VR-2650 Rammer Compactor

Model No. 68034-Serial No. 402000000 and Up

Model No. 68035-Serial No. 402000000 and Up

Model No. 68036-Serial No. 402000000 and Up

Introduction

This machine is designed to compact a wide array of soil substances, including clay, silt, gravel, sand, and loam.

Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely.

You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product.

Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 illustrates the location of the model and serial numbers on the product. Write the numbers in the space provided.

Important: With your mobile device, you can scan the QR code on the serial number decal (if equipped) to access warranty, parts, and other product information.

g240400

Figure 1

  1. Model and serial number plate

This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

g000502

Figure 2

  1. Safety alert symbol

This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.

Warning

CALIFORNIA

Proposition 65 Warning

This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Because in some areas there are local, state, or federal regulations requiring that a spark arrester be used on the engine of this machine, a spark arrester is available as an option. If you require a spark arrester, contact your Authorized Service Dealer. Genuine Toro spark arresters are approved by the USDA Forestry Service.

It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land without a spark arrester muffler maintained in working order, or the engine constricted, equipped, and maintained for the prevention of fire. Other states or federal areas may have similar laws.

The enclosed engine owner's manual is supplied for information regarding the US Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance, and warranty. Replacements may be ordered through the engine manufacturer.

Safety

Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol Graphic, which means: Caution, Warning, or Danger—personal safety instruction. Failure to comply with the instruction may result in personal injury or death.

Safe Operating Practices

This product is capable of causing serious injury. Always follow all safety instructions to avoid serious injury or death.

Warning

Engine exhaust contains carbon monoxide, an odorless, deadly poison which is lethal if inhaled.

Do not run the engine indoors or in an enclosed area.

Training

  • Read the Operator's Manual and other training material. If the operator(s) or mechanic(s) cannot read or understand the information, it is the owner's responsibility to explain this material to them.

  • Become familiar with the safe operation of the equipment, operator controls, and safety signs.

  • All operators and mechanics should be trained. The owner is responsible for training the users.

  • Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.

  • The owner/user can prevent and is responsible for accidents or injuries occurring people or damage to property.

Preparation

  • Wear appropriate clothing including hard hat, eye protection, long pants, substantial, slip-resistant footwear, and hearing protection. Tie back long hair, secure loose clothing, and do not wear loose jewelry.

  • Inspect the area where the equipment is to be used and ensure that all objects are removed from the area before use.

  • Use extra care when handling fuel. They are flammable and vapors are explosive.

    • Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

    • Use only an approved container

    • Do not remove the fuel cap or fill the fuel tank while the engine is running or hot.

    • Do not add or drain fuel in an enclosed space.

    • Do not store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or other appliance.

    • If you spill fuel, do not attempt to start the engine; avoid creating any source of ignition until the fuel vapors have dissipated.

  • Check that the shields are attached and functioning properly. Do not operate unless they are functioning properly.

Operation

  • Use your full attention while operating the machine. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur.

  • Never run an engine in an enclosed or poorly ventilated area.

  • Operate the machine only in good light, keeping away from holes and hidden hazards.

  • Stop on level ground, set the throttle to slow, and shut off the engine before leaving the operator's position for any reason.

  • Ensure that the area is clear of other people before operating the machine. Shut off the machine if anyone enters the area.

  • Keep bystanders out of the operating area. Stop the machine if anyone enters the area.

  • Keep your feet clear of the plate compactor.

  • Do not operate the machine while ill, tired, or under the influence of alcohol or drugs.

  • Do not change the engine governor setting or overspeed the engine.

  • Use care when loading or unloading the machine into a trailer or truck.

  • Do not touch parts which may be hot from operation. Allow them to cool before attempting to maintain, adjust, or service.

  • Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area, do not operate the machine; seek shelter.

Maintenance and Storage

  • Let the engine cool before storing and do not store the machine near an open flame.

  • Position the machine on a level surface, set the throttle to slow, and shut off the engine. Wait for all movement to stop before adjusting, cleaning, or repairing.

  • Clean debris from drives, mufflers, and the engine to help prevent fires. Clean up oil or fuel spills.

  • Do not store fuel near flames or drain indoors.

  • Never allow untrained personnel to service the machine.

  • Carefully release pressure from components with stored energy.

  • Disconnect the spark plug before making any repairs.

  • Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.

  • Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals.

  • Keep nuts and bolts tight. Keep equipment in good condition.

