Stone RP850G User manual

OPERATOR MANUAL
MODELS: RP850G and RP850D
REVISION: A 3/2002 P/N 56514
REVERSIBLE PLATE
A 100% employee-owned American manufacturer

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FOREWORD ................................................................................................................................................... 4
TECHNICAL DATA ........................................................................................................................................ 5 - 8
Machine Specifications ........................................................................................................................... 6 - 7
Noise and Vibration Data ........................................................................................................................ 8
HEALTH & SAFETY ..................................................................................................................................... 9 - 15
Safety Use ............................................................................................................................................... 10
Safety Preca tions ................................................................................................................................... 11 - 15
OPERATION ................................................................................................................................................... 17 - 24
Description .............................................................................................................................................. 18
Improper Use .......................................................................................................................................... 18
Who Is Allowed To Operate The Machine? ........................................................................................... 18
Conversions And Modifications To The Machine .................................................................................. 18
Safety Information In The Operating And Maintenance Instr ctions ..................................................... 18
Transporting The Machine ...................................................................................................................... 19
Starting The Machine .............................................................................................................................. 19
Prior to starting................................................................................................................................ 19
Starting ............................................................................................................................................ 19
Starting with battery j mp leads ...................................................................................................... 19
Starting in enclosed spaces, t nnels, mines, or deep ditches ........................................................... 19
Machine Control ..................................................................................................................................... 20
Parking The Machine .............................................................................................................................. 20
Filling F el .............................................................................................................................................. 20
Maintenance and Repairs ........................................................................................................................ 20 - 21
Handling Batteries .................................................................................................................................. 21
Testing ..................................................................................................................................................... 21
Eq ipment Overview .............................................................................................................................. 21
Operating Control At The Tow-Bar ........................................................................................................ 21 - 22
Adj sting The Tow-Bar .......................................................................................................................... 22
Operating The Engine (Honda) ............................................................................................................... 22
Starting the engine ........................................................................................................................... 22
Operating The Engine (Hatz) .................................................................................................................. 23
Starting the engine ........................................................................................................................... 23
Switching off the engine .................................................................................................................. 23
Electric start (Hatz only) ................................................................................................................. 23
Switching off the engine .................................................................................................................. 23 - 24
Operation ................................................................................................................................................ 24
Loading And Transportation ................................................................................................................... 24
MAINTENANCE ............................................................................................................................................. 25 - 28
General Notes ......................................................................................................................................... 26
Maintenance Sched le ............................................................................................................................ 27
L brication Sched le .............................................................................................................................. 28
Alternative L be Oil Table ..................................................................................................................... 28
Maintenance Work (Honda Engine) ....................................................................................................... 29
Filing p with f el ........................................................................................................................... 29
Checking the engine oil level .......................................................................................................... 29
Cleaning the air filter element ......................................................................................................... 29
Maintenance Work (Hatz Engine)........................................................................................................... 30
Filling p with f el .......................................................................................................................... 30
Checking the engine oil level .......................................................................................................... 30
Cleaning the dry air filter ................................................................................................................ 30 - 31
Cleaning .................................................................................................................................................. 31
CALIFORNIA PROPOSITION 65 WARNING ........................................................................................... 35
TABLE of CONTENTS RP850G / RP850D

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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 preven-
tion of accidents.
Stone Construction Equipment, Inc. is not
liable for the function of the machine when
used in an improper manner and 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 Yor 14471
Phone: [phone]
Fax: [phone]
Warranty Information
Please enter the following data. This will help expedite
any service or warranty work.
1. Machine Type: _______________________
Machine S/N: ________________________
. Engine Type: _________________________
Engine S/N: __________________________
3. VIN: _______________________________
4. Purchase Date: _______________________
5. Dealer/Distributor Information:
Name: ______________________________
Address: ____________________________
____________________________________
Phone #: ____________________________
Fax #: ______________________________
Location of above information:
1. Information on S/N tag.
. Information on engine tag.
3. Information on S/N tag - if applicable.
4. Date you purchased machine.
5. Dealer machine was purchased from.
FOREWORD

