Tomahawk TPC80H User manual

TPC80 / TPC80H
PLATE COMPACTOR Operation Manual

5. Compaction Tips
2
Table of Contents
1. Safety Information
1.1 Laws Pertaining to Spark Arresters
1.2 Operating Safety
1.3 Operator Safety while using Gasoline Engines
1.4 Service Safety
3. Operation
3.1 Recommended Fuel
3.2 Before Starting
3.3 To Start
3.4 To Stop
3.5 Application
3.6 Operation
4. Maintenance
4.1 Periodic Maintenance Schedule
4.2 Cleaning Plate
4.3 Drive Belt
4.4 Exciter Lubrication
4.5 Spark Plug
4.6 Engine Oil
4.7 Air Cleaner
4.8 Cleaning Sediment Cup
4.9 Carburetor Adjusment
4.10 Troubleshooting
4.11 Storage
4.12 Liing Machine
4.13 Transporting the Machine
2. Technical Data
2.1 Engine Data
2.2 Machine Data
3
4
4
5
5
7
7
7
8
9
8
9
10
10
10
11
11
12
13
14
14
15
16
16
17
17
6
6
7
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18

3
This manual provides information and procedures to safely operate and maintain this
model. 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 addi-
tional 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 informa-
tion 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. We expressly reserve the right to
make technical modifications, even without due notice, which aim at improving our ma-
chines or their safety standards.
1. Safety Information
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 improp-
er service.
This is the safety alert symbol. It 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.
DANGER
WARNING
CAUTION

CAUTION: Used without the safety alert symbol, CAUTION indicates a potentially hazard-
ous situation which, if not avoided, may result in property damage.
1.1 Laws Pertaining to Spark Arresters
Notice: State Health Safety Codes and Public Resources Codes specify that in certain loca-
tions spark arresters be used on internal combustion engines that use hydrocarbon fuels. A
spark arrester is a device designed to prevent accidental discharge of sparks or flames from
the engine exhaust. Spark arresters are qualified and rated by the United States Forest
Service for this purpose.
In order to comply with local laws regarding spark arresters, consult the engine distributor
or the local Health and Safety Administrator.
1.2 Operating Safety
Familiarity and proper training are required for the safe operation of equipment!
Equipment operated improperly or by untrained personnel can be dangerous! Read
the operating instructions contained in both this manual and the engine manual and famil-
iarize yourself with the location and proper use of all controls. Inexperienced operators
should receive instruction from someone familiar with the equipment before being allowed
to operate the machine.
1.2.1 NEVER allow anyone to operate this equipment without proper training. People
operating this equipment must be familiar with the risks and hazards associated with it.
1.2.2 NEVER touch the engine or muffler while the engine is on or immediately aer it has
been turned off. These areas get hot and may cause burns.
1.2.3 NEVER use accessories or attachments that are not recommended by Tomahawk
Power. Damage to equipment and injury to the user may result.
1.2.4 NEVER operate the machine with the beltguard missing. Exposed drive belt and
pulleys create potentially dangerous hazards that can cause serious injuries.
1.2.5 NEVER leave machine running unattended.
1.2.6 ALWAYS be sure operator is familiar with proper safety precautions and operation
techniques before using machine.
1.2.7 ALWAYS wear hearing protection when operating equipment.
1.2.8 ALWAYS wear protective clothing appropriate to the job site when operating equip-
ment.
1.2.9 ALWAYS wear hearing protection when operating equipment.
1.2.10 ALWAYS close fuel valve on engines equipped with one when machine is not being
operated.
4
WARNING

