MASTERPAC PMR60H User manual

Professional Compaction
OPERATION
MANUAL
TAMPING RAMMER
PMR60H PMR68H

1
Table of Contents
1. SAFETY INFORMATION.…………………………………………………………………. 2
1.1 Safety Precautions …………………..…………………………………………………… 2
1.2 Operating Safety……………………………………………………………………………3
1.3 Operator Safety while using Internal Combustion Engines…………………..………..4
1.4 Service Safety ……………………………………………………………………..……….5
1.5 Label Locations………………………………………………………………..……………6
1.6 Safety Labels……………………………….…………………………... ……….………7-8
1.7 Operating Labels……………………………….…………………………... …….……….9
2. OPERATION ………………………………………………………….….…………………... 10
2.1 Application…………………………………………………………….…………………………10
2.2 Structure ……….. ……………………………………………….…………….……..…………10
2.3 Before Starting……………………………………………………...………….……….……….10
2.4 To Start …………………………………………………………….………….…………….……11
2.5 Operation………………………………………………………………….…………………12
2.6 To Stop ………………………………………………………………..….………………….12
3. MAINTENANCE ……………………..…………………………………………….……..……. 13
3.1 Periodic Maintenance Schedule………………………………………..….………………13
3.2 Transporting ….………………………………………………………………………………14
3.3 Spark Plug……………………………………………………………………….……………14
3.4 Air Cleaner……………………………………………………………..……….…………….15
3.5 Storage ………………………………………………………………………....…………….15
3.6 Trouble Shooting…………………………………………….………………….….....….15-17
4. TECHNICAL DATA ………………………...………………….…………………..…..…….. 18
WARRANTY ……………….………………….…………….…….……………..……………..….19
MAINTENANCE RECORD ……………………………….…….….………..…..…….……….20
.
EC DECLARATION ……………………………………….………….………….…….…………21

2
SAFETY INFORMATON
1.1 Safety Precautions
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
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.
!
!
DANGER
!
WARNING
!
CAUTION

3
SAFETY INFORMATON
1.2 Operating Safety
Familiarity and proper training are required for the safe operation of equipment!
Equipment operated improperly or by untrained personnel can be dangerous! Read the
operating instructions and familiarize yourself with the location and proper use of all
instruments and controls. Inexperienced operators should receive instruction from
someone familiar with the equipment before being allowed to operate the rammer.
NEVER operate rammer in applications for which it is not intended.
NEVER allow improperly trained personnel to operate rammer.
NEVER touch hot muffler, engine cylinders, or cooling fins. Burns will result.
NEVER use accessories or attachments which are not recommended by
MASTERPAC for rammer. Damage to rammer and/or injury to user may result.
NEVER leave a running machine unattended.
NEVER run machine indoors or in an enclosed area such as a deep trench unless
adequate ventilation is provided. Exhaust gas from the engine contains poisonous
carbon monoxide gas; exposure to carbon monoxide can cause loss of
consciousness and may lead to death.
NEVER tamper with or disable the function of operating controls.
NEVER use choke to stop engine.
NEVER operate the machine in areas where explosions may occur.
ALWAYS remove or disconnect engine spark plug before servicing rammer, to
avoid accidental start-up.
ALWAYS read, understand, and follow procedures in Operation Manual before
attempting to operate equipment.
ALWAYS be sure that all other persons are at a safe distance from the rammer. Stop
the machine if people step into the working area of the machine.
ALWAYS be sure operator is familiar with proper safety precautions and operation
techniques before using rammer.
ALWAYS wear protective clothing when operating rammer. Wear goggles or safety
glasses, hearing protection, and safety shoes.
ALWAYS keep hands, feet, and loose clothing away from moving parts of rammer.
ALWAYS use common sense and caution when operating rammer.
ALWAYS be sure rammer will not tip over, roll slide, or fall when not being operated.
ALWAYS turn engine OFF when rammer is not being operated.
ALWAYS guide the rammer in such a way that the operator is not squeezed
between the rammer and solid objects. Special care is required when working on
uneven ground or when compacting coarse material. Make sure to stand firmly when
operating the machine under such conditions.
ALWAYS operate the rammer in such a way that there is no danger of it turning over
or falling in, when working near the edges of breaks, pits, slopes, trenches and
platforms.

