MBW GPR78H, GPR78D Service Manual

OPERATOR’S SAFETY

AND SERVICE MANUAL

GPR78

This manual covers the following serial numbers
and higher for each model listed:

GPR78...........................................7800110

VIBRATORY PLATES

MBW, Inc.

250 Hartford Rd • PO Box 440
Slinger, WI 53086-0440
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Website: www.mbw.com

MBW (UK) Ltd.

Units 2&3 CochraneStreet
Bolton BL3 6BN
England, UK
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]

MBW FRANCE S.A.R.L.

Z.A. d’Outreville
11 Rue Jean Baptiste
Néron,
60540 BORNEL
France
Email: [e-mail]
Phone:[phone]

L19604 / 04.14.D

©MBW, Inc. 2004

Printed in the USA

TABLE OF CONTENTS

Safety Information . . . . . . . . . . . . . . . . . . . . . . 1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Decals: GPR78H (Decal Set #16031) . . . . . . . 3

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 4

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Before Starting & Operating . . . . . . . . . . . . . . . . . . . . 5

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Starting Gasoline Engine . . . . . . . . . . . . . . . . . . . . . . 5

Starting Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . 5

Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Stopping Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Lifting/Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . 7

Fluid Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Belt Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Checking Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . 8

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Main Disassembly Procedure (Diesel Engine) . . . . . . 9

Main Disassembly Procedure (Gasoline Engine). . . 10

Exciter Oil Change Procedure . . . . . . . . . . . . . . . . . 10

Lower Hydraulic Seal Replacement . . . . . . . . . . . . . 10

Bleeding And Adjustment of Hydraulic Controls. . . . 11

Base plate Disassembly Procedure . . . . . . . . . . . . . 12

Handle Disassembly Procedure . . . . . . . . . . . . . . . . 13

Control Head Disassembly Procedure . . . . . . . . . . . 13

Base plate Assembly Procedure . . . . . . . . . . . . . . . 14

Control Head Assembly Procedure . . . . . . . . . . . . . 16

Handle Assembly Procedure . . . . . . . . . . . . . . . . . . 17

Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Parts Replacement Cycles and Tolerances . . . . . . . 19

Replacement Parts . . . . . . . . . . . . . . . . . . . . . 20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Base Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . 26

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Control Head Assembly . . . . . . . . . . . . . . . . . . . . . . 28

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Gasoline Engine Assembly . . . . . . . . . . . . . . . . . . . 30

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Diesel Engine Assembly. . . . . . . . . . . . . . . . . . . . . . 32

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

CALIFORNIA PROPOSITION 65 WARNING

WARNING

Engine exhaust and some of its constituents are

known in the state of California to cause cancer, birth

defects, and other reproductive harm.

SAFETY INFORMATION

WARNING

CAUTION

Introduction

This Safety Alert Symbol is used to call attention
to items or operations which may be dangerous
to those operating or working with this

equipment. The symbol can be found
throughout this manual and on the unit. Please read these
warnings and cautions, along with all decals, carefully
before attempting to operate the unit. Make sure every
individual who operates or works with this equipment is
familiar with all safety precautions.

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.

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: An internal

combustion engine discharges carbon
monoxide, a poisonous, odorless, invisible
gas. Death or serious illness may result if
inhaled. Operate only in an area with proper
ventilation. NEVER OPERATE IN A
CONFINED AREA!

DANGEROUS FUELS: Use extreme caution
when storing, handling and using fuels, as
they are highly volatile and explosive in vapor
state. Do not add fuel while engine is running.
Stop and cool the engine before adding fuel.
DO NOT SMOKE!

SAFETY GUARDS: It is the owner's
responsibility to ensure that all guards and
shields are in place and in working order.

IGNITION SYSTEMS: 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.

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.

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 repainting the unit, replace all decals. Decals
are available from authorized MBW distributors. Order the
decal set listed on the following page(s).

- 1 -

',(6(/02'(/

ENGINE

OIL DRAIN

15845

1. Check engine oil level.

2. Check fuel level.

3. Set engine speed control in the middle position.

4. Move decompression lever (if equipped) to the up
position. (Located on top of the engine)

5. Use key (if equipped) or starting handle to start
engine (Refer to engine instruction book for proper
“Manual Starting” procedure.)

