Before using this equipment, study the entire owner’s manual to become
familiar with its operation. Do not allow untrained or unauthorized personnel,
especially children, to operate this equipment. Use only factory authorized parts
for service.
This manual contains DANGER, WARNING, CAUTION callouts
which must be followed to reduce the possibility of personal injury,
damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential
DANGER
WARNING
CAUTION
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
1.2 Operating Safety
! ADDITIONAL HAZARDS
l Slip/Trip/Fall is a major cause of serious injury or death. Beware of uneven or
slippery work surfaces.
l Exercise care when working in the vicinity of unprotected holes or excavations.
l NEVER allow any person to operate the machine without adequate instruction.
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SAFETY INFORMATON
l ENSURE all operators read, understand and follow the operating instructions.
l SERIOUS INJURY could result from improper or careless use of this machine.
l Plate compactors are heavy units and should be positioned by two people of
appropriate strength. Using the lifting handles provided on the machine, along
with correct lifting techniques.
! MECHANICAL HAZARDS
l DO NOT operate the machine unless all protective guards are in place.
l KEEP handles and feet clear of rotating and moving parts as they will cause injury
if contacted.
l ENSURE that the motor operation switch is in the OFF position and the spark
plug ignition lead is disconnected before removing the guards or making
adjustments.
l ENSURE both the machine and the operator are stable by setting up on level
terrain and the machine will not tip over, slide of fall while in operation or
unattended.
l DO NOT leave the machine in operation while it is unattended.
l DO NOT pull the machine backward with transportation wheels, it only could be
pushed forward.
l ENSURE that the walls of a trench are stable and will not collapse due to the
action of the vibration, prior to commencing compaction.
l ENSURE that the area to be compacted does not contain any “live” electrical
cables, gas, water or communication services which may be damaged by the
action of vibration.
l EXERCISE CARE when operating unit. Exposure to vibration or repetitive work
actions may be harmful to hands and arms.
l NEVER stand on the unit while it is operating.
l DO NOT increase the governed no-load motor speed above 3,500 r/min. Any
increase may result in personal injury and damage to the machine.
l BE CAREFUL not to come in contact with the muffler when the engine is hot,
since it can cause severe burns.
l ENSURE that the repairs to the motor and machine are carried out by
COMPETENT personnel.
! FIRE & EXPLOSION HAZARDS
l PETROL is extremely flammable and explosive under certain conditions.
l ENSURE that the petrol is only stored in an approved storage container.
l DO NOT refuel the motor while it is in operation or hot.
l DO NOT refuel the motor in the vicinity of sparks, a naked flame or a person
smoking.
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SAFETY INFORMATON
l DO NOT over fill the fuel tank and avoid spilling petrol when refueling. Spilled
petrol or petrol vapour may ignite. If spillage occurs, ensure that the area is dry
before starting the motor.
l ENSURE that the fuel tank cap is securely fitted after refueling.
! CHEMICAL HAZARDS
l DO NOT operate or refuel a petrol or diesel motor in a confined area without
adequate ventilation.
l CARBON MONOXIDE exhaust gases from internal combustion motor driven
units can cause death in confined spaces.
! NOISE HAZARDS
l EXCESSIVE NOISE can lead to temporary or permanent loss of hearing.
l WEAR an approved hearing protection device to limit noise exposure. As
required by Occupational Health and Safety regulations.
PROTECTIVE CLOTHING
lALWAYS wear approved hearing protection when working in a confined work
space. Protective goggles and a dust mask should be worn when working in a
dusty environment. Protective clothing and footwear may also be desirable when
working with hot mix bitumen.
1.3 Operator Safety while using Internal Combustion Engines
l DO NOT smoke when refueling the engine or during any other fuel handling
operation.
l DO NOT refuel a hot or running engine.
l DO NOT refuel the engine near an open flame.
l DO NOT spill fuel when refueling the engine.
l If fuel is spilled during refueling, wipe it off from the engine immediately and
discard the rag in a safe place. Do not operate the unit if fuel or oil leaks
exist-repair immediately.
l NEVER operate this equipment in an explosive atmosphere.
l NEVER operate any gas powered equipment in a poorly ventilated or enclosed
area.
l NEVER perform any work on the unit while it is running. Before working on it,
stop the engine and disconnect the spark plug wire to prevent accidental
starting.
l Avoid prolonged breathing of exhaust gases.
