Tomahawk TPC170H Reverse Plate Compactor

Introduction

This manual provides information and procedures to safely operate and maintain the Tomahawk TPC170H Reverse Plate Compactor. 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 improperly 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 written permission from Tomahawk Power.

Any type of reproduction or distribution not authorized by Tomahawk Power represents an infringement of valid copyrights and will be prosecuted. Tomahawk Power expressly reserves the right to make technical modifications, even without due notice, which aim at improving its 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.

Safety Alert Symbol: This symbol 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.

CAUTION (without symbol): Indicates a potentially hazardous 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. Tomahawk Power does 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 surfaces. Maintain firm balance when operating under such conditions. Exercise special 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 appropriate strength, using the lifting handle provided with the machine according to the correct lifting techniques.
• Plate Compactors 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 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 off, 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 muffler when the engine is hot, as it can cause severe burns.
• ENSURE that repairs to the engine and machine are carried out by competent personnel.
• DO NOT use the machine near flammable material or in explosive environments.

1.3 Operator Safety while using Internal Combustion Engines

• Petrol is extremely flammable and explosive under certain conditions. Fuel trapped in the cylinder may eject from the spark plug opening.
• ENSURE that 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 after 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 environment. Protective clothing and footwear may also be desirable when working with hot mix bitumen.
• Store the machine properly in a clean, dry place.
• 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 only when the machine has cooled, and in a well-ventilated environment.
• 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 the engine to cool before performing any repairs or service.
• ALWAYS keep the area around the muffler free of debris such as leaves, paper, cartons, etc. A hot muffler could ignite the debris and start a fire.
• NEVER run the engine without the air filter.

1.4 Label Locations

Diagram showing various warning and information labels affixed to the compactor. The labels are detailed in the following section.

1.5 Safety and Operating Labels

Tomahawk machines use international pictorial labels where needed. These labels are described next:

2. Operation

2.1 Controls

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.

Diagram showing the compactor with numbered controls:

• 1. Lever for Forward/Reverse Operation
• 2. Throttle Control
• 3. Handle
• 4. Locking Device
• 5. Lifting Point
• 6. Refueling
• 7. Transport Wheel
• 8. Base Plate

2.2 Operating Principle

These instructions were compiled to provide information on how to obtain long and trouble-free use of the unit. Periodic maintenance 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 fluid 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 the air filter.
• Hydraulic fluid level.

NOTICE: Check the hydraulic fluid level and the oil level in the engine and exciter. Warranties are VOID if the machine is run without oil and hydraulic fluid.

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 the oil filter cap, pour the oil in, and reassemble the oil cap.
3. Make sure it is nearly at max., and fit the dipstick correctly back in place.
4. Check and refill oil up to the maximum level.
5. If start-up is difficult, purge air from the 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 the engine before starting.
7. Remove the fuel tank cap. Pour the fuel and reassemble the fuel tank cap. With low ambient temperatures (-10°C), add specific additives to diesel fuel to avoid paraffin 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. Set the accelerator to 50% speed.
10. Take the handle and pull the rope softly until it is extended to its full limit. Let the rope rewind completely. Start the engine by pulling strongly on the rope.
11. To stop the engine, move the accelerator lever into the stop position.

2.5.2 Gas Engine with Electric Starter

1. Do not actuate the starter for more than 20 seconds at a time. If the engine does not start, wait 1 minute before repeating the attempt. If the engine does not start after 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 off when the engine is running. For engines with a starting panel equipped with engine protection, make sure the OK light is ON.
3. After starting, idle for a few minutes according to the table:

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 left. 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 after several attempts, follow the troubleshooting 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 off.

2.6 To Stop

1. Push the throttle lever to “0” position.
2. Turn the key switch to “0” (off).
3. Close the fuel valve.

2.7 Application

This machine is suitable for:

• Trench compaction
• Road maintenance
• Brick paving
• Earthworks
• Landscaping
• Driveway topping

2.8 Operation

Run the engine at full throttle and allow the 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 for 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; too little moisture means inadequate compaction; too much moisture leaves water-filled voids that weaken the soil's load-bearing ability. Compaction of dry materials 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 maximum gradient of 20°.

Max. Admissible Inclination: 20°

2.11 How to Assemble Transport Wheel

Diagram showing the steps to assemble the transport wheel: 1. Attach wheel to the compactor. 2. Secure wheel. 3. Position compactor. 4. Compactor with transport wheel attached.

3. Maintenance

3.1 Periodic Maintenance Schedule

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

After 200 hours of operation, remove the upper belt cover to check the V-belt tension. Tension is proper if the belt bends about 0.4 in when depressed strongly with a finger between the shafts. Loose or worn V-belts reduce power transmission efficiency, causing weak compaction and reducing the life of the belt itself.

WARNING: 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 off.

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.

CAUTION: Whenever the compactor's vibration becomes weak or lost during normal operation (regardless of operation hours), check the V-belt and clutch immediately.

3.4 Air Cleaner

1. The air filter should be cleaned because if clogged, it may cause issues when starting the engine, reduce power, and shorten the engine's life substantially.
2. To clean or replace the air filter, loosen the wing nut on the air filter housing, remove the cover, and take out the 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 the spark plug gap to the recommended clearance. Refer to the engine manual.

WARNING: The muffler and engine cylinder become very hot during operation and remain hot for a while after stopping the engine. Allow the engine to cool before removing the spark plug.

NOTICE: A loose spark plug can become very hot and may cause engine damage.

3.6 Transport

1. Always shut off the engine before transporting the machine.
2. Make sure the lifting device has enough capacity to hold the machine (see nameplate on machine for weight).
3. Use the lifting point when lifting the machine.
4. NEVER stand underneath the machine while lifting.
5. Trolley wheel is optional for short-distance transportation.

3.7 Trouble Shooting

3.7.1 Machine Troubleshooting

3.7.2 Engine Troubleshooting

4. Technical Data

Working Size (in)

Sound Specification (According to 2000/14/EC)

Vibration Specification (According to ISO 2631 and EN 1033)

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 operating 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.

Impact damage is not covered under warranty. Clutches are not covered under any warranty.

Engines are officially guaranteed by Honda.

Maintenance Record

Preventative Maintenance and Routine Service Plan

Tomahawk Power's PCR5030 Reverse Plate Compactor has been assembled with care and will provide years of service. Preventive maintenance and routine service are essential to the long life of your plate compactor. After reading through this manual thoroughly, you will find that you can do some of the regular maintenance yourself. However, when in need of parts or major service, be sure to see your dealer. For your convenience, we have provided this space to record relevant data about your plate compactor.

Replacement Parts Used

Maintenance Log