6. After starting return engine speed control to the idle
position and allow engine to reach operation
temperature.

7. During operation run engine at full throttle, when
excessive kickback is noticed maximum compaction
has been reached.

8. To stop, return throttle to the idle position and allow
engine to idle for one minute then move control to
stop position.

DIESEL PLATE

OPERATING INSTRUCTIONS

15832

CAUTION

Machine may fall and cause

injury or damage if lifted
improperly.

15865

Lift only by lift hook

Weight~ #570 (259kg)








15848

WWW.MBW.COM

15874

M-B-W

FORWARD

REVERSE

14665

IDLE S TOP RU N

THROTTLE

19493

HYDRAULIC OIL

15844

U.S. PATENT 7,165,469

19326 HYDRAULIC PLATE

CAUTION

Read the Operation Instructions before operating this
piece of equipment.
Keep unauthorized and untrained people away from this
equipment.
ROTATING & MOVING PARTS! Make sure all guards
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 se rious bodily injury.

15867

15848

WWW.MBW.COM

15874

M-B-W

#15865

#19493

#15844

#19326

#14665

#13484

#12500

#15867

#15845

(BOTH SIDES)

#15848

#15846

#15832

#15874

Safety Decals: GPR78S (Decal Set #16031)

#15848

#15846

#15874

- 2 -

*$62/,1(02'(/

IDLE RUN

THROTTLE

19492

19791

WARNING

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
RELATING TO FIRE PREVENTION








CAUTION

Read the Operation Instructions before operating this
piece of equipment.
Keep unauthorized and untrained people away from this
equipment.
ROTATING & MOVING PARTS! Make sure all guards
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 se rious bodily injury.

15867

1. Check engine oil level.

2. Open fuel valve.

3. Choke engine. A warm engine may not need to be
choked.

4. Open throttle part way.

5. Pull starter rope.

6. After starting: open choke, return throttle to idle
position.

7. During operation, when excessive kickback is
noticed, maximum compaction has been reached.

8. To stop, return throttle to the idle p osition, use
engine stop switch, close fuel valve.

GASOLINE PLATE

OPERATING INSTRUCTIONS

15866

15848

WWW.MBW.COM

15874

M-B-W

15848

WWW.MBW.COM

15874

M-B-W

ENGINE

OIL DRAIN

15845

CAUTION

Machine may fall and cause

injury or damage if lifted
improperly.

16025

Lift only by lift hook

Weight~ #625 (284kg)

#15865

U.S. PATENT 7,165,469

19326 HYDRAULIC PLATE

FORWARD

REVERSE

14665

HYDRAULIC OIL

15844

UNLEADED GASOLINE

13481

#12500

#15845

#15846

#13481

(ON FUEL TANK)

#19492

(BOTH SIDES)

#14665

#15844

#15846

#19326

#15867

#15866

#13484

#15848

Safety Decals: GPR78H (Decal Set #16031)

- 3 -

#15874

#15846

#15848

#15874

SPECIFICATIONS

GRP78H GPR78D

CENTRIFUGAL FORCE 7875 lbf (35 kN) 7875 lbf (35 kN)

EXCITER (VPM) 4080 vpm 4080 vpm

TRAVEL SPEED 82 ft./min. (25 m/min.) 82 ft./min. (25 m/min.)

COMPACTION DEPTH 22 in. (56 cm) 22 in. (56 cm)

WIDTH x LENGTH 17.7 X 32.3 in. (45 X 82 cm) 17.7 X 32.3 in. (45 X 82 cm)

OPERATING WEIGHT 522 lb ( 237 kg) 567 lb ( 257 kg)

ENGINE Honda GX270 16.5 in.Š (270 cmŠ) Hatz 1B30 21.2 in.Š (347 cmŠ)

FUEL Gasoline Diesel

ENGINE SPEED 3600 rpm 3600 rpm

STARTER SYSTEM Recoil Recoil

PLATE EXTENSIONS 3 in. (7.6 cm) 40lb (18 kg) 3 in. (7.6 cm) 40lb (18 kg)

Specifications subject to change without notice.

No universal method or formula has been accepted for determining “Compaction Force”. All manufactures employ their
own method or formula.

- 4 -

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.

The MBW Reversible Plate Compactor is intended to
compact various soil types. Recommended soil types
include granular soils, gravel/sand mixtures, and semi­granular 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 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 & Operating

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 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.

diesel fuel or unleaded gasoline dependent on engine
type. (See Engine “Owner’s Manual”)

• FUEL FILTER - If clogged or damaged, replace.

