MASTERPAC PCR6040 Series User manual

1
TableofContents
1. SAFETYINFORMATION
1.1SafetyPrecautions .. ..2
1.2OperatingSafety .. ...3-4
1.3OperatorSafetywhileusing InternalCombustion Engines ... 4
1.4LabelLocations ... 5
1.5SafetyandOperatingLabels ..6-7
2. OPERATION
2.1Controls ...8
2.2OperatingPrinciple 9
2.3DeliveryChecks .9
2.4BeforeStarting .. ..9
2.5ToStart .. 10-11
2.6ToStop .. .. .. 11
2.7Application ..11
2.8 Operation ..12
2.9Operation-Driving .12
2.10Operationon Slop .12
3. MAITENANCE
3.1 PeriodicMaintenanceSchedule .. 13
3.2ExciterOil ... .. .. 14
3.3V-beltand clutch .. ..14
3.4AirCleaner ... .15
3.5SparkPlug .. .15
3.6Transport .. .. .15
4.7TroubleShooting .. .. . .16-18
4.TECHNICALDATA ... .. ..19-20
WARRANTY ... .....21
MAINTENANCERECORD .. .... .22
ECDECLARATION .. ....23

2
SAFETYINFORMATON
1. SAFETYINFORMATION
1.1SafetyPrecautions
Beforeoperating themachine,readboththemanualandtheenginemanual
carefullytobecomefamiliarwiththelocation and properuseofall controls.Do
notallowuntrainedorunauthorizedpersonnel,especiallychildren,tooperate
themachine. Useonlythepartsauthorizedbythefactoryforservice.
ThismanualcontainsDANGER,WARNING,CAUTIONcallouts
whichmustbefollowed toreducethe possibilityofpersonalinjury,
damagetotheequipment, orimproperservice.
Thisisthesafetyalertsymbol.Itisusedtoalertyou topotential
personalinjuryhazards. Obeyall safetymessagesthatfollowthis
symboltoavoidpossibleinjuryordeath.
DANGERindicatesahazardoussituationwhich,ifnotavoided,
will result indeathorseriousinjury.
WARNINGindicatesahazardoussituationwhich,ifnotavoided,
couldresult indeathorseriousinjury.
CAUTIONindicatesahazardoussituationwhich,ifnotavoided,
couldresult inminorormoderateinjury.
!
DANGER
!
WARNING
!
CAUTION
!

3
SAFETYINFORMATON
1.2OperatingSafety
lDO NOTmodifythemachine withoutthepriorconsentofthe manufacturer.We
don’t assumeresponsibilityforanyaccident duetoequipment modification.
lNEVERoperatethemachineinpurposeforwhichit isnot intended.
lSlip/Trip/Fall isamajorcauseofseriousinjuryordeath. Bewareof unevenor
slipperyworksurface. Makesureof afirm standwhenoperatingundersuch
condition.
lEspeciallycarewhenworkinginthe vicinityofunprotectedholesorexcavations.
lNEVERallowanypersontooperatethe machinewithoutadequateinstruction.
lENSUREall operatorsread,understandandfollowtheoperationinstructions.
lSeriousinjurycouldresult fromimproperorcareless useof the machine.
lPlatecompactorareheavy unitsandshouldbepositionedbytwopeopleof
appropriatestrength.Using theliftinghandleprovidedwiththe machine,
accordingtothecorrect lifting techniques.
lPlateCompactormayonlybeusedforcompactionjobs.
lDO NOToperatethe machine unless all protectiveguardsareinplace.
lENSUREthatthe engineswitchisinOFF position andthe sparkplugignition
leadisdisconnectedbeforeremovingtheguardsormakingadjustments.
lENSUREboththe machineand theoperatorarestablebysettinguponlevel
terrainandthemachinewill nottipover,slideoffall whileinoperation or
unattended.
lDO NOTleavethemachineinoperationwhileit isunattended.
lDONOTpull the machinebackwardwithtransportationwheels,itonlycouldbe
pushedforward.
lENSUREthatthe soil orsubsoil tobecompactedhasaenoughload carrying
capacity.
lENSUREthattheareatobe compacteddoesnotcontainany “live”electrical
cables,gas,waterorcommunication serviceswhichmaybedamagedbythe
actionof vibration.
lExposuretovibration orrepetitiveworkactionsmaybeharmfultohandsand
arms.
lNEVERstandon themachinewhileit isoperating.
lBecarefulandDO NOTcomeincontact withthe mufflerwhen the engineishot,
it cancausesevereburns.
lENSUREthattherepairstotheengineandmachine arecarriedoutby
competentpersonnel.
lDONOTusethemachinenearflammablematerialorinexplosive
environments.

