OPERATOR’S SAFETY AND SERVICE MANUAL R440 This manual covers the following serial numbers and higher for each model listed: 440H...........................4400004 SMART RAMMER MBW, Inc. MBW (UK) Ltd. 250 Hartford Rd • PO Box 440 Slinger, WI 53086-0440 Phone: (262) 644-5234 Fax: (262) 644-5169 Email: mbw@mbw.com Website: www.mbw.com Units 2&3 CochraneStreet Bolton BL3 6BN Phone: 01204 387784 Fax: 01204 387797 L18428 / 04.08.G ©MBW, Inc.
TABLE OF CONTENTS Safety Information . . . . . . . . . . . . . . . . . . . . . . 1 Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Safety Decals . . . . . . . . . . . . .
WARNING CALIFORNIA PROPOSITION 65 WARNING Engine exhaust and some of its constituents are known in the state of California to cause cancer, birth defects, and other reproductive harm.
SAFETY INFORMATION Introduction SAFE DRESS: Do not wear loose clothing, rings, wristwatches, etc. near machinery. This Safety Alert Symbol is used to call attention to items or operations which may be dangerous to those operating or working with this equipment. The symbol can be found throughout this manual and on the unit. Please read these warnings and cautions, along with all decals, carefully before attempting to operate the unit.
CAUTION Read the Operating Instructions before operating this piece of equipment. Keep unauthorized and untrained people away from this equipment. 14781 ROTATING & MOVING PARTS! Make sure all guards and safety devices are in place. Wear approved hearing protection, foot protection, eye protection and head protection.
SPECIFICATIONS 440H Operating Weight 142 lbs (64.4 kg) Height 41 in (104 cm) Width 15 in (38 cm) Length 29 in (74 cm) Engine Honda GX100 Shoe (W x L) 11 x 13.5 in (27.9 x 34.3 cm) Operating Noise Level1 93 dBA Compaction Force 3800 lbf (16.9 kN) per blow Travel Speed 55 ft/min (16.8 m/min) Compaction Area 2900 sqft/hr (269 sqm/hr) Percussion Rate up to 700 blows/min Engine Speed 3500 rpm Fuel Capacity 1.1 gal (4.2 L) Gearbox Oil Capacity 18 ounces (0.5L) Engine Oil Capacity 9.
OPERATION Introduction 4. MBW equipment is intended for use in very severe applications. They are powered by four cycle engines and are available in different sizes and a selection of engines. Choke engine if necessary (you may not need to choke a warm engine). 5. Pull starter rope repeatedly until engine starts. 6. Move choke lever to open position. 7. Allow engine to warm up for one or two minutes. This parts manual contains only standard parts.
MAINTENANCE WARNING CAUTION Always exercise the stopping procedure before servicing or lubricating the unit. Always verify fluid levels and check for leaks after changing fluids. After servicing the unit, replace and fasten all guards, shields, and covers to their original positions before resuming operation. Do not drain oil onto ground, into open streams, or down sewage drains.
2. If the oil is not visible in the sight gauge, add oil as required. See Fluid Levels for recommeneded type of oil. DO NOT OVERFILL THE PERCUSSION UNIT. Changing Percussion System Oil Refer to Lower Unit Assembly, page 16. 1. Remove the drain plug (#4) below the sight glass (#15) on the back of the springbox guard (#12). 2. Place an oil drain pan behind the shoe and tip the rammer back so the handle is on the ground. 3. Elevate the shoe until the lower assembly is horizontal.
SERVICE Assembly and disassembly should be performed by a service technician who has been factory trained on MBW equipment. The unit should be clean and free of debris. Pressure washing before disassembly is recommended. Service Tools 01629 Rubber Test Mat • Prior to assembly, wash all parts in a suitable cleaner or solvent. 06468 Springbox Tool 07205 Bellows Installation Tool 07353 Clutch Removal Tool 07552 Blind Hole Bearing Puller Tool Part No. • Check moving parts for wear and failure.
Clutch Removal 9. Refer to Engine Assembly, page 22. 1. Remove the jam nut (#8) and key (#5). Slide the clutch off engine crank. 2. Reinstall the clutch. Carefully insert woodruff key (#5) making sure key remains aligned with keyway 3. Reinstall jam nut (#8) with medium strength thread locker. Remove the gearbox assembly from the lower unit assembly. See Figure 2. Gearbox Removal NOTE: It is necessary to remove the Handle and the Engine to remove the Gearbox.
Breather Removal 1. Remove the hex head cap screw (#29) from the top of the breather assembly (#14). 2. Remove the plain washer (#30), cap (#17) and filter (#15). 3. Use a pipe wrench to remove the breather tube (#16). CAUTION Do not disassemble the breather assembly. 5. Install a retaining ring (#4) onto the pinion from inside the gearbox. 6. Press the needle bearing (#6) into the gearbox. The bearing must be pressed in with the numbers and letters facing outward.
Lower Unit Disassembly 9. NOTE: The lower unit can be separated from the drive unit (engine, gearbox and handle) without completely disassembling the rammer. If the lower unit has not already been separated, follow the “Gearbox Removal” instructions. 10. Place a drift pin or steel rod through the piston hole in the ram head (#16). Use this to hold the ram head from turning while removing the hex head cap screw and lockwasher (#20 & #21). Refer to Lower Unit Assembly, page 16. 11.
