Mikasa Mvc-40h User manual

FOR MORE INFORMATION

Version 1.0 (May 2022)

SERVICE MANUAL

MIKASA FORWARD PLATE COMPACTOR

MVC-40H, MVC-F60H, MVC-F80H,

MVC-T90H, MVC-T100D

PLATECOMPACTOR

MVC

SERVICE MANUAL

Table of contents

Work Site

Clothes And Protective

Cautions During Refuelinglothes And Protective

Prevention Of Burn And The Accident Of Getting Caught

Tools And Equipment

Use Of Genuine Parts And Appropriate Oil And V-belt

Tightening Torque Of Bolts And Nuts

Disposal Of Waste Material

Inspection And Maintenance Schedule Table

Opening Engine Oil

8.1

8.2

Changing Air Cleaner

Checking/Changing V-belt and Clutch

8.3

8.4

Inspection and Change of Vibrator Oil

Inspection and Change of Engine Bolt

8.5

8.6

Engine

Main Body

9.1

9.2

Disassemble

Assemble

7.1

7.2

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

INTRODUCTION ......................................................................................

CAUTIONS FOR MAINTENANCE TO SECURE SAFETY .......................

2. WARNING SIGNS ....................................................................................

INSPECTION BEFORE OPERATION ......................................................

4. TOOL ........................................................................................................

CAUTIONS BEFORE MAINTENANCE WORK ........................................

DISASSEMBLY AND ASSEMBLY OF VIBRATOR ..................................

REGULAR CHECK AND ADJUSTMENT .................................................

TROUBLESHOOTING .............................................................................

1．INTRODUCTION

For correct operation, maintenance and service of Plate Compactor, please read the separate operation manual before

your work for your safe work.

For the handling of engine, please read the separate engine operation manual and maintenance/service manual.

This service manual explains the maintenance standard and how to disassemble and assemble for Plate Compactor.

Please read this service manual for a better understanding of the maintenance standard, the structure and function of

each part.

To improve the performance and quality of this machine, the change might be made in this machine without notice. If

you have any questions, please contact with our distributor. For parts list, Mikasa WEB parts list is available at our

homepage (http://www.mikasas.com/).

●

2．WARNING SIGNS

The triangle shaped marks used in this manual and on the decals stuck on the main body

indicate common hazards. Be sure to read and observe the cautions described.

Warning labels indicating hazards to humans and to equipment.

DANGER

！

WARNING

！

CAUTION

！

CAUTION

！

Denotes an extreme hazard. It calls attention to a procedure, practice,

condition or the like, which, if not correctly performed or adhered to, is

likely to result in serious injury or death.

Denotes a hazard. It calls attention to a procedure, practice, condition

or the like, which, if not correctly performed or adhered to, could

result in serious injury or death.

Denotes a hazard. It calls attention to a procedure, practice, condition

or the like, which, if not correctly performed or adhered to, could

result in injury to people and may damage or destroy the product.

Failure to follow the instructions may result in damage to property.

！

(without at )

3．CAUTIONS FOR MAINTENANCE TO SECURE SAFETY

Do not work indoor or inside a tunnel where ventilation is poor. The emission from the

engine contains toxic gas such as carbon monoxide, and it is very dangerous if this

toxic gas and dust are inhaled. Also, to improve ventilation, please keep a proper

distance between this machine and a building when operating the machine.

Maintenance should be done in a place with a flat and hard surface to keep the

machine stable. Also, do maintenance at sufficient work space.

Before maintenance work, clean the floor. Oil on the floor, in particular, becomes the

cause of falling accident.

For maintenance work, have sufficient lighting in the work site. A portable lamp used to

illuminate the work area has to be protected by wire. In case if the lamp is broken, fuel

and oil might ignite.

To prepare for an accident, please have emergency medical supplies and fire

extinguisher ready at an easily accessible area.

3.1 Work Site

●

CAUTION

！

DANGER

！

To work safely, wear work clothes of appropriate size, and use suitable protective gear

such as helmet and safety shoes. The work clothes that do not fit the body size might

result in unpredicted injury because the clothes easily get caught by rotating part of the

machine.

When adding fuel

If fuel is filled to the top, it might overflow, and is dangerous.

After refueling, securely tighten the tank cap.

Start your work after the machine temperature drops. Especially, the muffler gets very

hot, and it will pose a danger of burn accident. Also, engine and engine oil as well as

vibrator become hot. Be careful not to get a burn.