4
SAFETYINFORMATON
lPetrolisextremelyflammableandexplosiveundercertainconditions.
lENSUREthat thepetrolisonlystored inan approvedstoragecontainer.
lDO NOTrefueltheenginewhileit isinoperationorhot.
lDONOToperateorrefueltheengineinaconfinedareawithoutadequate
ventilation.
lDO NOTrefuelthe engine inthevicinityofsparks, anaked flameorsmoking.
lDONOToverfill thefueltankandavoidspillingpetrolwhenrefueling.Spilled
petrolorpetrolvapourmayignite.Ifspillageoccurs,ensurethattheareaisdry
beforestartingthemotor.
lENSUREthat thefueltankcapissecurelyfitted afterrefueling.
lCarbonmonoxideexhaustgasesfromengine drivenunitscancausedeathin
confinedspaces.
lALWAYSwearanapprovedhearingprotection,Excessivenoisecanleadto
temporaryorpermanentloss of hearing.
lProtectivegogglesandadustmask shouldbewornwhenworkinginadusty
environment.Protectiveclothingand footwearmayalsobedesirablewhen
working withhotmixbitumen.
1.3 OperatorSafetywhileusing InternalCombustion Engines
lDO NOTsmokewhenrefueling theengineoroperatingthe machine.
lDO NOTrefuelahot orrunningengine.
lALWAYSkeep awayfromall hotorspark-generatingobjectswhenrefuelthe
engine.
lALWAYSrefill thefueltankuntil the machine hascooled,andina
well-ventilatedenvironments.
lDO NOTspill fuelwhen refuelingthe engine.
lALWAYStakecaretousetherighttypeoffuel.
lALWAYSinspect the fuelleakageregularly.
lNEVERperformanyworkonthemachinewhileitisrunning.Beforeworkingon
it, stoptheengineand disconnectthesparkplug wiretopreventaccidental
starting.
lAvoidprolongedbreathingofexhaust gases.
lALWAYStransportandhandlefuelonlywhen containedinapprovedsafety
containers.
lAvoidtouchorleanagainsthot exhaustpipes.
lAllowengine tocoolbeforeperforming anyrepairsorservice.
lALWAYSkeeptheareaaroundthemufflerfreeofdebrissuchasleaves,paper,
cartons,etc.Ahot mufflercouldignitethedebrisand startafire.
lNEVERrun theenginewithoutairfilter.

5
SAFETYINFORMATION
1.4LabelLocations

6
SAFETYINFORMATION
1.5Safetyand Operating Labels
MASTERPACmachinesuseinternationalpictoriallabelswhereneeded. Theselabelsare
describedbelow:
Label Meaning
DANGER!
Enginesemit carbonmonoxide;operateonlyin
well-ventilatearea. Readthe Operator’sManual
formachineinformation.Nosparks, flames,or
burning objectsnearthemachine.Shutoff the
enginebeforerefueling.Useonlyclean, filtered
unleadedgasoline.
WARNING!
Always wearhearing andeyeprotectionwhen
operatingthismachine.
CAUTION!
ReadandunderstandthesuppliedOperator’s
Manualbeforeoperating themachine. Failureto
do soincreasetherisk of injurytoyourselfor
others.
CAUTION
Liftingpoint.
WARNING!
Handinjuryif caughtinmovingbelt.
Always replacebeltguard.

