Meiwa RP300X User manual

OPERATION / MAINTENANCE
AND PARTS MANUAL
For RP300(X)
REVERSIBLE PLATE COMPACTOR
July 23, 2009

SECTION 1 -
SAFETY PRECAUTIONS AND GUIDELINES
Contents .......................................................................................................................................................................................... Page
OVERVIEW ......................................................................................................................................................................... 1
PRE-START INSPECTION................................................................................................................................................. 1
OPERATING ....................................................................................................................................................................... 2
MAINTENANCE ................................................................................................................................................................. 2
OERATING PROCEDURES ..............................................................................................................................………….. 3
OVERVIEW
BEFORE YOU OPERATE, MAINTAIN OR IN ANY OTHER WAY, OPERATE THIS MACHINE:
READ and STUDY this manual. KNOW how to safely use the unit’s controls and what you must do for safe maintenance.
The machine has been built in accordance with state-of-the-art standards and the recognized safety rules. Nevertheless, its
use may constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other material
property.
ALWAYS wear or use the proper safety items required for your personal protection.
For reasons of security, long hair must be tied back or otherwise secured, garments must be close fitting and no jewelry
–such as rings or watches - may be worn. Injury may result from being caught up in the machinery or from rings catching on
moving parts.
If you have ANYQUESTIONS about the safe use or maintenance of this unit, ASK YOUR SUPERVISOR OR CONTACT ANY
DISTRIBUTOR. NEVER GUESS - ALWAYS CHECK.
Never make any modifications, additions or convert HONDA engine GX240sions which might affect safety without the
supplier’s approval. This also applies to the installation and adjustment of safety devices and valves as well as to welding work
on load-bearing elements.
Observe all fire-warning and fire-fighting procedures.
PRE-START INSPECTION
INSPECT your machine. Have any malfunctioning, broken or missing parts corrected or replaced before use.
Check the machine at least once per working shift for obvious damage and defects. Report any changes (incl. changes in the
machine’s working behavior) to the competent organization/person immediately. If necessary, stop the machine immediately
and lock it.
Take the necessary precautions to ensure that themachine is used only when in a safe and reliable state.
Operate the machine only if all protective and safety oriented devices, such as removable safety devices, emergency shut-off
equipment, sound-proofing elements and exhausts, are in place and fully functional.
The electrical equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections
or scorched cables must be rectified immediately.
VERIFY that all the instruction and safety labels are in place and readable. These are as important as any other equipment on
the compactor. NEVER fill the fuel tank, with the engine running, while near an open flame, or while smoking. ALWAYS wipe
up any spilled fuel immediately.
1-1

SECTION 1 -
SAFETY PRECAUTIONS AND GUIDELINES
CHECK for WARNING tags placed on the machine. DO NOT operate the equipment until repairs have been made and the
WARNING tags have been removed by authorized personnel.
KNOW the location of the Emergency Shut-Down Control if the machine is so equipped.
OPERATING
In the event of safety-relevant modifications or changes in the behavior of the machine during operation, stop the machine
immediately and report the malfunction to the competent authority/person.
Always wear the prescribed ear protectors.
Always make sure that no person or obstruction is in your line of travel. Watch your step to avoid tripping.
USE extreme caution and be observant when working in close quarters or congested areas.
Before beginning work, familiarize yourself with the surroundings and circumstances of the site, such as obstacles in the
working and traveling area, the soil bearing capacity and any barriers separating the construction site from public roads.
When traveling on public roads, ways and places always observe the valid traffic regulations and, if necessary, make sure
beforehand that the machine is in a condition compatible with these regulations
Always keep at a distance from the edges of building pits and slopes.
DO NOT run the engine in a closed building for an extended length of time. EXHAUST FUMES CAN KILL.
DO NOT operate the compactor on non-compactable material, such as concrete or hardened asphalt.
MAINTENANCE
Observe the adjusting, maintenance and inspection activities and intervals set out in the operating instructions, including
information on the replacement of parts and equipment. These activities must be executed by skilled personnel only.
Ensure that the maintenance area is adequately secured.
After cleaning, examine all fuel, lubricant, and hydraulic fluid lines for leaks, loose connections, chafe marks and damage.
Any defects found must be rectified without delay.
Always tighten any screwed connections that have been loosened during maintenance and repair.
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SECTION 1 -
SAFETY PRECAUTIONS AND GUIDELINES
Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon
completion of the maintenance and repair work.
Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.
AVOID, whenever possible, servicing, cleaning or examining the unit with the engine running.
NEVER fill the fuel tank, with the engine running, while near an open flame, or while smoking. ALWAYS wipe up any spilled
fuel immediately.
ALWAYS disconnect the spark plug before performing any work on the unit.
DO NOT alter the engine governor settings from those indicated in the engine manual.
ALWAYS replace damaged or lost decals. Refer to the Parts Manual for the proper location and part number of all decals.
Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorized, as there may be
a risk of explosion and fire.
Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and
other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).
1-3