If maintenance work is started with the engine running, injury might occur because you

might get caught by the rotating part such as pulley and V-belt. Always stop the engine

before maintenance.

When lifting the machine body and the engine, always use a crane. When lifting the

machine and the engine, follow the cautions listed below. If the machine or the engine

is dropped, a serious accident might occur.

To operate a crane, a crane handling qualification is required. Have someone qualified

to handle and operate a crane do this work.

Before lifting, check the parts (especially, hook and anti-vibration rubber) of this

machine for damage and loosening/lack of bolts to secure safety.

Before lifting, stop the engine and shut the fuel cock.

Use sufficiently strong wire rope.

For lifting, use only the lifting hook. Do not use other part for lifting.

Never allow anyone or any animal come under the lifted machine.

For safety, do not lift to the height more than necessary.

Use an appropriate tool. If the tool that is not suitable for the part is used, not only the

damage on the part, but also unpredicted accident might occur.

Always use genuine parts.

If inappropriate parts are used, not only it will shorten the machine life, but it might lead

to unpredicted accident.

Always refuel in the well ventilated area.

Always refuel after the engine stopped and cooled sufficiently.

Select a flat surface location away from flammable material and Do not overfill

the tank. If spilled fuel, wipe it off well.

Never put fire near the refueling area. (Never refuel while smoking.)

3.2 Clothes And Protective

3.3 Cautions During Refuelinglothes And Protective

3.4 Prevention Of Burn And The Accident Of Getting Caught

●

WARNING

！

3.5 Tools And Equipment

WARNING

！

CAUTION

！

CAUTION

！

○

3.6 Use Of Genuine Parts And Appropriate Oil And V-belt

CAUTION

！

Tighten bolts and nuts with the tightening torque specified in this maintenance manual.

Over tightening torque and lack of tightening torque not only affect the machine life, but

also might occur unexpected accident.

Unnecessary engine oil and fuel should be kept in a container. Never dump it on the

ground or pour into the sewage system such as side ditch.

For disposal of unnecessary engine oil and fuel, follow the law and other regulations.

●

WARNING

！

3.8 Disposal Of Waste Material

CAUTION

！

3.7 Tightening Torque Of Bolts And Nuts

4．TOOLS

1. Wrench

Offset wrench/Socket wrench/Adjustable wrench

2. Hexagonal wrench 3. Plier

4. External snap ring plier/Internal snap ring plier(bent type can be also used)

6. Metal and plastic hammers 7. Pulley puller

8. Screw lock agent

(Locktite 243, 272)

9. Liquid gasket

＋ー

5. Screwdriver, flat and cross

10. Hour/Tacho Meter

(PULSE ENGINE TACHOMETER PET-2000DX)

Parts No. 9800-10130

11. Torch burner

Temperature

Morethan25℃

10〜25℃

10〜0℃

Lessthan0℃

Useoil

SAE#30

SAE#30,#20

SAE#20

SAE#10

5．INSPECTION BEFORE OPERATION

Set the machine on a level surface, then

remove the oil gauge of the vibrator. Check

the oil gauge to see if the oil is at the speci-

fied level. Use engine oil SAE10W-30 as

lubrication oil.

Remove the drain plug in Vibrator Assembly

and check the oil level. Make sure the oil

quantity is set at level of plug hole for check-

ing. Every month or every 200 hours of op-

eration, replace the oil.

A regular grade gasoline should be used in

the engine. When filling the fuel tank, make

sure the fuel filter is used.

Never refuel this machine while leaving the

engine running. There is danger of fire.

Never smoke, or put other flames close to

this machine while refueling. Serious haz-

ards such as burns and fire may result.

Choose a place free from flammable sub-

stances for refueling. Be careful not to spill

fuel. In case fuel should be spilled, wipe off

the spilled fuel completely.

Clean each part of the machine well to main-

tain dirt and dust-free condition. Pay special

attention to the soil adhered to the bottom of

the vibrating plate, engine cooling air inlet,

and the carburetor and air cleaner area to

keep those parts clean.

Check each part for any looseness of bolts.

Vibration causes bolts & nuts to loosen,

which might result in unexpected accident or

malfunction.

Inspect the guard hook, belt cover and an-

ti-vibration rubber, as well as to check the

function of speed adjustment wire and

speed adjusting lever.

Check V-belt tension. The belt should have

about 10 – 15mm of flexibility when pushed

strongly with a finger at the mid-point be-

tween the axes. If V-belt is loosened, power

is not transmitted well, which reduces com-

pacting force and shortens the life of V-belt.

