Operator's

Safety and

Service

Manual

GP4000

GP5500

It is the OWNER'S RESPONSIBILITY to communicate information on the

SAFE USE and OPERATION of this machine to the operators!

L1454/05.08 D

MBW Inc 2003

Printed in U.S.A.

MBW INC.

250 HARTFORD ROAD P.O. BOX 440

SLINGER, WI 53086-0440

PHONE: (262) 644-5234 FAX (262) 644-5169

WEB SITE: www.mbw.com

IN ENGLAND:

MBW (UK) LIMITED

Units 2 & 3 Cochrane Street

Bolton BL3 6BN, England

Phone: 01204 387784 FAX: 01204 387797

TABLE OF CONTENTS

SAFETY PRECAUTIONS

WARRANTY

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY NOTICE & DECALS

SAFETY DECAL LOCATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MBW WAREHOUSE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERIAL NUMBER LOCATION

OPERATING INSTRUCTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTS ORDERING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

DISASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7

8

6

7

3

4

1

2

5

REPLACEMENT AND TOLERANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

EXCITER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

HONDA ENGINE ASSEMBLY - GP4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

ROBIN ENGINE ASSEMBLY - GP5500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

HONDA ENGINE ASSEMBLY - GP5500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

YANMAR ENGINE ASSEMBLY - GP5500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

ROLL CAGE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 i

This page intentionally left blank

ii

SAFETY PRECAUTIONS

READ AND STUDY THE FOLLOWING SAFETY INFORMATION BEFORE ATTEMPTING TO OPERĆ

ATE THIS EQUIPMENT. IN ADDITION, ENSURE THAT EVERY INDIVIDUAL WHO OPERATES OR

WORKS WITH THIS EQUIPMENT IS FAMILIAR WITH THESE SAFETY PRECAUTIONS.

WARNING – LETHAL EXHAUST GAS!

An internal combustion engine discharges carbon monoxide, a poisonous, odorless invisible gas.

Death or serious illness may result if inhaled. Operate only in an area with good ventilation, NEVER IN

A CONFINED AREA!

WARNING – DANGEROUS FUELS!

Use extreme caution when storing, handling and using fuels - they are highly volatile and explosive in vapor state. Do not add fuel while engine is running. Stop and cool the engine before adding fuel. DO

NOT SMOKE!

SAFETY GUARDS

It is the owner's responsibility to ensure ALL GUARDS AND SHIELDS are in place and in working order.

IGNITION SYSTEMS

Breakerless, magneto and battery ignition systems CAN CAUSE SEVERE ELECTRICAL SHOCKS .

Avoid contacting these units or their wiring.

SAFE DRESS

DO NOT WEAR loose clothing, rings, wristwatches, etc., near machinery.

NOISE PROTECTION

Wear O.S.H.A. specified hearing protection devices.

FOOT PROTECTION

Wear O.S.H.A. specified steel tip safety shoes.

HEAD PROTECTION

Wear O.S.H.A. specified safety helmets.

EYE PROTECTION

Wear O.S.H.A. specified eye shields, safety glasses, and sweat bands.

OPERATOR

Keep children and bystanders off and away from the equipment.

REFERENCES

For details on safety rules and regulations in the United States, contact your local Occupational Safety and Health Administration (O.S.H.A.) office. Equipment operated in other countries must be operated and serviced in accordance and compliance with any and all safety requirements of that country.The

publication of these safety precautions is done for your information. MBW Inc. does not by the publiĆ cation of these precautions, imply or in any way represent that these are the sum of all dangers preĆ sent near MBW equipment. If you are operating MBW Inc. equipment, it is your responsibility to insure that such operation is in full accordance with all applicable safety requirements and codes. All reĆ quirements of the United States Federal Occupational Safety and Healthy Administration Act must be met when operated in areas that are under the jurisdiction of that United States Department.

1

SAFETY NOTICE & DECALS

IMPORTANT NOTICE

The

SAFETY ALERT SYMBOL"

is used to call attention to items or operations that may be dangerous to those operating or working with this equipment. The symbol can be found throughout the manual and on the unit itself. Please read these warnings carefully.

READ SAFETY DECALS CAREFULLY

Carefully read and follow all safety decals. Keep them in good condition. If decals become damaged, replace as required. If repainting, REPLACE ALL decals. Decal Kits are available from authorized MBW Distributors.

WARNING

When lifting, use handle bars located at base of plate.

Approximate weight:

AP2000:

GP3000Ć15:

GP3000:

GP4000:

GP5500:

175 lbs. (80 kg)

215 lbs. (98kg)

250 lbs. (114kg)

239 lbs. (108 kg)

282 lbs. (128 kg)

13478

#13478, EXCITER HOUSING

PLATES

OPERATING INSTRUCTIONS

1.

Check engine oil.

2.

