Tomahawk PCR5030 Series Guide

Tomahawk
Power
Reverse Plate
Compactor
PCR5030
Operation and Instruction Manual

2
Table of Contents
1. Safety Information
1.1 Safety Precautions
1.2 Operating Safety
1.3 Operator Safety while using Internal Combustion Engines
1.4 Label Locations
3. Maintenance
3.1 Periodic Maintenance Schedule
3.2 Exciter Oil
3.3 V-Belt and Clutch
3.4 Air Cleaner
4. Technical Data
2. Operation
2.1 Controls
2.2 Operating Principle
3
3
4
5
6
14
14
15
15
16
20
8
8
9
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1.5 Safety and Operating Labels 6
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Warranty 20
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Maintenance Record 21
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2.3 Delivery Checks
2.4 Before Starting
9
9
10
12
12
13
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2.9 Operating - Driving 13
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2.10 Operation on Slope
2.11 How to Assemble Transport Wheel
13
14
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2.5 To Start
2.6 To Stop
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2.7 Application
2.8 Operation
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3.5 Spark Plug
3.6 Transport
3.7 Trouble Shooting
16
16
17
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3
This manual provides information and procedures to safely operate and maintain this
model. For your own safety and protection from injury, carefully read, understand and
observe the safety instructions described in this manual.
Keep this manual or a copy of it with the machine. If you lose this manual or need an
additional copy, please contact Tomahawk Power LLC or visit www.tomahawk-power.com
This machine is built with user safety in mind; however, it can present hazards if improp-
erly operated and serviced. Follow operating instructions carefully. If you have questions
about operating or servicing this equipment, please contact Tomahawk Power.
The information contained in this manual is based on machines in production at the
time of publication. Tomahawk Power reserves the right to change any portion of this
information without notice. No part of this publication may be reproduced in any form or
by any means, electronic or mechanical, including photocopying, without express writ-
ten permission from Tomahawk Power.
Any type of reproduction or distribution not authorized by Tomahawk Power rep-
resents an infringement of valid copyrights and will be prosecuted. We expressly reserve
the right to make technical modifications, even without due notice, which aim at
improving our machines or their safety standards.
1. SAFETY INFORMATION
1.1 Safety Precautions
This manual contains DANGER, WARNING, CAUTION, and NOTE callouts which must be
followed to reduce the possibility of personal injury, damage to the equipment, or
improper service.
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury.
DANGER
WARNING
CAUTION

CAUTION: Used without the safety alert symbol, CAUTION indicates a potentially hazard-
ous situation which, if not avoided, may result in property damage.
1.2 Operating Safety
- DO NOT modify the machine without the prior consent of the manufacturer. We do not
assume responsibility for any accident due to equipment modification.
- NEVER operate the machine for any purpose for which it is not intended.
-Slip/Trip/Fall is a major cause of serious injury or death. Beware of uneven or slippery
work surface. Make sure to maintain firm balance when operating under such condi-
tions. Especially care when working in the vicinity of unprotected holes or excavations.
-NEVER allow any person to operate the machine without adequate instruction.
-ENSURE all operators read, understand and follow the operation instructions.
-Serious injury could result from improper or careless use of the machine.
-Plate compactors are heavy units and should be positioned by two people with appro-
priate strength, using the liing handle provided with the machine according to the
correct liing techniques.
-Plate Compactor may only be used for compaction jobs.
-DO NOT operate the machine unless all protective guards are in place.
-ENSURE that the engine switch is in the OFF position and the spark plug ignition lead is
disconnected before removing the guards or making adjustments.
-ENSURE both the machine and the operator are stable by setting up on level terrain so
that the machine will not tip over, slide o or fall while in operation or unattended.
-DO NOT leave the machine in operation, while it is unattended.
-DO NOT pull the machine backward with transportation wheels, it can only be pushed
forward.
-ENSURE that the soil or subsoil to be compacted has enough load carrying capacity.
-ENSURE that the area to be compacted does not contain any “live” electrical cables,
gas, or water, which may be damaged by the action of vibration.
-Exposure to vibration or repetitive work actions may be harmful to hands and arms.
-NEVER stand on the machine while it is operating.
-Be careful and DO NOT come in contact with the muler when the engine is hot, it can
cause severe burns.
-ENSURE that the repairs to the engine and machine are carried out by competent per-
sonnel.
-DO NOT use the machine near flammable material or in explosive environments.
4

