Tip the unit back when removing the cover from the gearbox 4 Remove the cover 2 the cover gasket 3 and the dowel pins 1 from the gearbox Tip the unit forward and drain any oil into an oil pan 6 Remove retaining ring 7 from piston Thread a 5 16 18 screw into the piston connecting pin 6 and remove the pin See Figure 1 _ Figure 1 Remove the six hex head flange screws page 16 21 holding the spring box guard page 16 12 to the bottom bellows ring page 16 4 7 Remove the gearbox assembly from the lower unit assembly See Figure 2 Figure 2 Gearbox Disassembly Refer to Gearbox Assembly page 14 Crank Gear Removal 1 Slip a retaining ring pliers through the slot opening in the crank gear 20 and remove the retaining ring 10 from the housing The retaining ring will remain between the crank gear and the bearing 2 Remove the SAE plug 19 from the rear of the gearbox Use a 3 8 in or 10mm diameter steel rod to press the crank gear out of the gearbox Remove the ball bearing 2 from the crank gear using a bearing puller Remove the large retaining ring 10 from the back of the crank gear Remove the small retaining ring 9 from the front of the offset shaft on the crank gear and remove the connecting rod 5 Remove the needle bearing 6 from the gearbox with a blind hole bearing puller tool MBW 07552 Pinion Removal 1 Remove
28. 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 LETHAL EXHAUST GAS 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 A CONFINED AREA DANGEROUS FUELS Use extreme caution when storing handling and using fuels as they are highly volatile and explosive in vapor state Do not add fuel while engine is running Stop and cool the engine before adding fuel DO NOT SMOKE SAFETY GUARDS t is the owner s responsibility to ensure that all guards and shields are in place and in working order IGNITION SYSTEMS Breakerless magneto and battery ignition systems can cause severe electrical shocks Avoid contacting these units or their wiring SAFE DRESS Do not wear loose clothing rings wristwatches etc near machinery
29. transported laying face down 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 lubricating the unit After servicing the unit replace and fasten all guards shields and covers to their original positions before resuming operation Maintenance Schedule A 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 EVERY 25 EVERY 300 SYSTEM MAINTENANCE DAILY HOURS HOURS YEARLY Check oil level System Shockmounts Check for cracks or deterioration oo ane epee 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 1002 SF SAE 10W 30 Motor SS Engine Refer to engine operator owner manual Engine Maintenance Refer to the engine owners manual for maintenance intervals and procedures Check and clean the air cleaner element at least once daily The air cleaner has a foam pre cleaner that can be washed Check the engine oil level by removing the dipstick the engine must be level The oil level should be between the marks on the dipstic
30. umber 4220945 and Lower 24 20032 HOUSING ASSEMBLY 422 26 FO1PW WASHER 5 32 X 3 8 X 18 GA ZP 28 F081304HCS HEAD CAP SCREW 1 2 13 X 1 2 GR5 ZP NEN O OJN CO N FO8SW WASHER 9 16 X 1 3 8 X 12 GA ZP KITS 20176 KIT SLIDE BEARING Includes items 25 amp slide bearings in lower unit 15 Lower Unit Assembly 16 1 06239 O RING 3 36 ID X 0 139 DIA 1 Wii 00000000004 11694 BELLOWS 4 PLY 16306 SPRING COMPRESSION 1 700 OD 2 wi s l 16325 COVER SPRINGBOX 10 18276 PLUG OIL LEVEL 11 19618 SHOE 11 CAST IRON 12 20023 SPRING BOX GUARD 14 20335 KIT RAM SHAFT Includes items 19 amp 7 from page 18 16 See kit 20176 SLIDE BEARING SPRING SEPARATOR 18 20044 RETAINING RING F081318HCS HEX HEAD SCREW 1 2 13 x 2 1 4 GD 5 ZP For serial number 4220810 and below 20 20 20883 LIFT HANDLE LOWER 22 F042006FWS FLANGE WHIZ LOCK SCREW 1 4 20x3 4 ZP 24 FO72020SCS SOCKET HEAD CAP SCREW 7 16 20 X 2 1 2 GR5 ZP 26 FO7LW LOCKWASHER 7 16 ZP aere BEARINGS nabdesioms 16 17 188 side beating n gearbox 20176 KIT SLIDE BEARINGS Includes items 16 17 18 amp slide bearing in gear box NEN NIO OJA OJN ees a lx 20173 SPRING BOX ASM Includes Items 1 5 6 8 13 15 thru 19 24 amp 25 20884 KIT LOWER LIFT HANDLE Gearbox and Lower Unit Assembly 18 1 07203 PIN DOWEL 1 4 x 1 2 20031 GE
31. wer unit has not already been separated follow the Gearbox Removal instructions 10 Place a drift pin or 5 8 dia steel rod into the connecting pin hole in the ram head 14 Use this to hold the ram head from turning while removing the flange lock nut 19 Remove and discard flange lock nut 19 Ref L Unit A bl 16 11 Remove the spring separator 15 and slide bearing Shoe and Spring box Guard Removal 16 1 Remove the socket head cap screws 24 amp 25 and 12 Remove upper springs 5 amp 6 and ram shaft 14 lock washers 26 that secure the shoe 11 to the 13 lower unit assembly remove the shoe 11 and lift handle 20 2 Lift the spring box guard 12 off the spring box Lower Unit Assembly assembly 3 Remove the o ring Z9 from the spring box guard A WARNING A 11 Remove the retaining ring 18 and ram shaft slide bearing 17 from top of spring box 13 Working with compressed springs Failure to Spring box Disassembly follow the next set of steps very carefully could result in injury or death A WARNING A Working with compressed springs Failure to Refer to Lower Unit Assembly page 16 follow the next set of steps very carefully could result in injury or death 1 Install the ram shaft slide bearing 17 and retaining ring 18 into the top of spring box 13 Flip the spring box assembly upside down Install ram shaft 14 into top
32. y disclaims liability for any damage or injury resulting directly or indirectly from design materials or operation of a New Machine or Demonstration Machine or any other MBW product MBW s liability with respect to any breach of warranty shall be limited to the provisions of this document and in no event shall exceed an amount equal to the purchase price of the New Machine or Demonstration Machine purchased from MBW 4 This warranty does not cover engines motors and other assemblies or components produced by other manufacturers and used on a New Machine or Demonstration Machine as said engines motors and other assemblies or components may have warranties provided by the manufacturer thereof This warranty does not apply to consumable items such as v belts filters trowel and screed blades seals shock mounts batteries and the like all of which are sold AS IS WHERE IS WITH ALL FAULTS 5 This warranty does not cover the cost of transportation and other expenses which may be connected with warranty service but not specifically mentioned herein 6 This warranty does not cover any 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 accom
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