SECTION 2 - INTRODUCTION
EXCELLENT CHOICE! MEIWA Reversible Compactor you have chosen will give you many hours of maintenance free
operation resulting in a faster return of your investment.
Safe operation depends on reliable equipment and the use of proper operating procedures. Performing the checks and
services described in this manual will help keep your machine in good condition. These recommended operation procedures
will help you to avoid unsafe practices.
Safety notes have been included throughout this manual to help you avoid injury and prevent damage to the equipment.
These notes are not intended to cover all eventualities; it is impossible to anticipate and evaluate all possible methods of
operation. Therefore, you are the only person who can guarantee safe operation and maintenance. It is important that any
procedure not specifically recommended in this manual be thoroughly evaluated from the standpoint of safety before it is
implemented.
Continuing improvement and advancement of product design may cause changes to your machine which may not be included
in this publication. Each publication is reviewed and revised, as required, to update and include these changes in later editions.
MEIWA reserves the right to modify or make changes within a specific model group without notice and without incurring any
liability to retrofit units previously shipped from the factory. Contact your MEIWA Distributor for non-routine maintenance
information that is not covered in this publication.
2-1

SECTION 3 - SYMBOL IDENTIFICATION AND METRIC CONVERSION
Contents Page
INTERNATIONAL MACHINE SYMBOLS ______________________________________________________________1
INTERNATIONAL HIGHWAY SYMBOLS ______________________________________________________________2
METRIC CONVERSIONS __________________________________________________________________________ 4
INTERNATIONAL MACHINE SYMBOLS
The following explains the meaning of international symbols that may appear on your machine
OIL PRESSURE
BRAKE
HOURS
WATER
TEMPERATURE HORN
NEUTRAL
ON / OFF
CAUTION
LOW ENGINE
RPM.
LIGHTS
FUEL
BRAKE-PARK
WATER SLOW
VIBRATION
BATTERY
FAST
AMPLITUDE
AMMETE OR
VOLTMETER
TRANSMISSION
FREQUENCY
AIR PRESSURE
GREASE
CAUTION-
PRESSURIZED
LOW AIR
PRESSURE
OIL
ENGINE RPM
HYDRAULIC OIL
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SECTION 3 - SYMBOL IDENTIFICATION AND METRIC CONVERSION
INTERNATIONAL HIGHWAY SYMBOLS
The following symbols may also appear in a yellow square instead of a red triangle.
Road bends Uneven road
Dangerous bend Ridge
Double bend Dip
Dangerous descent Slippery road
Steep ascent Loose gravel
Carriageway narrows
No entry for power driven
vehicles
Carriageway narrows
No entry for vehicles exceeding
length
“end of priority”sign
No entry for vehicles exceeding
length
Oncoming traffic has priority Falling rocks
Priority over oncoming traffic Pedestrian crossing
Swing bridge Road work
Road leads onto quay or river
bank Light signals
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SECTION 3 - SYMBOL IDENTIFICATION AND METRIC CONVERSION
Two-way traffic “give way”sign
Other dangers Stop sign (new)
Level crossing Stop sign (old)
Level crossing
“priority road”sign
No entry
No entry for vehicles exceeding
weight
Closed to all vehicles in both
directions
No entry for vehicles axle
weight exceeding
Intersection, user must give
way No u-turn
Intersection, user must give
way No turn direction shown
Intersection, user must give
way
No entry for power driven
vehicles
3-3