Engine

Refer to the engine manual for location of all controls and
features.

Starting Gasoline Engine

1. Open fuel valve.

2. Turn engine switch to “ON” position.

3. Set throttle to idle position.

4. Choke engine if necessary (you may not need to
choke a warm engine).

5. Pull starter rope repeatedly until engine starts.

6. Move choke lever to off or open position.

7. Allow engine to warm up for one or two minutes.

Starting Diesel Engine

For detailed instructions refer to the engine Manual.

1. When starting the engine, the throttle lever on the
handle must be in the idle position.

2. The engine has an automatic decompression
system, however it is recommended to slowly pull the
starter rope until you feel a slight resistance. Let the
starter rope recoil completely and pull the starter rope
quickly.

3. Let the engine warm up in the idle position for one or
two minutes.

• Know how to STOP the machine in case of an
emergency.

• Make sure hands, feet, and clothing are at a safe
distance from any moving parts.

• OIL LEVEL - Check the oil level in the engine. For more
information see “Lubrication” under the respective
engine’s “Owners Manual” or the Maintenance section of
this manual.

• AIR CLEANER - Check to ensure element is in good
condition and properly installed.

• FUEL SUPPLY - The engines on MBW Inc. compaction
equipment require an automotive grade of clean, fresh,

Operating

1. After the engine warms up, fully open throttle.

2. The compactor will begin vibrating and moving in a
forward direction. Never leave compactor idling

unattended.

3. The MBW Reversible Plate Compactor is designed to
shift into forward automaticly when control lever is
released. 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.

- 5 -

LIFT & SECURE HERE

Stopping Engine

WARNING

1. To stop the compactor from traveling forward, return
the engine throttle to idle position.

2. Whenever possible, it is recommended to let the
engine idle for one or two minutes before stopping.

3. Gas engines: Turn the switch on the engine to
“STOP” position.
Diesel engines: Move the throttle control to the
“STOP” position.

4. Turn off the fuel valve where applicable.

Lifting/Transporting

1. Lift unit by center lifting eye on roll cage.

2. The unit must be transported in the upright position.
DO NOT lay machine on its side.

3. Secure or tiedown unit using lift eye or roll cage when
transporting.

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.

- 6 -

MAINTENANCE

WARNING

CAUTION

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.

Always verify fluid levels and check for leaks after
changing fluids.

Do not drain oil onto ground, into open streams,
or down sewage drains.

Maintenance Schedule

SYSTEM MAINTENANCE

Engine Refer to engine operator/owner manual X

Clean cooling fins XX

Belt Check for wear and retighten X

Exciter Check for oil leaks X

Change oil XX

Tighten Bolts

Hydraulics Check level and refill X

Hardware

Check and tighten as needed

1

1

EACH

USE

EVERY 50

HOURS

XX

XX

EVERY 100

HOURS

EVERY 250

HOURS

YEARLY

Shockmounts Check for cracks or tears XX

1. Check all hardware after the first 5 hours of use, then follow the maintenance schedule.

Fluid Levels

SYSTEM FLUID VOLUME RECOMMENDED OIL

Exciter 24 oz.

Hydraulic Oil 4 oz. Chevron AW ISO or Rykon 32

Engine Refer to engine operator/owner manual

1. MBW #01058---- 6-Pack (8 oz. bottles)
MBW #17320---- 1 quart (32 oz.)

Engine Maintenance

Refer to the engine owner’s manual for maintenance
intervals and procedures.

®

MBW Ground Pounder

3. The engine operating speed should be set to 3600
RPM.

4. The engine idle speed must not exceed 1800 RPM. If
the idle speed is greater than 1800 RPM the clutch
may not disengage.

Exciter Oil

1

Engine Speed

1. Engine speed is factory set according to the speeds
listed in the Specifications section of this manual. Do
not tamper with the governor setting. The governor
establishes safe operating limits which must not be
exceeded.

2. Refer to the engine Owner’s Manual for procedure on
setting operating and idle speeds.

Belt Adjustment

If any belt stretch develops follow these steps:

Refer to MAIN ASSEMBLY, page 22.

- 7 -

FLUID LEVEL TO BE UP
TO BOTTOM EDGE OF
INSIDE HOLE.