5
-Petrol is extremely flammable and explosive under certain conditions.
Fuel trapped in the cylinder may eject from the spark plug opening.
-ENSURE that the petrol is only stored in an approved storage container.
-DO NOT refuel the engine while it is in operation or hot.
-DO NOT operate or refuel the engine in a confined area without adequate ventilation.
-DO NOT refuel the engine in the vicinity of sparks, a naked flame or smoking.
-DO NOT overfill the fuel tank and avoid spilling petrol when refueling. Spilled petrol or
petrol vapor may ignite. If spillage occurs, ensure that the area is dry before starting the
motor.
-ENSURE that the fuel tank cap is securely fitted aer refueling.
-Carbon monoxide exhaust gases from engine driven units can cause death in confined
spaces.
-ALWAYS wear approved hearing protection, as excessive noise can lead to temporary or
permanent loss of hearing.
-Protective goggles and a dust mask should be worn when working in a dusty environ-
ment. Protective clothing and footwear may also be desirable when working with hot
mix bitumen.
-Store the machine properly in a clean, dry place.
1.3 Operator Safety while using Internal Combustion Engines
-DO NOT smoke when refueling the engine or operating the machine.
-DO NOT refuel a hot or running engine.
-ALWAYS keep away from all hot or spark-generating objects when refueling the engine.
-ALWAYS refill the fuel tank until the machine has cooled, and in a well-ventilated envi-
ronment.
-DO NOT spill fuel when refueling the engine.
-ALWAYS take care to use the right type of fuel.
-ALWAYS inspect the fuel leakage regularly.
-NEVER perform any work on the machine while it is running. Before working on it, stop
the engine and disconnect the spark plug wire to prevent accidental starting.
-Avoid prolonged breathing of exhaust gases.
-ALWAYS transport and handle fuel only when contained in approved safety containers.
-Avoid touching or leaning against hot exhaust pipes.
-Allow engine to cool before performing any repairs or service.

6
-ALWAYS keep the area around the muler free of debris such as leaves, paper, cartons,
etc. A hot muler could ignite the debris and start a fire.
-NEVER run the engine without the air filter.
1.4 Label Locations
1.5 Safety and Operating Labels
Tomahawk machines use international pictorial labels where needed. These labels are
described next:

7
LABEL MEANING
DANGER! Engine emits carbon monoxide; operate only in
well-ventilated areas. Read the Operator’s Manual for
machine information. No sparks, flames, or burning
objects near the machine. Shut o the engine before refu-
eling. Use only clean, filtered, unleaded gasoline.
WARNING!
Always wear hearing and eye protection when operating
this machine.
CAUTION!
Read and understand the supplied Operator’s Manual
before operating the machine. Failure to do so increase
the risk of injury to yourself or others.
CAUTION！
Liing point.
WARNING!
Injuries to hand may be caused if caught in moving belt.
Alwats replace belt guard.
WARNING!
Hot surface!
NOTICE!
Throttle control lever:
Turtle=Idle or slow,
Rabbit=Full or fast.

8
A nameplate listing of the model number and serial number
is attached to each unit. Please record the information found
on this plate so it will be available if the nameplate is lost or
damaged. When requesting service information, the serial
number should be specified in the unit.
2. OPERATION
2.1 Controls
Ref.
1
2
3
4
Description
Lever for Forward/Reverse Operation
Throttle Control
Handle
Locking Device
Ref.
5
6
7
8
Description
Liing Point
Refueling
Transport Wheel
Base Plate

9
2.2 Operating Principle
The following instructions were compiled to provide you information on how to obtain
long and trouble free use of the unit. Periodic maintenance of this unit is essential. Read
the manual in its entirety and follow the instructions carefully. Failure to do so may
injure yourself or a bystander.
2.3 Delivery Checks
Upon receiving your new machine:
-Read the handbook completely—it could save a great deal of unnecessary expense.
-Read the engine manual supplied.
-Check the general condition of the equipment –has it been damaged during delivery?
-Check engine oil level, fuel levels, and hydraulic fuel level.
Recommended lubricants are detailed in the Care and Maintenance section.
2.4 Before Starting
Before starting the machine, check the following items:
-All handles are free from grease, oil and dirt.
-All control levers are in the neutral position.
-All bolted joints are tightened.
-Fuel level.
-The tension in the V-belt.
-Oil level in the engine.
-The state of air filter.
-Hydraulic fluid level.
NOTICE: Check the hydraulic fluid level and the oil level in the engine and exciter. The
warranties are VOID if the machine is run without oil and hydraulic fluid.