Open fuel valve.

3.

Choke engine. A warm engine may not need to be choked.

4.

Open throttle part way.

5.

Pull starter rope.

6.

After starting: open choke, return throttle to idle position.

7.

During operation, when excessive kickback is noticed, maximum compaction has been reached.

8.

To stop: Return throttle to idle position, use engine stop switch, close fuel valve.

13482

#13482, BELTGUARD / DECK

WARNING

CAUTION

Read the Operating Instructions before operating this piece of equipment.

Keep unauthorized and untrained people away from this equipment.

ROTATING & MOVING PARTS! Make sure all guards and safety devices are in place.

DO NOT RUN this machine in an enĆ closed area. The engine produces carĆ bon monoxide, a POISONOUS GAS.

Wear approved hearing protection, foot protection, eye protection and head protection.

SHUT OFF the engine before servicing, cleaning or adding fuel.

Failure to comply could result in seriĆ ous bodily injury.

#13483, ON BELTGUARD

ROTATING PARTS

Keep hands away!

12878

#12878, ON EXCITER HOUSING

CAUTION

HOT SURFACE

DO NOT TOUCH

#13484, ON BELTGUARD

SURFACE CHAUDE

NE PAS TOUCHER

#09311, EXCITER HOUSING

2

#01064, ON BELTGUARD

THROTTLE

01069

#01069, THROTTLE LEVER

SAFETY DECAL LOCATIONS

WARNING

When lifting, use handle bars located at base of plate.

Approximate weight:

AP2000:

GP3000Ć15:

GP3000:

GP4000:

GP5500:

175 lbs. (80 kg)

215 lbs. (98kg)

250 lbs. (114kg)

239 lbs. (108 kg)

282 lbs. (128 kg)

13478

#13478, ON EXCITER

HOUSING

CAUTION

HOT SURFACE

DO NOT TOUCH

SURFACE CHAUDE

NE PAS TOUCHER

#09311, EXCITER HOUSING

WARNING

ROTATING PARTS

Keep hands away!

#13484, ON BELTGUARD

12878

#12878, ON EXCITER HOUSING

PLATES

OPERATING INSTRUCTIONS

1. Check engine oil.

2. Open fuel valve.

3. Choke engine. A warm engine may not need to be choked.

4. Open throttle part way.

5. Pull starter rope.

6. After starting: open choke, return throttle to idle position.

7. During operation, when excessive kickĆ back is noticed, maximum compaction has been reached.

8. To stop: Return throttle to idle position,

#13482, ON BELTGUARD GP5500,

ON DECK GP4000

#01064, ON BELTGUARD

CAUTION

Read the Operating Instructions before operating this piece of equipment.

Keep unauthorized and untrained people away from this equipment.

ROTATING & MOVING PARTS! Make sure all guards and safety devices are in place.

DO NOT RUN this machine in an enclosed area.

The engine produces carbon monoxide, a POIĆ

SONOUS GAS.

Wear approved hearing protection, foot protection, eye protection and head protection.

SHUT OFF the engine before servicing, cleaning or adding fuel.

Failure to comply could result in serious bodily injury.

#13483, ON BELTGUARD

THROTTLE

01069

#01069, ON THROTTLE LEVER

3

WARRANTY

WARRANTY

THIS IS YOUR WARRANTY - PLEASE READ AND SAVE

1.

MBW Inc.

, Slinger Wisconsin, warrants each new machine against defects in material and workmanship under normal use and service for a period of six (6) months. This warranty commences the first day the machine is sold, assigned to a rental fleet, or otherwise put to first use.

2. The obligation under this warranty is limited to the replacement or repair of parts and/or machine at MBW

Inc.

factory branches or at authorized MBW Inc.

Distributors.

3. Machines altered or modified without MBW Inc.

written consent voids this warranty. Misuse, negligence, accidents or the operation of machines in any way other than recommended by MBW Inc.

will void this warranty. This warranty shall not apply to machines repaired by other than MBW Inc.

factory branches or authorized MBW Inc.

Distributors.

4. This warranty includes labor on all MBW Inc.

products. Labor must be performed at an authorized MBW

Inc.

Distributor.

5. The cost of transportation and other expenses connected therewith are not covered by this warranty.

6. Written authorization for the return of merchandise under warranty must be obtained from MBW Inc.

,

Slinger, Wisconsin. In England: MBW (UK) LIMITED, Bradley Fold Trading Estate Unit 6, Radcliffe Moor

Road, Bolton BL2 6RT.

7.

MBW Inc.

reserves the right to inspect and render final decision on each warranty case.

8.

MBW Inc.

reserves the right to improve or make product changes without incurring any obligation to update, refit, or install the same on machines previously sold.

9.

MBW Inc.

is not responsible for any liability or damage or injury directly or indirectly from design, material or operation of its products.

