Sakai PC800 User manual

PC800
SHOP MANUAL
3498-64964-0

Introduction
This manual provides important information to familiarize you with safe operating
and maintenance procedures for your SAKAI product. Even though you may be
familiar with similar equipment you must read and understand this manual before
operating or servicing this unit.
Safety is everyone’s business and it is one of your primary concerns. Knowing the
guidelines presented in this manual will help provide for your safety, for the safety
of those around you and for the proper operation and maintenance of the machine.
Improper operation is dangerous and can result in injury or death.
Sakai Heavy Industries cannot foresee all possible circumstances or varying
conditions to which the operator, serviceman or machine may be exposed to that
might lead to a potential hazard. Therefore, the warnings and cautions listed in
this manual and those placed on the machine are not intended to be all inclusive
and liability for personal injury or damage to equipment or property cannot be
assumed.
All information, specications and illustrations in this publication are based on
the product information available at the time that the publication was written. The
contents may change without prior notice due to modications of the model.
Refer to the engine manufacture’s shop manual for data relative to engine
maintenance and repairing.

PC800 ○
0
0-001
CONTENTS
1. SAFETY
1. GENERAL SAFETY
1-1. Understanding the Safety Symbols and Words1-001
1-2. General1-001
1-3. Qualications of Operators and Maintenance Personnel 1-002
1-4. Safety Practices and Policies1-002
1-5. Pre Start Inspection1-003
1-6. Safety Instructions1-003
1-7. Starting 1-004
1-8. Operating1-004
1-9. Stopping1-004
1-10. Maintenance1-005
1-11. Transporting the Machine 1-006
2. SPECIFICATIONS
1. SPECIFICATION DATA2-001
2. FUEL AND LUBRICANT
2-1. Fuel2-002
2-2. Engine Oil/Vibrator Oil2-002
3. TIGHTENING TORQUE CHART2-003
3. INSPECTION AND MAINTENANCE
1. INSPECTION AND MAINTENANCE
1-1. Engine3-001
1-2. Compactor Body3-001
1-3. V-belt3-001
1-4. Vibrator3-003
1-5. Air Cleaner3-003
4. PARTS CATALOGUE
1. GUIDE FOR USE OF PARTS CATALOGUE4-001
2. FRAME 4-002
3. VIBRATOR 4-004
4. NAME PLATE 4-006
5. SPRINKLER SYSTEM4-008
6. CARRIER (OPTION)4-010

SAFETY

1-001
SAFETY
1. GENERAL SAFETY
1-1. Understanding the Safety Symbols and Words
The words DANGER, WARNING, and CAUTION are used with the safety-alert symbol.
DANGER identies the most serious hazard. When the symbols DANGER, WARNING and
CAUTION are displayed, become alert. Your safety or those around you may be involved.
NOTICE is used to provide important information that is not hazard related.
DANGER: Indicates an imminently hazardous situation or condition which if not avoided
can result in serious personal injury or death.
WARNING: Indicates a potentially hazardous situation or condition which if not avoided
can result in serious personal injury or death.
CAUTION: Indicates a potentially hazardous situation or condition which if not avoided
may result in moderate personal injury or damage to the machine or
personal property.
(NOTICE): Indicates important information about operation or maintenance of the
machine that may cause damage, breakdown, or shortened service life of
the machine if you fail to observe or important point to maintain of quality in
maintenance works.
: Indicates standard value to judge whether measured value is good or not.
Items that indicate the weight of a part or equipment and require attention in wire
selection and operating posture for slinging operation.
N•m
In the assembly operation, tightening torque in locations that require particular
attention.
1-2. General
• Operators and maintenance personnel must be alert to recognize and avoid potential
hazards. They should also have comprehensive training, the required skills and necessary
tools to perform the job safely.
• The machine was built in accordance to the latest safety standards and recognized safety
rules. Nevertheless, misuse of the machine may result in risk to life and limb of the user or
nearby personnel and may cause damage to the machine or other property.
• The machine must only be used for its intended purpose as described in the Operator’s
Manual. It must be operated by safety-conscious persons who are fully aware of the risks
involved when operating the machine. Any malfunctions especially those affecting the safety
of the machine must be corrected immediately.
★

