Sakai PF120 Shop Manual Download

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SAKAI HEAVY INDUSTRIES, LTD.

Head of

ce:

Seiwa Bldg., 4-8, Shibadaimon 1-chome,

Minato-ku, Tokyo, Japan

Telephone:

+81-3-3434-3401

Global Service Division:

2500 Takayanagi, Kuki-shi, Saitama, Japan

Telephone:

+81-480-52-1111

Printed in Japan 2010.8.0

○

Summary of Contents for PF120

Page 1: ...PF120 150 SHOP MANUAL 3498 64884 0 ...

Page 2: ......

Page 3: ... 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...

Page 4: ......

Page 5: ...Operating 1 004 1 9 Stopping 1 004 1 10 Maintenance 1 004 1 11 Transporting the Machine 1 006 2 SPECIFICATIONS 1 SPECIFICATION DATA 2 001 1 1 PF120 2 001 1 2 PF150 2 002 2 FUEL AND LUBRICANT 2 003 2 1 Fuel 2 003 2 2 Recommended Lubricant 2 003 3 TIGHTENING TORQUE CHART 2 004 3 INSPECTION AND MAINTENANCE 1 INSPECTION AND MAINTENANCE 3 001 1 1 Engine 3 001 1 2 Compactor Body 3 001 1 3 V belt 3 001 1...

Page 6: ...IONS FOR DISASSEMBLY AND REASSRMBLY 5 001 2 REMOVAL AND INSTALLATION OF VIBRATIOR 5 002 2 1 Removal of Vibrator 5 002 2 1 1 Removal of Centrifugal clutch 5 004 2 1 2 Removal of Pulley 5 005 2 2 Installation of Vibrator 5 006 3 DISASSEMBLY AND REASSEMBLY OF VIBRATOR 5 007 3 1 Disassembly of Vibrator 5 007 3 1 1 Removal of Pin 5 009 3 1 2 Removal of Gear 5 009 3 2 Reassembly of Vibrator 5 010 3 2 1 ...

Page 7: ...SAFETY ...

Page 8: ......

Page 9: ...e 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 In the assembly operation tightening torque in locations that require particular attention 1 ...

Page 10: ... 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 ...

Page 11: ...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 imme...

Page 12: ...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 If this is not possible always park at a right angle to the slope and block the drums or tires Lock all lockable compartments 1 10 Maintenance In any perfor...

Page 13: ...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 specified rating Switch off the machine immediately if trouble occurs in the electric...

Page 14: ...ventilation 1 11 Transporting the Machine Use only suitable and approved trailers and haul vehicles and lifting equipment of sufficient capacity Entrust to experienced personnel the fastening and lifting of loads and instructing of crane operators Only experienced persons familiar with the operation of the machine may load and unload the machine Use ramps or a loading dock when loading or unloadin...

Page 15: ...SPECIFICATIONS ...

Page 16: ......

Page 17: ... mm 43 in Total Width 400 mm 15 5 in Total Height 995 mm 39 in Size of Tamping Plate L X W 600 mm X 400 mm 23 5 in X 15 5 in Performance Vibration Frequency 93 Hz 5 580 vpm Traveling Speed 0 23 m min 0 75 ft min Vibratory Force 26 kN 5 840 lbf Engine Manufacturer s Model HONDA model GX160U Maximum Output 4 1 kW 3 600 min 1 5 5 HP 3 600 rpm Fuel Gasoline Starting System Recoil starter ...

Page 18: ...Total Width 500 mm 19 5 in Total Height 995 mm 39 in Size of Tamping Plate L X W 700 mm X 500 mm 27 5 in X 19 5 in Performance Vibration Frequency 93 Hz 5 580 vpm Traveling Speed 0 23 m min 0 75 ft min Vibratory Force 31 kN 6 965 lbf Engine Manufacturer s Model HONDA model GX200U Maximum Output 4 8 kW 3 600 min 1 6 4 HP 3 600 rpm Fuel Gasoline Starting System Recoil starter ...