  • Stop and inspect the equipment if you strike an object. Make any necessary repairs before restarting.

  • Use only genuine Toro replacement parts to ensure that original standards are maintained.

Safety and Instructional Decals

Graphic

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing.
decal133-5619

133-5619

decal125-4966

125-4966

  1. Move left to start the engine.
  2. Move up to shut off the engine.
decal125-8181

125-8181

  1. Kickback hazard—read the Operator’s Manual before performing maintenance.
decal125-8182

125-8182

  1. Slow
  2. Variable speed control
  3. Fast
decal125-8183

125-8183

  1. Read the Operator’s Manual—check the oil level.
decal125-8191

125-8191

  1. Read the Operator’s Manual for information on starting the engine—1)Turn lever to the engine start position; 2)Close the choke; 3)Pull the recoil starter; 4)Open the choke.
  2. Read the Operator’s Manual for information on shutting off the engine—turn lever to engine stop position.
  3. Warning—read the Operator’s Manual; wear hearing protection.
  4. Warning—keep away from moving parts; keep all guards and shields in place.
  5. Warning—keep bystanders away when operating the machine.
  6. Choking hazard—do not run the engine in an enclosed location.
  7. Explosion hazard—shut off the engine and extinguish all flames before refueling the machine.

Product Overview

g023144

Figure 3

  1. Compactor shoe
  2. Oil fill plug and sight gauge
  3. Throttle lever
  4. Lift eye
  5. Fuel-tank cap
  6. Handle
  7. Fuel tank
  8. Recoil-starter handle
  9. Spring housing
  10. Lift handle

Become familiar with all the controls before you start the engine and operate the machine.

Engine On/Off Switch

The engine on/off switch allows the engine to run when it is in the RUN position. In the STOP position, it stops the fuel from flowing to the engine and prevents the engine from running (Figure 4 or Figure 5).

g023108

Figure 4

Models 68034 and 68035

  1. Switch—RUN position
  2. Switch—STOP position
  3. Stop
  4. Run
g023113

Figure 5

Model 68036

  1. Switch—RUN position
  2. Switch—STOP position
  3. Stop
  4. Run

Choke Lever

Use the choke lever (Figure 6 or Figure 7) to start a cold engine. Before pulling the recoil-starter handle, move the choke lever to the closed position. Once the engine is running, move the choke lever to the open position. Do not use the choke if the engine is already warmed up or if the air temperature is high.

g023107

Figure 6

Models 68034 and 68035

  1. OPEN position
  2. CLOSED position
  3. Choke lever
g023112

Figure 7

Model 68036

  1. Choke lever in the OPEN position
  2. Choke lever in the CLOSED position

Throttle Lever

The throttle lever controls the engine speed. When the lever is in the SLOW position, the engine runs at idle speed. This is also the starting position. When you move the lever to the FAST position, the centrifugal clutch engages, and the shoe of the machine vibrates and compacts.

g020101

Figure 8

  1. FAST position
  2. Variable control speed
  3. SLOW position

Note: Specifications and design are subject to change without notice.

Model680346803568036
Weight60 kg (132 lb)65 kg (144 lb)70 kg (154 lb)
Length77 cm (30.6 inches)75 cm (29.7 inches)85 cm (33.8 inches)
Width34 cm (13.5 inches)37 cm (14.9 inches)41 cm (16.4 inches)
Height106 cm (42 inches)106 cm (42 inches)111 cm (44 inches)
EngineHonda® GX100Honda® GX100Honda® GX120
Impact Force1205 kg (2,650 lb)1409 kg (3,100 lb)1591 kg (3,500 lb)
Maximum Blows/Minute727690655

Operation

Note: Determine the left and right sides of the machine from the normal operating position.

Important: Before operating, check the fuel and oil levels and remove debris from the machine. Also, ensure that the area is clear of people and debris. You should also know and have marked the locations of all utility lines.

Preparing to Use the Machine

  • Check that the ground is free of foreign objects, such as electrical cables, barbed wire, etc.

  • Review all the safety decals on the machine.

  • Use steel-toe shoes, a hard-hat, hearing protection, and eye protection. A mesh visor alone does not provide sufficient eye protection; supplement with protective glasses.

  • Ensure that you are familiar with safety regulations and shutdown procedures described in the Operator’s Manual.

  • Ensure that all guards are in place and in good condition.

  • Ensure that the compactor shoe is in place and in good condition.

