Newton Road,
Manor Royal,
Crawley,
West Sussex,
RH10 9FZ
Tell +44 (0) 1293 534742
Page 2
CONTENTS
1.SAFETY PRECAUTIONS2
SAFETY PICTOGRAMS USED ON FAIRPORT EQUIPMENT3
2.TECHNICAL DATA4
3.STARTING THE ENGINE5
4.OPERATOR INSTRUCTIONS5
5.GENERAL MAINTENANCE6
6.ENGINE6
7.VEE BELT ADJUSTMENT6
8.CENTRIFUGAL CLUTCH6
8.1. M TYPE CLUTCH6
8.2. B TYPE CLUTCH7
9.ENGINE MOUNTING PLATE AND ANTI-VIBRATION MOUNTS8
10.HANDLE, BRACKETS AND ANTI-VIBRATION MOUNTS8
11.WHEEL ARM ASSEMBLY8
12.VIBRATOR UNIT8
13.BLOCK COMPACTING ATTACHMENT PLATE9
14.PARTS LIST - BASE PLATE, ENGINE PLATE, B ELT GUARD AND ENGINES
12
15.PARTS LIST WHEEL ARM A ND HANDLE BRACKET16
16.PARTS LIST CLUTCH PULLEY ASSEMBLY18
16.1. M TYPE CLUTCH18
16.2. B TYPE CLUTCH18
17.PARTS LIST BLOCK COMPACTING ATTACHMENT PLATES19
18.WATER SPRINKLER KIT19
19.WARRANTY CONDITIONS AND CLAIMS PROCEDURE20
CONDITIONS20
CLAIMS PROCEDURE21
20.REPAIRS AND ESTIMATES21
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1.SAFETY PRECAUTIONS
Do not operate this m achine unless all guards are in position and secure.
Do not smoke when refuelling.
Do not refuel with engine running.
Wipe up spilt fuel.
Do not overfill.
Dispose of fuel contaminated wipes safely.
Do not run engine in enclosed areas without adequate ventilation.
Do not run engine in an area that has a hazardous or explosive atmosphere.
Disconnect H.T. lead from spark plug on petrol engines before carrying out any
maintenance.
Turn off fuel when not using machine.
Wear protective footwear, ear defenders and gloves.
Comply with site safety regulations.
Check condition of anti-vibration mounts between engine plate and base plate before
lifting.
Base plate width:460mm
Overall length960mm
Width, wheels down:600mm
Height, wheels up:870mm
Weight with Honda GX160:92.0 kg
Robin EY20:92.0kg
B&S 5HP:93.3kg
Yanmar L40AE:103.0kg
Noise Levels Honda GX 160
Guaranteed Sound power level:108. dB Lwa
Sound pressure level at Operators Ear:98 db Lpa
Test condition: To BS 500-4 2001
Hand/Arm Vibration (maximum axis)
Honda GX16013.8m/Sec
Test condition: To BS 500-4 2001
Performance
Vibration frequency 5500 V.P.M.
Centrifugal force1570 kg
2
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3.STARTING THE ENGINE
Check oil level.
Turn fuel tap on.
Put speed control lever to tick-over.
If engine is cold, close the choke (petrol engines only).
Turn engine switch to ON(1) position.
Pull the starter rope toggle lightly until resistance is felt, then pull briskly using quick
short pull. Do not pull rope to its full extent or allow toggle to snap back against
engine. Return it gently to avoid damage.
When engine is warm op en choke.
Position engine speed control lever to give required engine speed (usually full
speed).
Commence vibration - the compactor is self-travelling.
To stop engine, position t he engine speed control to slow and turn the engine switch
to off(0).
Turn the fuel valve to off.
4.OPERATOR INSTRUCTIONS
Read section (1) - Safety.
NOTE: Drive between engine and vibrator is through a centrifugal clutch. Vibration
will commence as engine speed is increased.
Position the engine speed control lever to give required speed (usually full speed).