4
SAFETY INFORMATON
1.3 Operator Safety while using Internal Combustion Engines
DO NOT smoke when refueling the engine or during any other fuel handling
operation.
DO NOT refuel a hot or running engine.
DO NOT refuel the engine near an open flame.
DO NOT spill fuel when refueling the engine.
DO NOT smoke while operating rammer.
DO NOT operate rammer near open flames.
ALWAYS refill fuel tank in well-ventilated area.
ALWAYS replace fuel tank cap after refueling.
ALWAYS check fuel lines, fuel cap, and fuel tank for leaks and cracks before
starting engine. Do not run machine if fuel leaks are present, or fuel cap or fuel
lines are loose.
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.
NEVER operate this equipment in an explosive atmosphere.
NEVER operate any gas powered equipment in a poorly ventilated or enclosed
area.
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.
Avoid prolonged breathing of exhaust gases.
Avoid contact with hot exhaust systems and engine parts.
Allow engine to cool before performing any repairs or service.
ALWAYS transport and handle fuel only when contained in approved safety
containers.
ALWAYS keep the area around the muffler free of debris such as leaves, paper,
cartons, etc. Ahot muffler could ignite the debris and start a fire.

5
SAFETY INFORMATION
1.4 Service Safety
Poorly maintained equipment can become a safety hazard! In order for the equipment to
operate safely and properly over a long period of time, periodic maintenance and
occasional repairs are necessary.
DO NOT attempt to clean or service rammer while it is running.
DO NOT operate rammer with safety devices or guards removed or not in working
order.
DO NOT operate rammer without air cleaner.
DO NOT remove air cleaner paper element, precleaner, or air cleaner cover while
operating rammer.
DO NOT alter engine speeds. Run engine only at speeds specified in Technical Data
Section.
ALWAYS replace safety devices and guards after repairs and maintenance.
ALWAYS keep area around muffler free of debris in order to reduce to chance of
an accidental fire.
ALWAYS do Periodic Maintenance as recommended in Operation Manual.
ALWAYS clean debris from engine cooling fins.
ALWAYS replace worn or damaged components with spare parts designed and
recommended by MASTERPAC for servicing this rammer.

6
SAFETY INFORMATION
1.5 Label Locations

7
SAFETY INFORMATION
1.6 Safety Labels
MASTERPAC machines use international pictorial labels where needed. These labels are
described below:
Label
Meaning
This model-in label contains important safety and
operating information. If it becomes illegible, the cover
must be replaced. Reger to the Parts Manual for
ordering information.
DANGER!
Engines emit carbon monoxide; operate only in
well-ventilate 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.
CAUTION！
Lifting point.
CAUTION!
Use only clean, filtered gasoline fuel.
WARNING!
Hot surface!

8
SAFETY INFORMATION
Label
Meaning
CAUTION!
For optimal control, performance, and minimal
hand/arm vibration, grasp handle as shown.
WARNING!
Serious injury if struck by compressed spring or
cover. If the spring system cover is removed
improperly, the springs can eject.
Guaranteed sound power level in dB(A).
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.

9
SAFETY INFORMATION
1.7 Operating Labels
MASTERPAC machines use international pictorial labels where needed. These labels are
described below:
Start the engine:
①Turn the engine switch to the ON position
②Close the choke.
③Pull the rewind starter.
④Open the choke.
Stop the engine:
Turn the engine switch to OFF position.
Fuel valve:
Closed
Open
Engine stop button:
Press to stop engine.
Choke:
O: Open
I: Closed
NOTICE!
Throttle control lever:
Turtle = Idle or Slow
Rabbit = Full or Fast