4
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SAFETY INFORMATION
l Avoid contact with hot exhaust systems and engine parts.
l Allow engine to cool before performing any repairs or service.
l ALWAYS transport and handle fuel only when contained in approved safety
containers.
l ALWAYS keep the area around the muffler free of debris such as leaves, paper,
cartons, etc. A hot muffler could ignite the debris and start a fire.
1.4 Label Locations
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SAFETY INFORMATION
1.5 Safety and Operating Labels
MASTERPAC machines use international pictorial labels where needed. These labels are
described below:
Label Meaning
DANGER!
Engines emit carbon monoxide; operate only in
well-ventilated area. Read the Operation Manual
for machine information. No sparks, flames, or
burning objects near the machine. Shut off the
engine before refueling. Use only clean, filtered
unleaded gasoline.
WARNING!
Always wear hearing and eye protection when
operating this machine.
CAUTION!
Read and understand the supplied Operation
Manual before operating the machine. Failure to
do so increase the risk of injury to yourself or
others.
CAUTION!
Lifting point.
WARNING!
Hand injury if caught in moving belt.
Always replace belt guard.
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SAFETY INFORMATION
Label Meaning
WARNING!
Hot surface!
Guaranteed sound power level in dB(A).
NOTICE!
Throttle control lever:
Turtle = Idle or Slow
Rabbit = Full or Fast
A nameplate listing the model number and serial
number is attached to each unit. Please record
the information found on this plate so it will be
available if the nameplate lost or damaged.
When requesting service information, the serial
number should be specified of the unit.
Company logo
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TECHNICAL DATA
2. TECHNICAL DATA
Model PC4012H PC4012R PC4012L PC4012A
Engine Type
Honda
GX160
Robin EX17
Lombardini
LD225
Hatz 1B20
Power kw(hp)4.0(5.5) 4.2(5.7) 3.5(4.8) 3.5(4.8)
Operating Weight kg(lb)
85(187) 85(187) 98(216) 98(216)
Plate Size LxW cm(in)57x40(22x16)
Centrifugal Force kN12
Vibration Frequency vpm(hz)5400(90)
Travel Speed m/min(ft/min) 22(72)
Exciter Lubrication L0.15, SG15W-40 motor oil
Model PC4515H PC4515R PC4515L PC4515A
Engine Type
Honda
GX160
Robin EX17
Lombardini
LD225
Hatz 1B20
Power kw(hp)4.0(5.5) 4.2(5.7) 3.5(4.8) 3.5(4.8)
Operating Weight kg(lb)
Vibration Frequency vpm(hz)5400(90)
Travel Speed m/min(ft/min) 24(78)
Exciter Lubrication L0.15, SG15W-40 motor oil
Model PC5018H PC5018R PC5018L PC5018A
Engine Type
Honda
GX160
Robin EX17
Lombardini
LD225
Hatz 1B20
Power kw(hp)4.0(5.5) 4.2(5.7) 3.5(4.8) 3.5(4.8)
Operating Weight kg(lb)
113(249) 113(249) 126(278) 126(278)
Plate Size LxW cm(in)57x50(22x20)
Centrifugal Force kN18
Vibration Frequency vpm(hz)5400(90)
Travel Speed m/min(ft/min) 20(66)
Exciter Lubrication L0.25, SG15W-40 motor oil
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TECHNICAL DATA
Model PC5021H PC5021R PC5021L PC5021A
Engine Type
Honda
GX160
Robin EX17
Lombardini
LD225
Hatz 1B20
Power kw(hp)4.0(5.5) 4.2(5.7) 3.5(4.8) 3.5(4.8)
Operating Weight kg(lb)
115(254) 115(254) 128(282) 128(282)
Plate Size LxW cm(in)57x50(22x20)
Centrifugal Force kN21
Vibration Frequency vpm(hz)5400(90)
Travel Speed m/min(ft/min) 22(72)
Exciter Lubrication L0.25, SG15W-40 motor oil
Working Size (mm):
Model A B C D
PC4012 Series 1030 970 558 400
PC4515 Series 1070 940 558 450
PC5018 Series 1045 945 558 500
PC5021 Series 1065 950 558 500
Sound Specification (According to 2000/14/EC)
Model
PC4012/4515/5018/5021
series with Petrol Engine
PC4012/4515/5018/5021
series with Diesel Engine
Measured sound power level 102dB(A) 105dB(A)
Guaranteed sound power level 108dB(A) 108dB(A)
Vibration Specification (According to ISO 2631 and EN 1033) : 5 m/s2
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OPERATION
3. Operation
3.1 Operating Principle
The following instructions were compiled to provide you information on how to obtain long
and trouble free use of the unit. Periodic maintenance of this unit is essential. Read the
manual in its entirety and follow the instructions carefully. Failure to do so may injure
yourself or a bystander.