1-002
SAFETY
• The machine is designed specically for the compaction of asphalt or soil road construction
materials. Use of the machine for other purposes such as towing other equipment is
considered contrary to the designated use. The manufacturer cannot be responsible or held
liable for any damage resulting from such use. The risk for such use lies entirely with the
user.
• Operating the machine within the limits of its designated use also involves compliance with
the inspection and maintenance requirements contained in the Operation and Maintenance
Manual.
1-3. Qualications of Operators and Maintenance Personnel
• Work on the machine must be performed by qualied personnel only. Individual
responsibilities of personnel regarding operation, maintenance, repair of the machine must
be clearly stated.
• Dene the operator’s responsibilities; the operator should have authority to refuse
instructions that are contrary to safety.
• Do not allow persons being trained to operate or perform maintenance on the machine
without constant supervision by an experienced person.
• Work on the electrical system of the machine must be done only by an experienced person
or under the guidance of a skilled electrician and according to electrical engineering rules
and regulations.
• Work on the frame, brakes, hydraulic and steering systems must be performed by skilled
personnel with special knowledge and training for such work.
1-4. Safety Practices and Policies
• Keep the manuals in the container provided on the machine. Manuals must always be
available at the site where the machine is being used.
• The operator or user of the machine must be aware of all applicable or legal and mandatory
regulations relevant to accident prevention and environmental protection. These regulations
may also deal with handling of hazardous substances, the required proper personal safety
and protective equipment and trafc or jobsite regulations.
• Machine operating instructions should also be supplemented with detailed instructions
pertaining to the specic jobsite or work location.
• Always be sure the persons working on the machine have read the operating instructions
and all safety precautions before beginning work. Reading safety instructions after work has
already begun is too late.
• Wear close tting garments and always tie back and secure long hair, also avoid wearing
jewelry such as rings. Injury can result from loose clothing, hair or jewelry being caught up
in the machinery or rotating parts.
• Use protective equipment as required by the circumstances or by law.

1-003
SAFETY
• Observe all safety instructions and warnings attached to the machine.
• Make sure all safety instructions and warnings on the machine are complete and perfectly
legible.
• Stop the machine immediately in the event of any malfunction. Report any malfunction
immediately to the supervisor or other person of authority.
• Never make any modications to the machine which might affect safety without the
manufacturer’s approval.
• Always perform the recommended routine inspections and adjustments according to the
prescribed intervals.
1-5. Pre Start Inspection
• Inspect your machine daily. Ensure that the routine maintenance and lubrication are
properly performed. Repair or replace any malfunctioning, broken or missing parts before
using the machine. Refer to the inspection and maintenance or maintenance schedule in
the Operator’s Manual.
• Check that all instructions and safety stickers are in place and readable.
• Never ll the fuel tank with the engine running or while near an open ame or while smoking.
• Always clean up any spilled fuel.
• Check for any warning tags placed on the machine, do not operate the machine until all
repairs have been made and warning tags have been removed by authorized personnel.
• Know how to shut-down or stop the machine immediately in case of emergency.
• Know the capabilities and limitations of the machine such as speed and gradeability.
• Be aware of the dimensions of the machine such as height, weight especially for
transporting.
1-6. Safety Instructions
• Take all necessary precautions to ensure that the machine is used only when in a safe and
reliable condition.
• Avoid any operational mode that might compromise safety.
• Operate the machine only if all protective and safety devices are in place and fully
functional.