  • Ensure that everyone, including children and animals, maintain a distance of at least 15 m (50 ft) from the machine.

Adding Fuel

  • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method).

  • Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use. Never use gasoline that contains more than 10% ethanol by volume, such as E15 (contains 15% ethanol), E20 (contains 20% ethanol), or E85 (contains up to 85% ethanol). Using unapproved gasoline may cause performance problems and/or engine damage which may not be covered under warranty.

  • Do not use gasoline containing methanol.

  • Do not store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used.

  • Do not add oil to gasoline.

Danger

In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property.

  • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills.

  • Never fill the fuel tank inside an enclosed trailer.

  • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 6 to 13 mm (1/4 to 1/2 inch) below the bottom of the filler neck. This empty space in the tank allows fuel to expand.

  • Never smoke when handling fuel, and stay away from an open flame or where fuel fumes may be ignited by a spark.

  • Store fuel in an approved container and keep it out of the reach of children. Do not use fuel that has been stored for more than 30 days.

  • Do not operate without entire exhaust system in place and in proper working condition.

Danger

In certain conditions during fueling, static electricity can be released causing a spark which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property.

  • Always place fuel containers on the ground away from your vehicle before filling.

  • Do not fill fuel containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.

  • When practical, remove fuel-powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground.

  • If this is not possible, then refuel such equipment on a truck or trailer from a portable container rather than from a fuel dispenser nozzle.

  • If a fuel dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

Warning

Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness.

  • Avoid prolonged breathing of vapors.

  • Keep your face away from nozzle and fuel tank or conditioner bottle opening.

  • Avoid contact with skin; wash off spills with soap and water.

Using Stabilizer/Conditioner

Use a fuel stabilizer/conditioner in the machine to provide the following benefits:

  • Keeps fuel fresh during storage of 90 days or less. For longer storage it is recommended that the fuel tank be drained.

  • Cleans the engine while it runs

  • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting

    Important: Do not use fuel additives containing methanol or ethanol.

    Add the correct amount of fuel stabilizer/conditioner to the fuel.

    Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.

Filling the Fuel Tank

  1. Park the machine on a level surface and stop the engine.

  2. Allow the engine to cool.

  3. Clean around the fuel tank cap and remove it (Figure 9).

    g020337

    Figure 9

    1. Fill with fuel here
    2. Fuel cap
    3. Fuel container

  4. Add fuel to the fuel tank, until the level is 6 to 13 mm (1/4 to 1/2 inch) below the bottom of the filler neck.

    Important: This space in the tank allows fuel to expand. Do not fill the fuel tank completely full.

  5. Install the fuel tank cap securely.

  6. Wipe up any spilled fuel.

Checking the Machine-Fluid Levels

Starting the Engine

  1. Move the engine on/off switch to the RUN position (counterclockwise); refer to Engine On/Off Switch.

  2. Move the choke lever to the CLOSED position if you are starting a cold engine; refer to Choke Lever.

    Note: A warm or hot engine may not require choking.

  3. Move the throttle lever to the SLOW position; refer to Throttle Lever.

  4. Pull the recoil-starter handle lightly until you feel resistance, then pull the handle briskly. Gently return the handle to the original position.

  5. After the engine starts, gradually move the choke lever back to the OPEN position. If the engine stalls or hesitates, move the choke lever back to the CLOSED position again until the engine warms up. Then move it to the OPEN position.

Shutting Off the Engine

  1. Move the throttle lever to the SLOW position. If the engine has been working hard or is hot, let it run for a minute. This helps to cool the engine before stopping.

    Important: To shut off the engine immediately, you can move the engine on/off switch to the STOP position before moving the throttle lever to the SLOW position.

  2. Move the engine on/off switch to the STOP position (clockwise).

Transporting the Machine

Caution

If you tip the machine when the engine on/off switch is in the RUN position, fuel can leak out of the fuel tank. A fuel leak could lead to a fire and cause serious personal injury.

Drain the fuel tank or ensure that the engine on/off switch is in the STOP position before tipping the machine.

Important: Before transporting the machine, secure it with straps or chains to prevent it from falling or tipping over. Ensure that the lifting device and straps or chains are properly rated; refer to Specifications.

If possible, keep the machine standing upright when transporting it. Secure it with straps or chains; do not let it fall over.

If you must transport the machine horizontally, do so as follows:

  1. Shut off the engine and allow it to cool for 15 minutes. Ensure that the engine on/off switch is in the STOP position.