In addition, the generated compaction force

will lead to irregular vibrations when the

engine revolutions are increased, and may

result in a machine failure.

Set the engine on a level surface to check

the oil level. If the oil level is low, add oil.

Use the following engine oil.

●

Conduct inspection while the engine is

stopped.If you get caught in the rotating

parts, you may suffer serious damage.

Conduct inspection after making this ma-

chine level and checking that the body

does not move.

DANGER

！

Quality

Gasoline engine oil, Grade SE or above

Viscosity: SAE No. 30 at 20°C and above (summer)

SAE10W-30

Fig. 1

Upper level

Lower level

(refil needed) Oil gauge

DANGER

！

Fig. 2

※ The illustration is shown for model, "MVC-F60"

Pour water into the water tank for sprinkling

work.

Note:

Pour water only. If you should put liquids

other than water, the resin, tank cap seal,

etc. may deteriorate or swell, leading to

leakage or damage.

The water tank can be removed by pulling it

upward. When mounting the water tank

again, insert the hook into the groove of the

water tank securely. The amount of sprin-

kling water can be adjusted by the cock.

Disassembly and assembly of this machine, with inspection and change of vibrator oil included,

should be done on a horizontal surface area. Before disassembly and assembly, understand well

the normal assembly condition so that you will not make assembly error.

If oil seal, gasket, packing, O-ring or lock washer is disassembled, replace it with a new one each

time.

The contact surface between vibrating case and vibrator cover should be sealed with Packing or

O-ring. (Clean the contact surface and be careful about O-ring position when assembling.)

Apply Liquid Gasket (Three bond 1215 or equivalent) on the each side of packing of Case Cover.

When tightening bolts and nuts, tighten them according to the specified standard torque and

applying the screw lock agent (Loctite, etc.). For bolts and nuts with no specification, refer to the

“Tightening torque list”. (When applying screw lock agent, degrease and clean the screw part with

the brake cleaner, etc.)

Note) The bolts used on this machine are all of the right hand thread.

When disassembling and assembling, work in the maintenance shop without dirt and dust.

When the bolts applied the screw lock agent (Loctite, etc.) are difficult to loosen, they loosen

easily by heating them with a torch burner. Then, replace the heated bolt with a new one. It

should be a specified high tension bolt (genuine parts).

Use correct tools correctly.

6．CAUTIONS BEFORE MAINTENANCE WORK

Tightening torque list

To change the unit to kgf

・

cm, convert with 1 N

・

m = 10.197 kgf

・

cm.

(unit: kgf-cm, 1kgf-cm=9.80665N-cm)

6mm 8mm 10mm 12mm 14mm 16mm 18mm 20mm

4T(SS41) 70 150 300 500 750 1,100 1,400 2,000

6-8T(S45C) 100 250 500 800 1,300 2,000 2,700 3,800

11T(SCM3) 150 400 800 1,200 2,000 2,900 4,200 5,600

When the mating material is aluminum. 100 300～350 650～700

Thread diameter

Material

(Bolts used on the machine are all right-hand thread.)

400

750

400

Specific points Item

Tightening torque

Drain bolt for Vibrator Plug

Outside of Shock Absorber

Inside of Shock Absorber

M10 Bolts

M10 Nuts (F60H/F70H/F80H)

M10 Nuts

Tightening torque at specific points (kg-cm)

Application point Type of Screw lock agent

To assemble vibrator on vibrating plate Locktite272

To assemble case cover

Locktite243

To assemble pulley to vibrator

To assemble Clutch AY to Engine

To assemble shock absorber between

engine base and vibrating plate

Screw lock agent application point

Take off belt cover and V-belt.

Take off Vibrator AY from Vibrating plate.

If the bolts is difficult to loosen, heat the

bolts with Torch burner.

Put off Drain Plug and drain the oil from

vibrator.

Put off the bolt, pulley and key from Potor

shaft.

Put off the bolt and case cover of Recoil

starter side. And take off oil seal from case

cover.

Take off the Rotor shaft from vibrating

case. And remove bearing from Rotor

shaft.

Put off the bolts and Case cover of pulley

side from vibrating case.

Assemble in reverse order of disassembly.

Replace Oil seal, Packing and O-ring to

the new one.

Each parts especially thread parts should

be clean up.

After cleaning the bearing, maintain the

bearing. In case, replace the bearing,

please use C3 or C4 type.

Please take care the oil seal orientation,

damage and deformation.

Apply grease on Oil seal lip and Bearing

insertion part.