7
SAFETYINFORMATION
Label Meaning
WARNING!
Hot surface!
NOTICE!
Throttlecontrollever:
Turtle=Idleorslow,
Rabbit=Full orfast.
Anameplatelistingthemodelnumberand serial
numberisattachedtoeachunit.Pleaserecord
theinformationfoundonthisplatesoit will be
availableifthenameplatelostordamaged.
When requestingserviceinformation, the serial
numbershouldbe specifiedof the unit.
Anameplatelistingthemodelnumberand serial
numberisattachedtoeachunit.Pleaserecord
theinformationfoundonthisplatesoit will be
availableifthenameplatelostordamaged.
When requestingserviceinformation, the serial
numbershouldbe specifiedof the unit.
Anameplatelistingthemodelnumberand serial
numberisattachedtoeachunit.Pleaserecord
theinformationfoundonthisplatesoit will be
availableifthenameplatelostordamaged.
When requestingserviceinformation, the serial
numbershouldbe specifiedof the unit.

8
OPERATION
2. OPERATION
2.1Controls
Ref. Description Ref. Description
1 LeverforForward/ReverseOperation 5 Engine
2 ThrottleControl 6 BasePlate
3 LiftingPoint 7 Handle
4 Refueling
3
1
2
4
5
6
7

9
OPERATION
2.2Operating Principle
The followinginstructionswerecompiled toprovide youinformation on howtoobtainlong
and troublefree useofthe unit. Periodicmaintenanceofthisunitisessential.Readthe
manualinitsentiretyand followthe instructionscarefully.Failuretodosomayinjure
yourselforabystander.
2.3DeliveryChecks
Immediatelyontakingdeliveryofyournewmachine and beforeputtingit intoservice.
lRead thehandbookcompletely—it couldsaveagreat dealofunnecessaryexpense.
lRead theengine manualsupplied.
lCheck the generalcondition ofthe equipment –hasit been damaged duringdelivery?
lCheck engine oil level.
lCheck fuellevels.
lHydraulicfluidlevel
Recommended lubricantsaredetailedintheCareandMaintenancesection.
2.4BeforeStarting
Beforestartingthe machine, check the followingitems:
lAll handlesarefree fromgrease, oil and dirt.
lAll controlleversareinthe neutralposition.
lAll bolted jointsaretightened.
lFuellevel.
lThetensionintheV-belt.
lOil levelinthe engine.
lThestateofairfilter..
lHydraulicfluidlevel.
NOTICE: Check the hydraulicfluidleveland the oil levelinthe engine and exciter.
The warrantiesareVOIDifthe machine run withoutoil and hydraulicfluid.

10
OPERATION
2.5ToStart
2.5.1DieselEngine Lombardini
1.Donot actuatestarterformorethan 20 secondsat atime. Ifengine doesnot start, wait
1minutebeforerepeatingattempt. Ifengine doesnotstartaftertwoattempts,tracethe
causeaccordingtoDiagnosisChart.
2.Keyalwaysinon(1st)position when engine isrunning. Makesurethat all the warning
lightsareoffwhen the engine isrunning. Forengineswithstartingpanelequipped
withengine protection, makesurethe OKlight onlykeepsON.
1st position -Warninglight on.2nd Position -Starting.
3.Afterstarting, at idlespeed forafewminutesaccordingtotable:
Temperature Time
δ -20°C5’
-20°C/ -10°C 2’
-10°C-5°C 1’
2.5.2PetrolEngine
1.Openthe fueltapbymovingthefuelON/OFF
leverfullytothe right.
2.Ifstartingtheenginefromcold,setthechokeON
bymovingthechokeleverfullytotheleft.If
restartingawarm engine,thechokeisusuallynot
required.However,iftheenginehascooledtoa
degree, partialchokemayberequired.
3.TurntheengineON/OFF switchclockwisetothe
“1”position.
4.Setthethrottletotheidleposition bymovingthe throttleleverfullytothe right. Do
notstarttheengineonfull throttle,asthecompactorwill vibrateassoonasthe
enginestarts.

