Sakai RS45 User manual

RS45, RS55E, RS65, RS75
SHOP MANUAL
3498-64694-0

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, specifications 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 modifications of the model.
Refer to the engine manufacture’s shop manual for data relative to engine
maintenance and repairing.

RS45, RS55E, RS65E, RS75 ۑ
0
CONTENTS
1. SAFETY
1. GENERAL SAFETYxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 1-001
1-1. Understanding the Safety Symbols and Words xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 1-001
1-2. General xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 1-001
1-3. Qualifications of Operators and Maintenance Personnel xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 1-002
1-4. Safety Practices and Policies xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 1-002
1-5. Pre Start Inspectionxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 1-003
1-6. Safety Instructions xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 1-003
1-7. Startingxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 1-003
1-8. Operatingxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 1-004
1-9. Stopping xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 1-004
1-10. Maintenancexxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 1-004
1-11. Transporting the Machinexxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 1-006
2. SPECIFICATIONS
1. SPECIFICATION DATA xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 2-001
1-1. RS45:Chassis number 10000-19999, 30000-39999 xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 2-001
1-2. RS45:Chassis number 20000-29999 xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 2-002
1-3. RS55Exxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 2-003
1-4. RS65:Chassis number 10000-29999 xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 2-004
1-5. RS65:Chassis number 30000-39999 xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 2-005
1-6. RS75:Chassis number 10000-29999 xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 2-006
1-7. RS75:Chassis number 30000-39999 xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 2-007
1-8. RS75(KRF4):Chassis number 80000-89999xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 2-008
2. FUEL AND LUBRICANTxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 2-009
2-1. Fuel xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 2-009
2-2. Engine oil/Vibrator oil xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 2-009
3. TIGHTENING TORQUE CHART xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 2-010
3. INSPECTION AND MAINTENANCE
1. INSPECTION AND MAINTENANCE xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 3-001
1-1. Enginexxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 3-001
1-2. Rammer Body xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 3-001
1-3. Spark Plug xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 3-001
1-4. Air Cleanerxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 3-002
1-5. Rammer cylinderxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 3-005

RS45, RS55E, RS65E, RS75 ۑ
0
1-6. Checking bolts in each section for their tightness xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 3-005
1-7. Replacement of fuel filter (Only application model) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 3-005
2. BASIC TROUBLESHOOTINGxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 3-006
4. PARTS CATALOGUE
1. GUIDE FOR USE OF PARTS CATALOGUE xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-001
2. RS45 xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-002
2-1. Frame xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-002
2-1-1. Frame (HONDA Engine, Chassis number : 10000-19999, 30000-39999) xxxxxxxxxxxxxx 4-002
2-1-2. Frame (ROBIN Engine, Chassis number : 20000-20700) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-004
2-1-3. Frame (ROBIN Engine, Chassis number : 20701-29999) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-006
2-2. CASE xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-008
2-3. CYLINDER ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-010
2-4. SHOE ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-012
2-5. TANK ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-014
2-6. LEVER ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-016
2-6-1. Lever assy (Chassis number : 10000-19999, 20000-20700, 30000-39999)xxxxxxxxxxxx 4-016
2-6-2. Lever assy (Chassis number : 20701-29999) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-018
2-7. NAME PLATExxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-020
2-7-1. Name plate (Chassis number : 10000-10264, 30000-39999) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-020
2-7-2. Name plate (Chassis number : 10265-19999) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-022
2-7-3. Name plate (Chassis number : 20000-29999) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-024
3. RS55E xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-026
3-1. Frame xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-026
3-2. CASE ASSYxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-028
3-3. CYLINDER ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-030
3-4. SHOE ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-032
3-5. TANK ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-034
3-6. LEVER ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-036
3-7. NAME PLATExxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-038
4. RS65 xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-040
4-1. Frame (1)xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-040
4-1-1. Frame (1) (HONDA Engine, Chassis number : 10000-29999) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-040
4-1-2. Frame (1) (ROBIN Engine, Chassis number : 30000-31602)xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-042
4-1-3. Frame (1) (ROBIN Engine, Chassis number : 31603-39999)xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-044
4-2. FRAME (2) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-046
4-2-1. Frame (2) (HONDA Engine, Chassis number : 10000-29999) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-046
4-2-2. Frame (2) (ROBIN Engine, Chassis number : 30000-31602)xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-048
4-2-3. Frame (2) (ROBIN Engine, Chassis number : 31603-39999)xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-050