5
1.2.11 ALWAYS store equipment properly when it is not being used. Equipment should be
stored in a clean, dry location out of the reach of children.
1.2.12 ALWAYS operate machine with all safety devices and guards in place and in working
order. DO NOT modify or remove safety devices. DO NOT operate machine if any safety
devices or guards are missing or inoperative.
1.2.13 ALWAYS read, understand, and follow procedures in Operator's Manual before
attempting to operate equipment.
1.3 Operator Safety while using Internal Combustion Engines
Internal combustion engines present special hazards during operation and fueling!
Read and follow warning instructions in engine owner's manual and safety guidelines
below. Failure to follow warnings and DANGER safety guidelines could result in severe
injury or death.
1.3.1 DO NOT run machine indoors or in an enclosed area such as a deep trench unless
adequate ventilation, through such items as exhaust fans or hoses is provided. Exhaust gas
from the engine contains poisonous carbon monoxide gas; exposure to carbon monoxide
can cause loss of consciousness and may lead to death.
1.3.2 DO NOT smoke while operating machine.
1.3.3 DO NOT smoke when refueling engine.
1.3.4 DO NOT refuel hot or running engine.
1.3.5 DO NOT refuel engine near open flame.
1.3.6 DO NOT spill fuel when refueling engine.
1.3.7 DO NOT run engine near open flames.
1.3.8 ALWAYS refill fuel tank in well-ventilated area.
1.3.9 ALWAYS replace fuel tank cap aer refueling.
1.3.10 ALWAYS check fuel lines and fuel tank for leaks and cracks before starting engine.
1.3.11 DO NOT run machine if fuel leaks are present or fuel lines are loose.
1.4 Service Safety
Poorly maintained equipment can become a safety hazard! In order for the equip
ment to operate safely and properly over a long period of time, periodic maintenance
and occasional repairs are necessary.
1.4.1 DO NOT attempt to clean or service machine while it is running. Rotating parts can
cause severe injury.
1.4.2 DO NOT crank a flooded engine with the spark plug removed on gasoline-powered
engines. Fuel trapped in the cylinder will squirt out the spark plug opening.
DANGER
WARNING

1.4.3 DO NOT test for spark on gasoline-powered engines, if engine is flooded or the smell
of gasoline is present. A stray spark could ignite fumes.
1.4.4 DO NOT use gasoline or other types of fuels or flammable solvents to clean parts,
especially in enclosed areas. Fumes from fuels and solvents can become explosive.
1.4.5 ALWAYS keep area around muffler free of debris such as leaves, paper, cartons, etc. A
hot muffler could ignite them, starting a fire.
1.4.6 ALWAYS replace worn or damaged components with spare parts designed and
recommended by Tomahawk Power.
1.4.7 ALWAYS disconnect spark plug on machines equipped with gasoline engines, before
servicing, to avoid accidental start-up.
1.4.8 ALWAYS keep machine clean and labels legible. Replace all missing and hard-to-read
labels. Labels provide important operating instructions and warn of dangers and hazards.
2. Technical Data
2.1 Engine Data
6
Model TPC80 - 5.5HP Kohler Model TPC80 - 6HP Kohler Model TPC80H - 5.5HP Honda Model
Engine Make Kohler CH255 Kohler CH260 Honda GX160
Engine Type Air-cooled 4-stroke OHV Air-cooled 4-stroke OHV Air-cooled 4-stroke OHV
Start Type Pull Pull Pull
Horsepower 5.5 6 5.5
Engine Displacement 177cc 208cc 163cc
Peak Torque 11.2 -lb 10.42 -lb 7.6 -lb
Engine Rated Speed 4,000 RPM 4,000 RPM 4,000 RPM
Bore 68 mm 70 mm 68 mm
Stroke 49 mm 54 mm 45 mm
Engine Lubrication SAE 10W30 SG / SF SAE 10W30 SG / SF SAE 10W30 SG / SF
Oil Capacity 0.63 US qt. (0.6 L) 0.625 US qt. (0.6 L) 0.61 US qt. (0.58 L)
Fuel Type 91 Octane Gasoline 91 Octane Gasoline 91 Octane Gasoline
Fuel Tank Capacity 3.8 U.S. qts (3.6 liters) 3.8 U.S. qts (3.6 liters) 3.3 U.S. qts (3.1 liters)
Engine Dimensions 12.7” x 15.2” x 14.2” (L x W x H) 12.7” x 15.2” x 14.2” (L x W x H) 12.2” x 14.3” x 13.6” (L x W x H)
Engine Dry Weight 38.7 lbs 38.7 lbs 33 lbs
Engine Warranty 3 Year 3 Year 3 Year
Spark Plug NGK BPR 6ES NGK BPR 6ES NGK BPR 6ES