10
2.5 To Start
2.5 .1 Diesel Engine
1. Oil filling and level inspections must be carried out with the engine on a flat surface.
2. Remove oil filter cap, pour the oil in and reassemble oil cap.
3. Make sure that it is nearly at max., fit the dipstick correctly back in place.
4. Check and refill oil up to the maximum level.
5. Should start-up be diicult, purge air from union as indicated in the figure.
6. Do not fill the fuel tank completely, but just up to 1cm (0.39 in) from the top of the
tank, to provide space for fuel movement. Wipe any fuel spillage from engine before
starting.
7. Remove fuel tank cap. Pour the fuel and reassemble fuel tank cap. With low ambient
temperatures (-10°C) add specific additives to diesel fuel, to avoid paraine crystals
solidification.
8. To eliminate any possible water and dirt residue from the tank bottom, remove the
plug (A) and open the cock (B) to enable discharging. Once the operation is over, close
the cock and screw back the protecting plug.
9. Accelerator at 50% speed.

11
2.5.2 Gas Engine with Electric Starter
1. Do not actuate starter for more than 20 seconds at a time. If engine does not start, wait
1 minute before repeating attempt. If engine does not start aer two attempts, trace the
cause according to the Diagnosis Chart.
2. Make sure the key is always in the (1st) position when the engine is running. Make sure
that all warning lights are o when the engine is running. For engines with a starting
panel equipped with engine protection, make sure the OK light only is ON.
3. Aer starting, idle speed for a few minutes according to table:
10. Take the handle and pull the rope soly until it is extended to its full limit. Let the
rope rewind completely. Start the engine pulling strongly on the rope.
11. To stop the engine, move the accelerator lever into the stop position.
1st Position - Warning light ON 2nd Position - Starting
Temperature Time
δ- 20° C 5’
- 20° C / - 10 ° C 2’
- 10° C / - 5 ° C 1’

12
2.5.3 Petrol Engine
1. Open the fuel tap by moving the fuel ON/OFF
lever fully to the right.
2. If starting the engine from cold, set the choke to ON
by moving the choke lever fully to the le. If restarting
a warm engine, the choke is usually not required.
However, if the engine has cooled to a degree, partial
choke may be required.
3. Turn the engine ON/OFF lever clockwise to the 1”
position.
4. Set the throttle to the idle position by moving the throttle lever fully to the right. Do
not start the engine on full throttle, as the compactor will vibrate as soon as the engine
starts.
5. Taking a firm hold of the control handle with one hand, grasp the recoil starter handle
with the other. Pull the recoil starter until the engine’s resistance is felt, then let the
starter return.
6. Take care not to pull the recoil starter fully out, pull the starter handle briskly.
7. Repeat until the engine fires.
8. Once the engine fires, gradually set the choke lever to the OFF position by moving it to
the right.
9. If the engine fails to fire aer several attempts, follow the trouble-shooting guide on
page 8.
10. To stop the engine, set the throttle to idle and turn the engine ON /OFF lever counter
clockwise to the “0” position.
11. Turn the fuel lever o.
2.6 To Stop
1. Push the throttle lever to “O” position.
2. Turn the key switch to “O” (o).
3. Close the fuel valve.
2.7 Application
Trench compaction
Road maintenance
Brick paving
Earthworks
Landscaping
Driveway topping