11
OPERATION
5.Takingafirm holdofthecontrolhandlewithonehand,grasptherecoil starter
handlewiththeother. Pull therecoilstarteruntilengine resistanceisfelt, thenlet
starterreturn.
6.Takingcarenottopull thestarter’scopefullyout, pull the starterhandlebriskly.
7.Repeatuntil theenginefires.
8.Oncethe enginefiresgradually,setthechokelevertotheOFFpositionbymoving
it totheright.
9.Iftheengine failstofireafterseveralattempts,followthe trouble-shootingguide
on page9.
10.Tostop the engine,setthe throttletoidleandturntheengine ON/OFF switch
anticlockwisetothe “0”position.
11.Turnthe fueloff.
2.6ToStop
1.Pushthe throttleleverto “O”position.
2.Turnthe keyswitchto “O”(off).
3.Closethefuelvalve.
2.7Application
TrenchcompactionEarthworks
RoadmaintenanceLandscaping
Brick paving Drivewaytopping
2.8Operation
Run engine atfull throttleand allowplatetopull itselfalong atitsnormalspeed.
Dependingonthe materialbeingcompacted,threeorfourpassesarerecommendedto
achievethebestcompaction.
The machineisbest suited tothecompactionofbituminousand granularmaterialse.g.
granularsoilssuchassiltandclayarebestcompactedusingtheimpact forceproduced
byavibratingrammer.Wherepossiblethesiteshouldbegraded andleveled before
commencing compaction.
Correctmoisturecontentinsoil isvitaltopropercompaction.Wateractsasalubricant
tohelpslidesoil particlestogether.Toolittlemoisturemeansinadequatecompaction;
too muchmoistureleaveswater-filledvoidsthatweaken thesoil’sload-bearingability.
Compactionofdrymaterialswill befacilitatedbymoisteningwithawaterhosefitted
withasprinkler. Excessivewatering orwatercontentwill causethemachinetostall.
The optionalwatertankkitisrecommended whenthemachineisusedonbituminous
surfacesasthewaterfilmpreventsabuildup ofmaterialonthe underside oftheplate.

12
OPERATION
2.9Operation Driving
1.ForwardOperation: Movetheforward/reverseleverforwards.
2.ReverseOperation: Movetheforward/reverseleverbackwards.
2.10Operation on Slop
1.The operatormust neverstand inthe directionofdescent.
2.Must neverexceedtheMax. gradientof20°.
Max.AdmissibleInclination
20°
20°

13
MAINTENANCE
3. MAINTENANCE
3.1PeriodicMaintenanceSchedule
Refertoenginemanufacturer’sOperationManualforadditionalinformation on engine
maintenance.AcopyoftheengineOperationManualwassupplied withthemachine.
Daily
Atfirst
20
hours
Every
50
hours
Every
100
hours
Every
250
hours
Every
500
hours
Every
1000
hours
Check oil level ●
Check airfilter ●
Check fordamageandleaks ●
Changeengine oil ●
Cleanairfilter ●
Check V-belt ●
Cleancoolingsystem ●
Check exciteroil ●
Check hydraulicoil lever ●
Changeexciteroil ●
Changeengine oil ●
Changeoil filter ●
Check valveclearance ●
Changefuelfilter ●
Changehydraulicfluidfilter ●
Changehydraulicoil ●
Theseinspectionintervalsareforoperation undernormal
conditions.Adjustyourinspectionintervalsbasedon thenumber
hoursplatecompactorisinuse, andparticularworking conditions.
!
CAUTION

14
MAINTENANCE
3.2ExciterOil
Whenchanging theexciteroil,placetheexciteron aflat,horizontalsurface,removethe
drainpluglocated atthebottom-right of the vibrator, andsimplytipthecompactorto
draintheoil.Notethat the oil will drainmoreeasilywhileit ishot. DO NOTpourintoo
muchoil.
3.3V-beltand Clutch
3.3.1Checking theV-belt
After200hoursofoperation,removetheupperbelt
covertochecktheV-belttension (Figure2).Tension is
properifthebeltbendsabout10mm whendepressed
stronglywithfingerbetweenshafts.Looseorworn
V-beltsreducespowertransmissionefficiency,causing
weakcompactionandreducesthe lifeofthebelt itself.
NEVER attempttocheck theV-beltwiththeengineisrunning. Severe
injurycanoccurifyourhandgetcaughtbetweentheV-beltandthe
clutch.Always usesafetygloves.
3.3.2Checking theClutch
ChecktheclutchsimultaneouslywithV-beltchecking.Withbeltremoved,checkouter
drumof theclutchforseizureand “V”grooveforwearordamagewithyoureyes. Clean
the “V”grooveasnecessary.Wearoflining orshoeshouldbechecked withrunning
check.Ifthe shoeisworn,powertransmission becomesdeficientandslippingwill
result.
Wheneverthecompactor’svibrationbecomesweakorlostduring
normaloperation regardless ofoperation hours,check theV-beltand
clutchimmediately.
!
CAUTION
!
WARNING