SECTION 3 - SYMBOL IDENTIFICATION AND METRIC CONVERSION
TO CONVERT
OMREGNET FRA INTO TIL MULTIPLY BY MULTIPLICERES MED
Bar Pound/sq.in 14.50
Bar Kilopascals 100.
Centigrade Fahrenheit (C° x 9/5) + 32
Centimeters Inches 0.3937
Centimeters Millimeters 10.0
Circumference Radians 6.283
Cubic centimeters cu.inches 0.06102
Degrees (angle) Radians 0.01745
Degrees/sec. Revolutions/min 0.1667
Feet Meters 0.3048
Feet/min Meters/min. 0.3048
Foot-pounds Kg-meters 0.1383
Gallons Liters 3.785
Hertz Vibrations/min. 60.
Horsepower Kilowatts 0.7457
Inches Centimeters 2.540
Inches Millimeters 25.40
Kilograms Pounds .250
Kilogram meters -Pounds 7.233
Kilopascal Pounds/sq.in 0.1450
Kilopascal Bars 0.01
Kilowatts Horsepower 1.341
Liters Gallons (U.S. liq) 0.2642
Liters Pints (U.S. liq) 2.113
Liters Quarts (U.S. liq) 1.057
Meters Feet 3.281
Meters Inches 39.37
Meters/min Feet/sec 0.05468
Miles/hr kms/hr 1.609
Millimeters Inches 0.03937
Newtons Pounds 4.448
Newton-meter Pound-feet 0.737
Pounds Kilograms 0.4536
Pounds Newtons 0.225
Pound feet Newton-meter 1.356
Pounds/ft. kgs/meter 1.488
Pounds/sq in Bars 0.06895
Pounds/sq in Kilopascals 6.895
Quarts (liq) Liters 0.9463
Radians Degrees 57.30
Radians/sec Revolutions/min 9.549
Revolutions/min Degrees/sec 6.0
Revolutions/min Radians/sec 0.1047
Temperature (°C) + 17.78 Temperature (°F) 1.8
Temperature (°F) - 32 Temperature (°C) 5/9
Tons (short) Tons (metric) 0.9078
Vibrations/min Hertz 0.0167
3-4

SECTION 4 - OPERATING INSTRUCTIONS
Contents Page
SAFETY CHECKS - PRE-STARTING _________________________________________________________________1
INSPECTION PRIOR TO OPERATION ________________________________________________________________2
OPERATION _____________________________________________________________________________________2
STORAGE ______________________________________________________________________________________6
Improper maintenance can be hazardous.
Read and understand SECTION 1 - SAFETY PRECAUTIONS AND GUIDELINES before you perform any maintenance,
service or repairs.
SAFETY CHECKS - PRE-STARTING
Before starting each day, in addition to the 10 hour daily routine maintenance, check or inspect the following items to ensure
trouble free performance.
1. Check fluid lines, hoses, fittings, filler openings, drain plugs, pressure cap, muffler, safety shrouds and the area underneath
the unit for signs of leakage or damage. Fix any leaks and correct any damage before operating.
2. Inspect the entire unit for damaged or missing parts and repair or replace them as needed.
3. Check the fuel level. If necessary, fill the fuel tank with the proper fuel.
4. Check all fastening hardware to ensure it is adequately tightened and that none is missing or broken.
5. Do not operate faulty equipment.
6. Be observant of people and obstructions within the work area.
BEFORE OPERATING THE UNIT
1. Read the instruction manual and the engine manual.
2. Ensure that the 10 hour daily routine maintenance is performed.
4-1