13
2. OPERATION
2.1 Controls
2.8 Operation
Run engine at full throttle and allow plate to pull itself along at its normal speed.
Depending on the material being compacted, three or four passes are recommended to
achieve the best compaction.
The machine is best suited to the compaction of bituminous and granular materials.
Granular soils such as silt and clay are best compacted using the impact force produced
by a vibrating rammer. Where possible, the site should be graded and leveled before
commencing compaction.
Correct moisture content in soil is vital for proper compaction. Water acts as a lubricant
and too little moisture means inadequate compaction; too much moisture leaves
water-filled voids that weaken the soil’s load-bearing ability. Compaction of dry materi-
als will be facilitated by moistening with a water hose fitted with a sprinkler. Excessive
watering or water content will cause the machine to stall.
The optional water tank kit is recommended when the machine is used on bituminous
surfaces as the water film prevents a build up of material on the underside of the plate.
2.9 Operation - Driving
2.9.1 Forward Operation:
Move the forward/reverse lever forwards.
2.9.2 Reverse Operation:
Move the forward/reverse lever backwards.
2.10 Operation on Slope
1. The operator must never stand in the direction of descent.
2. Must never exceed the Max. gradient of 20°
Max. Admissible Inclination

14
2.11 How to Assemble Transport Wheel
3. Maintenance
3.1 Periodic Maintenance Schedule
Daily
Check oil level
Check air filter
Check for damage and leaks
Check V-belt
Clean cooling system
Check exciter oil
Check hydraulic oil lever
Change exciter oil
Change engine oil
Change oil fiter
Check valve clearance
Change fuel filter
Change hydraulic fluid filter
Change hydraulic oil
Change engine oil
Clean air filter
Aer
first 20
hours
Every
500
hours
Every
1000
hours
Every
50
hours
Every
100
hours
Every
250
hours

15
These inspection intervals are for operation under normal conditions.
Adjust your inspection intervals based on the number of hours the plate
compactor is in use, and particular working conditions.
3.2 Exciter Oil
When changing the exciter oil, place the exciter on a flat, horizontal surface, remove the
drain plug located at the bottom-right of the vibrator, and simply tip the compactor to
drain the oil. Note that the oil will drain more easily while it is hot. DO NOT pour in too
much oil.
3.3 V-Belt and Clutch
3.3.1 Checking the V-Belt
Aer 200 hours of operation, remove the upper belt cover
to check the V-belt tension (Figure 2). Tension is proper if
the belt bends about 0.4 in when depressed strongly with
finger between shas. Loose or worn V-belts reduces power
transmission eiciency, causing weak compaction, reducing
the life of the belt itself.
NEVER attempt to check the V-belt while the engine is running. Severe
injury can occur if your hand is caught between the V-belt and the clutch.
Always use safety gloves, while the engine is o.
3.3.2 Checking the Clutch
With the belt removed, check the outer drum of the clutch for seizure and the “V” groove
for wear or damage. Clean the “V” groove as necessary. Wear of lining or shoe should be
checked. If the shoe is worn, power transmission will become deficient and slipping will
result.
Whenever the compactor’s vibration becomes weak or lost during normal
operation (regardless of operation hours), check the V-belt and clutch
immediately.
CAUTION
WARNING
CAUTION

16
3.4 Air Cleaner
1. The air filter should be cleaned because if clogged it may cause
issues when starting the engine, less power and may shorten the
engine’s life substantially.
2. To clean replace air filter loosen the wing nut on the air filter
housing (Figure 1), remove the cover and take out air filter
cartridge. If only cleaning of the air filter is desired blow through
the air filter cartridge from the inside, moving a jet of dry
compressed air up and down until all dust is removed.
3.5 Spark Plug
Check and clean spark plugs regularly. A fouled, dirty spark plug may cause hard starting
and poor engine performance. Set spark plug gap to recommended clearance. Refer to
engine manual.
The muler and engine cylinder become very hot during operation and
remain hot for a while aer stopping the engine. Allow engine to cool
before removing spark plug.
NOTICE: A loose spark plug can become very hot and may cause engine damage.
3.6 Transport
1. Always shut o the engine before transporting the machine.
2. Make sure liing device has enough capacity to hold machine (see nameplate on ma-
chine for weight).
3. Use liing point when liing the machine.
4. NEVER stand underneath the machine while liing.
5. Trolley wheel is optional for short distance transportation.
WARNING