Page 19: ... Recommended Lubricant Lubricant Service classification Ambient temp and applicable viscosity rating 15 30 C Cold 0 40 C Moderate 5 55 C Tropical Engine oil API grade SD SAE 10W 30 SAE 30 SAE 40 Vibrator oil API grade SD SAE 10W 30 SAE 30 SAE 40 Hydraulic oil Wear resistant ISO VG32 over VI 140 ISO VG32 over VI 140 ISO VG68 over VI 110 ...

Page 20: ...43 253 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 28...

Page 21: ...INSPECTION AND MAINTENANCE ...

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Page 23: ... it deflects 10 mm 0 4 in to 15 mm 0 6 in with a pressure applied with your thumb to a center point between both shafts If deflection is found too excessive replace the V belt with the new one RPF 3330 Parts No 1487 47034 0 1 4 Vibrator 1 Stop the engine and keep the compactor level 2 Remove the fill drain plug to check that the oil spills out of the plug 3 Supply oil if it has been found insuffic...

Page 24: ...filter elements if they are to be reused Paper air filter element Tap the filter element several times on a hard surface to remove dirt Blow compressed air not exceeding 207 kPa 30 psi through the filter element from the inside Never try to brush off dirt brushing will force dirt into the fibers Foam air filter element Clean in warm soapy water rinse and allow to dry thoroughly Clean in nonflammab...

Page 25: ...t vertical position to remove the oil plug Check that the oil is filled up to a level that is almost overflows out of the port If it is found insufficient replenish the specified hydraulic oil 2 Replacement of hydraulic oil are to be carried out after 500 hours of initial operation and every 1000 hours of operation thereafter Specified oil quantity when in replacement 0 17 L 0 045 gal PF120 03004 ...

Page 26: ...lush fuel system and fill with recommended fuel Cylinder compression is too low Check cylinder head gasket valve or valve seat Check excessive carbon has accumulated in combustion chamber Check piston ring piston or cylinder for worn Check and adjust valve clearance Tighten cylinder head and spark plug correctly Recoil starter internal mechanism malfunction Disassemble check and clean recoil start...

Page 27: ...PARTS CATALOGUE ...

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Page 29: ...lowing abbreviated words are used in this parts catalogue LH Lefthand viewed from behind of vehicle RH Righthand viewed from behind of vehicle Inc Key number of parts constituting an assembly OP Option N S Parts not to be supplied by a single piece A S Parts to be supplied as an assembly composed or a kit of parts AR As required Dom For use in Japan Exp For use in countries other than Japan SEE PA...

Page 30: ...0 16 27 28 1 21 22 20 A 51 50 52 53 47 48 49 54 47 48 49 42 41 43 6 8 7 39 40 A 2 29 14 13 15 11 10 12 6 7 8 B 23 24 25 17 19 5 4 3 34 45 44 46 44 46 45 34 9 B 42 41 43 18 26 9 33 37 30 31 32 38 36 35 0488 47801 0 10006 A See 4 Vibrator ...

Page 31: ...ER 2 25 2170 08016 0 ﾜｯｼｬ WASHER 2 26 1487 47034 0 V ﾍﾞﾙﾄ V BELT 1 27 1487 47016 0 ｶﾊﾞｰ COVER 1 28 1484 47025 0 ｶﾊﾞｰ COVER 1 29 1487 47020 0 ｶﾞｰﾄﾞ GUARD 1 30 2100 12030 1 ﾎﾞﾙﾄ BOLT 2 31 2171 12030 0 ｽﾌﾟﾘﾝｸﾞﾜｯｼｬ SPRING WASHER 2 32 2170 12025 0 ﾜｯｼｬ WASHER 2 33 1487 47018 0 ﾍﾞｰｽ BASE 1 34 1487 47022 0 ﾌﾞﾗｹｯﾄ BRACKET 2 35 1488 47002 1 ﾌﾟﾚｰﾄ PLATE 1 36 2107 08035 3 ﾎﾞﾙﾄ BOLT 4 37 2107 16160 3 ﾎﾞﾙﾄ BOL...

Page 32: ...UE 3 HANDLE PF120 40 37 A 28 30 29 7 8 9 10 12 11 42 4 3 2 1 6 43 13 40 B 39 35 34 33 37 39 36 36 A 20 C C 41 21 14 15 23 27 24 5 26 25 27 24 23 15 14 5 26 25 32 31 20 19 22 38 38 33 35 34 B 16 17 18 0487 12801 0 10044 C ...