    The engine on/off switch is also a fuel valve. Ensuring that it is in the STOP position prevents fuel from leaking out of the fuel tank.

  2. Use a lifting device with adequate lifting capacity (at least 75 kg, or 165.3 lb) to lift the machine into the transport vehicle.

    Important: Attach chains or other lifting-device components to only the lift eye of the machine; refer to Figure 3.

  3. Carefully position the machine as shown in Figure 10, and secure it with straps or chains to prevent it from moving or tipping.

    Important: Do not lay the machine onto the right or left side; the engine oil can leak into the air intake or the exhaust system. Lay the machine tipped forward only, so that it rests on the front bar.

    g023106

    Figure 10

  4. After transporting the machine, stand the machine in an upright position to allow the oil to drain through the engine and settle back into the crankcase.

    Important: Allow the oil to settle for at least 2 minutes after standing the machine upright before you start the engine.

Operating Tips

  • Keep the machine upright so that it contacts the ground with the entire shoe, rather than with just the front or back edge of the shoe.

  • Allow the machine to do the work; pushing downward on the handle limits the effectiveness of the machine.

  • On level surfaces, the machine moves forward in rapid jumps. On uneven surfaces, tilt the machine as necessary to assist the forward movement.

  • The jump height of the machine increases as the ground becomes more compacted.

Maintenance

Note: Determine the left and right sides of the machine from the normal operating position.

Important: You may tip the machine forward, if you drain the fuel tank or move the engine on/off switch to the STOP position, to make cleaning or servicing the machine easier. If you lay the machine onto the side, oil can drain out of the crankcase into the air cleaner or the muffler.Allow the oil to settle for at least 2 minutes after standing the machine upright before you start the engine.

Recommended Maintenance Schedule(s)

Maintenance Service IntervalMaintenance Procedure
After the first 25 operating hours
  • Change the engine oil.
  • Change the spring-housing oil.
    		•
    Before each use or daily
  • Check the air filter.
  • Check the spring-housing oil.
  • Check the compactor shoe.
  • Remove debris from the machine.
    		•
    Every 50 hours
  • Clean the air-filter elements (more frequently if conditions are dusty or sandy).
  • Clean the prefilter (Models 68034 and 68035).
    		•
    Every 100 hours
  • Change the engine oil (more frequently if the operating conditions are extremely dusty or sandy).
  • Change the spring-housing oil.
  • Check the spark plug.
    		•
    Every 200 hours
  • Replace the paper air-filter element (more frequently if conditions are dusty or sandy).
    		•
    Yearly or before storage
  • Change the engine oil.
  • Change the spring-housing oil.
    		•

    Important: Refer to your engine owner’s manual for additional maintenance procedures.

    Pre-Maintenance Procedures

    Before performing maintenance on the machine, do the following:

    1. Ensure that the engine and muffler are cool.

    2. Disable the engine by disconnecting the spark-plug wire; refer to Disconnecting the Spark-Plug Wire.

    Disconnecting the Spark-Plug Wire

    Pull the spark-plug wire off the terminal of the spark plug (Figure 11 or Figure 12).

    g023119

    Figure 11

    Models 68034 and 68035

    1. Spark-plug wire
    g023120

    Figure 12

    Model 68036

    1. Spark-plug wire

    Engine Maintenance

    Servicing the Air Cleaner

    Important: Do not operate the engine without the air-filter assembly; extreme engine damage can occur.

    Note: If the engine is low on power, produces black smoke, or runs unevenly, the air filter may be clogged.

