Reversible Plate Compactor TPC400Z Operator’s Manual
1 Foreword Foreword Thank you very much for purchasing your new machine from Tomahawk Power. This Operator’s Manual contains information and procedures for the safe operation and maintenance of your new machine. In concern about your own safety and to prevent potential hazards & accidents, kindly read this manual carefully and familiarize yourself with safety information, warnings and operating procedures.
Table of Contents 1. Technical Data 18 2. Description 23 2.1 Dimensions ..................................................................................................20 2.2 Max. admissible inclination ..........................................................................20 2.3 Description of function .................................................................................21 3. Transport to work site /Recommendations on compaction 23 3.1 Transport to work site ........................
6. Faults 34 6.1 Forward speed too low ...............................................................................34 6.2 Reverse speed too low ...............................................................................34 6.3 No reverse motion ......................................................................................34 6.4 Loss of hydraulic oil ....................................................................................35 6.5 Engine does not start ...............................
Safety Information’s 2.1 Principle State of the art This machine has been designed and manufactured in accordance to the recognized safety standards and ergonomics factors. Nevertheless, when used improperly, dangers to the operator’s life and limb of the operator or to third persons or damage to the machine or other machine parts cannot be excluded. Proper use The machine must only be used for the following purposes: • • • Compaction of soils. Compaction of asphalt. Shaking in of paving stones.
Requirements for operation The ability to operate the machine safely requires: • • • Proper transport, storage and setup. Careful operation. Careful service and maintenance. • • Operate the machine only as intended and only when in proper working condition. Operate the machine in a safety-conscious manner with all safety devices attached and enabled. Do not modify or disable any safety devices. Before starting operation, check that all control and safety devices are functioning properly.
Operator's manual Always keep the operator's manual near the machine or near the worksite for quick reference. If you have misplaced the operator's manual or require an additional copy, contact your Tomahawk Power Equipments representative or download the operator's manual from the Internet (www.Tomahawk-Power.com). Always handover this operator's manual to other operators or to the future owner of the machine.
2.2 Qualification of the operating personnel Operator qualifications Only trained personnel are permitted to start and operate the machine. The following rules also apply: • • • • • • • You are at least 18 years of age. You are physically and mentally fit. You have received instruction on how to independently operate the machine. You have received instruction in the proper use of the machine. You are familiar with required safety devices.
2.3 Protective gear Work clothing Clothing should be appropriate, i.e. should be close-fitting but not restrict your movement. When on construction sites, do not wear long hair loosely, loose clothing or jewelry including rings. These objects can easily get caught or be drawn in by moving machine parts. Only wear clothing made of material that is not easily flammable. Personal protective gear Wear personal protective gear to avoid injuries or health hazards: • • • • • Non-skid, hard-toed shoes.
Lifting When lifting the machine, observe the following instructions: • • • • • • • Designate a skilled person to guide you for the lifting procedure. You must be able to see or hear this person. Use only suitable and certified hoisting gear, lifting tackle and load-bearing equipment with sufficient lifting capacities. Only use the attachment points described in the operator's manual. Attach the machine securely to the hoisting gear. Ensure that no one is nearby or under the machine.
Safety in the work area When working with the machine especially pay attention to the following points: • • Electric lines or pipes in work area. Gas lines or water lines in the work area. Starting the machine Observe the safety information and warning notices located on the machine and in the operator's manual. Never attempt to start a machine that requires maintenance or repairs. Start the machine as directed in the operator's manual.
Vibrations When manually operated machines are intensively used, long-term damage caused by vibrations cannot be precluded. Observe the relevant legal instructions and guidelines to minimize vibration stress. Details on vibration stress associated with the machine can be found in the chapter Technical Data. 2.6 Safety during the operation of vibratory plates Integrated driving mechanism Machines with integrated driving mechanism must not be set down or stored on the transport device.
Check the effects of vibration Compacting work in the vicinity of buildings can lead to structural damage. For this reason you must always check the possible effects of vibrations on surrounding buildings in the run-up to work. You must take the following points into special consideration when evaluating the effects of vibration: • Vibration behavior, sensitivity and resonance frequency of surrounding buildings. • Distance of the buildings from the vibration site (= worksite). • Condition of the soil.