10. Warranty card must be returned to MBW Inc.

, P.O. Box 440, Slinger, Wisconsin 53086-0440, within 10 days after purchase, assignment to a rental fleet, or first use. In England: MBW (UK) LIMITED, Bradley Fold

Trading Estate Unit 6, Radcliffe Moor Road, Bolton BL2 6RT. Failure to return warranty card as specified renders the warranty null and void.

11. Requests for warranty must be submitted in writing within 30 days after machine failure to MBW Inc.

, P.O.

Box 440, Slinger, Wisconsin 53086-0440. In England: MBW (UK) LIMITED, Bradley Fold Trading Estate

Unit 6, Radcliffe Moor Road, Bolton BL2 6RT.

12. THE FOREGOING WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR

IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE, AND OF ALL

OTHER OBLIGATION OR LIABILITIES ON OUR PART, AND WE NEITHER ASSUME NOR AUTHORIZE ANY

OTHER PERSON TO ASSUME FOR US ANY OTHER LIABILITY OR WARRANTY IN CONNECTION WITH

THE SALE OR SERVICE OF ANY OF OUR PRODUCTS. LIKEWISE, THIS WARRANTY SHALL NOT APPLY

WITH RESPECT TO ENGINES, MOTORS AND OTHER COMPONENT PARTS PRODUCED BY OTHER

MANUFACTURERS AND USED ON MBW PRODUCTS, BUT SUCH ITEMS SHALL HAVE SUCH

WARRANTIES AS MAY BE PROVIDED BY THE MANUFACTURER THEREOF.

MBW INC.

250 HARTFORD ROAD P.O. BOX 440

SLINGER, WI 53086-0440

PHONE: (262) 644-5234 FAX (262) 644-5169

MBW CORPORATE INTERNET ADDRESS

E-MAIL: [email protected]

IN ENGLAND:

MBW (UK) LIMITED

WEB SITE: www.mbw.com

Units 2 & 3 Cochrane Street

Bolton BL3 6BN, England

Phone: 01204 387784 FAX: 01204 387797

4

MBW WAREHOUSE LOCATIONS

is at your service

MBW Inc. has established a network of reputable Distributors 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. If you cannot locate an MBW Inc. Distributor in your area, contact one of our Sales Branches or MBW Inc. The locations and phone numbers of the

Sales Branches are listed below.

Remember - you own the best. If repairs are needed use only MBW Inc. parts purchased from

Authorized MBW Inc. Distributors.

Sales Branches:

2 . MBW (UK) LIMITED 1 . MBW Inc.

250 Hartford Rd.

P.O. Box 440

Slinger, WI 53086Ć0440

Phone: (262) 644Ć5234

FAX: (262) 644-5169

E-MAIL ON THE WORLD WIDE WEB [email protected]

WEB SITE ON THE INTERNET www.mbw.com

Units 2 & 3 Cochrane Street

Bolton BL3 6BN, England

Phone: 01204 387784

FAX: 01204 387797

1

Great Britain

2

5

SPECIFICATIONS

GP4000 GP5500

Operating Weight

Plate Size -

W x L

Compaction Force

Exciter Speed

Compaction Depth

UNITS lbs (kg) in

(cm) lb (kg) vpm in (cm)

GP4000H

224 (102)

21 X 25

(53 X 64)

4200 (1905)

4700

18 (47)

GP5500H

275 (125)

23 X24

(58 X 61)

5800 (2610)

4700

20 (51)

GP5500R

273 (124)

23 X 24

(58 X 61)

5800 (2610)

4700

20 (51)

GP5500Y

287 (130)

23 X 24

(58 x 61)

5800 (2610)

4700

20 (51)

Travel Speed (Fwd, Rev)

Operating Noise Level 1

Compaction Area

Normal Operating Engine Speed 4

Engine Idling Speed 5 ft/min (m/min) dBA @ operator's ear sqft/h (sqm/h) rpm rpm

130 (38)

90 2 -98 3

13650 (1268)

3400

1200

130 (38)

90 2 -98 3

14950 (1450)

3400

1200

130 (38)

90 2 -98 3

14950 (1450)

3400

1200

130 (38)

90 2 -98 3

14950 (1450)

3400

1200

Engine Model

Power Rating @ Normal Operating

Speed hp (kW)

Honda GX160

5.5 (4.1)

Honda GX270

8 (6)

Robin EX27

8 (6)

Yanmar Diesel

L60E-D

6 (4.5)

1.

Noise levels are based on operating conditions. Background noise will increase noise levels.

2.

Unit operating on loose gravel surface material.

3.

Unit operating on highly compacted coarse gravel surface material. Hearing protection is recommended and may be required by law. It is the users responsibility to assess the noise level at the operation site and determine whether hearĆ ing protection is required.

4.