    Cleaning the Prefilter

    Models 68034 and 68035

    1. Open the cover of the machine (Figure 13).

      g020404

      Figure 13

    2. Remove the screws that secure the cover to the prefilter housing (Figure 14), and remove the cover.

      g023121

      Figure 14

      1. Prefilter housing
      2. Prefilter

    3. Remove the prefilter.

    4. Clean the prefilter as follows:

      1. Wash the prefilter using a mild detergent and water.

      2. Squeeze it dry with a clean cloth.

      3. Soak it with new engine oil.

      4. Gently wind the prefilter in an absorbent cloth, and squeeze out the excess oil.

    5. Install the prefilter as follows:

      1. Align the prefilter inside of the cover.

      2. Align the prefilter cover to the housing.

      3. Secure the cover to the housing with the screws.

    Servicing the Air Filter

    Models 68034 and 68035

    1. Remove the screws that secure the cover to the air-filter housing (Figure 15)

      g023122

      Figure 15

      1. Air-filter housing
      2. Air filter

    2. Remove the air filter from the housing as shown in Figure 15.

    3. Inspect the air filter and replace it if it is damaged, excessively dirty, or saturated with oil or fuel.

    4. Align the air filter inside of the cover.

    5. Align the air filter cover to the housing.

    6. Secure the cover housing with the screws.

    Servicing the Air Filter

    Model 68036

    1. Open the latch of the air-filter cover (Figure 16).

      g023124

      Figure 16

      1. Latch
      2. Cover
      3. Paper element
      4. Foam element

    2. Remove the air filter from the housing as shown in Figure 16.

    3. Remove the foam element from the paper element.

    4. Inspect the elements and replace them if they are damaged or excessively dirty.

      Note: If the paper element is saturated with oil or fuel, replace it.

    5. Tap the paper element several times on a hard surface to remove the dirt.

    6. Clean the foam element in warm, soapy water or in a nonflammable solvent.

      Note: Do not use fuel to clean the foam element because it could create a risk of fire or explosion.

    7. Rinse and dry the foam element thoroughly.

    8. Dip the foam element in clean engine oil, then squeeze out the excess oil.

      Note: Excess oil in the foam element restricts the air flow through the element and may reach the paper filter and clog it.

    9. Wipe dirt from the housing and the cover with a moist rag.

      Note: Be careful to prevent dirt and debris from entering the air duct leading to the carburetor.

    10. Install the air-cleaner elements and ensure that they are properly positioned (Figure 17).

      Important: Ensure that the open end of the air-cleaner elements are facing inward toward the machine, as the machine will not run if the elements are not placed in the proper air orientation due to air restriction (Figure 17).

      g024809

      Figure 17

      1. Open end of the paper element
      2. Open end of the foam element

    11. Secure the cover to the housing with the latch.

    Servicing the Engine Oil

    Oil Type: 4-cycle engine oil that meets or exceeds the requirements for API service category SJ, SL, SM, or higher.

    Crankcase Capacity:

    • 0.28 L (9.47 fl oz) for models 68034 and 68035

    • 0.40 L (13.53 fl oz) for model 68036

    Viscosity: SAE 10W-30 is recommended for general use.

    Checking the Engine-Oil Level

    1. Shut off the engine and allow it to cool.

    2. Tilt the machine so that the engine is level.

      Important: Prop the machine in this position to ensure that it does not fall over.

    3. Clean around the oil dipstick.

    4. Remove the dipstick and wipe the end clean.

    5. Slide the dipstick fully into the dipstick tube without threading it into the filler neck.

    6. Pull the dipstick out and look at the end.

      The oil should be level with the upper-limit mark (Figure 18).

      g019686

      Figure 18

      1. Filler tube
      2. Dipstick
      3. Upper limit
      4. Lower limit
      5. Oil-drain bolt

      Important: Running the engine with a low oil level can cause engine damage. This type of damage is not covered by warranty.

    7. If the oil level is low, slowly pour only enough oil into the crankcase to raise the level to the upper limit.

      Important: Do not overfill the crankcase with oil because the engine may be damaged.

    8. Install and secure the dipstick.

    Changing the Engine Oil

    Toro Premium Engine Oil is available from your authorized Toro distributor.

    1. Start the engine and let it run for 5 minutes; refer to Starting the Engine.

    2. Shut off the engine; refer to Shutting Off the Engine.

    3. Tilt the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely.

    4. Place a drain pan under the oil-drain hole.

    5. Remove the drain plug and drain the oil from the engine (Figure 19).

      g020104

      Figure 19

      1. Oil pan
      2. Oil-drain hole
      3. Oil-fill hole

    6. When the oil has drained completely, install the plug and wipe up any spilled oil.

      Note: Dispose of the used oil at a certified recycling center.

    7. Remove the dipstick and slowly pour approximately 80 percent of the specified amount of oil into the engine (Figure 19).

    8. Slowly add additional oil to bring the oil level to the upper-limit mark on the dipstick; refer to Checking the Engine-Oil Level.

    9. Install and secure the dipstick.

    Servicing the Spring-Housing Oil

    Oil Type: 4-cycle engine oil that meets or exceeds the requirements for API service category SJ, SL, SM, or higher.