1. Remove the belt guard, refer to engine assembly
pages.

2. Loosen (do not remove) the four hex head
capscrews (#28) securing the engine deck to the
base plate.

3. Tighten the belt by lifting the engine deck to provide
3/8 - 3/4 inch of “play” on one side of the belt. Be

sure to keep the engine deck level with the base
plate when adjusting the belt.

4. Retighten the four hex head capscrews (#28).

5. Reinstall the belt guard.

Checking Hydraulic Fluid

1. To avoid contaminating the hydraulic oil clean all dirt
& debris from around the fill plug on handle.

2. Remove fill plug. With handle in operating position, oil
level to be at bottom edge of inside hole as shown.

- 8 -

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

SIZE GRADE 2 GRADE 5 GRADE 8

1/4-20 49 in

1/4-28 56 in
5/16-18 8 ft
5/16-24 9 ft

3/8-16 15 ft

3/8-24 17 ft
7/16-14 24 ft
7/16-20 27 ft

1/2-13 37 ft

1/2-20 41 ft
9/16-12 53 ft

5/8-11 73 ft

5/8-18 83 ft

3/4-16 144 ft

1-8 188 ft

1-14 210 ft

1-1/2-6 652 ft

M 6 3 ft
M 8 6 ft

M 10 10 ft

•lbs 76 in•lbs 9 ft•lbs

•lbs 87 in•lbs 10 ft•lbs

•lbs 13 ft•lbs 18 ft•lbs

•lbs 14 ft•lbs 20 ft•lbs

•lbs 23 ft•lbs 33 ft•lbs

•lbs 26 ft•lbs 37 ft•lbs

•lbs 37 ft•lbs 52 ft•lbs

•lbs 41 ft•lbs 58 ft•lbs

•lbs 57 ft•lbs 80 ft•lbs

•lbs 64 ft•lbs 90 ft•lbs

•lbs 82 ft•lbs 115 ft•lbs

•lbs 112 ft•lbs 159 ft•lbs

•lbs 112 ft•lbs 180 ft•lbs

•lbs 200 ft•lbs 315 ft•lbs

•lbs 483 ft•lbs 682 ft•lbs

•lbs 541 ft•lbs 764 ft•lbs

•lbs 1462 ft•lbs 2371 ft•lbs

•lbs 4 ft•lbs 7 ft•lbs

•lbs 10 ft•lbs 18 ft•lbs

•lbs 20 ft•lbs 30 ft•lbs

CONVERSIONS

•lbs x 0.083 = ft•lbs

in

•lbs x 12 = in•lbs

ft

•lbs x 0.1383 = kg•m

ft

•lbs x 1.3558 = N•m

ft

Service Tools

Part No. Description

17320 Ground Pounder® Exciter Oil

016129 Rubber Test Mat

16031 Decal Set

Main Disassembly Procedure (Diesel Engine)

Refer to Main Assembly, page 22 for disassembly.

1. Clean all visible debris from the machine before
servicing.

2. Remove the four hex head capscrews (#28) securing
the engine deck (#19) to the base plate (#4). Use
caution as the engine deck will drop down.

Refer to Diesel Engine Assembly, page 32 Sections of

this manual for belt guard & belt removal.

3. Remove the four socket head capscrews (#15)
securing the belt guard (5) to the mount plate (#11) on
the engine (#8) and remove the belt guard.

4. Slide the belt (#3) off the clutch (#10).

5. Remove the two flange screws (#23) securing the
bellows retainer (#13), and remove the retainer.

6. Push the lip of the bellows (#3) through the hole in the
engine deck.

7. Disconnect the hydraulic line (#20) 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. Remove tie strap holding
hydraulic hose & throttle cable together. Be careful

to use a drain pan to catch the hydraulic oil.

8. Use the main lift hook on the roll cage (#5) to
separate the engine deck from the base plate. Be

careful to guide the hydraulic line through the
handle assembly and engine deck as the
subassemblies are separated to prevent damage
to components. If further disassembly of the engine

deck is required proceed to step 9. If base plate
service is required refer to the Base plate
Disassembly Procedure section of this manual.

9. Disconnect the throttle cable (#21) from the engine.

10. Remove the handle assembly by removing the four
flange screws (#26) securing the handle mount (#6)
to the engine deck.

11. Remove the four hex head capscrews (#26) securing
the roll cage to the engine deck and remove the roll
cage.

- 9 -