Page 33: ...2 2 ﾎｰｽ HOSE 1 21 2265 02002 2 ｱﾀﾞﾌﾟﾀ ADAPTER 1 INC 22 22 2630 02011 0 O ﾘﾝｸﾞ O RING 1 23 1487 47026 0 防振ｺﾞﾑ DAMPER 2 24 1487 47035 0 ﾌﾟﾚｰﾄ PLATE 2 25 2107 06016 3 ﾎﾞﾙﾄ BOLT 6 26 2172 06010 1 ｺﾆｶﾙﾜｯｼｬ CONICAL SPRING WASHER 6 27 2150 05050 0 ｽﾌﾟﾘﾝｸﾞﾋﾟﾝ SPRING PIN 2 28 2100 08025 1 ﾎﾞﾙﾄ BOLT 1 29 2170 08016 0 ﾜｯｼｬ WASHER 1 30 2171 08020 0 ｽﾌﾟﾘﾝｸﾞﾜｯｼｬ SPRING WASHER 1 31 2120 08065 0 ﾅｯﾄ NUT 1 32 4911...

Page 34: ...4 006 PARTS CATALOGUE 4 VIBRATOR PF120 34 9 5 6 7 22 24 23 4 1 35 A B B A 29 26 30 34 17 28 27 25 34 12 11 10 14 13 2 3 16 33 17 31 32 15 34 18 19 21 19 20 8 31 32 36 0488 47001 0 10005 0 ...

Page 35: ...1 17 2194 10030 1 C ｽﾅｯﾌﾟﾘﾝｸﾞ C RETAINING RING 2 18 1487 47004 0 ｷﾞﾔ GEAR 1 19 2501 06914 0 ﾎﾞｰﾙﾍﾞｱﾘﾝｸﾞ BALL BEARING 2 20 2107 06030 3 ﾎﾞﾙﾄ BOLT 4 21 1484 47009 0 ﾎﾞｽ BOSS 1 22 2100 10020 1 ﾎﾞﾙﾄ BOLT 1 23 2171 10025 0 ｽﾌﾟﾘﾝｸﾞﾜｯｼｬ SPRING WASHER 1 24 3931 00328 0 ﾜｯｼｬ WASHER 1 25 2196 08025 1 ｷｰ SUNK KEY 1 26 2602 02085 0 ｵｲﾙｼｰﾙ OIL SEAL 1 27 2194 04017 0 ｽﾅｯﾌﾟﾘﾝｸﾞ RETAINING RING 1 28 1487 47003 0 ｷ...

Page 36: ...4 008 PARTS CATALOGUE 5 NAME PLATE PF120 0488 19803 0 10019 0 9 8 7 6 2 3 4 5 ...

Page 37: ...DECAL 1 DANGER 4 3998 15491 2 ﾃﾞｶｰﾙ DECAL 1 WARNING 5 1462 19006 0 ﾃﾞｶｰﾙ DECAL 1 HOT 6 1487 19003 1 ﾃﾞｶｰﾙ DECAL 1 V BELT 7 1488 19003 0 ﾃﾞｶｰﾙ DECAL 1 8 1596 19003 0 ﾃﾞｶｰﾙ DECAL 1 SAKAI 9 1579 47510 1 ﾃﾞｶｰﾙ DECAL 1 OIL 記号 Key No 部品番号 Parts No 部品名称 Parts Name 数量 Q ty 備考 Remarks ...

Page 38: ...0 16 27 28 1 21 22 20 A 51 50 52 53 47 48 49 54 47 48 49 42 41 43 6 8 7 39 40 A 2 29 14 13 15 11 10 12 6 7 8 B 23 24 25 17 19 5 4 3 34 45 44 46 44 46 45 34 9 B 42 41 43 18 26 9 33 37 30 31 32 38 36 35 0487 47801 0 10042 A See 8 Vibrator ...