7
2.2 Machine Data
3. Operation
3.1 Recommended Fuel
The engine requires regular grade unleaded gasoline, 87 octane or higher. Use only fresh,
clean gasoline. Gasoline containing water or dirt will damage fuel system. Consult engine
owner's manual for complete fuel specifications.
3.2 Before Starting
3.2.1 Read and understand safety and operating instructions at beginning of this manual.
3.2.2 Check:
-Oil level in engine
-Fuel level
-Condition of air cleaner
-Tightness of external fasteners
-Condition of fuel lines
Model TPC80 - 5.5HP Kohler Model TPC80 - 6HP Kohler Model TPC80H - 5.5HP Honda Model
Centrifugal Force 13 Kn 13 Kn 13 Kn
Max Exciter Speed 5800 RPM 5800 RPM 5800 RPM
Compaction Force 3000 lb/3000 lb/3000 lb/
Compaction of Cohesive Soils 22 inches 22 inches 22 inches
Vibration Frequency 100 Hz 100 Hz 100 Hz
Vibrations per Minute 6400 6400 6400
Max Travel Speed 79 /min 79 /min 79 /min
Plate Depth 21 inches 21 inches 21 inches
Package Dimensions 17 inches 17 inches 17 inches
Weight 176 lbs 176 lbs 170 lbs
Product Warranty 1 Year 1 Year 1 Year
CA (CARB) Compliant Yes Yes Yes
EPA Compliant Yes Yes Yes

3.3 TO Start (Fig.1)
3.3.1 Open fuel valve by moving lever to the right (a1).
Note: If engine is cold, move choke lever to close position (b1). If engine is hot, set choke to
open position (b2).
3.3.2 Turn engine switch to "ON" (e1).
3.3.3 Open throttle by moving it slightly to le(d1).
3.3.4 Pull starter rope (c).
Note: If the oil level in the engine is low, the engine will not start. If this happens, add oil to
engine. Some engines are equipped with an oil alert light that will come on while pulling
the starter rope.
3.3.5 Open choke as engine warms (b2).
3.3.6 Open throttle fully to operate.
8
a1
a2 b2
b1
OFF ON
c2
c3
c1
d2
d1
e1
Fig. 1

9
3.4 To Stop
3.4.1 Reduce engine RPM to idle by moving throttle completely to right (d2).
3.4.2 Turn engine switch to "OFF".
3.4.3 Close fuel valve by moving lever to the le(a2).
3.5 Application
This plate is designed for compacting loose, granular soils, gravel, and paving stones. It is
intended to be used in confined areas and areas next to structures such as walls, curbs, and
foundations. Plates equipped with water tanks can be used for compacting asphalt.
This plate is not recommended for compacting cohesive soils with a heavy clay content. For
cohesive soil, use a Tomahawk PMR68.
3.6 Operation (Fig.2)
Run engine at full throttle and allow plate to pull itself along at its normal speed. When
operating on an incline it may be necessary to assist plate by pushing it forward slightly.
Depending on the material being compacted, three or four passes are recommended to
achieve the best compaction.
While a certain amount of moisture in the soil is necessary, excessive moisture may cause
soil particles to stick together and prevent good compaction. If soil is extremely wet, allow
it to dry somewhat before compacting.
If soil is so dry as to create dust clouds while operating plate, some moisture should be
added to the ground material to improve compaction. This will also reduce service to the
air filter.
When using the plate on paving stones, attach a pad to the bottom of the plate to prevent
chipping or grinding surface of the stones. A special polyurethane pad designed for this
purpose is available as an optional accessory.
CAUTION: DO NOT operate plate on concrete or on extremely hard, dry, compacted surfac-
es. The plate will jump rather than vibrate and could damage both plate and engine.