    Capacity: 0.47 L (15.89 fl oz)

    Viscosity: SAE 10W-30 is recommended for general use.

    Checking the Spring-Housing Oil

    Check the spring-housing oil as follows:

    1. Carefully tip the machine slightly backward so that the machine stands completely upright and vertical.

      Important: Prop the machine in this position to ensure that it does not fall over.

    2. Check the oil sight plug (Figure 20), and ensure that the oil level is halfway between the top and bottom of the oil sight plug.

      g023141

      Figure 20

      1. Oil sight plug

    3. If the oil level is low, add oil; refer to Adding Oil to the Spring Housing.

    Changing the Spring-Housing Oil

    1. Start the engine and let it run for 5 minutes; refer to Starting the Engine.

    2. Shut off the engine; refer to Shutting Off the Engine.

    3. Ensure that the engine on/off switch is in the STOP position so that the fuel does not leak out of the fuel tank.

    4. Tilt the machine so that the oil sight plug faces downward to ensure that the oil drains completely (Figure 21).

      g023142

      Figure 21

      1. Oil sight plug
      2. Drain pan

    5. Place a drain pan under the oil sight plug (Figure 21).

    6. Remove the oil sight plug (Figure 21).

    7. Drain the oil out of the hole in the housing (Figure 21).

    8. Clean the threads on the oil sight plug and apply 3 layers of PTFE thread-sealing tape.

    9. Add oil to the spring housing; refer to Adding Oil to the Spring Housing.

    10. Install and torque the oil sight plug to 54 N∙m (39.8 ft-lb).

    Important: Allow the oil to settle for at least 2 minutes after standing the machine upright before starting the engine.

    Adding Oil to the Spring Housing

    1. Tilt the machine so that the oil sight plug is facing upward (Figure 22).

      g023143

      Figure 22

      1. Opening for the oil

    2. Remove the oil sight plug.

    3. Clean the threads on the oil sight plug and apply 3 layers of PTFE thread-sealing tape.

    4. Add the oil to the spring housing in increments to ensure that you do not overfill the machine; refer to Checking the Spring-Housing Oil to ensure that the oil is at the correct level.

      Note: The oil capacity of the spring housing is 0.47 L (0.5 US qt); add the full amount only if the spring housing is empty.

    5. Install and torque the oil sight plug to 54 N∙m (39.8 ft-lb).

    Important: Allow the oil to settle for at least 2 minutes after standing the machine upright before starting the engine.

    Servicing the Spark Plug

    Ensure that the air gap between the center electrode and the side electrode is correct before installing the spark plug. Use a spark-plug wrench for removing and installing the spark plug and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug if necessary.

    Models 68034 and 68035: Use a DENSO U16FSR-UB or an NGK CR5HSB spark plug.

    Model 68036: Use a DENSO W14EPR-U or an NGK BP4ES spark plug.

    Removing the Spark Plug

    1. Shut off the machine and let it cool.

    2. Disconnect the wire from the spark plug (Figure 23).

      g014506

      Figure 23

      1. Spark plug
      2. Wire

    3. Clean around the spark plug.

    4. Use a spark-plug wrench to remove the spark plug and the metal washer.

    Checking the Spark Plug

    1. Look at the center of the spark plug (Figure 24). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means that the air cleaner is dirty.

      Important: Do not clean the spark plug. Always replace the spark plug when it has a black coating, worn electrodes, an oily film, or cracks.

      g023105

      Figure 24

      1. Side electrode
      2. Center electrode
      3. Insulator
      4. 0.60 to 0.70 mm (0.024 to 0.028 inch) gap (Models 68034 and 68035)
      5. 0.70 to 0.80 mm (0.028 to 0.031 inch) gap (Model 68036)

    2. Check the gap between the center and side electrodes (Figure 24).

    3. If the gap is not within the specified range, do the following:

      1. If the gap is too small, carefully bend the side electrode away from the center electrode until the gap between the electrodes is correct.

      2. If the gap is too large, carefully bend the side electrode toward the center electrode until the gap between the electrodes is correct.

    Installing the Spark Plug

    1. Thread the spark plug into the spark-plug hole.

    2. Tighten the spark plug to 27 N∙m (20 ft-lb).

      Important: Ensure that the spark plug is tightened to the specified torque value. A loose spark plug may cause damage to the cylinder, while an overtightened spark plug may cause damage to the cylinder-head threads.