Normal motor operating speed is factory preset. If this needs adjustment contact your nearest MBW Sales Branch, or

MBW Inc.

5.

Motor idle speed is factory preset and adjustment should not be required. If the unit needs adjustment refer to the enĆ gine owner's manual.

6

SERIAL NUMBER LOCATION

1. The serial number decal is located on top of the engine deck, behind the engine.

2. The serial number is also stamped on the side of the exciter housing.

STAMPED LOCATION

EXCITER HOUSING

(Write model number in box)

(Write serial number in box)

GP4000 LOCATION

The units Year of Manufacture can be determined by the serial number. Contact your nearest Sales

Branch or MBW Inc. for this information.

GP5500 LOCATION

PARTS ORDERING PROCEDURE

The Warranty is stated in this book on page NO TAG. Failure to return Warranty Registration Card renders the

Warranty null and void.

An Owner's Manual" for the engine is also furnished. Engine parts may be ordered from any authorized dealer.

Refer to the engine Owner's Manual" for exploded views and part identifications.

PARTS ORDERING:

MBW Inc. parts are available worldwide and must be ordered through your local MBW Inc. Distributor. If you canĆ not locate an MBW Inc. Distributor in your area, refer to page NO TAG of this manual to locate the MBW Inc.

Sales Branch nearest you and call for assistance.

ALWAYS INCLUDE :

1. Model and Serial Number of machine when ordering MBW Parts .

2. Model and Serial Number of engine when ordering Engine Parts .

3. Item Part Number, Description, and Quantity.

4. Company Name, Address, Zip Code, and Purchase Order Number.

5. Preferred method of shipping.

REMEMBER - you own the best. If repairs are needed use only MBW Inc. parts purchased from

Authorized MBW Inc. Distributors.

7

OPERATING INSTRUCTIONS

INTRODUCTION

MBW Inc. Compaction Equipment is intended for use in very severe applications. They are powĆ ered by four cycle engines and are available in different sizes and a selection of engines.

This parts manual contains only standard or standard option parts. Variations of these parts as well as other special parts are not included. Contact your local MBW, Inc. Distributor for assisĆ tance in identifying parts not included in this manual.

BEFORE OPERATION

Check for damage to unit upon initial receipt and startup.

REMEMBER!

It is the owner's responsibility to communicate information on the safe use and proper operation of this unit to the operators.

Before operating, review

SAFETY PRECAUTIONS

listed on page 1 of this manual.

Familiarize yourself with the operation of the unit and confirm that all controls function properly

BEFORE

starting engine.

Know how to

STOP

the unit.

Make sure hands, feet, and clothing are at a safe distance from any moveable parts prior to starting.

OIL LEVEL -

Check the oil level in the engine. For more information see

Engine oil

in the engine Owner's Manual".

AIR CLEANER -

Check to ensure element is in good condition and properly installed.

Clean filter element if it's clogged. Replace it if it's damaged.

FUEL SUPPLY -

The engines on MBW Inc. Compaction equipment require a high grade of clean, fresh, unleaded gasoline.

FUEL FILTER -

Check to ensure element is in good condition. Replace it if it's clogged or damaged.

8

STARTING ENGINE

For detailed instructions refer to engine Owner's Manual.

1. Open throttle slightly. WARNING!! The enĆ gine speed must NOT be high enough to enĆ gage the clutch!

3. Open fuel valve.

4. Turn engine switch to the On" position.

2. Choke engine if necessary. (You may not need to choke a warm engine.)

5. Pull starter rope.

6. After engine starts, move choke lever back to open position.

OPERATING

1. After engine warms up, pull throttle lever to acĆ celerate engine speed. Plate will begin vibratĆ ing and move forward. There is no neutral position.

2. Run the unit on the ground being compacted until excessive kickback is noticed or when inĆ dicated by soil testing methods. DO NOT opĆ erate on extremely hard surfaces such as concrete.

3. When working on sloped surfaces, hitch a towĆ ing rope to the compactor and have an assisĆ tant help pull the compactor uphill.

STOPPING

1. Move throttle lever to idle position and allow engine to return to an idle speed.

2. Turn the engine switch on the Honda Engine to the Off" position.

3. Close fuel valve

STOP THE ENGINE BEFORE:

ADDING FUEL OR OIL

LEAVING EQUIPMENT UNATTENDED, FOR ANY AMOUNT OF TIME

MAKING ANY REPAIRS OR ADJUSTMENTS TO UNIT

LIFTING/TRANSPORTATION

1. The unit may be lifted by the handles provided on the front of the plate and the handle in the back of the unit on the deck. If your unit has a roll cage, it may be lifted by the upper section of the roll cage. DO NOT lift the unit by the hanĆ dle as it may cause injury or damage.

2. The unit should be transported in the upright position and secured or tied down by the roll cage or handles provided on the plate. DO

NOT lay the machine on its sides or top.