10
OPERATION
2 Operation
2.1 Application
Rammers are designed to compact loose soils and gravel to prevent settling and
to provide a firm, solid base for the placement of footings, concrete slabs,
foundations, gas piping works, water pipe works and cable backfill works, etc.
Please do not use in such as following cases. It may cause damage
because machine is likely to be unbalanced.
Pile foundation
Hard soil excessively compacted over normal condition
Steep bank slope
Tamping Rammer is to be used for compacting cohesive clay, gravels, and
patching work on asphalt, etc.
2.2 Structure
The upper part is made up of Power source, Clutch, Connecting Rod and Operating
Handle, Fuel Tank that connected via Shock Absorbing Rubber to body. Bottom end is
made up of Spring Cylinder (Sliding part), Foot Plate that ramps body, Foot and
Bellows that covers sliding part.
2.3 Before Starting
This machine is of oil bath lubrication system.
Check the oil level through a window at rear end of the foot. Replenish oil if oil is not
visible at the window. For lubrication, use automobile engine oil of 10W-30 SE, SF
or better grade. Capacity is 830cc.
Fill the fuel tank with regular gasoline (unleaded). Simultaneously, check engine oil
and make it a habit to replenish on the earlier side. Low lubrication oil level may
result in engine seizure due to consumption during operation. Nevertheless, oil
level should be checked prior to start up without fail. For lubrication, use automobile
engine oil of 10W-30 SE, SF or better grade. See Engine Operating Manual for
further detail.
Check every bolt, nut or screwed area for tightness. Loosened due to vibration
may result in unexpectedly serious trouble. Be sure to tighten any screwed
area.
Remove dirt and dust. Particularly clean the vicinity of recoil starter and foot.
!
WARNING

11
OPERATION
2.4To Start
1. Open the fuel shut-off valve by moving the fuel cock level to the open position.
2. Set the engine ON/OFF switch to the “ON” position.
3. Grip the recoil starter handle and pull it until you feel slight resistance. Then pull
sharply and quickly. Return the recoil starter handle to the starter case before
releasing.
4. Grip the recoil starter handle and pull it a little to feel a slight resistance. Then pull it
powerfully from there. To release the handle do not release it at the position where it
has been pulled to, but release it after returning closely to the starter case.
5. If the engine has started, while listening to explosion sounds, return the choke lever
slowly to full-open position. Be sure to perform a warm-up run for the period 3 to 5
minutes at low speed, while paying careful attention to gas leakage or abnormal
sound.
6. If it is difficult to start the engine by repeatedly pulling the starter rope, remove
ignition plug and check the sparking performance. If the plug is wet due to excessive
fuel intake or soiled, replace the coil or clean sufficiently to its internals. With the
ignition plug removed, pull the recoil starter handle 2-3 times to discharge excessive
blended gas.

12
OPERATION
2.5 Operation
1. Turning the choke level to open the choke. Running the engine for 5 minutes at low
speed to warm the engine.
2. Move the throttle level quickly to the “FULL OPEN”position. DO NOT move the
throttle level slowly as this may cause damage to the clutch or spring.
Make sure that the throttle lever is moved to the FULL OPEN position.
Operating the rammer at less than full speeds can result in damage to
the clutch springs or foot.
3. After starting to tamping action, adjusts the jumping motion to suit particular soil
condition by lightly controlling the throttle lever. When the engine speed falls
between the set values shown on the engine, your work can be carried out at the
best efficiently. Increasing the engine speed unnecessarily, does not cause the
compaction force to increase. On the contrary, a resultant resonance causes the
compaction force to decrease, damaging the machine.
4. Under cold weather, the oil in the machine being viscous, resistance at reciprocating
part is greater causing the tamping rammer to perform somewhat irregular
movement. Therefore, it is recommended to perform warm-up run while moving the
throttle lever repeatedly between ON and OFF positions, before entering the work.
5. Soil contacting surface of the foot is lined with heat-treated metal sheet for extra
strength. However, for compacting cobblestone, use the filling-up soil for example
so that the foot hits the soil uniformly.
6. The tamping rammer has been designed to advance while jumping. For quicker
advance, erect the machine by pushing its handle down slightly so that flat surface
of the foot at its rear-end contacts the ground.
7. To stop the tamping action, move throttle lever quickly from the FULLOPEN to IDLE
position.
2.6 To Stop
2.6.1 Normal shutdown
1. With the throttle lever closed from ON to OFF, run the engine for 3-5 minutes at low
speed, and after temperature is lowered, turn the switch to the “OFF”position.
2. Close the fuel shut-off valve by moving the fuel cock lever to the CLOSED position.
2.6.2 Emergency shutdown
Move the throttle lever quickly to the IDLE position, and turn the engine ON/OFF switch
to the OFF position.
!
CAUTION