Commence compaction. The compactor is self travelling. Its speed of travel and the
number of passes required to achieve optimum compaction depends on the type and
condition of material being compacted and the layer dep th.
Uniformly graded granular material compacts far more efficiently than wet cohesive
material.
When compacting block paving always use a rubber att achment mat, contact your
agent for details.
When compacting blacktop always use a water spray, contact your agent for details.
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Do not run the machine on solid concrete surfaces, as this is likely to cause damage.
5.GENERAL MAINTENANCE
Top up engine oil daily and change regularly using the correct grade of oil in
accordance with the engine manufacturers instructions. If the machine is working
continuously, check the oil level and top up twice daily.
Clean the air filter element regularly. In very dry, dusty condit ions, this should be
done daily.
Lightly oil the wheel spindles and wheel arm spindles monthly.
Check tightness of all nuts and bolts monthly.
6.ENGINE
Removal
Unfasten screws (19) and remove the guard (20) and the vee belt (16). Remove the
engine mounting bolts (21) and nuts and lift off engine. For engine service, re fer to
the manufacturer’s instructions.
Replacement
To refit engine, reverse removal instructions. Set engine speed to 3300 r.p.m.
7.VEE BELT ADJUSTMENT
Unfasten screws (19), remove the guard and check belt tension. It is important to
note that belt tension in this application is much less than is generally accepted as
normal. Too high a belt tension may lead to engine damage due to excessive
transmission of vibration from the power pack through the vee belt.
To adjust belt tension, loosen the engine mounting nuts and screws (21) and move
the engine backwards towards the handle until the front of the engine mounting plate
moves downwards slightly. Adjust the engine position to allow the moun ting plate to
just return to normal level position and tighten the engine mounting nuts and screws
after making a final check that the clutch pulley is in line with the bottom pulley.
8.CENTRIFUGAL CLUTCH
8.1. M TYPE CLUTCH
Removal
Remove the guard and vee belt.
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Remove the four bolts (15) and nuts which hold the clutch assembly toget her. Warm
the front cover bearing housing (14) and tap the back of the vee belt pulley to
withdraw the pulley and front cover. The clutch shoes and inside face of the pulley
can now be inspected. If no further work is required, reassemble in reverse ord er.
To further dismantle remove the outer bearing (6) and spacer (13) using a suitable
extractor.
To remove the clutch, release the locking tab from the taper lock nut (17) and remove
the nut and lock washer. Use a suitable extractor to pull the clutch off the taper lock
sleeve. If both the clutch and taper lock sleeve move together, continue to pull u ntil
they have moved about 3m m along the shaft adaptor. Now remove pulley extractor
and screw on taper lock nut for about 3 turns. Place a short length of tube over the
end of the shaft so that the end of the tube bears against the taper lock nut. Give the
tube a sharp tap with a hammer to release the taper lock. The taper lock and clutch
can now be easily withdrawn.
Lever out key (1), unscrew the countersunk screw (4) and withdraw the shaft
adaptor. If the shaft adaptor is screwed o nto a threaded shaft, grip the large
diameter with "Mole" grips and unscrew (right hand thread).
Replacement
Re-assemble in reverse order. To position the pulley assembly and clutch correctly,
fit the distance ring (7) against the shoulder on the shaft adaptor with the re cessed
side facing outwards. The taper sleeve butts up against the distance ring.
8.2. B TYPE CLUTCH
Removal
To remove the clutch from an engine with a 3/4" keywayed shaft unscrew screw (33),
withdraw spacer (29) and pull clutch assembly of f shaf t.
To remove clutch from a n engine with a 5/8" unf shaft unscrew nut (34), remove
washer (35) and withdraw clutch assembly. It is possible that when nut (34) is
unscrewed shaft adaptor (37) will unscrew from the engine shaft rather than the nut
unscrewing from the adaptor. If this h appens remove entire assembly, grip the
shoulder end of the adaptor in a vice suitably supported internally with a short length
of 5/8" bar inserted into the end of the adaptor and unscrew nut (34) as above.