1-004
SAFETY
1-7. Starting
• Watch that the warning lights and indicators during start-up and shutdown are working in
accordance with operating instructions.
• Watch that no one is in danger before starting and when moving the machine.
• Hold the handle securely with your left hand to x the machine body and pull the starter
knob forcibly with your right hand to start the engine.
• When pulling up the starter knob, pull it from immediately behind the handle to prevent your
hand from hitting the handle.
1-8. Operating
• Always make sure that there are no obstructions or persons in your line of travel before
starting the compactor in motion.
• Use caution and be very observant when operating in close quarters and congested areas.
• Do not operate the compactor for driving a pile or on a solid ground exceeding capacity of
the machine such as surface paved with asphalt, concrete, cobblestone, and solid rock.
Otherwise, this may cause damage to the machine as too much stress is applied to the
machine body.
• Do not get your hands off the handle while operating.
• When operating the compactor on a slope, operate it within a gradient of 1/4 (approx. 14
degrees).
• When operating the compactor on a ground surface with a large roughness and a large
level difference, or on a steep slope, take care that you will not be injured in your wrist due
to overturn or slip of the machine body.
In addition, this may cause earlier damage to the machine as an excessive stress is also
applied to the machine body.
• Be sure to stop the engine before leaving the compactor unattended.
• Never allow anyone to stand in the articulation area of the machine when the engine is
running.
• Do not attempt to control the compactor travel speed with the throttle control. Maintain
engine speed at the full operating RPM.
• Do not run the engine in a closed building for an extended period of time. Exhaust fumes
can kill.
1-9. Stopping
• Always park the machine in a safe area on solid and level ground.
• Lock all lockable compartments.

1-005
SAFETY
1-10. Maintenance
• In any performing any work concerning the operation, adjustment or modication of the
machine or it’s safety devices or any work related to maintenance, inspection or repair,
always follow the start-up and shut-down procedures in the Operator’s Manual and the
Maintenance Manual.
• Ensure that the maintenance area is safe and secure.
• If the machine is shut down for maintenance or repair work
it must be secured against inadvertent starting by removing
the starter key and attaching a warning sign to the starter
switch.
• The machine must be parked on stable and level ground.
• Immediately after the engine has stopped, the exhaust
system, engine, radiator coolant, engine oil, hydraulic uid
and other lubricants and components will be very hot.
Fluids can be under pressure, removing the radiator cap
or draining oil or changing lters can cause serious burns.
Wait until the machine has cooled down.
• Use care when attaching and securing lifting tackle to
individual parts and large assemblies being removed
or repositioned for repair purposes to avoid the risk of
accident. Use lifting devices that are in perfect condition and
of sufcient lifting capacity. Never stand under suspended
loads.
• Always use the proper tools and workshop equipment in
good condition when performing maintenance or repairs on
the machine.
• Clean the machine, especially threaded connections of any traces of oil or fuel before
carrying out any maintenance or repairs. Never use aggressive detergents. Use lint free
cleaning rags.
• Examine all fuel, lubricant and hydraulic uid lines and connectors for leaks, loose
connections chafe marks or damage after cleaning.
• Repair or replace defective parts immediately.
• Never ll the fuel tank with the engine running, while near an open ame or while smoking.
Always clean up any spilled fuel.
• Ensure safe operation, optimum performance of the machine and its warranty by using only
genuine SAKAI replacement parts.

1-006
SAFETY
• Use only the specied uids and lubricants. Substitute only products known to be equivalent
from reputable manufacturers.
• Disconnect the battery cables when working on the electrical system
or when welding on the compactor.
• Be sure the battery area is well ventilated (clear of fumes) should it be
necessary to connect a jumper cable or battery charger. Fumes can
ignite from a spark and may explode.
• Be sure battery charger is OFF when making connections if charging is required.
• Use only original fuses with the specied rating. Switch off the machine immediately if
trouble occurs in the electrical system.
• Work on the electrical system may only be carried out by a qualied electrician or by a
specially trained person according to electrical engineering principles.
• Inspect the electrical equipment of the machine at regular intervals. Defects such as loose
connections or burnt or scorched wires must be repaired or replaced immediately.
• Do not weld, ame cut or perform grinding on the machine unless expressly authorized,
as there may be a risk of re or explosion. Disconnect the battery when welding on the
machine.
• Clean the machine and its surrounding from dust or other ammable substances and make
sure the area is adequately ventilated before beginning welding, ame cutting or grinding
operations.
• Observe all product safety regulations when handling fuel, oils, grease, engine coolant and
other chemical substances. Be careful especially when these items are hot as there is a risk
of burning or scalding.
• Operate internal combustion engines and fuel operated heating systems
only in adequately ventilated premises. Before starting the engine in an
enclosed area, make sure there is sufcient ventilation.
1-11. Transporting the Machine
• Load and unload the machine in/from a transporting vehicle with two persons in order to
avoid an accidental drop of the machine.
• Drain fuel from the fuel tank, the carburetor, and the fuel strainer before transporting it on a
long distance or on a rough road.

