Stone RP522 User manual

OPERATOR MANUAL
MODELS: RP522 & RP652
REVERSIBLE PLATE
A 100% employee-owned American manufacturer
REVISION: B 5/01 P/N 56400

TABLE of CONTENTS RP522 & RP652
FOREWORD ............................................................................................................................... 5
LIMITED WARRANTY ................................................................................................................. 6
SECTION 1 - TECHNICAL DATA ................................................................................................ 7 - 10
1.1 Specifications ................................................................................................................. 8 - 9
1.2 Noise and Vibration Data............................................................................................... 10
SECTION 2 - HEALTH & SAFETY .............................................................................................. 11 - 16
SECTION 3 - OPERATION............................................................................................................ 17 - 23
3.1 General Information ....................................................................................................... 18
3.2 Description ..................................................................................................................... 18
3.3 Normal Use .................................................................................................................... 18
3. Improper Use .................................................................................................................18
3.5 Who Is Allowed To Operate The Machine? .................................................................. 19
3.6 Conversions and Modifications To The Machine .......................................................... 19
3.7 Safety Information In The Operating and Maintenance Instructions ............................ 19
3.8 Transporting The Machine............................................................................................. 19
3.9 Before Starting Operations ............................................................................................ 19
3.10 Starting The Machine ..................................................................................................... 20
3.11 Starting In Enclosed Spaces, Tunnels, Mines or Deep Ditches ..................................... 20
3.12 Machine Control ............................................................................................................ 20
3.13 Parking The Machine ..................................................................................................... 20
3.1 Filling Gasoline.............................................................................................................. 20
3.15 Operating Control At The Tow-Bar ............................................................................... 21
3.16 Adjusting The Tow-Bar ................................................................................................. 21
3.17 To Start The Engine ....................................................................................................... 22
3.18 Operation ....................................................................................................................... 22
3.19 To Stop The Engine ....................................................................................................... 22
3.20 Loading and Transportation ........................................................................................... 23
SECTION 4 - MAINTENANCE ..................................................................................................... 25 - 34
.1 Maintenance and Repairs ............................................................................................... 26
.2 Testing ............................................................................................................................ 26
.3 General Notes ................................................................................................................ 26 - 27
. Maintenance Work (Honda Engine) .............................................................................. 27
.5 Filling Up With Fuel ...................................................................................................... 27
.6 Checking The Engine Oil Level .................................................................................... 27

TABLE of CONTENTS RP522 & RP652
.7 Cleaning The Air Filter Element .................................................................................... 28
.8 Cleaning The Machine ................................................................................................... 28
.9 Screw Connections ........................................................................................................ 28
.10 Checking Rubber Buffer ................................................................................................ 28
.11 Checking The V-Belt...................................................................................................... 28 - 29
.12 Exciter: Oil Level/Oil Change ....................................................................................... 29
.13 Filling and Bleeding The Circuit ................................................................................... 29 - 30
.1 Maintenance Schedule ................................................................................................... 31
.15 Lubrication Schedule ..................................................................................................... 32
.16 Alternative Lube Oil Table ............................................................................................ 32
.17 Torque Information and Charts ...................................................................................... 33 - 3
CALIFORNIA PROPOSITION 65 WARNING ........................................................................... 35i 9