9

SERVICE INSTRUCTIONS

NEVER attempt to service or lubricate unit with engine running.

After servicing unit, restore 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.

CHECKING EXCITER DRIVE BELT

Refer to FIGURE 3, page 20.

1. Remove beltguard (item #15).

2. Replace drive belt if it is damaged or cracked.

3. Apply moderate thumb pressure to the drive belt halfway between the pulleys. The belt should deflect approximately 3/8"(9mm).

NOTE: If the shockmounts (item #2) move, apply less pressure.

4. If belt deflects more than 3/8"(9 mm), it must be tightened. To tighten belt, loosen the four enĆ gine mounting screws. Pull the engine back and retighten the four screws.

5. Repeat step 3.

6. When proper belt deflection is reached, reinĆ stall beltguard.

CHECKING EXCITER OIL

Change Exciter Oil every year or 500 hours, whichever comes first. MBW recommends the use of its own Ground Pounder Exciter Oil exclusively (see Exciter Oil, page 16). Failure to do so could result in premature exciter failure.

1. Clean debris from exciter housing and plate.

Place unit on a flat, level surface.

2. Remove bolt on exciter cover (see FIGURE 1).

3. The oil level should be up to the bottom of the bolt hole. If oil level is low, add Ground

Pounder Exciter Oil.

4. Allow excess oil to run out.

5. Reinstall bolt using Teflon sealant.

6. Discard oil and other contaminated debris in a proper container.

FIGURE 1: OIL PLUG LOCATION

10

CHANGING EXCITER OIL

MBW recommends the use of its own Ground Pounder Exciter oil exclusively (see Exciter Oil, page 16). Failure to do so could result in premature exciter failure.

1. Clean debris from exciter housing and plate.

Place unit on a flat, level surface.

5. Pour 6 oz. of Ground Pounder exciter housing.

Exciter Oil into

2. Remove bolt on exciter cover (see FIGURE 1, page 10).

3. Tilt the unit 90° on its side so the oil drains into a container.

4. Tilt unit to an upright position and clean excess oil off the unit. DO NOT allow any debris into the housing.

6. Allow excess oil to run out.

7. Reinstall bolt using Teflon sealant.

8. Discard oil and other contaminated debris in a proper container.

CLEANUP

1. Clean dirt and debris from Ground Pounder daily.

2. Replace any decals that become damaged.

3. If repainting Ground Pounder , BE SURE that

ALL DECALS which apply to your unit are masked properly or replaced.

11

DISASSEMBLY INSTRUCTIONS

CAUTION: Assembly and Disassembly should be performed by a service technician who has been factory trained on MBW Inc. equipment.

The unit should be clean and free of debris, especially around the exciter housing cover. Steam cleaning is recommended.

ENGINE REMOVAL

1. Remove beltguard.

2. Remove the four engine mounting screws and mounting bars.

3. Remove belt from engine.

4. Lift engine off.

EXCITER DISASSEMBLY

Refer to FIGURE 2, page 18.

1. Clean the housing and drain the oil (see

CHANGING EXCITER OIL, page 11).

2. Remove pulley (item #1) and key (item #8) for

GP4000 . Remove the tapered bushing (item

#13) and sheave (item #12) for GP5500 . Refer to FIGURE 3, page 20.

3. Remove six bolts (item #15) from exciter cover.

4. Install two of the bolts you just removed, into the holes with plugs. Run them in evenly as far as you can, this will remove the cover and the exciter shaft assembly.

5. Remove cover gasket (item #4).

6. Remove seal (item #8) from cover.

(You will destroy the seal)

7. Remove retaining ring (item #11) and press out exciter shaft (item #5) from the cover.

8. Remove retaining ring (item #2) and press out the bearing (item #9) from the cover.

9. Remove six bolts (item #15) from exciter cover on other side.

10.Repeat steps 4 and 5.

11.Remove retaining ring (item #2) and press out the bearing (item #7) from the cover.

12

HANDLE DISASSEMBLY

Refer to FIGURE 3, page 20.

1. Remove cotter pins (item #5).

2. Unscrew the hex head cap screws (item #21) with lockwashers (item #23) from handle brackets (item #11).

3. Remove the handle.

DECK REMOVAL

Refer to FIGURE 3, page 20.

1. Remove four hex head cap screws (item #20 &

#21) with lockwashers (item #23).

2. Lift deck from housing assy (item #16).

13

ASSEMBLY INSTRUCTIONS

Prior to assembly wash all parts in a suitable cleaner or solvent.

Check moving parts for wear and failure. Refer to REPLACEMENT AND TOLERANCE CHART for tolerances and replacement cycles.

Replace all seals and gaskets at every overhaul or disassembly.

For torque settings other than those listed, see torque chart.

EXCITER ASSEMBLY

Refer to FIGURE 2, page 17.