SPECIFICATIONS

2-001
SPECIFICATIONS
1. SPECIFICATION DATA
0496-99004-0-10111-
A
710
915
585 330
960
500
432
475
560
Model PC800
Weight 99 kg (220 lbs. )
Dimensions
Overall length 915 mm (36.0 in. )
Overall width 500 mm ( 19.5 in. )
Overall height 960 mm (38.0 in. )
Vibrating plate (width × length) 500 mm × 585 mm (19.5 in. × 23.0 in. )
Compaction width 500 mm (19.5 in. )
Speed 25 to 30 m/min (82 to 98 ft/min )
Vibration
performance
Frequency 97.0 Hz
Centrifugal force 16.2 kN (3,640 lbs. )
Engine
Name HONDA GX160 Gasoline Engine
Model Air-cooled, 4-cycle, 25° inclined, 1-cylinder
Displacement 0.163 L (9.9 cu.in )
Performance
Continuos rated output 2.9 kW (3.9 HP )
at 3,600 min-1
Max. output –
–
Max. torque 11.0 N·m (8.1 lbf·ft )
at 2,500 min-1
Air cleaner Dry type
Starting system Recoil starter
Power line Transmission V-belt
Vibrating system Vibrator Eccentric shaft type
Clutch Centrifugal type

2-002
SPECIFICATIONS
2. FUEL AND LUBRICANT
2-1. Fuel
Fuel to be employed: Regular gasoline for automobile
Fuel tank capacity: 3.6 liters
2-2. Engine Oil/Vibrator Oil
Season Ambient temperature Viscosity rating
(API/SE or higher grade)
Summer 25°C and above SAE#30
Spring/Autumn 10°C to 25°C SAE#20 or #30
Winter -10°C to 10°C SAE#20
All-year-round Regardless of temperature SAE 10W-30

2-003
SPECIFICATIONS
3. TIGHTENING TORQUE CHART
N·m (lbf·ft)
Nominal
Dia. Pitch Strength Classification
6.8 8.8 10.9 12.9
Metric coarse screw
5 0.8 4.9 (3.6) 5.9 (4.4) 7.8 (5.8) 7.8 (5.8)
6 1.0 7.8 (5.8) 9.8 (7.2) 13 (9.6) 13 (9.6)
8 1.25 17 (13) 23 (17) 31 (23) 31 (23)
10 1.5 39 (29) 49 (36) 59 (44) 59 (44)
12 1.75 69 (51) 78 (58) 108 (80) 108 (80)
14 2.0 98 (72) 127 (94) 167 (123) 167 (123)
16 2.0 157 (116) 196 (145) 265 (195) 265 (195)
18 2.5 196 (145) 245 (181) 343 (253) 343 (253)
20 2.5 294 (217) 392 (289) 539 (398) 539 (398)
22 2.5 441 (325) 539 (398) 686 (506) 686 (506)
24 3.0 539 (398) 637 (470) 883 (651) 883 (651)
27 3.0 785 (579) 981 (724) 1324 (977) 1324 (977)
30 3.5 1079 (796) 1324 (977) 1765 (1302) 1765 (1302)
Metric fine screw
10 1.25 39 (29) 49 (36) 69 (51) 69 (51)
12 1.25 69 (51) 88 (65) 118 (87) 118 (87)
14 1.5 108 (80) 137 (101) 186 (137) 186 (137)
16 1.5 167 (123) 206 (152) 284 (209) 284 (209)
18 1.5 245 (181) 294 (217) 392 (289) 392 (289)
20 1.5 343 (253) 441 (325) 588 (434) 588 (434)
22 1.5 490 (361) 588 (434) 785 (579) 785 (579)
24 2.0 588 (434) 735 (542) 981 (724) 981 (724)
27 2.0 834 (615) 1030 (760) 1422 (1049) 1422 (1049)
30 2.0 1177 (868) 1422 (1049) 1961 (1446) 1961 (1446)