To dismantle the clutch remove circlips (27) and (28) and press out hub(24) complete
with shoes and springs.
If it is necessary to remove the shoes and springs note first the orientation of the
shoes in the hub and which notch is located on the hub. Care also should be taken
when removing the springs.
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Replacement
Replacement is the reverse of the above procedure but ensure the shoes are
replaced to the same orientation as the ones removed.
9.ENGINE MOUNTING PLATE AND ANTI-VIBRATION MOUNTS
Removal
Unscrew screws (27) and lift off the engine plate. The anti-vibration mounts can now
be removed after unscrewing nu ts (63).
Replacement
Inspect anti-vibration mounts for deterioration, cracking, tearing etc. and renew if
necessary.
Refit anti-vibration mounts to brackets on base plate ensuring a star washer is
between the mount and the bracket and that there is also one under the nut. Do not
tighten the nuts at this stage.
Refit engine base plate fully tightening screws (27) reme mbering to place star
washers under head of screws. If a mount tends to twist when screw (27) is
tightened, ensure nut (63) is loose.
Finally, tighten nuts (63).
10.HANDLE, BRACKETS AND ANTI- VIBRATION MOUNTS
To remove handle, unscrew special screws (47). The handle can now be lifted clear.
When re-fitting the handle, ensure that star washers are placed between the handle
and the anti-vibration mount to prevent the mount from twisting when the special
screws (47) are tightened.
Dismantling of the brackets is straight forward, but take care not to over tighten the
locking lever bolt (43) when reassembling.
11.WHEEL ARM ASSEMBLY
Dismantling and reassembly of the wheel arm is straightforward. However, prior to
reassembly it is worthwhile applying a thin coating of graphite grease to the wheel
arm pivot and to the wheel axle. It should be noted that the dished side of disc spring
(48) faces the wheel arm.
12.VIBRATOR UNIT
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Dismantling
Remove brackets (38).
To remove the pulley (32) release the locking tab of the taper lock nut (31) and
unscrew the locknut approximately two turns. Place supporting wedges between the
pulley and the vibrator ca se end plate (30). Position a short length of tube over the
end of the shaft so that it bears against the taperlock nut. Give the tube a sharp tap
with a hammer to release the taper lock and remove pulley and taper lock from shaft.
Unscrew the cap head screws retaining the end plate and remove the end plates.
If it is felt that the bearings are not worn, but need regreasing, use Castrol BM2 or an
equivalent grease. Half fill the bearings and fully fill the end caps. If the bearings are
to be renewed, continue dismantling a s follows.
Strike the long end of the vibrator spindle with a copper faced mallet. This will drive
out the vibrator spindle and far bearing. Remove the near bea rin g by striking it with a
suitable drift inserted from the far end.
Reassembly
Grease the bearings as described above
First place a bearing sh ield (64) over the short end of the vibrator spindle with
grooved side facing outwards and then press on a bearing. Apply a thin layer of
grease to the outside of the bearing and to the bearing housing. Offer the bearing,
spindle and bearing shield to the housing and force home using copper faced mallet
or press. Fasten the rear cover (36) into position using cap head screws (33)
Place a bearing shield o ver the end of the shaft. Lightly grease the inner and outer
surfaces of the second be aring and also the shaft and housing. Force the bearing
onto the shaft and int o the housing using a suitable tubular drift an d copper faced
mallet. Renew the seal in the end plate and refit end plate.
NOTE: Some older base plates might not have a shoulder in the bearing housing.
For these applications only Nilos ring, Part No. W81053 may be used. These fit on
the shaft between shoulder and bearin g. If they are not available, pre lubricated
bearings; Part No. W81020 with shields may be fitted. For housings that do h ave a
shoulder, bearing shield, Part No. W51788 should be used.
Replace the bottom pulley and taper lock, but do not tighten until the engine is in
position and pulley adjustment can be checked.