Apply Liquid Gasket (Three bond 1215 or

equivalent) on the each side of packing of

Case Cover.

Use Screw Lock Agent for the following

point.

Bolts to fix Vibrator AY on Vibrating

plate Locktite272.

Bolts to fix Vibrator case cover Lock-

tite243.

Bolt to fix the pulley of vibrator side

Locktite243.

7．DISASSEMBLY AND ASSEMBLY OF VIBRATOR

7.1 Disassemble

7.2 Assemble

After fixing the case cover of recoil starter

side, apply glue on the inside of Cover

Seal. And fix it on the case cover.

After assembly pour Engine oil

SAE10W-30 to Vibrator.

10.

DRAIN

PLUG

VIBRATING CASE

BEARING

KEY

ECCENTRIC

ROTOR SHAFT

BEARING

PACKING

(or O-ring)

CASE COVER(A)

OIL SEAL

PULLEY

BOLT

CASE COVER(B)

PACKING (or O-ring)

COVER SEAL

※ The illustration is shown for model, "MVC-F60"

Fig. 3

Model

MVC-40H/50H

MVC-F60H/F70H/F80H

MVC-T90H

Vibratoroilquantity

300cc

140cc

200cc

8．REGULAR CHECK AND ADJUSTMENT

8.1 Inspection And Maintenance Schedule Table

For details about the check and maintenance of the engine, please refer to the attached engine operation manual.

Caution: The above table shows the check frequency for standard condition.

The check frequency may vary depending on the condition in which the machine is used.

For check of bolt and nut looseness and tightening, please see the following tightening torque list.

Tightening torque list (unit: kgf-cm, 1kgf-cm=9.80665N-cm)

6mm 8mm 10mm 12mm 14mm 16mm 18mm 20mm

4T(SS41) 70 150 300 500 750 1,100 1,400 2,000

6-8T(S45C) 100 250 500 800 1,300 2,000 2,700 3,800

11T(SCM3) 150 400 800 1,200 2,000 2,900 4,200 5,600

When the mating material is aluminum. 100 300～350 650～700

Thread diameter

Material

(Bolts used on the machine are all right-hand thread.)

Check parts

Appearance

Fuel tank

Fuel system

Engine oil

Shock absorber

Vibrator oil

Air cleaner element

Guard frame

Bolts and nuts

Engine oil

Engine oil filter

Vibrator oil

V-belt for vibrator

Clutch

Engine bolt

Vibrator oil

Fuel filter

Fuel pipes

Air cleaner element

Check frequency

Daily

(before starting)

Every 20 hours

Every 100 hours

Every 200 hours

Every 300 hours

Every 2 years

As necessary in time

Check items

Flaw, deformation

Leakage

Leakage, oil level, dirt

Crack, damage, wear

Leakage

Dust, deformation

Breakage, flaw, loosened

or missing bolts and nuts

Looseness, missing

Replace only after]

the first 20 hours

Change

Washing

Leakage, oil level, dirt

Flaw, deformation

Dirt, flaw, wear

Wear, deformation,

degradation

Change

Oils

Engine oil

Perform the first engine oil change after 20

hours of operation, then change at every

100 hours.

When the air cleaner element becomes

dirty, the engine does not start smoothly,

and sufficient output cannot be obtained.

Machine operation will be affected and the

engine life will be shortened greatly. Do not

forget to clean the element. (For details,

please see the separate engine operation

manual.) If the element cannot be cleaned,

replace it with a new one.

8.2 Opening Engine Oil 8.3 Changing Air Cleaner

Checking V-belt

Remove the belt cover and check that

V-belt is properly stretched every 200 hours.

Press on the portion midway between the

two shafts with your fingers strongly. The

belt is properly stretched if that portion bows

by about 10-15 mm.

Checking the clutch

Inspect Clutch concurrently with the inspec-

tion of V-belt. Check visually for burning of

each clutch-shoe. Check for wear the lining

shoe or the like, in the operation check. If

the shoe wears, power transmission is not

performed properly and Clutch slips. Check

wear or any damage to V-groove also. If

V-groove is stained, clean it thoroughly.

Checking Bolt, Engine

The part of Bolt, Engine is made of rubber

material, of which the inferiority like fatigue

or worn leads V-belt tension low. Whenever

checking V-belt, inspect this part for the

reason as well as Shock Absorbing Rubber.