3.2 Delivery Checks
Immediately on taking delivery of your new equipment and before putting it into service.
l Read the operation manual completely—it could save a great deal of unnecessary
expense.
l Read the engine manual supplied.
l Check the general condition of the equipment –has it been damaged during delivery?
l Check engine oil level.
l Check fuel levels.
Recommended lubricants are detailed in the Care and Maintenance section.
3.3 Before Starting
The following Pre-start-up inspection must be performed before the start of each work
session or after every four hours of use, whichever is first.If any fault is discovered, the
compactor must not be used until the fault is rectified.
1. Thoroughly inspect the compactor for signs of damage. Check components are
present and secure. Pay special attention to the belt drive safety guard fitted
between the engine and the vibrator unit.
2. Check the engine oil level and top up as necessary.
3. Check the engine fuel level and top up as necessary.
4. Check for fuel and oil leaks.
NOTICE: Check the oil level in the engine and exciter. Engine and compactor warranties are
VOID if this unit is run without oil.
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OPERATION
3.4 To Start
3.4.1 Diesel Engine
1. Oil filling and level inspections must be carried out with the engine on a flat surface.
2. Remove oil filter cap, pour the oil in and reassemble oil cap.
3. Make sure that is nearly at max., fit the dipstick correctly back in place
4. Check and refill oil up to the maximum level.
5. Should start-up be difficult, purge air from union as indicated in the figure.
6. Do not fill the fuel tank completely , but just up to 1 cm (0.39 in) from the top of the
tank, to provide space for fuel movement. Wipe any fuel spillage from engine before
starting.
7. Remove fuel tank cap. Pour the fuel and reassemble fuel tank cap. With low
ambient temperatures (-10°C) add specific additives to diesel fuel, to avoid paraffine
crystals solidification.
8. To eliminate any possible water and dirt residue from the tank bottom, remove the
plug (A) and open the cock (B) to enable discharging. Once the operation is over,
close the cock and screw back the protecting plug.
9. Accelerator at 50 % speed.
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OPERATION
10. Take the handle and pull softly the rope until it is extended to its full limit. Let the
rope rewind completely. Start the engine pulling strongly the rope.
11. To stop the engine, lever and/or key in stop position, accelerator lever in stop
position.
3.4.2 Petrol Engine
1. Open the fuel tap by moving the fuel ON/OFF
lever fully to the right.
2. If starting the engine from cold, set the choke ON
by moving the choke lever fully to the left. If
restarting a warm engine, the choke is usually not
required. However, if the engine has cooled to a
degree, partial choke may be required.
3. Turn the engine ON/OFF switch clockwise to the
“1” position.
4. Set the throttle to the idle position by moving the throttle lever fully to the right. Do
not start the engine on full throttle, as the compactor will vibrate as soon as the
engine starts.
5. Taking a firm hold of the control handle with one hand, grasp the recoil starter
handle with the other. Pull the recoil starter until engine resistance is felt, then let
starter return.
6. Taking care not to pull the starter’s cope fully out, pull the starter handle briskly.
7. Repeat until the engine fires.
8. Once the engine fires gradually, set the choke lever to the OFF position by moving
it to the right.
9. If the engine fails to fire after several attempts, follow the trouble-shooting guide .
10. To stop the engine, set the throttle to idle and turn the engine ON /OFF switch
anticlockwise to the “0” position.
Run engine at full throttle and allow plate to pull itself along at its normal speed. When
operating it may be necessary to assist plate by pushing it forward slightly. Depending
on the material being compacted, three or four passes are recommended to achieve the
best compaction.
The machine is best suited to the compaction of bituminous and granular materials e.g.
granular soils such as silt and clay are best compacted using the impact force produced
by a vibrating rammer. Where possible the site should be graded and leveled before
commencing compaction.