4. Maintenance
4.1 Periodic Maintenance
The chart below lists basic engine maintenance. Refer to engine manufacturer's Operation
Manual for additional information on engine maintenance.
4.2 Cleaning Plate
Clean the plate aer use to remove dirt, stones, and mud caught under the engine console.
If plate is being used in a dusty area, check engine cylinder cooling fins for heavy dirt accu-
mulation. Keep engine cylinder fins clean to prevent engine from overheating.
10
Daily
before
starting
Check fuel level.
Check engine oil level.
Inspect fuel lines.
Check and adjust drive belt.
Clean air cleaner elements.
Inspect shockmounts for
damage.
Change engine oil.
Clean engine cooling fins.
Clean sediment cup / fuel
filter.
Check and clean spark plug.
Check and adjust valve
clearance.
Change exciter oil.
Inspect air filter. Replace
as needed.
Check and tighten external
hardware.
Aer
first 20
hours
Every 2
weeks or
50 hours
Every
month or
100 hours
Every
year or
300 hours

11
4.3 Drive Belt (Fig.3)
On new machines or aer installing a new belt, check belt tension aer first 20 hours of
operation. Check and adjust belt every 50 hours thereaer.
To change the belt:
4.3.1 Remove the four hex nuts securing the belt cover. (B-C)
4.3.2 Remove the 1st belt. Use a scredriver to ease the 1st belt offby placing under the belt
and on the lip of the pulley, then pulling up. Remove the 2nd belt using the same technique
and shiing the 2nd belt from the inner groove to the outer groove and then offof the
pulley. (D-F)
4.3.3 Install a new belt on pulley. Place around the inner groove of the lower pulley and the
inner groove of the upper pulley. (G) Holding the belt firm, turn the pulley clockwise. (H)
Repeat for the 2nd belt.
4.3.4 Replace Belt
4.4 Exciter Lubrication (Fig. 4)
The exciter assembly is a self-contained, sealed unit. The bearings are lubricated using
automatic transmission fluid (see Technical Data for type). Change fluid once every year or
300 hours of operation. When changing fluid, replace O-ring.
Fig. 3
A B C D
E F G H

4.5 Spark Plug (Fig. 5)
Clean or replace spark plug as needed to ensure proper operation. Refer to the engine
owner's manual.
The muffler becomes very hot during operation and remains hot for a while aer stopping
the engine. Do not touch the muffler while it is hot.
Note: Refer to the Technical Data for the recommended spark plug type and the electrode
gap setting (page 6).
To change fluid:
4.4.1 Remove the rubber cap from the front of the compactor’s housing. (A)
4.4.2 Remove the drain nut from the compactor’s exciter box with a 19mm socket. (B)
12
Fig. 4
4.4.3 Tip baseplate up and drain fluid from exciter
assembly. Dispose of used fluid in an appropriate
manner. Contact local recycling center.
4.4.4 Add 150 ml (5 ounces) of automatic transmis-
sion fluid to exciter housing and fasten end cover to
exciter. Do not overfill exciter or bearings may over-
heat.
4.4.5 Set up console assembly to baseplate and
install belt, beltguard, and hose to water tank.
A
B

13
4.6 Engine Oil (Fig. 6)
4.6.1 Drain oil while the engine is still warm.
4.6.2 Remove the oil fill plug (a) and drain plug (b) to
drain oil.
4.6.3 Install drain plug.
4.6.3 Fill the engine crankcase through the oil
opening (b), to the upper mark on the dipstick (c).
Do not thread in the dipstick to check the level. See
Technical Data for oil quantity and type (page 6).
4.6.4 When the crankcase is full, reinstall the dipstick.
Note: In the interests of environmental protection, place a plastic sheet and a container
under the machine to collect any liquid which drains off. Dispose of this liquid in accor-
dance with environmental protection legislation.
4.5.1 Remove spark plug and inspect it.
4.5.2 Replace plug if the insulator is cracked or
chipped.
4.5.3 Clean spark plug electrodes with a wire brush.
4.5.4 Set the electrode gap (a).
4.5.5 Tighten spark plug securely.
CAUTION: A loose spark plug can become very hot and
may cause engine damage.
a
Fig. 5
Fig. 6
a
b
c