(Fig.4)

8.4 Checking/Changing V-belt and Clutch

Make this machine level, and remove the oil

level plug off the vibrator. Check that vibra-

tor oil is provided up to the mouth level. The

oil level plug is on the right side of the vibra-

tor case (opposite to the belt side). (Refer to

Fig.1 on page 5.)

Use the engine oil #10W-30 for vibrator oil.

Refer to page 8 for the amount. Drain the

vibrator oil completely by removing the plug

and tilting the body once a month or every

200 hours’ operation. Replace with new oil.

Replace immediately when it was found the

wear, deformation or degradation of elastic

rubber material, which may cause V-belt

come off or the engine to vibration damage

directly and excessively. ( Fig.4 )

8.6 Inspection and Change of Engine Bolt

8.5 Inspection and Change of Vibrator Oil

When the vibration weakens during op-

eration, or this machine does not

vibrate at all though the engine rotates

normally, conduct the inspection or

change of the V-belt and clutch without

regard to the regular inspection of

every 200 hours.

Always stop the engine before inspec-

tion and adjustment. If you are caught

in a rotating part, serious injury might

occur.

●

CAUTION

！

Engine bolt

Indication of replacement:

Replace Engine bolt immediately when the

thickness is less than 10 mm combined with

metal plate and rubber

< Cross section of Engine bolt >

10mm or less

※ The illustration is shown for model, "MVC-F60"

Fig. 4

Fuel is supplied, but

Spark Plug does

not ignite

Electricity reaches

to High Voltage Cable

Electricity does not

reach to High Voltage

Cable

Bridging Spark Plug

Carbon accumulated on Spark Plug

Short circuit due to insulation problems of

Spark Plug

Inappropriate gap of Spark Plug

Short circuit of Stop Switch

Ignition coil problems

Oil Sensor problem

e wrong fuel is used

Mixing of water or dust contamination

Air Cleaner not working

Intake/Exhaust Valve is stuck or pushed up

Piston Ring, Cylinder wear enough

Cylinder head, Spark Plug tightening problem

Head gasket or Spark Plug Gasket breaks

irt of Air Cleaner

Carbon accumulated in Cylinder.

Fuel Level in Carburetor inproper

Compression is

good

Compression is

not good

No fuel in tank

Fuel Cock does not open properly

Clogging of Fuel Filter

Clogging of Tank Cap Air Hole

Air trapped in fuel pipe

Fuel supplied, and

Spark Plug

ignites

Fuel does not reach

to Carburetor

Compression is

good and no firing

problem

Insufficient compression (see the item “compression is not good.” )

Compression is

good, but no firing

Water mixed in fuel

Dirt of Spark Plug

Ignition Coil problem

Lowered power

Engine overheating

Carbon accumulated inside combustion chamber and exhaust hole.

Thermal value of Spark Plug is poor

Dirt and breakage of Cooling Fin

Revolution fluctuation

Governor adjustment inappropriate

Governor Spring problem

Fuel flows in proper

Air taken from Intake Pipe line

Clogging of Pilot Jet ( Idle speed fluctuates improper)

Clogging of dust from rotating part

Weakening of Spiral Spring

9．TROUBLESHOOTING

(1) Starting problems

(2) Operation problems

(3) Recoil starter problems

Recoil starter operation not good

9.1 Engine

9.2 Main Body

Insufficient engine output and inappropriate high speed set revolution

Slipping of clutch

Slipping of V-belt

Too much vibrator oil

Failure inside vibrator

Low travel speed and

vibration weak

PRINTEDINJAPAN

MIKASASANGYOCO.,LTD.

1-4-3,Kanda-Sarugakucho,Chiyoda-ku,Tokyo,101-0064,Japan

Parchem Construction Supplies Pty Ltd

1956 Dandenong Road, Clayton VIC 3168, Australia

Phone: 1300 353 986

flextool.com.au

ABN 80 069 961 968

This manual summarises our best knowledge of the product based on the information available at the time of publication. You should read this manual carefully and

consider the information in the context of how the product will be used. Our responsibility for products sold is subject to our standard terms and conditions of sale.

DISCLAIMER:

Any advice, recommendation, information, assistance or service provided by us in this manual is given in good faith and is believed by us to be appropriate and reliable.

However, any advice, recommendation, information, assistance or service provided by us is provided without liability or responsibility PROVIDED THAT the foregoing shall

not exclude, limit, restrict or modify the right entitlements and remedies conferred upon any person or the liabilities imposed upon us by any condition or warranty implied

by Commonwealth, State or Territory Act or ordinance void or prohibiting such exclusion limitation or modification. The product can be expected to perform as indicated