17
SYMPTOM POSSIBLE CAUSES SOLUTION
Does not advance.
The V-belt is slipping.
The clutch is slipping.
Adjust or change the V-belt.
Check or change the clutch.
Lack of hydraulic oil.
Air in the circuit.
Add oil.
Check and purge the circuit.
Too much hydraulic oil. Drain the excess oil.
-Loss of oil-tightness.
-Hydraulic hose is defective. Change the defective parts.
It vibrates, but does
not move.
Travels reverse very
slowly.
Travels forward very
slowly.
Hydraulic oil leaks.
The vibrator may be on a
slippery surface.
Try on new surface.
3.7 Troubleshooting
3.7.1 Machine Troubleshooting

18
3.7.2 Engine Troubleshooting
SYMPTOM POSSIBLE CAUSES SOLUTION
Diicult to start, fuel is
available, but no SPARK
at spark plug.
Spark plug bridging.
Carbon deposit on spark plug.
Check gap, insulation or replace
spark plug.
Clean or replace spark plug.
Short circuit due to deficiency.
Improper spark plug gap.
Check spark plug insulation, replace if
needed.
Set to proper gap.
Diicult to start, fuel is
available, SPARK is
present and compression
is normal.
Wrong fuel type.
Water or dust in fuel system?
Flush fuel system and replace with
correct type of fuel.
Flush fuel system.
Air cleaner dirty. Clean or replace air cleaner.
Diicult to start, fuel is
available, and SPARK is
present at spark plug.
ON/OFF switch is shorted.
Ignition coil defective.
Check switch wiring, replace switch.
Replace ignition coil.
Improper spark gap, points dirty.
Condenser insulation worn or
short circuiting.
Set correct spark gap and clean points.
Replace condenser.
Spark plug wire broken or
short circuiting. Replace defective spark plug wiring.
Diicult to start, fuel is
available, spark is
present and
compression is low.
Suction/exhaust valve stuck or
protruded?
Piston ring and/or cylinder worn. Replace piston rings and or piston.
Cylinder head and/or spark plug
not tighetened properly.
Head gasket and/or spark plug
gasket damaged.
Torque cylinder head bolts and spark
plug.
Replace head and spark plug gaskets.
“Weak in power”
compression is proper
but misfires.
Water in fuel system.
Dirty spark plug.
Clean or replace spark plug.
Flush fuel system and replace with
correct type of fuel.
Ignition coil defective. Replace ignition coil.
No fuel present at
carburetor.
Fuel not available in fuel tank.
Fuel cock does not open properly.
Fill with correct type of fuel.
Apply lubricant to loosen fuel cock
level, replace if necessary.
Fuel filter clogged.
Fuel tank cap breather hole
clogged.
Replace fuel filter.
Clean or replace fuel tank cap.
Air in fuel line. Bleed fuel line.
Re-seat valves.

19
SYMPTOM POSSIBLE CAUSES SOLUTION
“Weak in power”
compression is proper
and does not misfire.
Air cleaner not clean.
Improper level in carburetor.
Clean or replace air cleaner.
Check float adjustment, re-build
carburetor.
Defective spark plug. Clean or replace spark plug.
Engine overheats.
Spark plug heat value improper.
Correct type of fuel.
Replace with correct type of spark plug.
Replace with correct type of fuel.
Cooling fins dirty. Clean cooling fins.
Rotational speed
fluctuates.
Governor adjusted correctly.
Governor spring defective.
Adjust governor.
Replace governor spring.
Fuel flow restricted. Check entire fuel system for leaks or clogs.
Recoil starter
malfunction.
Recoil mechanism clogged with
dust and dirt.
Spiral spring loose.
Clean recoil assembly with soap
and water.
Replace spiral spring.

20
TECHNICAL DATA
Working Size (in):
Model A B C D
PC5030 Series 49.9 39.7 27.3 19.6
Sound Specification (According to 2000/14/EC)
Model Guaranteed sound power level
PC5030 series with Petrol Engine 108dB(A)
Vibration Specification (According to ISO 2631 and EN 1033) :
Model
PCR5030 4.5 m/s2
WARRANTY
Tomahawk Power products are covered by a Warranty for a period of twelve (12) months
from the date of purchase against defects in material or workmanship provided that:
-The product concerned has been operated and maintained in accordance with the oper-
ating instructions.
-Has not been damaged by accident, misuse or abuse.
-Has not been tampered with or repaired by any unauthorized person.
The owner is responsible for the cost of transportation to and from the authorized
repairer and the unit is at the owner’s risk while in transit to and from the repairer.