9. Remove the springbox tool rods from the assembly. CAUTION 10. The springbox warning decal (page 2, #01326) should be clean and highly visible. If not, the old decal should be completely removed and replaced with a new decal. 6. 11. Lightly oil a new o-ring (#9) and place it into the groove in the springbox guard (#12). Rotate the gearbox assembly so the front of the gearbox is aligned with the front of the lower unit. 7. 12. Slide the springbox guard over the ram head onto the springbox.
Parts Replacement Cycles and Tolerances Bearings Replace anytime a bearing is rough, binding, discolored or removed from housing or shaft. Bellows Replace when they are worn, cracked, or to the point of leaking. Clutch Replace clutch if shoes and/or springs show signs of heat damage or if it does not disengage below 2000 rpm. Crank Gear Replace if teeth are cracked or if they become sharp. Engine Components Refer to your engine manufacturer’s Owner’s Manual. Guide Bushings Replace if a 0.025” (0.
REPLACEMENT PARTS The warranty is stated in this book on page 24. Failure to return the Warranty Registration Card renders the warranty null and void. MBW has established a network of reputable distributors/ dealers with trained mechanics and full facilities for maintenance and rebuilding, and to carry an adequate parts stock in all areas of the country. Their sales engineers are available for professional consultation.
14 19 2 6 1 16 12 13 28 15 17 30 29 26 20 21 5 3 2 8 4 10 9 23 7 25 27 24 Gearbox Assembly - 14 - 22 18 11 10
ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. PART NO. 01001 01103 01105 01244 06161 06259 06262 06264 06265 06266 06274 06413 06423 06904 06905 06908 06910 09476 09618 13733 15959 16021 16304 16451 16745 18522 18525 F01PW F081304HCS F08SW DESCRIPTION RETAINING RING, EXT. 5100-137 BEARING, BALL BEARING, BALL RETIANING RING, EXT. 5160-112 ROD ASSEMBLY, CONNECTING BEARING, NEEDLE BUSHING RETAINING RING, INT. N5000-187 RETAINING RING, EXT.
24 6 23 5 16 22 3 17 7 8 19 10 12 21 20 15 11 2 1 4 9 18 Lower Unit Assembly - 16 -
ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. PART NO. 06173 06237 07154 09618 11694 16311 16323 16324 16330 16423 18135 18136 18276 18462 18475 F042005FSS F042006FWS F081318HCS F08LW 18695 18694 18693 19621 DESCRIPTION COVER O-RING, 4.122 ID X 0.103 DIA RING, CLAMPING FITTING, PLUG PARKER 4HP 50N BELLOWS, 4 PLY RING, CLAMPING, BELLOWS WASHER, 2.125 OD X 0.516 ID PISTON O-RING, 2.72 ID X 0.
Gearbox and Lower Unit Assembly - 18 -
ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. PART NO. 07203 16313 16349 16361 18133 19585 18523 F051807FWS F051810SSSD F0518HN F071418SCS F07LW F042006FWS DESCRIPTION PIN,DOWEL 1/4 x 1/2 COVER, RAMMER GEARBOX PIN, GROOVED GASKET, COVER LOWER UNIT, 440 RAMMER SHOE, CAST IRON, 11”, 13 DEG., (INCLUDES ITEMS #11 & #12) GEARBOX, 440 FWLS, 5/16-18 X 7/8 ZP SOCKET HEAD SET SCREW, 5/16-18UNC X1.
Handle Assembly - 20 -
ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 29. 30. 31. 32. PART NO.
HONDA GX100 6 11 2 7 1 5 8 4 9 10 Engine Assembly - 22 - 12 3
ITEM 1. 2. 3. 4. 5. 6. PART NO. 17164 17197 17217 17593 18053 18530 7. 8. 9. 10. 11. 12. 13. F0518FN M12CHJN Q5580402 DESCRIPTION STUD ADAPTER, GX100 REDUCER, BARBED CLUTCH, RAMMER, 4-STROKE KEY, WOODRUFF, METRIC 4X13 ENGINE, HONDA, GX100KR4, 3HP (Includes items 2, 4, 9 and 13. Also includes 7,8,13,14 on page 20) NUT, FLANGE 5/16-18 ZP NUT, HEX JAM M12 X 1.25 ZP HEX HEAD FLANGE SCREW, M8-1.25 X 40mm (Not provided by MBW Inc.) PIN, DOWEL, 6mm X 10mm (Not provided by MBW Inc.) FUEL LINE, 3/16 ID X 5.
WARRANTY WHAT DOES THIS WARRANTY COVER? MBW, Incorporated (MBW) warrants each New Machine against defects in material and workmanship for a period of twelve (12) months. "New Machine" means a machine shipped directly from MBW or authorized MBW dealer to the end user. This warranty commences on the first day the machine is sold, assigned to a rental fleet, or otherwise put to first use. batteries, and the like, all of which are sold AS IS/WHERE IS WITH ALL FAULTS.