Page 39: ...2 25 2170 08016 0 ﾜｯｼｬ WASHER 2 26 1487 47034 0 V ﾍﾞﾙﾄ V BELT 1 27 1487 47016 0 ｶﾊﾞｰ COVER 1 28 1484 47025 0 ｶﾊﾞｰ COVER 1 29 1487 47020 0 ｶﾞｰﾄﾞ GUARD 1 30 2100 12030 1 ﾎﾞﾙﾄ BOLT 2 31 2171 12030 0 ｽﾌﾟﾘﾝｸﾞﾜｯｼｬ SPRING WASHER 2 32 2170 12025 0 ﾜｯｼｬ WASHER 2 33 1487 47018 0 ﾍﾞｰｽ BASE 1 34 1487 47022 0 ﾌﾞﾗｹｯﾄ BRACKET 2 35 1487 47009 1 ﾌﾟﾚｰﾄ PLATE 1 36 2107 08035 3 ﾎﾞﾙﾄ BOLT 4 37 2107 16160 3 ﾎﾞﾙﾄ BOLT 6...

Page 40: ...UE 7 HANDLE PF150 40 37 A 28 30 29 7 8 9 10 12 11 42 4 3 2 1 6 43 13 40 B 39 35 34 33 37 39 36 36 A 20 C C 41 21 14 15 23 27 24 5 26 25 27 24 23 15 14 5 26 25 32 31 20 19 22 38 38 33 35 34 B 16 17 18 0487 12801 0 10044 C ...

Page 41: ... 10097 2 ﾎｰｽ HOSE 1 21 2265 02002 2 ｱﾀﾞﾌﾟﾀ ADAPTER 1 INC 22 22 2630 02011 0 O ﾘﾝｸﾞ O RING 1 23 1487 47026 0 防振ｺﾞﾑ DAMPER 2 24 1487 47035 0 ﾌﾟﾚｰﾄ PLATE 2 25 2107 06016 3 ﾎﾞﾙﾄ BOLT 6 26 2172 06010 1 ｺﾆｶﾙﾜｯｼｬ CONICAL SPRING WASHER 6 27 2150 05050 0 ｽﾌﾟﾘﾝｸﾞﾋﾟﾝ SPRING PIN 2 28 2100 08025 1 ﾎﾞﾙﾄ BOLT 1 29 2170 08016 0 ﾜｯｼｬ WASHER 1 30 2171 08020 0 ｽﾌﾟﾘﾝｸﾞﾜｯｼｬ SPRING WASHER 1 31 2120 08065 0 ﾅｯﾄ NUT 1 32...

Page 42: ...4 014 PARTS CATALOGUE 8 VIBRATOR PF150 34 9 5 6 7 22 24 23 4 1 35 A B B A 29 26 30 34 17 28 27 25 34 12 11 10 14 13 2 3 16 33 17 31 32 15 34 18 19 21 19 20 8 31 32 36 0487 47001 0 20041 0 ...

Page 43: ...1 17 2194 10030 1 C ｽﾅｯﾌﾟﾘﾝｸﾞ C RETAINING RING 2 18 1487 47004 0 ｷﾞﾔ GEAR 1 19 2501 06914 0 ﾎﾞｰﾙﾍﾞｱﾘﾝｸﾞ BALL BEARING 2 20 2107 06030 3 ﾎﾞﾙﾄ BOLT 4 21 1484 47009 0 ﾎﾞｽ BOSS 1 22 2100 10020 1 ﾎﾞﾙﾄ BOLT 1 23 2171 10025 0 ｽﾌﾟﾘﾝｸﾞﾜｯｼｬ SPRING WASHER 1 24 3931 00328 0 ﾜｯｼｬ WASHER 1 25 2196 08025 1 ｷｰ SUNK KEY 1 26 2602 02085 0 ｵｲﾙｼｰﾙ OIL SEAL 1 27 2194 04017 0 ｽﾅｯﾌﾟﾘﾝｸﾞ RETAINING RING 1 28 1487 47003 0 ｷ...

Page 44: ...4 016 PARTS CATALOGUE 9 NAME PLATE PF150 0487 19803 0 10076 0 9 8 7 6 2 3 4 5 ...