1. Press bearing (item #7) into cover (item #10).

Then, install retaining ring (item #2) into posiĆ tion.

2. Apply a thin layer of grease to outer flange and put a new gasket (item #4) in place.

3. Press this assembly, into the housing assemĆ bly (item #12). Be sure to place oil drain in the down position.

Then, install the six flange whiz-lock screws (item #15).

4. Press bearing (item #9) into cover (item #6).

Then, install retaining ring (item #2) into posiĆ tion.

5. Press exciter shaft (item #5) into cover assemĆ bly. Then, install retaining ring (item #11) into position.

6. Press a new seal (item #8) into cover (item #6).

7. Press this assembly, into the housing assemĆ bly (item #12). Then, install the six flange whiz-lock screws (item #15).

8. Install pulley (item #1, fig. 3) and key (item #8, fig 3) for GP4000 . Install the tapered bushing

(item #13, fig 3) and sheave (item #12, fig 3) for GP5500 .

DECK ASSEMBLY

Refer to FIGURE 3, page 19.

1. Install the two hex head cap screws (item #21) with lockwashers (item #23) into the front mounts.

2. Install the remaining two hex head cap screws

(item #21) with lockwashers (item #23) into the rear mounts.

14

HANDLE ASSEMBLY

Refer to FIGURE 3, page 19.

1. Install handle brackets (item #11) onto the handle.

2. Install hex head cap screws (item #21) with lockwashers (item #23).

3. Install cotter pins (item #5). Make sure nylon bushings (items #3 & #4) are in place.

ENGINE ASSEMBLY

1. Place engine on deck.

2. Install four engine mounting screws and mounting bars. DO NOT TIGHTEN

3. Install the drive belt.

4. Refer to checking exciter drive belt section on page 10 and do steps 2 thru 6.

15

REPLACEMENT AND TOLERANCE CHART

Part

Air Cleaner Element

Bearings

Clutch

Exciter Oil

TOLERANCE OR REPLACEMENT CYCLE

Replace after 50 hours if engine is operating under good clean air conditions. Service and replace more frequently if under extremely dusty or dirty conditions.

Replace anytime a Bearing is rough, binding or discolored.

Replace the Clutch if the Shoes and Spring show signs of heat damĆ age or if the Clutch engages below 2000 rpm.

Replace once every season or every 500 hours. Use 6 ounces of oil from the 6Ćpack of MBW #01058 Ground Pounder Exciter Oil.

Hardware

Seals and Gaskets

Spark Plug

ReĆtorque all bolts after the first eight hours of operation and check every 25 hours.

Replace at every overhaul or teardown and when exciter is rebuilt.

See the engine manufacturer's Operator's Manual.

Special MBW Tools and Kits #00134 Universal Load Cart

#01058 6ĆPack Ground Pounder Exciter Oil

#01603 Kit, Decal GP4000/5500

Safety Decals

#01629 Test Mat, Rubber

#02484 Kit, Roll Cage GP5500

#07585 Kit, Gasket and Seal

#13907 Kit, Roll Cage GP4000

Replace if they become damaged or illegible.

TORQUE CHART

SIZE

10Ć24

10Ć32

1/4Ć20

1/4Ć28

5/16Ć18

5/16Ć24

3/8Ć16

3/8Ć24

7/16Ć14

7/16Ć20

1/2Ć13

1/2Ć20

TIGHTENING TORQUE

GRADE 2

32 inĆlb

32 inĆlb

70 inĆlb

85 inĆlb

150 inĆlb

165 inĆlb

260 inĆlb

300 inĆlb

35 ftĆlb

45 ftĆlb

50 ftĆlb

70 ftĆlb

GRADE5

40 inĆlb

32 inĆlb

115 inĆlb

140 inĆlb

250 inĆlb

270 inĆlb

35 ftĆlb

40 ftĆlb

55 ftĆlb

75 ftĆlb

80 ftĆlb

105 ftĆlb

CONVERSIONS

in lbs x 0.083 = ftĆlbs ft lbs x 12 = inĆlbs ft lbs x 0.1383 = kgĆm ft lbs x 1.3558 = N m

REMEMBER - you own the best. If repairs are needed use only MBW Inc. parts purchased from

Authorized MBW Inc. Distributors.

16

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17

FIGURE 2: EXCITER ASSEMBLY

18

EXCITER ASSEMBLY

18.

19.

20.

21.

26.

27.

28.

29.

22.

23.

24.

25.

30.

31.

32.

ITEM NO PART NO DESCRIPTION

1.

00066 FILTER RETAINER

6.

7.

8.

4.

5.

2.

3.

01000

01072

06098

07446

12822

07455

07456

07457

INTERNAL RETAINING RING

FILTER

GASKET

EXCITER SHAFT (GP5500)

EXCITER SHAFT (GP4000)

FRONT COVER

CYLINDRICAL ROLLER BEARING

OIL SEAL

13.