    3. Connect the wire to the spark plug.

    Checking the Compactor Shoe

    Among the most critical elements of the machine is the compactor shoe. It is also the most subject to damage and wear. In the course of compacting a wide array of granular objects, the machine encounters numerous abrasives and objects, such as dirt, stones, and occasionally a large rock or buried scrap.

    The wear of the compactor shoe can significantly impair the efficiency and performance of the machine. Therefore, it is important to make frequent checks of the condition of the compactor shoe for leaks and cracks. (Figure 25).

    g020338

    Figure 25

    1. Compactor shoe

    Removing Debris from the Machine

    Regular cleaning and washing will increase the life span of the machine. Clean the machine immediately after use, before the dirt hardens.

    Check before cleaning that the fuel tank cap is properly in place to avoid getting water in the tank.

    Use care when using a high-pressure sprayer because it can damage warning decals, instruction signs, and the engine.

    Storage

    For storage over 30 days, prepare the machine as follows:

    1. Remove dirt and grime from the external parts of the entire machine, especially the engine. Clean all granular objects from the outside of the engine cylinder-head fins and the blower housing.

      Important: You can wash the machine with mild detergent and water.

    2. Add a petroleum-based stabilizer/conditioner to the fuel in the tank. Follow the mixing instructions from the stabilizer manufacturer. Do not use an alcohol-based stabilizer (ethanol or methanol).

      Note: Fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times.

      Important: Do not store stabilizer/conditioned fuel over 90 days.

    3. Run the engine to distribute conditioned fuel through the fuel system (5 minutes).

    4. Shut off the engine, allow it to cool, and drain the fuel tank using a pump-type siphon. Dispose of fuel properly; recycle it according to local codes.

    5. Start the engine and run it until it stops.

    6. Choke the engine.

    7. Start and run the engine until it will not start again.

    8. Service the air cleaner; refer to Figure 13.

    9. Change the engine crankcase oil; refer to Figure 19.

    10. Remove the spark plug and check the condition; refer to Figure 23 and Figure 24.

    11. With the spark plug removed from the engine, pour 30 ml (2 tablespoons) of engine oil into the spark-plug hole.

    12. Pull the recoil-starter handle slowly to crank the engine and distribute the oil inside the cylinder.

    13. Install the spark plug, but do not install the wire on the spark plug.

    14. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged.

    15. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer.

    16. Store the machine in a clean, dry garage or storage area.

      Important: Store the machine in the upright position. Do not tip the machine on its side, or leave the machine tipped forward with the front bar down for a long period of time.

    17. Cover the machine to protect it and keep it clean.

    Removing the Machine from Storage

    1. Check and tighten all fasteners.

    2. Inspect the spark plug and replace it if it is dirty, worn, or cracked; refer to the engine Operator’s Manual.

    3. Install the spark plug until it is hand-tight, then an additional 1/2 turn if it is new, otherwise, tighten it an additional 1/8 to 1/4 turn.

    4. Perform any needed maintenance procedures.

    5. Check the engine-oil level; refer to Checking the Engine-Oil Level.

      Important: Store the machine in the upright position. Do not tip the machine on its side, or leave the machine tipped forward with the front bar down for a long period of time.

    6. Check the spring-housing oil level; refer to Checking the Spring-Housing Oil.

    7. Fill the fuel tank with fresh fuel; refer to Filling the Fuel Tank.

    8. Connect the wire to the spark plug.

    Troubleshooting

    ProblemPossible CauseCorrective Action
    The engine does not start.
    1. The air filter for Model 68036 is placed backwards in the air-filter cover.
    2. The engine on/off switch is in the stop position.
    3. The choke is open.
    4. The fuel tank is empty.
    5. The spark-plug wire is loose or disconnected.
    6. The spark plug is fouled or improperly gapped.
    1. Switch the orientation of the air filter in the air-filter cover.
    2. Move the switch to the run position.
    3. Close the choke when starting a cold engine.
    4. Fill the tank with fresh fuel.
    5. Connect the spark-plug wire.
    6. Correct the electrode gap or replace the spark plug.
    The engine runs rough.
    1. The choke is closed.
    2. The air filter is clogged.
    3. There is water or contaminants in the fuel.
    4. The spark plug is worn or has buildup on the electrodes.
    1. Open the choke.
    2. Clean or replace the air filter.
    3. Drain and fill the tank with fresh fuel.
    4. Correct the electrode gap or replace the spark plug.