TECHNICAL DATA

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TECHNICAL DATA RP850G / RP850D
MACHINE SPECIFICATIONS

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TECHNICAL DATA RP850G / RP850D
MACHINE SPECIFICATIONS
RP850G / RP850D SPECIFICATIONS
MODEL RP850G RP850D
Dimensions
Length L 53.7 in (1365 mm) 53.7 in (1365 mm)
Length L1 33.9 in (860 mm) 33.9 in (860 mm)
Length L2 16.1 in (410 mm) 16.1 in (410 mm)
Height H 29.5 in (750 mm) 30.7 in (780 mm)
Height H1 40.2 in (1,020 mm) 40.2 in (1,020 mm)
Height H2 46.5 in (1,180 mm) 46.5 in (1,180 mm)
Width Basic Unit I 17.7 in (450 mm) 17.7 in (450 mm)
Width Basic Unit II 23.6 in (600 mm) 23.6 in (600 mm)
Weights
Basic Unit I 529.1 lbs (240 kg) 584.2 lbs (265 kg)
Basic Unit II 562.2 lbs (255 kg) 617.3 lbs (280 kg)
Drive
Motor Type Honda GX 270 Gasoline Hatz 1 B 30 Diesel
Type of Construction 1 Cylinder, 4-Stroke 1 Cylinder, 4-Stroke
Power 9.0 HP (6.6 kW) 6.0 HP (4.6 kW)
by speed 3,100 RPM (51.6 Hz) 3,000 RPM (50 Hz)
Cooling System Air Air
Fuel Consumption .5 gal/hr (2.1 liters/hr) .3 gal/hr (1.3 liters/hr)
Maximum Sloping Position 20°30°
Maximum Gradeability 35% 35%
Drive Via Centrifugal Clutch and V-Belt Via Centrifugal Clutch and V-Belt
Shift (forward/reverse) Hydraulic Hydraulic
Operating Speed
Basic Unit I 85 ft/min (0 - 26 m/min) 85 ft/min (0 - 26 m/min)
Basic Unit II 85 ft/min 0 - 26 m/min 85 ft/min 0 - 26 m/min
Vibration
Centrifugal Force 8,542.7 lbs (38 kN) 8,542.7 lbs (38 kN)
Vibration Frequency 3,900 VPM (65 Hz) 3,900 VPM (65 Hz)
Maximum Performance
Basic Unit I 7,535 ft2/hr (700 m2/hr) 7,535 ft2/hr (700 m2/hr)
Basic Unit II 10,075 ft2/hr (936 m2/hr) 10,075 ft2/hr (936 m2/hr)
Filing Quantities
Fuel Tank 1.6 gal (6.0 liters) 1.3 gal (5.0 liters)
Optional Extras
Vulkollan Plate X X
Protective Cover X X
Electric Starter -- X
Mounting Brackets 75 X X

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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 use.
NOISE DATA
The noise emission specified in appendix 1. subclause 1.7.4.f of the EC machine directive for
Honda 103.7 dB(A) 114.8 dB(A)
Hatz 104.7 dB(A) 114.8 dB(A)
These noise levels were measured according to ISO 3744 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, determined according to ISO 866 , part 1, is about
4.8 m/s2 (Honda) and 3.9 m/s2 (Hatz).
TECHNICAL DATA Noise and Vibration Data
The sound pressure
level at the operator
workplace is LPA
The sound power
level LWA

HEALTH & SAFETY

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HEALTH & SAFETY Sa ety Precautions
SAFETY USE
Thesemachinesaredesignedtocarry outthe function
of compacting material of the non-cohesive,
bituminous and granular varieties.
If used correctly they will provide an effective and
safemeansofcompaction andmeet theappropriate
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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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 1-800-888-99 6 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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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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HEALTH & SAFETY Sa ety Precautions
 Caution: Escaping hydraulic fluid under pressure can have sufficient
force to penetrate the skin, causing serious personal injury.
 Hydraulic fluid escaping under pressure from a very small hole can be
almost invisible. Use a piece of cardboard or wood to search for
possible leaks.
 Never use your hands to detect pressure leaks.
 Hydraulic tank temperature can reach 180o F maximum.
 Qualified personnel only. No untrained operators. Serious injury may
occur.
 Users must be trained to operate this machine. Read the Operator's
Manual and Engine Owner's Manual. Learn to operate this roller
safely.
 Do not operate across the sides of hills, machine may tip over.
 Do not operate at the edge of mats or roads, machine may tip over.
 Do not park the machine on hills.
 Hydraulic system produces high pressures--incorrect hose replacement
can cause serious personal injury. When performing service, refer to
Operator's Manual for hose identification and connections.
 Pressurized release of fluids from hydraulic system can cause serious
burns.