Safety precautions when refueling Please observe the following safety-relevant instructions when refueling: • • • • • • • • • • • • • • Do not refuel near open flames. Do not smoke. Turn off the engine before refueling and allow it to cool down. Refuel in a well-ventilated environment. Wear fuel-proof protective gloves and, if there is the possibility of spraying, protective goggles and clothing. Do not inhale fuel vapors. Avoid skin and eye contact with fuel.
2.8 Safety during the operation of hydraulic machines Hydraulic oil • Hydraulic oil is harmful to health. • Wear safety glasses and safety gloves when handling hydraulic oil. • Avoid direct skin contact with hydraulic oil. Remove hydraulic oil from the skin immediately with soap and water. • • • • Make sure that no hydraulic oil comes gets in the eyes or on the body. See a physician immediately if hydraulic oil gets into the eyes or is swallowed. Do not eat and drink while handling hydraulic oil.
Working on the battery Always take the following safety measures when working with the battery: • • • • • • No fire, sparks, or smoking while working with batteries. Batteries contain corrosive acid. Use acid-proof protective gloves and protective goggles when working with batteries. Avoid short circuits due to improper connection or bypassing with tools. Disconnect the negative terminal first when disconnecting the battery. Connect the positive terminal first when connecting the battery.
Technical Data 1. Technical Data TPC400Z Operating weight 410 kg: Forward/reverse speed 26 m/min: Surface compaction perform 912 ance m2/h: Power transmission From drive engine directly to exciter unit via automatic centrifugal and V-belts Exciter Vibrations 70 Hz: Centrifugal force 11250 lbs per sq ft kN: Multi grade oil Shell Omala Oil 100 Oil quantity l: Drive motor Piston displacement Engine speed 0.
Hydraulic control Hydraulic oil Shell Omala Oil 100 Technical Data TPC400Z Oil quantity l: 0,4 LPA: 95 dB(A) m/s2: 3,6 m/s2 1,0 Special lubricating grase The weighted effec-tive acceleration value, determined according to EN ISO 5349 Uncertainty K (*) In accordance with the installed useful outlet power according to Directive 2000/14/EG.
Description 2.3 Description of function 2.3.1 The vibration required for compaction is produced by the exciter (5) which is firmly joined to the lower mass (8). This exciter (5) is designed as a central vibrator with aligned vibrations. Such a principle permits the direction of vibration to be changed by turning the eccentric weights. In this way an infinitely variable transition between vibration in forward motion, at standstill and in reverse motion is possible.
2.3.3 The centrifugal clutch (4) interrupts flow of power to the exciter (5) at low engine speed and thus permits perfect idling of the drive engine (11). 2.3.4 The automatic V-belt pulley (13) combined with the centrifugal clutch (4) Ensures optimum tension of the exciter V-belt (6) during operation and relief of the tension of the exciter V-belt (6) when the machine is being relocated or transported. 2.3.
Transport to work site /Recommendations on compaction 3. Transport to work site /Recommendations on compaction 3.1 Transport to work site Conditions: • To transport the vibration plate, only use suitable lifting equipment with a minimum loadbearing capacity of 500 kg. • Always switch off engine before transporting the machine! • Vertically set guide handle head and lock into place using the lock hook (41). • Only attach suitable tackle at the central lifting point (40) provided.
3.2 Recommendations on compaction 3.2.1 Ground conditions The maximum compaction depth depends on several factors relating to the ground condition, such as moisture, grain distribution etc, it is therefore not possible to specify exact values. Recommendation: In each case determine the maximum compaction depth with compaction tests and soil samples. 3.2.
Operation 4. Operation 4.1 Starting 4.1.1 Conditions: Oil: Check oil level with oil dipstick, if necessary top up with Shell Omala Oil 100 through oil filler neck. Fuel: When pouring diesel fuel into the filler neck (15), maintain absolute cleanliness. Impurities in the fuel can cause breakdowns in the injection system and premature clogging of the fuel filter. Air filter: Clean air filter dry, dusty conditions. 4.1.