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These instructions include:
Safety regulations
Operating instructions
Maintenance instructions
These instructions have been prepared for
operation on the construction site and for the
maintenance engineer.
These instructions are intended to simplify operation
of the machine and to avoid malfunctions through
improper operation.
Observing the maintenance instructions will increase
the reliability and service life of the machine when
used on the construction site and reduce repair costs
and downtimes.
Always keep these instructions at the place of use
of the machine.
Only operate the machine as instructed and follow
these instructions.
Observe the safety regulations as well as the
guidelines of the civil engineering trade
association. Observe the safety rules for the
operation of road rollers and compactors and the
pertinent regulations for the prevention of
accidents.
Stone Construction Equipment Inc. is not liable for
the function of the machine when used in an improper
manner or for other than the intended purpose.
Operating errors improper maintenance and the use of
incorrect operating materials are not covered by the
warranty.
The above information does not extend the warranty
and liability conditions of business of Stone
Construction Equipment Inc.
Stone Construction Equipment Inc.
P.O. Box 150 Honeoye New York 14471
Phone: [phone]
Fax: [phone]
FOREWORD
Warranty Information
Please enter the following data. This will help
expedite any service or warranty work.
1. Machine Type: _______________________
Machine S/N: ________________________
2. Engine Type: _________________________
Engine S/N: __________________________
3. VIN: _______________________________
. Purchase Date: _______________________
5. Dealer/Distributor Information:
Name: ______________________________
Address: ____________________________
____________________________________
Phone #: ____________________________
Fax #: ______________________________
Location of above information:
1. Information on S/N tag.
2. Information on engine tag.
3. Information on S/N tag - if applicable.
. Date you purchased machine.
5. Dealer machine was purchased from.

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L i m i t e d W a r r a n t y
The Manufacturer warrants that products manufactured shall be free from defects in material and
workmanship that develop under normal use for a period of 90 days for concrete vibrators and electric
pumps, one year for Rhino®, Bulldog®, Wolfpac Rollers, trowels, Stompers®, saws, forward plates,
engine powered pumps, and 6 months for all other products from the date of shipment. The foregoing
shall be the exclusive remedy of the buyer and the exclusive liability of the Manufacturer. Our warranty
excludes normal replaceable wear items, i.e. gaskets, wear plates, seals, O-rings, V-belts, drive chains,
clutches, etc. Any equipment, part or product which is furnished by the Manufacturer but manufactured by
another, bearsonlythewarrantygivenbysuchothermanufacturer. (TheManufacturerextendsthewarranty
period to “Lifetime” for the drum bearings and seals for the mortar mixers, and agrees to furnish, free of
charge, the bearings and seals only upon receipt of the defective parts. The warranty is two years for
eccentric bearings on the forward plate compactors, mortar and plaster mixer drums, trowel gearboxes
andfiveyearsontheBulldogtrenchrollereccentricbearings.) A WarrantyEvaluation Formmustaccompany
all defective parts. Warranty is voided by product abuse, alterations, and use of equipment in applications
for which it was not intended, use of non-manufacturer parts, or failure to follow documented service
instructions. Theforegoingwarranty isexclusive of allother warrantieswhether writtenor oral, expressed
or implied. No warranty of merchantability or fitness for a particular purpose shall apply. The agents,
dealerand employeesofManufacturer arenotauthorized tomakemodificationtothiswarranty,or additional
warranties binding on Manufacturer. Therefore, additional statements, whether oral or written, do not
constitute warranty and should not be relied upon.
TheManufacturer’ssole responsibilityfor anybreachoftheforegoing provisionof thiscontract,withrespect
toany product orpart notconforming to theWarrantyor the descriptionherein contained,is at itsoption (a)
to repair, replace or refund such product or parts upon the prepaid return thereof to location designated
specifically by the Manufacturer. Product returns not shipped prepaid or on an economical transportation
basis will be refused (b) as an alternative to the foregoing modes of settlement - the Manufacturer’s dealer
to repair defective units with reimbursement for expenses, except labor, and be reviewed with the
Manufacturer prior to repair. AWarranty Evaluation Form must accompany all warranty claims.
Except as set forth hereinabove and without limitation of the above, there are no warranties or other
affirmations which extends beyond the description of the products and the fact hereof, or as to operational
efficiency, product reliability or maintainability or compatibility with products furnished by others. In no
event whether as a result of breach of contract or warranty or alleged negligence, shall the Manufacturer
beliable for specialor consequential damagesincluding butnot limited to:Loss ofprofitsor revenues,loss
of use of the product or any associated product, cost of capital, cost of substitute products, facilities or
services or claims of customers.
Noclaim willbeallowed forproducts lostor damagedintransit. Such claimsshould befiled withthecarrier
within fifteen days.
EffectiveApril 1, 1998.
4/98 P/N 51018
Stone Construction Equipment, Inc.
32 East Main Street, P. O. Box 150
Honeoye, NY 14471-0150
Phone: [phone] • 1-716-229-5141
Fax: [phone]
www.stone-equip.com • e-mail: [email protected]
Bred Tough, Born To Work. The
Way It Ought To Be.