13.BLOCK COMPACTING ATTACHMENT PLATE
For Fabricated Base Plate
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On some base plates it will be necessary to mark out and drill the fixing holes. It is
recommended that the base plate is removed to make this easier. Place the base
plate the right way up onto the edge of the attachment plate abutting one of the studs
and with the sloping face of the base plate nesting in the sloping fa ce of the
attachment plate. Mark the edge of the base plate where the front holes and stud s in
the attachment plate come and use these marks to scribe underneath the base plate
the transverse centre lines of the holes to be drilled. Mark the front to back centre
line. Drill three 11mm diameter holes through the front sloping face, one on the
centre line and 205mm each side of the centre line and drill two 11mm diameter
holes 115mm each side of the centre line for the studs. Refit the base plate. Fit the
attachment plate with the fastenings provided.
Check tightness of fastenings after 15 minutes operation.
For Cast Base Plate
Place the compactor on the attachment plate a nd check that the holes in the
attachment plate line up with the slots in the base plate. Fasten attachment to base
plate with screws and washers provided. The large diameter washers with a flat are
fitted on the inside of the front and the fully rounded large diamete r washers are fitted
at the rear.
Check tightness of fastenings after 15 minutes operation.
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PARTS DIAGRAM - BASE PLATE, ENGINE PLATE AND BELT GUARD
N.B.To prevent torsional distortion of A-V mounts tighten screws 27 before
tightening nuts 63.
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14.PARTS LIST - BASE PLATE, ENGINE PLATE, BELT GUARD
25bW51772Engine plate (Yanmar L40 engine)1
26439/10M10 Star washer28
27469/10/16M10 x 16 Csk. Skt. Screw4
28W51809Eccentric weight and shaft1
29W81054Ball bearing (for use with ring item 64)2
29W81020Ball bearing (with out ring item 64 )2
30W50243Front cover1
31W80098Taper sleeve1
32aW51810Lower pulley for use with M type clutch 1
32bW55036Lower pulley for use with B type clutch1
33455/6/22M6 x 22 cap. hd. screw8
34435/10/30M10 x 30 hex. hd. bolt4
35480/10M10 Nyloc nut4
36W50240Rear cover1
37W80466A.V. mount4
W88909A.V. mount after Oct 20024
38W51812Front bracket2
39W51808Base plate1
51439/8M8 star washer7
63480/10M10 nut4
64W51788Bearing shield (for shouldered brg hsg) 2
64W81053Nilos ring (for straight through brg. hsg) 2
65W81246Lip seal1
Additional requirements for diesel version (not illustrated)
W51773Rear buffer bracket2
W51774Rear buffer2
Engine Part Numbers
Honda GX160 screwed shaftW81732
Honda GX160 keywayed shaftW81731
Robin EY20 screwed shaftW81798
Robin EY20 keywayed shaftW81776
13W50101Spacer1
14W50103End cover1
15435/6/40M6 Hex. Hd bolt x 40 long4
16aW80223Vee belt A36 (diesel engines)1
16bW80465Vee belt A33 (petrol engines)1
17W80097Taper sleeve1
18480/6M6 Nyloc nut4
92351Clutch assembly (5/8” UNF shaft)
91026Clutch assembly (3/4” keywayed shaft)
* Check size required (3/4" shafts only)
** Fit pins with split facing inwards to centre of engine shaft. Grind off ends of pins
flush to face of hub.
92333Block compacting attachment plate kit comprising parts listed below:
W51822Attachment plate1
435/10/40M10 x 40 hex. bolt3
480/10M10 Nyloc nut5
420/10M10 washer8
18.WATER SPRINKLER KIT
(not illustrated)
92332Water sprinkler kit comprising parts listed below
W51670Strap1
W51671Bracket1
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W80568Tank1
W878681/4 X 1/8 bush1
P80210Tap1
W80045Plastic feed pipe1.4m
W80528Clip4
W51783Sprinkler tube1
W878561/4bspt plug2
480/12M12 Nyloc nut2
429/12M12 washer2
435/6/55M6 X 55 hex hd bolt4
480/6M6 Nyloc nut4
19.WARRANTY CONDITIONS AND CLAIMS PROCEDURE
All products supplied by Fairport Construction Equipment Ltd (hereafter referred to as
FCE) are warranted to be free of defects due to faulty materials or workmanship for a
period of 12 months from the date of original despatch from FCE or as specified
All spare parts used in repairs carried out by FCE or an authorised dealer or
repairer – 3 months.