4.7 Air Filter (Fig. 7)
NEVER use gasoline or other types of low flash point solvents for cleaning the air
cleaner. A fire or explosion could result.
NEVER run engine without air cleaner: Severe engine damage will occur.
4.8 Cleaning Sediment Cup (Fig. 8)
4.8.1 Turn fuel valve off.
4.8.2 Remove sediment cup (a) and O-ring (b).
4.8.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them.
4.8.4 Turn fuel valve on and check for leaks.
14
The engine is equipped with a dual element air cleaner.
Under normal operating conditions, elements should
be cleaned once every week. Under severe, dry and
dusty conditions, the elements should be maintained
daily. Replace an element when saturated with dirt that
cannot be removed.
4.7.1 Remove the air cleaner cover (a). Remove both
elements and inspect them for holes or tears. Replace
damaged elements.
4.7.2 Wash the foam element (b) in a solution of mild
detergent and warm water. Rinse it thoroughly in clean
water. Allow the element to dry thoroughly.
4.7.3 Tap the paper element (c) lightly to remove
excess dirt or blow compressed air through the filter
from the inside out. Replace the paper element if it
appears heavily soiled.
WARNING
CAUTION
Fig. 7
a
c
b

15
4.9 Carburetor Adjustment (Fig. 9)
4.9.1 Start the engine and allow it to warm up to operating temperature.
4.9.2 Set the pilot screw (a) 2 turns out. See Note.
4.9.3 With the engine idling, turn the pilot screw (a) in or out to the setting that produces
the highest rpm.
4.9.4 Aer the pilot screw is adjusted, turn the throttle stop screw (b) to obtain the stan-
dard idle speed. See Technical Data.
Note: On some engines the pilot screw is fitted with a limiter cap (c) to prevent excessive
enrichment of the air-fuel mixture in order to comply with emission regulations. The mix-
ture is set at the factory and no adjustment should be necessary. Do not attempt to remove
the limiter cap. The limiter cap cannot be removed without breaking the pilot screw.
Fig. 8
Fig. 9
a
b
a
cb

4.10 Troubleshooting
4.11 Storage
If plate is being stored for more than 30 days:
4.11.1 Remove loose stones and dirt from plate.
4.11.2 Clean engine cylinder cooling fins.
4.11.3 Clean or replace air filter.
4.11.4 Change exciter oil.
4.11.5 Change engine oil and follow procedures described in engine manual for engine
storage.
16
Problem / Symptom
-Plate does not develop
full speed.
-Poor compaction.
-Engine running, no
vibration.
• Engine throttle control is not completely open.
• Throttle control is not adjusted correctly.
• Ground is too wet, plate sticking. Allow soil to dry
before compacting.
• Drive belt is loose or worn, slipping on pulleys. Adjust or
replace belt. Check that the engine mounting bolts are
tight.
• Exciter bearings binding. Check condition and level of
oil in exciter. Add or change oil.
• Air filter is clogged with dust, reducing engine
performance. Clean or replace air filter.
• Engine speed is too low. Check the engine speed with
tachometer. Adjust or repair engine to run at correct the
speed. Refer to engine manual.
• Engine throttle is not open.
• Drive belt is loose or broken. Adjust or replace.
• Clutch is damaged. Inspect and replace clutch.
• Engine speed is low. Check engine speed.
• Too much oil in exciter. Adjust oil to the correct level.
-Plate jumps or
compacts unevenly.
• Ground surface is too hard.
• Shockmounts loose or damaged.
Reason / Remedy