13
MAINTENANCE
3 MAINTENANCE
3.1 Periodic Maintenance Schedule
The chart below lists basic maintenance. Refer to engine manufacturer’s Operator’s
Manual for additional information on engine maintenance. A copy of the engine
Operator’s Manual was supplied with the machine when it was shipped.
Daily
Before
Starting
After
First 5
hours
Every
Week or
25 hours
Every
month or
100 hours
Every 3
months or
300 hours
Check fuel level.
●
Check oil level of machine.
●
Check fuel line and fittings for
cracks or leaks.
●
Tighten ramming shoe hardware.
●
●
Check and tighten engine cylinder
screws.
●
●
Check and tighten external
hardware.
●
●
Clean engine cooling fins.
●
Clean and check spark plug gap.
●
Replace spark plug.
●
Clean recoil starter.
●
Change ramming system oil. *
●
Clean engine muffler and exhaust
port.
●
* Change ramming system oil after first 50 hours of operation.
Note: If engine performance is poor, check, clean, and replace air filter elements as needed.

14
MAINTENANCE
3.2 Transporting
1. Shutdown engine for transportation.
2. For transportation, tighten fuel tank cap securely and close fuel cock to prevent fuel
from spilling.
3. Drain fuel for transportation over long distance or bad road.
4. Secure machine firmly to prevent it from moving or tipping.
5. Rammer should be transported in such position as it is placed on level ground. In case
of it must be laid down for transportation, drain fuel tank as well as carburetor and
make sure that oil plug is tightened securely, then tie it to the vehicle at points (a) and
(b).
6. Direction to lay down the rammer, must be such that air cleaner comes to top.After
laying it, make sure that there is no leak of fuel from cap (c).
7. Make sure lifting device has enough capacity to hold machine (see identification plate
on machine for weight). Use central lifting point (a) when lifting machine.
8. Use trolley kit (supplied as optional) for short distance transportation.
3.3 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
remain hot for a while after stopping the engine. Allow engine to cool
before removing spark plug.
NOTICE: A loose spark plug can become very hot and may cause engine damage.
!
WARNING
a
b
c

15
MAINTENANCE
3.4 Air Cleaner
Maintaining a clean engine will extend engine life. Keep air filter clean at all times.
Clean air filter using the recommended solvent daily. See engine manual for proper
cleaning procedure. Let the filter dry before reinstalling.
NEVER use gasoline or other types of low flash point solvents for
cleaning the air cleaner. A fire or explosion could result.
3.5 Storage
Rammer should be stored in such position as it is placed on level, after engine and
machine have been cooled down. Be sure to secure the rammer as necessary to
avoid falling down. If the rammer has to be laid down inevitably, tighten fuel tank cap
and engine oil plug securely and wait until engine and machine are cooled down.After
laying it down, make sure that there is no leak of fuel or oil. (If fuel leaks, drain the
tank)
3.5.1 Long-Term Storage
Drain fuel from fuel tank, fuel line and carburetor.
Remove spark plug and pour a few drops of motor oil into cylinder. Crank engine
3 to 4 times so that oil reaches all internal parts.
Clean exterior with a cloth soaked in clean oil.
Store unit covered with plastic sheet in moisture free and dust free location out of
direct sunlight.
3.6 Troubleshooting
3.6.1 Rammer Troubleshooting
SYMPTOM
POSSIBLE PROBLEM
SOLUTION
Engine rotates
but amplitude
not uniform or
does not strike
Operating speed of throttle
lever is incorrectly set?
Set throttle lever to correct position.
Oil in excess?
Drain excess oil. Bring to correct level.
Clutch slips?
Replace or adjust clutch.
Spring Failure?
Replace spiral spring.
Speed of engine improper?
Adjust engine speed to correct operating
RPM setting.
!
WARNING