15
MAINTENANCE
3.4AirCleaner
1.The airfilterelementshouldbecleanedbecauseaclogged
aircleanercancausepoorenginestarting, lackofpowerand
shorten enginelifesubstantially.
2.Tocleanorreplaceairfilterloosen thewingnuton theair
filterhousing (Figure1), removethe coverand takeoutair
filtercartridge. If onlycleaningof theairfilterisdesired blow
throughthe airfiltercartridge fromtheinside, moving ajet of
drycompressedairupanddownuntil all dustisremoved.
3.5SparkPlug
Check andcleansparkplugsregularly.Afouled,dirtysparkplugmaycausehard
startingand poorengineperformance. Setsparkplug gaptorecommended clearance.
Refertoenginemanual.
The mufflerandenginecylinderbecomeveryhot duringoperationand
remainhot forawhileafterstopping theengine.Allowenginetocool
beforeremovingsparkplug.
NOTICE:Aloosesparkplug canbecomeveryhotandmaycauseenginedamage.
3.6Transport
1.Always shutoff enginebeforetransportingthemachine.
2.Makesureliftingdevicehasenoughcapacitytoholdmachine(see nameplateon
machineforweight).
3.Useliftingpointwhen liftingthemachine.
4.NEVERstandunderneaththemachinewhilelifting.
5.Trolleywheelasoptionalisusedforshort distancetransportation.
!
WARNING

16
MAINTENANCE
3.7Troubleshooting
3.7.1MachineTroubleshooting
SYMPTOM POSSIBLECAUSES SOLUTION
The V-belt slipping. Adjust orchange theV-belt.
It doesnotadvance. The clutchisslipping. Check orchangethe clutch.
It vibrates,
butdoesnot move. The vibratormaybe ona slipperysurface. Tryon theright surface.
Lack of hydraulicoil. Top uptheoil.
Travelsreversevery
slowly. Airinthe circuit. Check andpurgethecircuit.
Travelsforwardvery
Slowly. Too muchhydraulicoil. Drainthe excess oil.
Hydraulicoil
Leaks.Loss of oil-tightness, Hydraulichosedefective. Changethe defectiveparts .

17
MAINTENANCE
3.7.2EngineTroubleshooting
SYMPTOM POSSIBLECAUSE SOLUTION
Sparkplugbridging. Check gap,insulationorreplace
sparkplug.
Carbondepositonspark
plug. Cleanorreplacesparkplug.
Shortcircuitduetodeficient.
Checksparkpluginsulation,
replaceifworn.
Difficult tostart, "fuel
isavailable, butno
SPARKat spark
plug".
Impropersparkplug gap. Settopropergap.
ON/OFF switchisshorted. Check switchwiring, replace
switch.
Ignition coil defective. Replaceignitioncoil.
Impropersparkgap,points
dirty. Setcorrectsparkgapand clean points.
Condenserinsulationwornor
short circuiting. Replacecondenser.
Difficult tostart, "fuel
isavailable, and
SPARKispresent at
sparkplug.
Sparkplugwirebroken or
short circuiting. Replacedefectivesparkplug wiring
Wrongfueltype. Flushfuelsystem,and replace
withcorrect typeoffuel.
Waterordust infuelsystem? Flushfuelsystem.
Difficult tostart, "fuel
isavailable, sparkis
presentand
compression is
normal". Aircleanerdirty. Cleanorreplaceaircleaner.
Suction/exhaust valvestuck.
orprotruded? Re-seat valves.
Pistonringand/orcylinder
worn. Replacepiston ringsand or piston.
Cylinderheadand/orspark
plugnot tightenedproperly. Torquecylinderheadboltsand sparkplug.
Difficult tostart, "fuel
isavailable, sparkis
presentand
compression islow.
Headgasket and/orspark
pluggasket damaged. Replaceheadand sparkplug gaskets.