RS45, RS55E, RS65E, RS75 ۑ
0
4-3. CYLINDER ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-052
4-4. SHOE ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-054
4-5. TANK ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-056
4-6. LEVER ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-058
4-6-1. Lever assy (Chassis number : 10000-31602) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-060
4-6-2. Lever assy (Chassis number : 31603-39999) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-062
4-7. NAME PLATExxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-062
4-7-1. Name plate (Chassis number : 10000-12572) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-062
4-7-2. Name plate (Chassis number : 12573-19999, 20000-29999) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-064
4-7-3. Name plate (Chassis number : 30000-31602) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-066
4-7-4. Name plate (Chassis number : 31603-39999) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-068
5. RS75 xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-070
5-1. Frame (1)xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-070
5-1-1. Frame (1) (HONDA Engine, Chassis number : 10000-29999, 80000-89999) xxxxxxxxxxxx 4-070
5-1-2. Frame (1) (ROBIN Engine, Chassis number : 30000-30782) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-072
5-1-3. Frame (1) (ROBIN Engine, Chassis number : 30783-39999) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-074
5-2. FRAME (2)xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-076
5-2-1. Frame (2) (HONDA Engine, Chassis number : 10000-29999, 80000-89999) xxxxxxxxxxx 4-076
5-2-2. Frame (2) (ROBIN Engine, Chassis number : 30000-30782)xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-078
5-2-3. Frame (2) (ROBIN Engine, Chassis number : 30783-39999)xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-080
5-3. CYLINDER ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-082
5-4. SHOE ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-084
5-5. TANK ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-086
5-6. LEVER ASSY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-088
5-6-1. Lever assy (Chassis number : 10000-30787 80000-89999)xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-088
5-6-2. Lever assy (Chassis number : 30783-39999) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-090
5-7. NAME PLATExxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-092
5-7-1. Name plate (Chassis number : 10000-29999, 80000-89999) xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-092
5-7-2. Name plate (Chassis number : 30000-30782)xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-094
5-7-3. Name plate (Chassis number : 30783-39999)xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 4-096
5. RAMMING SYSTEM
1. PRECAUTIONS FOR DISASSEMBLY AND REASSRMBLY xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 5-001
2. REMOVAL AND INSTALLATION OF RAMMING SYSTEMxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 5-002
2-1. Removal of Ramming System (Combined throttle lever and fuel valve type)xxxxxxxxxxxxxxx 5-002
2-2. Removal of Ramming System (Separated throttle lever and fuel valve type )xxxxxxxxxxxxxx 5-004
2-3. Removal of Centrifugal Clutch xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 5-006
2-4. Installation of Ramming Systemxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 5-007

3. DISASSEMBLY AND REASSEMBLY OF RAMMING SYSTEMxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 5-008
3-1. Disassembly of Crank Casexxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 5-009
3-2. Disassembly of Cylinder xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 5-010
3-3. Removal of Connecting Rod xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 5-012
3-4. Removal of Gear xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 5-012
3-5. Removal of Bellows and Outer cylinder xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 5-013
3-6. Removal of Adapter xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 5-014
3-7. Removal of Slider xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 5-015
3-8. Reassembly of Crank case/Cylinderxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 5-016

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 identifies 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.
ۻ: 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 specifically for tamping earth and sand, soil, gravel and asphalt.
The manufacturer cannot be responsible or held liable for any damage resulting from other
types of jobs. 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. Qualifications of Operators and Maintenance Personnel
• Work on the machine must be performed by qualified personnel only. Individual
responsibilities of personnel regarding operation, maintenance, repair of the machine must
be clearly stated.
• Define 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 traffic or jobsite regulations.
• Machine operating instructions should also be supplemented with detailed instructions
pertaining to the specific 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 fitting 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 modifications 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 fill the fuel tank with the engine running or while near an open flame 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.
1-7. 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.
• When the engine is started, the rammer may hop around suddenly. Hold on to the handle
firmly and then start the engine. If you do not know the correct way to go about this, get help
from more experienced personnel before starting the engine.