If the goods have been purchased through a stockist the above warranty periods also
apply from receipt of the goods by the user of the equip ment up to a total of a further
6 months from date of despatch from FCE whichever is earlier.
Filter elements, gauges and oils are specifically excluded from this warranty.
FCE shall at their option repair or replace d uring normal working hours goods
accepted as faulty free of charge to the user.
For proprietary items such as engines, the original manufacturer’s warranty and
conditions shall apply.
CONDITIONS
The goods shall be returned at the purchaser’s expense to FCE or to a destination
FCE may reasonably direct. Carriage costs will be refunded if warranty is accepted.
Warranty claims will not be considered where there is evidence that failure has been
caused by carelessness, improper use, negligence, inadequate servicing, incorrect
engine speeds, fair wear and tear or non-compliance with instructions issued by the
manufacturer.
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To the extent permitted by law, the liability of FCE under this section is confined only
to providing a remedy for defective goods and does not extend to any consequential
loss, loss of profit, injury or damage suffered.
Warranty will not be accepted on dismantled goods unless dismantling was carried
out with the written permission of FCE.
No claim shall be considered if other than genuine parts supplied by FCE have been
used.
Products are only covered by this warranty in the country to where they were
supplied by FCE.
Warranty on products applies only to the original user of the equipment.
This warranty shall not apply if the serial number or other identifying numbers or
marks applied by FCE have been removed, defaced or are otherwise illegible.
CLAIMS PROCEDURE
Check that the goods are still under warranty before returning them to FCE (see
above for warranty periods).
Return the goods to FCE with an order number for the work to proceed. If warranty is
accepted no charge will be made. If warranty is not accepted a quotation will be
given for the repair and the conditions under the section headed REPAIRS AND
ESTIMATES will apply.
In the customer’s interest, goods must be accompanied by documentation detailing
the nature of the fault or its symptoms. Phrases such as ‘Faulty’ are unacceptable
and will result in delays and possible charges to defray costs incurred in identifying
the fault.
In the case of hydraulic breakers and power packs, both the breaker and the pack
should be returned
20.REPAIRS AND ESTIMATES
When returning a machine, or an assembly for repair, always include an Advice Note
quoting model and serial number of the machine.
An official order must also be forwarded to FCE giving detailed instructions. No
repair work can be carried out unless covered by an official order.
An estimate will be submitted before proceeding with any repair. To partly cover the
cost in dismantling, cleaning and inspection, a small charge will be made, this
however will be waived upon receipt of your official instructions to proceed with the
repair.
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In the event of the estimate not being accepted, a further charge will be made to
defray the rebuilding of the machine. Estimates must be treated as approximate only
as it may be found necessary to use additional parts on further examination.
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EC Declaration of Conformity
We Fairport Construction Equipment Limited
Blagden Street
Sheffield
S2 5QS
Declare that the product
PP 193 Fitted with Honda GX160 engine
Manufactured from 1 Sept 2004
conforms to the following Directives:
89/336/EEC, 89/392/EEC, 91/368/EEC, 2000/14/EC
uses the following standards:
BS EN 292-1, BS EN 292-2, BS EN 294
conforms to the following Statutory Instruments
The Supply of Machinery (Safety) Regulations 1992 & amendments
Complies with the relevant essential health and safety
requirements of the Machinery Directive
Technical Construction File no.93331
Noise Construction Technical File PP193 2004
Technical Manager
Signature
Position
R.J.Castle I.Eng M.I.Mech.E.
Signed byDate
12/12/2005
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