18
MAINTENANCE
SYMPTOM POSSIBLECAUSE SOLUTION
Fuelnotavailableinfuel
tank. Fill withcorrecttype offuel.
Fuelcock doesnotopen
properly. Applylubricanttoloosenfuel cock level, replaceif necessary.
Fuelfilterclogged. Replacefuelfilter.
Fueltankcapbreatherhole
clogged. Cleanorreplacefueltankcap.
Nofuelpresentat
carburetor.
Airinfuelline. Bleedfuelline.
Aircleanernot clean. Cleanorreplaceaircleaner.
Improperlevelincarburetor. Checkfloatadjustment, re-build
carburetor.
"Weakinpower"
compression is
properanddoesnot
mistire. DefectiveSparkplug. Cleanorreplacesparkplug.
Waterinfuelsystem. Flushfuelsystem,and replace
withcorrect typeoffuel.
Dirtysparkplug. Cleanorreplacesparkplug.
"Weakinpower"
compression is
properbut mistires. Ignition coil defective. Replaceignitioncoil.
Sparkplugheatvalue
improper. Replacewithcorrecttype of sparkplug.
Correct typeoffuel. Replacewithcorrect typeoffuel.
Engineoverheats.
Coolingfinsdirty. Cleancoolingfins.
Governoradjustedcorrectly. Adjust governor.
Governorspringdefective. Replacegovernorspring.
Rotationalspeed
fluctuates. Fuelflowrestricted. Checkentirefuelsystemfor
leaks orclogs.
Recoil mechanismclogged
withdustanddirt. Clean recoil assemblywithsoap
andwater.
Recoil starter
malfunction. Sprialspringloose. Replacesprialspring.

19
TECHNICALDATA
4.TECHNICALDATA
PCR6040Series
Model PCR6040H PCR6040L PCR6040A
Enginetype HondaGX270 Lombardini
15LD440 Hatz1B40
Power kw(hp) 6.6(9.0) 8.1(11) 7.5(10.2)
Operatingweight kg(lb) 355(783) 375(825) 378(833)
PlatesizeLxW cm(in) 90x60(35x24)
Centrifugalforce kN 40
VibrationFrequency vpm(hz) 4140(69)
TravelSpeed m/min(ft/min) 20-24(66-79)
ExciterLubrication (L) SG15W-40 （1.8L）
Hydraulicoil (L) L-HM46 （0.44L）
PCR6550Series
Model PCR6550H PCR6550L PCR6550A
Enginetype HondaGX390 Lombardini
15LD440 Hatz1B40
Power kw(hp) 9.6(13.0) 8.1(11) 7.5(10.2)
Operatingweight kg(lb) 396(873) 410(904) 413(911)
PlatesizeLxW cm(in) 90x65(35x26)
Centrifugalforce kN 50
VibrationFrequency vpm(hz) 4140(69)
TravelSpeed m/min(ft/min) 20-25(66-82)
ExciterLubrication (L) SG15W-40 （1.8L）
Hydraulicoil (L) L-HM46 （0.44L）
PCR7060Series
Model PCR7060L PCR7060A
Enginetype Lombardini15LD440 Hatz1B40
Power kw(hp) 8.1(11) 7.5(10.2)
Operatingweight kg(lb) 465(1025) 468(1032)
PlatesizeLxW cm(in) 90x70(35x28)
Centrifugalforce kN 60
VibrationFrequency vpm(hz) 4140(69)
TravelSpeed m/min(ft/min) 20-25(66-82)
ExciterLubrication (L) SG15W-40 （1.8L）
Hydraulicoil (L) L-HM46 （0.44L）