14.

15.

16.

17.

9.

10.

11.

12.

07458

07460

07469

13856

SPHERICAL ROLLER BEARING

REAR COVER

EXTERNAL RETAINING RING

EXCITER HOUSING (GP4000)

13857

F0205SP

EXCITER HOUSING (GP5500)

SPIROL PIN, 1/8" x 5/8"

F051804HCS HEX HEAD CAP SCREW, 5/16-18 x 1/2"

F051808FWS FLANGE WHIZ-LOCK SCREW, 5/16-18 x 1"

F05BFW BRASS FLAT WASHER, 5/16"

F0618SPP SOCKET PIPE PLUG, 3/8-18

19

2

12

1

1

1

5

1

1

QTY

1

1

1

1

1

2

1

2

1

1

1

FIGURE 3: PLATE ASSEMBLY

20

PLATE ASSEMBLY

ITEM NO PART NO DESCRIPTION

1.* 00003 EXCITER PULLEY

6.*

7.**

8.*

9.**

4.

5.

2.

3.

01011

01018

01019

01056

01099

01161

01283

02715

SHOCKMOUNT

OUTER NYLON BUSHING

INNER NYLON BUSHING

HAIRPIN

WASHER

KEY, 1/4" x 1/4" x 1Ć1/2"

KEY, 1/4" x 1/4" x 1Ć1/4"

HANDLE SPACER (NOT SHOWN BETWEEN DECK AND SHOCKMOUNTS)

10.

11.

12.**

13.**

02717

06921

07452

07453

HANDLE ASSEMBLY (Includes items 3 & 4)

HANDLE BRACKET

TWO GROOVE SHEAVE

SPLIT TAPER BUSHING

14.

15.

12637

12832

12879

13861

ENGINE DECK

BELTGUARD (GP4000)

BELTGUARD (GP5500)

EXCITER & PLATE ASSEMBLY (GP4000) 16.

13862 EXCITER & PLATE ASSEMBLY (GP5500)

17.** F051808HCS HEX HEAD CAP SCREW, 5/16-18 x 1"

18.*

19.

20.

F051814FWS FLANGE WHIZ-LOCK SCREW, 5/16-18 x 1Ć3/4"

F061607FWS FLANGE WHIZ-LOCK SCREW, 3/8-16 x 7/8"

F081305HCS HEX HEAD CAP SCREW, 1/2-13 x 5/8"

21.

22.**

23.

24.

25.

26.

F081306HCS HEX HEAD CAP SCREW, 1/2-13 x 3/4"

F081310HCS HEX HEAD CAP SCREW, 1/2-13 x 1Ć1/4"

F08LW

F08PW

LOCKWASHER, 1/2"

PLAIN WASHER, 1/2"

27.

28.

29.

30.

* PARTS USED ON GP4000 ONLY

** PARTS USED ON GP5500 ONLY

21

1

1

1

1

1

1

1

2

1

3

1

3

2

14

4

16

2

QTY

1

1

2

1

1

2

2

8

2

4

9

7

5

2

6

8

10

1

3

FIGURE 4: HONDA ENGINE

HONDA ENGINE ASSEMBLY - GP4000

ITEM NO PART NO DESCRIPTION

8.

9.

6.

7.

10.

3.

4.

5.

1.

2.

00031

00032

01182

01444

16105

MOUNTING BAR

KEY, 3/16" SQUARE x 1Ć5/8" LONG

V-BELT, AĆ34

ENGINE, HONDA GX160 5.5 hp

CENTRIFUGAL CLUTCH (S/N 1151054 and above)

05999

14993

CENTRIFUGAL CLUTCH (S/N 1151053 and below)

COUNTERSINK WASHER

F051814HCS HEX HEAD CAP SCREW, 5/16-18 x 1Ć3/4" LONG

F052408FSS FLAT HEAD SET SCREW, 5/16-24 x 1" LONG

F05LW

F05SW

LOCKWASHER, 5/16"

PLAIN WASHER, 5/16"

QTY

1

1

1

2

1

1

4

1

4

4

22

6

2

5

4

3

1

7

9

10

8

FIGURE 5: ROBIN EX27 ENGINE

ROBIN ENGINE ASSEMBLY - GP5500

ITEM NO PART NO DESCRIPTION

7.

8.

9.

10.

11.

12.

3.

4.

5.

6.

1.

2.