1. TECHNICAL DATA

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1. TECHNICAL DATA
H
2
H
1
H
L2
L1
L
1.1 MACHINE SPECIFICATIONS

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1.1 Specifications - Stone RP522 & RP652
Dimensions in in / mm
Length L
Length L1
Length L2
Height H
Height H1
Height H2
Width basic unit l
Width basic unit ll
Weights in lbs / kg
Basic unit l
Basic unit ll
Drive
Engine Type
Type of Construction
Performance HP / kW
At Revolutions (min -1)
Cooling
Fuel Consumption (g/h / l/h)
Max. Gradient
Max. Gradeability
Drive
Control Fwd/Rvs
Operating Speed in ft/min / m/min
Basic unit l
Basic unit ll
ibration
Centrifugal Force (lbs / kN)
Vibration Frequency (vpm / Hz)
Amplitude (in / mm)
Maximum Performance in sq/ft/hr / m2/hr
Basic unit l
Basic Unit ll
Filling Quantities in gal / l
Fuel
Optional Extras
Vulkollan Plate
RP522
44.88 in / 1140 mm
23.62 in / 600 mm
10.0 in / 254 mm
24.01 in / 610 mm
40.16 in / 1020 mm
46.46 in / 1180 mm
15.75 in / 400 mm
15.75 in / 400 mm
220.5 lbs / 100 kg
220.5 lbs / 100 kg
Honda GX 120
1 cyl. 4-stroke-gasoline
4.0 HP / 2.9 kW
3600
Air
.237 g/h / 0 9 l/h
20º
35%
via centrifugal clutch
and v-belt
hydraulic
0 - 82 ft/min / 0 - 25 m/min
0 - 82 ft/min / 0 - 25 m/min
4947 lbs / 22 kN
5880 vpm / 98 Hz
.047 in / 1.2 mm
6456 sq/ft/hr / 600 m2/hr
6456 sq/ft/hr / 600 m2/hr
.66 gal / 2.5 l
X
RP652
44.88 in / 1140 mm
27.56 in / 700 mm
12.99 in / 330 mm
29.13 in / 740 mm
40.16 in / 1020 mm
46.46 in / 1180 mm
19.69 in / 500 mm
27.56 in / 700 mm
407.9 lbs / 185 kg
429.9 lbs / 195 kg
Honda GX270
1 cyl. 4-stroke-gasoline
9.0 HP / 6.6 kW
3600
Air
.55 g/h / 2 1 l/h
20º
35%
via centrifugal clutch
and v-belt
hydraulic
0 - 72 ft/min / 0 - 22 m/min
0 - 62 ft/min / 0 - 19 m/min
6519 lbs / 29 kN
5700 vpm / 95 Hz
.047 in / 1.2 mm
7101 sq/ft/hr / 660 m2/hr
8606 sq/ft/hr / 800 m2/hr
1.58 gal / 6.0 l
X

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1. TECHNICAL DATA
RP522
RP652
the sound pressure
level at the operator
place LPA
97,3 dB(A)
92,3 dB(A)
the sound power level
LWA
111,7 dB(A)
109,3 dB(A)
1.2 NOISE AND VIBRATION DATA
The following listed noise and vibration data according to the EC machine directive in the version (91/368/
EEC) was determined at the rated speed of the drive motor with vibration with the machine placed on a
resilient base.
Values can deviate in normal use depending on the conditions prevailing at the place of use.
NOISE DATA
The noise emission specified in appendix 1, subclause 1.7. .f of the EC machine directive for
These noise levels were measured according to ISO 37 for the sound power level (LWA ) and ISO 6081 for
the sound pressure level (LPA ) at the operator workplace.
Since the permissible noise rating level of 89 dB(A) can be exceeded with this machine, the
operator must wear suitable hearing protection.
VIBRATION DATA
Hand-arm vibration values according to appendix 1, subclause 3.6.3.a of the EC machine directive.
The weighted effective value of acceleration, determination according to ISO 8662, part 1, is about 10 m/s2.
Noise & Vibration Data / Torque In ormation