SECTION 4 - OPERATING INSTRUCTIONS
INSPECTION PRIOR TO OPERATION
START-UP PROCEDURES
ELECTRIC START
Remove the operating handle by pulling the handle pin.
Move the operating handle manually down to the operating position.
1. Position the throttle lever (1, Figure 4-1)to the “high”position.
2. Position the fuel cock to the “0”position.
3. Turn the starter-key (1, Figure 4-2) clockwise to the “start”position.
4. Release the starter-key as soon as the engine starts running.
5. Shift the throttle lever “low”position immediately after the engine starts.
Figure 4-1 Figure 4-2
MANUAL START (IN CASE OF BATTERY TROUBLE)
Remove the operating handle by pulling the handle pin.
Move the operating handle manually down to the operating position.
1. Position the throttle lever (1, Figure 4-1) to the “high”position.
2. Position the fuel cock to the “0”position.
3. Pull out the recoil-starting handle (1, Figure 4-3).
a.) Pull out the handle to the point where you feel strong resistance, and then return it to the initial position.
b.) Push down the decompression lever (1, Figure 4-4). It will return automatically when the recoil starter is pulled.
c.) Pull out the recoil-starting handle briskly with both handles.
4. Shift the throttle lever (1, Figure 4-1) to the “low”position immediately after the engine starts.
Figure 4-3 Figure4-4
4-2

SECTION 4 - OPERATING INSTRUCTIONS
Avoid pulling the rope completely out, the recoil starter could be damaged and the rope broken. Allow the rope to return to the
original position.
COMPACTOR OPERATION
1. After start-up of the engine, allow the engine to warm up at slow speed without load for about 5 minutes.
2. Shift the throttle lever (1, Figure 4-1) to the “high”position. This allows the unit to start vibration. Always operate the unit with
the “high”position to avoid the damage of the clutch.
3. Move the direction control lever (1, Figure 4-5) either “forward”or “reverse”position to achieve the desired direction and
safe speed of travel as determined by the conditions. The further the direction control lever is moved from “neutral”(center)
position, the greater the speed in that direction.
4. Operator must beleft or right side of the compactor whenever the unit travels to the reverse direction. Do not operate behind
the operating handle when the unit is traveling in reverse.
Figure 4-5
SHUT-DOWN PROCEDURE
1. Position the throttle lever (1, Figure 4-1)to the “low”speed position.
2. Allow the engine to idle for about 5 minutes.
3. Shift the throttle lever (1, Figure 4-1) to the “stop”position.
4. Turn the starter-key (1, Figure 4-2)to the “OFF”position.
5. Closethe fuel cock to the “S”position.
STORAGE
1. Drain the fuel from the fuel tank.
2. Close the fuel cock.
3. Move up the operating handle vertically and fix with the handle pin.
4. Clean the unit of all dirt, grease or other material.
Store in a clean, dry location. Use the cover after the engine has cooled enough, if storage will be for a long time.
4-3

SECTION 4 - OPERATING INSTRUCTIONS
TOWING
In the event of an engine problem or other malfunction, it may be necessary to remove the compactor from the job site.
The lifting hook has been provided in the machine’s center of gravity for ease of lifting the compactor onto or off of the
transporter.
Do not lift any other point except the lifting hook to avoid machine damage.
Release handle pin (1, Figure 4-6). Using the lifting hook (1, Figure 4-7) lift the compactor off the transporter.
Figure 4-6 Figure4-7
4-4

SECTION 5 - FUEL AND LUBRICATION SPECIFICATIONS
Contents Page
GENERAL INFORMATION ________________________________________________________________________ 1
GENERAL INFORMATION
Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the unit. Different
lubricants
are needed and some components in the unit require more frequent lubrication than others.
Specific recommendations of brand and grade of lubricants are not made here due to regional availability, operating
conditions,
and the continual development of improved products. Where questions arise, refer to the requirements and specifications in
the manufacturer's manual.
All oil levels are to be checked with the machine parked on a level surface, and whilethe oil is cold, unless otherwise specified.
5-1

SECTION 6 - INITIAL BREAK-IN MAINTENANCE
Contents Page
ENGINE OIL ___________________________________________________________________________________ 2
BATTERY _____________________________________________________________________________________ 2
OIL FILTER ____________________________________________________________________________________ 3
VIBRIATION SHAFT CASE OIL ____________________________________________________________________ 3
Improper maintenance can be hazardous.
Read and understand SECTION 1 - SAFETY PRECAUTIONS AND GUIDELINES before you perform any maintenance,
service or repairs.
Any new equipment requires an initial modification of the maintenance schedule to properly break-in the various systems and
component units. Perform this one time initial break-in maintenance after 20 to 30 hours of operation
IN ADDITION to the normal maintenance schedule. After this initial phase, the regular intervals
should be followed.
Hot oil and/or components can burn.
Oil must be at normal operating temperature when draining.
Avoid contact with hot oil or components.
6-1