Correct moisture content in soil is vital to proper compaction. Water acts as a lubricant
to help slide soil particles together. Too little moisture means inadequate compaction;
too much moisture leaves water-filled voids that weaken the soil’s load-bearing ability.
Compaction of dry materials will be facilitated by moistening with a water hose fitted
with a sprinkler. Excessive watering or water content will cause the machine to stall.
The optional water tank kit is recommended when the machine is used on bituminous
surfaces as the water film prevents a build up of material on the underside of the plate.
3.8 Max. admissible inclination
20°
20°
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OPERATION
3.9 Main parts and accessories
A. Throttle Lever
B. Handle
C. Protective Frame
D. Exciter
E. Blet cover
F. Base plate
G. Belt
H. Clutch
I. Wheel (option)
J. Water Tank (option)
K. Rubber Mat (option)
D
K
J
C
A
B
I
E
F
G
H
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At first 20
!
MAINTENANCE
4 MAINTENANCE
4.1 Periodic Maintenance Schedule
Refer to engine manufacturer’s Operation Manual for additional information on engine
maintenance. A copy of the engine Operation Manual was supplied with the machine
when it was shipped. To service the engine, tilt the seat forward.
(Starting check)
Daily
●
Every 50
hours
hours
Every
100
hours
Every
200
hours
Loosened of lost screws
Damage of any part
Function of controlling system part
Exciter oil check
Exciter oil replacement
V-belt (clutch) check
Leakage of oil fuel
Tightness of fastening Threads
Engine oil check and replenishment
Engine oil replenishment
Air cleaner cleaning
●
●
●
●
●
●
●
●
●
●
These inspection intervals are for operation under normal
conditions. Adjust your inspection intervals based on the number
CAUTION
hours plate compactor is in use, and particular working conditions.
4.2 Exciter
When changing the exciter oil, remove the drain plug located at the bottom-right of the
vibrator, and simply tip the compactor to drain the oil. Note that the oil will drain more
easily while it is hot.
●
●
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!
!
MAINTENANCE
4.3 V-belt and Clutch
4.3.1 Checking the V-belt
After 200 hours of operation, remove the upper belt
cover to check the V-belt tension (Figure 2). Tension is
proper if the belt bends about 10mm when depressed
strongly with finger between shafts. Loose or worn
V-belts reduces power transmission efficiency, causing
weak compaction and reduces the life of the belt itself.
NEVER attempt to check the V-belt with the engine running. Severe
WARNING
4.3.2 Replacing the V-belt
Remove the belt covers. Engage an offset wrench (13mm) or the like to vibrator pulley (lower)
fastening bolt. Engage waste cloth or the like at midway of V-belt on the left side and while
pulling it back strongly, rotate the offset wrench clockwise so that the V-belt will come off.
4.3.3 Checking the Clutch
Check the clutch simultaneously with V-belt checking. With belt removed, check outer
drum of the clutch for seizure and “V” groove for wear or damage with your eyes. Clean
the “V” groove as necessary. Wear of lining or shoe should be checked with running
check. If the shoe is worn, power transmission becomes deficient and slipping will
result.
CAUTION
4.4 Air Cleaner
1. The air filter element should be cleaned because a clogged
air cleaner can cause poor engine starting, lack of power and
shorten engine life substantially.
2. To clean or replace air filter loosen the wing nut on the air
filter housing (Figure 1), remove the cover and take out air
filter cartridge. If only cleaning of the air filter is desired blow
through the air filter cartridge from the inside, moving a jet of
dry compressed air up and down until all dust is removed.
injury can occur if your hand gets caught between the V-belt and the
clutch. Always use safety gloves.
Whenever the compactor’s vibration becomes weak or lost during
normal operation regardless of operation hours, check the V-belt and
clutch immediately.
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!
MAINTENANCE
4.5 Spark Plug
Check and clean spark plugs regularly. A fouled, dirty spark plug may cause hard
starting and poor engine performance. Set spark plug gap to recommended clearance.
Refer to engine manual.
The muffler and engine cylinder become very hot during operation and
WARNING
NOTICE: A loose spark plug can become very hot and may cause engine damage.
4.6 Transporting Trowels
1. Always shut off engine when transporting machine.
2. Make sure lifting device has enough capacity to hold machine (see nameplate on
machine for weight).