16
MAINTENANCE
3.6.2 Engine Troubleshooting
SYMPTOM
POSSIBLE CAUSE
SOLUTION
Difficult to start
Fuel is available but
spark plug will not
ignite.(Power
available at high
tension code.)
Ignition plug being bridging?
Check ignition system.
Carbon deposit at ignition?
Clean or replace
ignition.
Short circuit due to deficient
insulator?
Replace insulators.
Improper spark gap?
Set spark plug gap to
the correct gap.
fuel is available but
spark plug will not
ignite.(Power NOT
available at high
tension code.)
Short circuit at stop switch?
Check stop switch
circuit. Replace stop
switch if defective.
Ignition coil defective?
Replace ignition coil.
Fuel is available and
spark plug ignites
(compression
normal).
Muffler clogged with carbon
deposits?
Clean or replace
muffler.
Mixed fuel quality is inadequate?
Check fuel to oil
mixture.
Fuel in use inadequate (water,
dust)?
Flush fuel system and
replace with fresh fuel.
Air cleaner clogged?
Clean or replac air
cleaner.
Fuel is available and
spark plug ignites
(compression
normal).
Defective cylinder head gasket?
Tighten cylinder head
bolts or replace head
gasket.
Cylinder worn?
Replace cylinder.
Spark plug loose?
Tighten spark plug.

17
MAINTENANCE
SYMPTOM
POSSIBLE CAUSE
SOLUTION
Operation not satisfactory
Not enough power
available
(compression
normal, no
missfiring)
Air cleaner clogged?
Clean or replace air cleaner.
Air in fuel line?
Bleed (remove air) from fuel
line.
Fuel level in carburetor float
chamber improper?
Adjust carburetor float.
Carbon deposit in cylinder?
Clean or replace cylinder.
Not enough power
available
(compression
normal, no
missfiring)
Ignition coil defective?
Flush fuel system and
replace with fresh fuel.
Ignition plug often shorts?
Replace ignition wires, clean
ignition.
Fuel in use inadequate (water,
dust)?
Flush fuel system and
replace with fresh fuel.
Engine overheats.
Mixed fuel quality is inadequate?
Check fuel to oil mixture.
Excessive carbon deposition in
combustion chamber?
Clean or replace crankcase.
Exhaust or muffler clogged with
carbon?
Clean or replace muffler.
Spark plug heat value incorrect?
Replace spark plug with
correct type spark plug.
Rotational speed
fluctuates.
Governor adjustment improper?
Adjust governor to correct
lever.
Gvoernor spring defective?
Clean or replace ignition.
Fuel flow erractic?
Check fuel line.
Air taken in through suction line?
Check suction line.
Recoil starter not
working properly.
Dust in rotating part?
Clean recoil starter
assembly.
Spiral spring failure?
Replace spiral spring.

18
TECHNICAL DATA
4. TECHNICAL DATA
Model
PMR60H
PMR68H
Engine type
Honda GX100
Honda GX100
Engine speed operating rpm
3800±100
3800±100
Power kw (hp)
2.2 (3.0)
2.2 (3.0)
Weight kg (lb)
60 (132)
68 (150)
Impact Force kN
10.7
12.8
Jumping stroke
mm (in)
50-85 (2-3.4)
40-85 (1.6-3.4)
Fuel tank Capacity L
3.5
3.5
Shoe Size
mm (in)
265x338 (10.4x13.3)
285x340 (11.2x13.4)
Ramming System Lubrication
0.8L, CD10W-30
Working Size mm:
Model
A
B
C
D
E
PMR60H
1055
345
685
265
338
PMR68H
1055
410
705
285
340
Sound Specification (According to 2000/14/EC)
Measured sound Power level
105 dB(A)
Guaranteed sound power level
106 dB(A)
Sound power level limit
108 dB(A)
Hand-Arm vibration Specification (According to ISO 5394, EN 1033 and EN500-4):
6.8m/s2

19
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:
The product concerned has been operated and maintained in accordance with the
operating instructions.
Has not been damaged by accident, misuse or abuse.
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
manufacturer. Please refer to the annex for engine warranty.