SECTION 6 - INITIAL BREAK-IN MAINTENANCE
ENGINE OIL
Drain the engine oil after the first 20 hours of operation. Rremove engine oil plug (1, Figure 6-1) and drain engine oil. Fill with
the correct amount of the recommended oil and check the oil level with the oil check gauge (2, Figure 6-1).
Figure 6-1
BATTERY ELECTROLYTE
Check the liquid level of battery electrolyte every month and refill with distilled water if the liquid level is low.
Maintain the battery (1, Figure 6-2) properly.
Battery electrolyte evaporates and therefore the volume decreases.
Insufficient electrolyte may damage battery and overflow of electrolyte may damage the bed.
Battery electrolyte spilled onto skin may cause burn skin. If electrolyte is spilled onto skin wash with water immediately and
seek medical treatment if necesary. Spilling electrolyte onto clothing will damage clothing.
Figure 6-2
6-2

SECTION 7 - 10 HOUR OR DAILY ROUTINE MAINTENANCE
Contents Page
TROUBLE SHOOTING _____________________________________________________________________ 1
GENERAL MAINTENANCE _________________________ ________________________________________ 2
Improper maintenance can be hazardous.
Read and understand SECTION 1 - SAFETY PRECAUTIONS AND GUIDELINES before you perform any maintenance,
service or repairs.
It is recommended that the following steps be performed at the beginning and end of each 8 to 10 hour shift or daily, whichever
comes first.
ENGINE OIL
Check the engine's oil level at the start of each day and maintain it to the full mark on the dipstick. Insert the dipstick gauge (1,
Figure7-1) and check the full mark on the dipstick. Do not screw the dipstick in first. This will give a false reading on the gauge.
Fill with new engine oil at the dipstick gauge port (1, figure 7-1) . See Engine Oil, section 6.
Figure 7-1
7-1

SECTION 7 - 10 HOUR OR DAILY ROUTINE MAINTENANCE
FUEL
Fuel is flammable. May cause severe injury or death.
Shut down the engine, extinguish all open flames and do not smoke while filling the tank.
Always wipe up any spilled fuel.
Shut down the engine before filling with fuel.
Clean around the fuel tank cap before removing and fill the tank with the recommended diesel oil per the specifications in
“FUEL
AND LUBRICATION”. Do not over fill with fuel. Proper fuel level is the red mark at the inlet. Clean around the fuel tank cap
after filling the fuel.
AIR CLEANER
Lossen butterfly nut and remove cleaner cover. Check the inner element. Do not wash the inner element, wet type element
is used. Change the inner element. Install the cover and tighten the butterfly nut.
FASTENING HARDWARE
Ensure all hardware is adequately tightened and that none is missing or broken.
7-2

7-2
SECTION 8 - 10 HOUR OR DAILY ROUTINE MAINTENANCE
Contents Page
ENGINEOIL_____________________________________________________________________________ 1
AIR CLEANER ___________________________________________________________________________ 2
FASTENING HARDWARE __________________________________________________________________ 2
It is recommended that the following steps be performed at the beginning and end of each 8 to 10 hour shift or daily, whichever
comes first.
Improper maintenance can be hazardous.
Read and understand SECTION 1 - SAFETY PRECAUTIONS AND GUIDELINES before you perform any maintenance,
service or repairs.
ENGINE OIL
Check the engine's oil level at the start of each day and maintain it to the full mark on the dipstick. Insert the dipstick and check
the full mark on the dipstick. See Section 10.
FUEL
Fuel is flammable. May cause severe injury or death.
Shutdown the engine, extinguish all open flames and do not smoke while working with fuel.
Always wipe up spilled fuel
Shutdown the engine before filling with fuel.
Clean the area around the fuel tank cap before removing. Fill the tank with unleaded gasoline. Do not overfill. The proper level
is the red mark on the inlet.
Clean around the fuel tank cap after filling.
8-1

SECTION 8 - 50 HOUR OR WEEKLY ROUTINE MAINTENANCE
* No 50 hour or weekly routine maintenance is required. *
8-2