3. Use lifting point (a) when lifting machine.
4. Trolley wheel (b) as optional is used for short distance transportation.
remain hot for a while after stopping the engine. Allow engine to cool
before removing spark plug.
a
b
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MAINTENANCE
4.7 Troubleshooting
4.7.1 Machine troubleshooting
SYMPTOM POSSIBLE CAUSES SOLUTION
Engine speed too low? Set engine speed to correct RPM.
Travel speed
too low, and
Clutch slips? Check or replace clutch.
V-belt slips? Adjust or replace V-belt.
vibration is
weak.
Excessive oil in vibration? Drain excess oil and fill to proper level.
Malfunction in vibrator
Correct type of fuel? Replace with correct type of fuel.
Cooling fins dirty? Clean cooling fins.
Governor adjusted correctly? Adjust governor.
Governor spring defective? Replace governor spring.
Fuel flow restricted?
Recoil mechanism clogged
with dust and dirt?
Check entire fuel system for
leaks or clogs.
Clean recoil assembly with soap
and water.
Spiral spring loose? Replace spiral spring.
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WARRANTY
MASTERPAC products are covered by warranty for a period of twelve (12) months from the
date of purchase against defects in material or workmanship provided that:
l The product concerned has been operated and maintained in accordance with the
operating instructions.
l Has not been damaged by accident, misuse or abuse.
l Has not been tampered with or repaired by any unauthorized person.
The owner is responsible for the cost of transportation to and from the authorized repairer
and the unit is at the owners risk while in transit to and from the repairer.
Impact damage is not covered under warranty. Clutches are not covered under any
warranty.
Engines are officially guaranteed by Honda, Robin, Lombardini and Hatz
manufacturers. Please refer to the annex for engine warranty.
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MAINTENANCE RECORD
PREVENTATIVE MAINTENANCE AND ROUTINE SERVICE PLAN
MASTERPAC plate compactor has been assembled with care and will provide years of
service. Preventative maintenance and routine service are essential to the long life of your
plate compactor. After reading through this manual thoroughly, you will find that you can
do some of the regular maintenance yourself. However, when in need of parts or major
service, be sure to see your dealer. For your convenience we have provided this space to
record relevant data about your plate compactor .
Invoice Number: Type of Machine:
Date Purchased: Dealer Name:
Serial Number: Dealer Phone:
REPLACEMENT PARTS USED MAINTENANCE LOG
PART NO. DESCRIPTION QTY COST DATE DATE OPERATION
hereby certifies that the construction equipment specified hereunder / bescheinigt, da. das Bauger.t / certifica
que la máquina de construcción / atteste que le matériel :
Has been sound tested per Directive 2000/14/EC / In Übereinstimmung mit Richtlinie 2000/14/EG bewertet worden ist / Ha sido
ensayado en conformidad con la norma 2000/14/CE / A é ré mis à I’épreuve conforme aux dispositions de la directive 2000/14/CEE:
Conformity Assessment Procedure/
Konformitätsbewertungsverfahren/
Procedimiento para ensayar
conformidad / Procédé pour
I’épreuve de conformité
Name and address of notified
body / Bei folgender
einbezogener Prüfstelle /
Oficina matriculadora /
Organisme agrée
Measured sound power level /
Gemessener Schallleistungspegel
/ Nivel de potencia acú stica
determinado / Niveau de
puissance acoustique fixé
Guaranteed sound power level /
Garantierter Schallleistungspegel /
Nivel de potencia acústica
garantizado / Niveau de puissance
acoustique garanti
Annex VI / Anhang VI /
Anex VI / Annexe VI
AV TECHNOLOGY
AVTECH House, Arkle
Avenue, Stanley Green
Trading Estate Handforth,
Cheshire, SK9 3RW,
United Kingkom.
PC4012/4515/5018/5021 series
with Petrol Engine 102dB
PC4012/4515/5018/5021 series
with Diesel Engine 105dB
PC4012/4515/5018/5021 series
with Petrol Engine 108dB
PC4012/4515/5018/5021 series
with Diesel Engine 108dB
has been produced in accordance with the following standards:/in übereinstimmung mit folgenden Richtlinien
hergestellt worden ist:/ha sido fabricado en conformidad con las siguientes normas: / a été produit
conformément aux dispositions des directives européennes ci-après :