4.12 Liing Machine
See Technical Data for the weight of the machine.
To limachine manually:
4.12.1 Stop the engine.
4.12.2 Obtain help from a partner and plan the li.
4.12.3 Grasp the machine by its cage and liing slot.
4.12.4 Lithe machine.
To reduce risk of back injury while liing, keep your feet flat on ground and
shoulder width apart. Keep your head up and back straight.
To limachine mechanically:
CAUTION: Before attempting to li, be sure that all liing devices can safely handle the
weight of the machine. See Technical Data (page 7) for the weight of the machine.
Attach hook, harness, or cable to the machine as shown and lias desired.
CAUTION: DO NOT lithe vibroplate by its guide handle. The vibroplate can shi, causing it
to fall.
4.13 Transporting the Machine
To avoid burns or fire hazards, let the engine cool before transporting the machine
or storing indoors.
4.13.1 Turn the fuel valve to the offposition and keep the engine level to prevent fuel from
spilling.
4.13.2 Tie down the machine on vehicle to prevent the machine from sliding or tipping
over.
WARNING
WARNING
17

1718
5. Compaction Tips
5.1 Soil Drop Test: Soil preparedness refers to the “wetness” of the dirt or soil. Soil needs
to be 50% dry and 50% wet, before starting compaction. A simple “hand test” can deter-
mine this. Pick up a handful of soil with your hand and squeeze the dirt. Observe whether
the soil is powdery or if it breaks apart when dropped. If the soil does break apart, it means
that it is too dry. If the soil keeps together in one piece when dropped, it is ready for com-
paction.
5.2 Soil Testing: Testing: The function of this step is to measure the density of an aggregate
material to ensure the increase of density when driving out air. At a low moisture content
level, there are more soil particles assembling together. In order to determine if the soil is
compacted properly, there are several methods.
5.2.1 Soil Testing: Test strips are useful to determine the method of compaction and
understand how many passes of your plate compactor are needed to achieve the optimum
compaction. Every layer of compacted soil meets a specific percentage on the proctor
curve. Through soil testing, it is possible to identify optimum moisture. Soil testing mea-
sures the soil density compared to the degree of compaction specifications, as well as the
effect of the moisture.
A common laboratory method called the Proctor Compaction Test can be used to deter-
mine the optimal moisture content for a given soil type. The goal of this method is to
understand the soil’s maximum dry density. A second method of soil testing is known as
the California Test 216 and is used to find the relative compaction of untreated and treated
soils.
Four factors account for optimum compaction including lithickness, pressure, and soil
moisture content. During the compaction process, the soil's moisture adds density and
lubricates soil particles, until there is a maximum dry unit weight without voids in the soil.
The table below explains the different outcomes and properties of fill materials.

19
5.3 Compaction Terms
5.3.1 Cohesive soils: Clays and mixes have a particular particle size of less than .003” or
.002” and are typically classified as cohesive soils. This type of soil is primarily used for
retaining pond beds and mound fills. These soils are dense due to the strongly bound mo-
lecular attraction. Cohesive soils and water will not mix easily, but only once the soils are
moist it will feel sticky.
5.3.2 Granular soils: These soils have particle sizes of .003” or greater, like sand. Water
drains easily through the soils particles of granular soils. The larger the particles, the larger
the equipment needed to achieve lower frequencies and higher compaction force. Plate
compactors are typically the best option for compacting granular soils - however, depend-
ing on the vibration frequency and particle size, reversible plate compactors and double
drum rollers may be more appropriate for this type of work.
5.3.3 Mixed soils: Sometimes soils can be a mixture of both types, cohesive and granular.
Thus choosing the appropriate compaction equipment is more difficult. We recommend
testing your equipment to match the best machine to the desired job.

1720
5.3.4 Static force: Found in the deadweight of machines, static force applies pressure
downward on soil surfaces. As a result, soil particles compress in the topsoil layer.
5.3.5 Vibratory force: This force is engine-driven, creating a downward force, in addition to
the machine's static weight. Vibrations compress the soil material closer together to
increase density.
5.3.6 Types of compaction: There are four types of compaction that can be applied to soils
or asphalt. Each one takes place using one of the two types of the forces explained above
(static or vibratory).
1. Vibration: Periodic motion of particles with rotating weight in opposite directions
from a position of equilibrium.
2. Impact: An action of one object coming into contact with another.
3. Kneading: Force is applied by alternating movement in adjacent positions.
4. Pressure: The process of continuous physical force against solid materials.