2. HEALTH & SAFETY

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SAFETY USE
These machines are designed to carry out the function
of compacting material of the non-cohesive, bituminous
and granular varieties.
If used correctly they will provide an effective and safe
means of compaction and meet the appropriate
performance standards.
It is essential that the driver/operator of the machine is
adequately trained in its safe operation, be authorized
to drive it, and have sufficient knowledge of the
machine to ensure that it is in full working order before
being put to use.

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2. HEALTH & SAFETY Sa ety Precautions
Before using this equipment, study this entire 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.
When warning decals are destroyed or missing, contact
the Manufacturer immediately at 1-800-888-9926 for
replacement. For the safety of yourself and others, it is
imperative that the following rules are observed. Failure
to do so may result in serious injury or death.
SAFETY PRECAUTIONS
 This notation appears before warnings in the text. It means that
the step which follows must be carried out to avoid the possibility
of personal injury or death. These warnings are intended to help
the technician avoid any potential hazards encountered in the
normal service procedures. We strongly recommend that the
reader takes advantage of the information provided to prevent
personal injury or injury to others.
FOLLOW SAFETY INSTRUCTIONS
 Carefully read all safety messages and decals in this manual and
on your machine safety signs. Keep decals in good condition.
Replace missing or damaged decals. Be sure new equipment
components and repair parts include the current safety signs.
Replacement safety signs and decals are available through your
dealer.
 Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.
 Keep your machine in proper working condition. Unauthorized
modifications to the machine may impair the function and/or
safety and affect machine life.
 If you do not understand any part of this manual and need
assistance, contact your dealer.
UNDERSTAND SIGNAL WORDS
 A signal word  DANGER, WARNING, or CAUTION  is used
with the safety-alert symbol. DANGER identifies the most
serious hazards.
 DANGER or WARNING safety signs are located near specific
hazards.
 General precautions are listed on CAUTION safety signs.
CAUTION also calls attention to safety messages in this manual.

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2. HEALTH & SAFETY Sa ety Precautions
 Never operate unit in a poorly ventilated or enclosed area.
 Avoid prolonged breathing of exhaust gases.
 Engine exhaust fumes can cause sickness or death.
HOT SURFACES
 Muffler, engine, and engine shroud may be hot.
 Allow all components in the engine compartment to cool before
performing any service work.
USE COMMON SENSE WHEN HANDLING FUELS
 Transport and handle fuel only when contained in approved
safety container.
 Do not smoke when refueling or during any other fuel
handling operation.
 Do not refuel while the engine is running or while it is still
hot.
 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 equipment if fuel or oil leaks exist - repair
immediately.
 Never operate this equipment in an explosive atmosphere.
 Keep feet clear of all plates.
 Keep work area free of bystanders.
 For foot protection, wear steel toe shoes or toe pads.
 Ear protection required when operating this equipment.

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2. HEALTH & SAFETY Sa ety Precautions
PRACTICE SAFE MAINTENANCE
 Understand service procedure before doing work. Keep area clean
and dry.
 Never lubricate, service or adjust machine while it is moving.
Keep hands, feet, and clothing from power-driven parts. Disengage
all power and operate controls to relieve pressure. Lower
equipment to the ground. Stop the engine. Remove the key. Allow
machine to cool.
 Securely support any machine elements that must be raised for
service work.
 Keep all parts in good condition and properly installed. Fix
damage immediately. Replace worn or broken parts. Remove any
buildup of grease, oil, or debris.
 Disconnect battery ground cable (-) before making adjustments on
electrical systems or welding on machine.
PREPARE FOR EMERGENCIES
 Be prepared if a fire starts.
 Keep a first aid kit and fire extinguisher handy.
 Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
WEAR PROTECTIVE CLOTHING
 Wear close fitting clothing and safety equipment appropriate to
the job.
 Prolonged exposure to loud noise can cause impairment or loss of
hearing.
 Wear a suitable hearing protective device such as earmuffs or
earplugs to protect against objectionable or uncomfortable loud
noises.
 Operating equipment safely requires the full attention of the
operator. Do not wear radio or music headphones while
operating machine.