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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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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.
 Air conditioning refrigerants escaping into the air can damage the
Earths atmosphere. Government regulations may require a certified
air conditioning service center to recover and recycle used air
conditioning refrigerants.
 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. Engine will
start with PTO engaged if normal circuitry is bypassed.
 Start engine only from operators station with PTO disengaged or in
neutral.

OPERATION

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OPERATION RP850G / RP850D
Thi STONE machine ha been built according to
the tate-of-the-art in compliance with the pertinent
rule . Neverthele , the e machine can till
con titute a hazard to per on and property if:
- not used for the intended purpose,
- not operated by suitable qualified and
instructed personnel,
- modified or converted in an improper manner,
- the pertinent safety regulations are not
observed.
For thi rea on, any per on entru ted with the
operation, maintenance or repair of the machine i
obligated to read and follow the operating
in truction and particularly to ob erve the afety
regulation . If nece ary, thi mu t be confirmed by
the ignature of the company u ing the machine.
Furthermore, the following mu t be made known
and ob erved:
- pertinent regulations for the prevention of
accidents,
- generally recognized safety rules,
- country-specific regulations
DESCRIPTION
The RP850G/RP850D is a reversible vibrating plate
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.
The RP850G/RP850D is suitable 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 sett paving can be
compacted.
IMPROPER USE
The machine can constitute hazards if not used by
instructed personnel of for other than the intended
purpose. Machine is not to be used on hard concrete,
hardened bituminous surfacing or frozen soil.
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.
CONVERSIONS AND MODIFICATIONS TO THE
MACHINE
Unauthorized modifications and conversions 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.
SAFETY INFORMATION IN THE OPERATING
AND MAINTENANCE INSTRUCTIONS
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.
Danger:
Refers to orders and prohibitions designed to
prevent injury or extensive damage.

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OPERATION RP850G / RP850D
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.
STARTING THE MACHINE
Prior to tarting
- Park the machine on level ground.
- Check the engine oil level.
- Check the fuel level.
- Top up missing lubricants according to the
lubrication specifications chart.
- Check screw conditions for tightness.
- Check condition of engine and machine.
- Observe the safety regulations.
- Observe the operating and maintenance
instructions.
- Before putting the machine into service, please
read the operating manual for the engine.
Familiarize yourself with the operating and control
elements and 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 footware,
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.
Starting
For machines with hand start, only use the safety
cranks tested by the manufacturer and precisely follow
the operating instructions of the engine manufacturer.
To crank-start diesel engines, note the correct position
to the engine and the correct hand position on the
crank.
The hand crank must be turned with maximum force
until the engine starts, otherwise the crank can
rebound.
precisely follow the starting and stopping procedures
specified in the operating instructions and observe
indicator lights.
Only start and operate machine with an electric starter
from the instrument panel.
Starting and operation of the machine in potentially
explosive atmospheres is forbidden!
Starting with battery jump lead
Connect positive to positive and negative to negative
(earthing lead). Always connect the earthing lead last
and disconnect first! Incorrect connection will cause
serious damage to the electrical system.

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OPERATION RP850G / RP850D
Starting in enclo ed pace , tunnel , mine or deep
ditche
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
40 and 41).
MACHINE CONTROL
Operating devices that adjust themselves automatically
when released in normal use must 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
notices, 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.
PARKING THE MACHINE
Park the machine on a firm, 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.
FILLING FUEL
Only fill fuel 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.
MAINTENANCE AND REPAIRS
Observe the maintenance, inspection and adjustments
and intervals specified in the operating instructions, as
well as the information for part replacement.
Maintenance work must be undertaken only by
qualified and authorized persons.
Maintenance and repairs must only be undertaken with
the drive stationary.
Only carry out maintenance and repairs when the
machine is parked on a firm and even surface and is
secured to prevent it from rolling.
When changing larger assemblies and individual
components, only use suitable and perfectly
functioning hoisting and lifting gear with suitable
bearing capacity. Attach and secure parts to lifting gear
carefully!
Spare parts must comply with the technical
requirements of the manufacturer. Therefore only use
original spare parts.
Before working on hydraulic lines, these must
previously be rendered pressureless. Hydraulic oil
discharging under pressure can cause serious injuries.
Work on hydraulic devices must be undertaken only by
persons with a special knowledge of hydraulics and the
necessary experience.