1-004
SAFETY
1-8. Operating
• Always make sure that there are no obstructions or persons in your line of travel before
starting the rammer in motion.
• Use caution and be very observant when operating in close quarters and congested areas.
• Never allow anyone to stand in the articulation area of the machine when the engine is
running.
• Do not attempt to control the rammer 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.
• Always pay attention to your foothold, and operate the rammer in a natural, stable posture
that keeps the rammer balanced.
• During operation, keep your feet away from compacting plate. Placing your foot on the
compacting plate is dangerous and could lead to injury.
• Compaction material may scatter about depending on its type. Be aware of the safety of
others around the machine when operating it.
1-9. Stopping
• Always park the machine in a safe area on solid and level ground.
• Lock all lockable compartments.
1-10. Maintenance
• In any performing any work concerning the operation, adjustment or modification 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 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 fluid
and other lubricants and components will be very hot.
Fluids can be under pressure, removing the radiator cap
or draining oil or changing filters can cause serious burns.
Wait until the machine has cooled down.

1-005
SAFETY
• 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 sufficient 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 fluid lines and connectors for leaks, loose
connections chafe marks or damage after cleaning.
• Repair or replace defective parts immediately.
• Never fill the fuel tank with the engine running, while near an open flame 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.
• Use only the specified fluids 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 rammer.
• 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 specified 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 qualified 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, flame cut or perform grinding on the machine unless expressly authorized,
as there may be a risk of fire or explosion. Disconnect the battery when welding on the
machine.
• Clean the machine and its surrounding from dust or other flammable substances and make
sure the area is adequately ventilated before beginning welding, flame 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 sufficient ventilation.

1-006
SAFETY
1-11. Transporting the Machine
• Always shutdown the engine when transporting the rammer.
• Tighten the fuel tank cap securely and close the fuel cock to prevent fuel from spilling.
• Drain fuel when transporting the rammer over long distances or bad roads.
• Load and unload the rammer in/from a transporting vehicle with two parsons in order to
avoid an accidental drop.
• Hold the handle at its front and rear part to prevent your finger and/or hand from being
caught between the handle and the machine body when lifting up the rammer by holding the
handle.
• Make sure lifting device has enough capacity to hold the
rammer and use the center lifting point when lifting it.
• Always inspect crane lifting cable for wear, damage, or
abuse.
Protect cable from any sharp edge. Do not use if there are
any signs of cut wires, excessive wear, or other detects.
Replace damaged cable immediately to avoid injury or
death.

SPECIFICATIONS

2-001
SPECIFICATIONS
1. SPECIFICATION DATA
1-1. RS45:Chassis number 10000-19999, 30000-39999
370
230 340
700
870
965
RS45-02001
Model SAKAI RS45 RAMMER
Physical
Machine Weight *1 49 kg (108 lbs.)
Total Length 700 mm (27.6 in.)
Total Width 370 mm (14.6 in.)
Total Height 965 mm (38.0 in.)
Size of Tamping Plate (L) X (W) 340 mm X 230 mm (13.4 in. X 9.1 in.)
Performance
Traveling Stroke 40-60 mm (1.6-2.4 in.)
Frequency 10.8-11.5 Hz (650-690 vpm)
Traveling Speed 8-12 m/min (26-39 ft/min)
Engine
Manufacturer's Model HONDA model GX100KR
Maximum Output *2 2.2 kW/3600 min-1 (3.0 HP/3600 rpm)
Fuel Gasoline
Starting System Recoil starter
*1. Indicating condition of the weight:
The weight to be indicated includes half the weight of fuel of the tank capacity.
*2. Engine output indication:
This indicates maximum output at the operating speed.

2-002
SPECIFICATIONS
1-2. RS45:Chassis number 20000-29999
385 675
1025
875
340
230
RS45-02002
Model SAKAI RS45 RAMMER
Physical
Machine Weight *1 48 kg (106 lbs.)
Total Length 675 mm (26.6 in.)
Total Width 385 mm (15.2 in.)
Total Height 1025 mm (40.4 in.)
Size of Tamping Plate (L) X (W) 340 mm X 230 mm (13.4 in. X 9.1 in.)
Performance
Traveling Stroke 40-60 mm (1.6-2.4 in.)
Frequency 10.8-11.5 Hz (650-690 vpm)
Traveling Speed 8-12 m/min (26-39 ft/min)
Engine
Manufacturer's Model ROBIN model EH09-2D
Maximum Output *2 2.0 kW/4000 min-1 (2.7 HP/4000 rpm)
Fuel Gasoline
Starting System Recoil starter
*1. Indicating condition of the weight:
The weight to be indicated includes half the weight of fuel of the tank capacity.
*2. Engine output indication:
This indicates maximum output at the operating speed.