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2. HEALTH & SAFETY Sa ety Precautions
 Starting fluid (ether) is highly flammable, do not use or an
explosion or fire may result.
DISPOSE OF WASTE PROPERLY
 Improperly disposing of waste can threaten the environment and
ecology. Potentially harmful waste used with equipment include
such items as oil, fuel, coolant, brake fluid, filters, and batteries.
 Use leakproof containers when draining fluids. Do not use food or
beverage containers that may mislead someone into drinking from
them.
 Do not pour waste onto the ground, down a drain, or into any water
source.
 Inquire on the proper way to recycle or dispose of waste from your
local environmental or recycling center.
PREVENT BYPASS STARTING
 Avoid possible injury or death from engine runaway.
 Do not start engine by shorting across starter terminal.
 Start engine only from operators station.

3. OPERATION

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3. OPERATION RP522 & RP652
3.1 GENERAL INFORMATION
This machine has been built according to the state-
of-the-art in compliance with the pertinent rules.
Nevertheless, these machines can still constitute a
hazard to persons and property if:
Not used for the intended purpose.
Not operated by suitably qualified and
instructed personnel.
Modified or converted in an improper
manner.
The pertinent safety regulations are not
observed.
For this reason, any person entrusted with the
operation, maintenance, or repair of the machine is
obligated to read and follow the operating
instructions and particularly to observe the safety
regulations.
If necessary, this must be confirmed by the signature
of the company using the machine.
Furthermore, the following must be made known
and observed:
Pertinent regulations for the prevention of
accidents.
Generally recognized safety rules.
Country-specific regulations.
3.2 DESCRIPTION
The RP522 and RP652 are reversible vibrating
plates operating on the basis of the twin-shaft
vibration system principle.
The engine drives the exciter on the baseplate via a
centrifugal clutch and a V-belt. The exciter
produces the vibration required for compaction as a
result of the built-in imbalance.
The machine is guided at the tow-bar grip. It is
operated with the operating controls on the tow-bar.
TAKE GREAT CARE ON DOWNSLOPES. THE
MACHINE COULD SLIP DUE TO LOOSE
MATERIAL OR IF THE SURFACE IS
SLIPPERY. DO NOT WORK ON HARD
CONCRETE OR SET ASPHALT SURFACING.
Equipment Overview
1. Engine
2. Central point suspension
3. Tow-bar
. Operating control/tow-bar
5. Base plate with exciter
3.3 NORMAL USE
This machine is only intended for all compaction
work in the fields of Civil Engineering and Road
Construction.
All ground materials such as sand, gravel, sludge,
crushed stone, asphalt, and composite set paving can
be compacted.
3.4 IMPROPER USE
The machine can constitute hazards if not used by
instructed personnel or for other than the intended
purpose. The machine is not to be used on hard
concrete, hardened bituminous surfacing or frozen
soil.
2 3 41
5