17440 ENGINE, ROBIN EX27 9 HP

05909

06469

SPACER

SKYHOOK

F061608FWS FLANGE WHIZ-LOCK SCREW, 3/8-16 X 1"

07932

07877

TERMINAL, PIN STYLE FEMALE

CASING, LINED THROTTLE WIRE

07662

06361

WIRE, THROTTLE

KIT, CABLE CLAMP

F061614HCS HEX HEAD CAP SCREW, 3/8-16 X 1-3/4"

F0616FN HEX WHIZ-LOCK NUT, 3/8-16

QTY

4

4

1

1

1

4

1

1

1

4

23

1

7

6

3

5

9

8

4

2

FIGURE 6: HONDA ENGINE

HONDA ENGINE ASSEMBLY - GP5500

ITEM NO PART NO DESCRIPTION

8.

9.

6.

7.

10.

11.

12.

3.

4.

5.

1.

2.

15674 ENGINE, HONDA, GX270 16.5 cu/in (270 cu/cm)

05935

06934

12968

14992

V-BELT, AXĆ35

DOUBLE GROOVE CENTRIFUGAL CLUTCH

MOUNTING BAR

COUNTERSINK WASHER

F061614HCS HEX HEAD CAP SCREW, 3/8-16 x 1Ć3/4" LONG

F06LW LOCKWASHER, 3/8"

F06SW PLAIN WASHER, 3/8"

F072008FSS FLAT HEAD SET SCREW, 7/16-20 x 1" LONG

QTY

1

2

1

1

2

4

1

4

4

24

14

11

1

2

20

4

5 13

12

19

17

15

16

PTO SIDE

10

8

7

16

15

18

23

21

27

24

29

30

26

22

25

3 18

9

SPRING ATTACHES AS SHOWN,

USE THE THIRD HOLES FROM

CENTER PIVOT.

GOVERNOR ATTACHED

TO ENGINE

6

FIGURE 7: YANMAR ENGINE

YANMAR ENGINE ASSEMBLY - GP5500

ITEM NO PART NO DESCRIPTION

25.

26.

27.

28.

29.

30.

21.

22.

23.

24.

17.

18.

19.

20.

13.

14.

15.

16.

9.

10.

11.

12.

5.

6.

7.

8.

1.

2.

3.

4.

00387

02198

02428

02558

02559

05477

05714

05935

ENGINE, YANMAR L60E-D 6hp

THROTTLE CONTROL ASM

ENGINE ADAPTOR

MOUNT, THROTTLE

SPACER, 3/4 X 3/8 X 1.2

SWIVEL (included with item 2)

WASHER, PILOT

V-BELT, AX-35

06934

07912

07921

08388

CLUTCH, CENTRIFUGAL DOUBLE GROOVE

WIRE, THROTTLE

CASING

HEX HEAD CAP SCREW, M8 X 80MM LONG

F04LW LOCKWASHER, 1/4"

F042004HCS HEX HEAD CAP SCREW, 1/4-20 X 1/2" LONG

F06LW

F06SW

LOCKWASHER, 3/8"

PLAIN WASHER, 3/8"

F0616LN LOCKNUT, 3/8-16

F061614HCS HEX HEAD CAP SCREW, 3/8-16 X 1-3/4" LONG

F072008SCS SOCKET HEAD CAP SCREW, 7/16-20 X 1" LONG

J0021008000 LOCKWASHER, 8MM

Z11425266051 LEVER, SPEED CONTROL

Z11425266112 BRACKET, ACCELERATOR

Z11425266250 SPRING, RETURN

Z11425066200 SPRING, SHORT

Z11497066010 SPRING, LONG

Z26476060142 BOLT, M6 X 14MM LONG

Z26106060202 BOLT, M6 X 20MM LONG

Z10210067080 BOLT, ADJUSTING

Z11425066440 BOLT, ADJUSTING

Z26757060002 LOCKNUT, M6

25

28

QTY

1

1

1

1

1

2

1

1

1

1

1

2

4

8

8

8

2

2

1

2

1

1

1

2

2

1

1

1

1

1

FIGURE 8: ROLL CAGE

ROLL CAGE - GP4000-GP5500

ITEM NO PART NO DESCRIPTION

1.

2.

3.

4.

5.

13882

02483

13907

02484

ROLL CAGE (GP4000)

ROLL CAGE (GP5500)

KIT, GP4000 ROLL CAGE (includes items 1, 3, 4, & 5)

KIT, GP5500 ROLL CAGE (includes items 1, 3, 4, & 5)

F0518FN FLANGE WHIZ-LOCK NUT, 5/16-18

F051806FWS FLANGE WHIZ-LOCK SCREW 5/16-18 X 3/4" LONG

F051808FWS FLANGE WHIZ-LOCK SCREW 5/16-18 X 1" LONG

MOUNT ROLL CAGE TO LOCATE HOLE POSITION IN THE BELTGUARD.

MARK POSITION. REMOVE ROLL CAGE AND DRILL TWO 13/32 DIA.

HOLES. REINSTALL ROLL CAGE WITH HARDWARE PROVIDED.

26

QTY

1

1

9

7

2