Wait until the engine stops before repeating the starting procedure. NOTICEImproper use can damage the compression lever. If the engine does not start, proceed as follows before attempting to start again: 1. Press the compression lever down fully and then pull it up. 2. Start the engine again. 4.2 Mechanical oil pressure control It is necessary to reactivate the mechanical oil pressure control in the following cases: • After the initial filling - first filling - of the fuel tank or if the tank has run dry.
4.3 Forward and reverse motion The engine speed can be infinitely varied on the throttle control lever. The direction of travel is determinate with the shift lever (6). Depending on the position of the shift lever (6), the vibration plate compacts in forward direction, at standstill or in reverse direction. The forward and reverse speeds can be varied by selecting intermediate positions of the shift lever (6) or the machine can be employed for particularly intensive compaction at standstill. 4.
4.6 Additional notes on starting at very low temperatures! Never use starting sprays or similar - they are forbidden because they are dangerous. Only use original Wacker crank. If cranking, is too slow, the engine can start running in the opposite direction of rotation. In this case the air is drawn in through the exhaust and the exhaust gases excape through the air filter. Risk of fire! Switch off engine and start it again.
Maintenance 5. Maintenance 5.1 Maintenance schedule Check all external screw connections for tight fit appox. 8 hours alfter first operation. Component Maintenance work Maintenance interval Drive engine First oil change and filter. Valve clearance Cold engine: Check valve clearance, and adjust if necessary. Inlet valve 0,1 mm - outlet valve 0,2 mm. Air filter Check dry type air filter - clean or replace filter cartridge if necessary (pay attention to the maintenance indication).
5.2 Engine oil 5.2.1 Check oil level: • • Check oil level with oil dipstick (15). If the oil level is too low, top up with Fuchs Titan Unic 10W40 MC though the filler neck. 5.2.2 Changing the oil: 1. 2. 3. 4. 5. 6. Let engine warm up. Loosen oil drain screw. Loosen fastening screws and place bracket over used oil container. Remove oil drain screw and pour oil into container. Screw oil drain screw back in and refasten bracket. Pour in 1,0 l of oil through the filler neck (19).
5.3 Hydraulic control 5.3.1 Check oil level: 1. 2. 3. 4. 5. Move handle bar (23) into working position of 45 degree Move the Shock handle bar (22) to full reverse position Open filler bore (21). Oil level must be at mark, if necessary top up with hydraulic oil Shell Omala oil 100. Close filler bore (21).
5.4 Exciter 5.4.1 Check oil level: 1. 2. 3. 4. 5. Tilt the vibration plate for 10 degree. Open filler bore (25). The oil level must reach the start of the thread of the filler bore. If necessary, pour in Shell Omala oil 100 through filler bore (use funnel 0.8 l). Close filler bore. (Tightening torque 100 Nm) 5.4.2 Changing the oil: 1. 2. 3. 4. 5. Open filler bore (30). Tilt vibration plate and keep it tilted until the oil has run out. Place vibration plate in horizontal position. Pour in 0.
5.5 Exciter V-belt It is not necessary to retighten the V-belt owing to the use of the automatic centrifugal clutch. Should the V-belt width fall below 15,5 mm the V-belt must be replaced. 5.5.1 Changing the exciter V-belt: 1. Remove belt guard (5) by removing the Bolt on both sides 2. Undo screw (30). 3. Remove the centrifugal clutch (31) from the engine along with belt (32) and rotate the exciter pulley for the trouble free operation 4. Change exciter V-belt (32). 5.
Faults 6. Faults 6.1 Forward speed too low Cause Remedy To little hydraulic oil in the centre pole head. Top up hydraulic oil. Air in hydraulic control. Bleed system. 6.2 Reverse speed too low 6.
6.4 Loss of hydraulic oil Cause Remedy Leaks, Hydraulic hose defective Contact Tomahawk Power Service Dept 6.