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3. OPERATION RP522 & RP652
3.5 WHO IS ALLOWED TO OPERATE
THE MACHINE?
Only suitably qualified, instructed, and authorized
persons over 18 years of age may operate the
machine. Maintenance and repairs, particularly on
the hydraulic system, require special knowledge and
must be undertaken only by qualified personnel.
3.6 CONVERSIONS AND MODIFICATIONS
TO THE MACHINE
Unauthorized modifications and conversion of the
machine are not permitted for safety reasons.
Spare parts and special equipment not delivered by
us are also not approved by us. The installation and/
or the use of such parts can also have a detrimental
effect on the operating safety.
The manufacturer disclaims all liability for any
damage resulting from the use of non-original parts
or special equipment.
3.7 SAFETY INFORMATION IN THE
OPERATING AND MAINTENANCE
INSTRUCTIONS
The following signs and designations are used in the
manual to designate instructions of particular
importance:
Important - Refers to special information on how to
use the machine most efficiently.
Attention - Refers to special information and/or
orders and prohibitions directed towards preventing
damage.
Refers to orders and
prohibitions designed to prevent injury or extensive
damage.
3.8 TRANSPORTING THE MACHINE
Only load and transport the machine as specified in
the operating instructions.
Only use suitable means of transport and lifting gear
with sufficient bearing capacity.
Attach suitable slinging means to the points of
attachment provided.
Only use sturdy loading ramps with sufficient
bearing capacity. The ramp inclination must be
flatter than the gradient climbing ability of the
machine.
Secure the machine to prevent it from tilting or
slipping.
It is highly dangerous to walk or stand under
suspended loads.
Secure the machine on transport vehicles to prevent
it from rolling, slipping, and tilting.
3.9 BEFORE STARTING OPERATIONS
WEAR PERSONAL PROTECTIVE
EQUIPMENT TO PREVENT LOSS OF
HEARING. OBSERVE THE SAFETY
REGULATIONS. OBSERVE THE OPERATING
AND MAINTENANCE INSTRUCTIONS.
BEFORE PUTTING THE MACHINE INTO
SERVICE, PLEASE READ THE OPERATING
MANUAL FOR THE ENGINE.
Park the machine on level ground.
Check the engine oil level.
Check the fuel level.
Top off missing lubricants according to the
lubricant chart.
Check screw connections for tightness.
Check condition of engine and machine.
WARNING
WARNING

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3. OPERATION RP522 & RP652
3.10 STARTING THE MACHINE
Prior to starting, familiarize yourself with the
operating and control elements, the mode of
operation of the machine, and the working
environment. This includes, e.g. obstacles in the
working area, bearing capacity of the ground, and the
necessary safety provisions.
Use personal protective equipment (safety footwear,
hearing protection, etc.).
Check to ensure that all safety devices are firmly in
place.
Do not start the machine if instruments or control
devices are faulty.
For machines with hand-start, only use the safety
cranks tested by the manufacturer, and precisely
follow the operating instructions of the engine
manufacturer.
Precisely follow the starting and stopping procedures
specified in the operating instructions and observe
indicator lights.
Starting and operation of the machine in potentially
explosive atmospheres is forbidden!
3.11 STARTING IN ENCLOSED SPACES,
TUNNELS, MINES OR DEEP DITCHES
Engine exhaust fumes are highly dangerous!
For this reason, when operating the machine in
enclosed spaces, tunnels, mines or deep ditches, it is
important to ensure that there is sufficient air to
breathe (see UVV Construction Work, VBG 37,
paragraphs 0 and 1).
3.12 MACHINE CONTROL
Operating devices that adjust themselves
automatically when released in normal use must not
be locked.
Check protective devices and brakes for proper
functioning prior to operation.
When reversing, particularly on the edges and banks
of ditches, as well as in front of obstacles, the
machine operator can fall or be crushed.
Always keep a safe distance away from the edges and
banks of ditches and refrain from any actions that
could cause the machine to topple over.
Always control the machine so that hand injuries
through hard objects are avoided.
Always ascend slopes carefully in a direct path.
Reverse up steep slopes to prevent the machine from
toppling over onto the machine operator.
If faults on the safety devices or other faults
detrimental to the safe operation of the machine are
noticed, operation of the machine must be stopped
immediately and the faults remedied.
When undertaking compaction work in the vicinity of
buildings or above pipelines and similar, check the
effect of the vibrations on the buildings and pipes
and stop compaction work if necessary.
3.13 PARKING THE MACHINE
Park the machine on a firm and level surface.
Shut down the drive and secure it to prevent
accidental movement and unauthorized use. If
available, close the fuel valve. Do not place or store
equipment with integrated moving gear on the
chassis. The moving gear is intended only for
transportation purposes.
3.14 FILLING GASOLINE
Only fill gasoline with the engine shut down. No
open fire, do not smoke. Do not spill any fuel.
Collect discharging fuel in a suitable container and
prevent fuel from seeping into the soil. Ensure that
the filler cap is tight.
Leaky fuel tanks constitute an explosion hazard and
must therefore be replaced immediately.