Page 45: ...DECAL 1 DANGER 4 3998 15491 2 ﾃﾞｶｰﾙ DECAL 1 WARNING 5 1462 19006 0 ﾃﾞｶｰﾙ DECAL 1 HOT 6 1487 19003 1 ﾃﾞｶｰﾙ DECAL 1 V BELT 7 1487 19008 0 ﾃﾞｶｰﾙ DECAL 1 8 1596 19003 0 ﾃﾞｶｰﾙ DECAL 1 SAKAI 9 1579 47510 1 ﾃﾞｶｰﾙ DECAL 1 OIL 記号 Key No 部品番号 Parts No 部品名称 Parts Name 数量 Q ty 備考 Remarks ...

Page 46: ......

Page 47: ...VIBRATOR ...

Page 48: ......

Page 49: ...ing hoses do not twist them or allow them to interfere with other parts Replace gaskets O rings split cotter pin and lock plates with new parts Properly bend split cotter pins and lock plates When applying an adhesive first clean and remove oil grease from the surfaces properly Then apply two or three drops to the threaded areas When applying a liquid gasket first clean and remove oil grease from ...

Page 50: ...5 002 VIBRATOR 2 REMOVAL AND INSTALLATION OF VIBRATOR 2 1 Removal of Vibrator A 6 7 16 A 1 22 5 21 16 B 15 8 9 3 2 19 18 20 14 13 B 17 4 25 24 23 12 11 10 ...

Page 51: ...e belt 14 Centrifugal clutch 1 Refer to the 2 1 1 Removal of Centrifugal clutch 17 Pulley 1 Refer to the 2 1 2 Removal of Pulley 15 Cover 1 Remove the two M8 25 bolts 9 and the four M8 20 bolts 8 5 Engine 1 Remove the M10 20 bolt 6 and the engine drain hose 7 Remove the four M8 35 bolts 21 20 Base 1 Remove the M8 30 bolt 23 and the band 25 Disconnect the hydraulic hose 24 NOTE Attach a plug to the...

Page 52: ...nsistent with the part numbers of the vibrator shown on page 5 002 1 Remove the four bolts and recoil starter Bolt PF120 05002 Recoil starter PF120 05003 Crankshaft bolt PF120 05004 10 2 Hold down the crankshaft bolt 3 Rotate the M8 35 centrifugal clutch mounting bolt 10 in a counterclockwise direction to remove ...

Page 53: ...e the centrifugal clutch 14 CAUTION Be careful not to damage the thread groove of the crankshaft 2 1 2 Removal of Pulley 1 Remove the M10 20 pulley mounting bolt PF120 05007 Puller Pulley 2 Use the puller to remove the pulley CAUTION Be careful not to damage the thread groove of the shaft ...

Page 54: ...ting surface Apply a thread locking agent to the vibrator mounting bolt 19 Before mounting the engine 5 onto the base 20 temporarily install the cover 15 with two bolts 9 first to fix the engine mount position Apply a thread locking agent to the M8 35 centrifugal clutch mounting bolt 10 Confirm the amount of hydraulic oil for the forward reverse lever after installing the hydraulic hose 24 Refer t...

Page 55: ......

Page 56: ...3 DISASSEMBLY AND REASSEMBLY OF VIBRATOR 3 1 Disassembly of Vibrator 13 11 10 4 A B B A 8 3 1 6 14 5 9 12 6 5 7 2 5 007 VIBRATOR ...

Page 57: ... Remove the two M8 30 bolts 6 and the weight 5 on the fixed side shaft Remove the retaining ring 8 13 Gear variable weight side 1 Remove the two M8 30 bolts 6 and the weight 5 on the variable side shaft Remove the gear 9 1 Refer to 3 1 1 Removal of Pin 1 Remove the three M8 40 bolts 1 and the cylinder gear assembly 2 1 Refer to 3 1 2 Removal of Gear 2 Cylinder 1 Remove the M10 nut 4 5 008 VIBRATOR...

Page 58: ...do the C retaining ring 3 from gear 13 2 Use a jig to remove the cylinder 2 from the gear 13 Jig part number 9010 02023 0 3 1 1 Removal of Pin The lead line numbers shown in the illustration below are consistent with the part numbers of the vibrator shown on page 5 007 1 After removing the weight on the variable side shaft tap the pin 14 out of the gear CAUTION Be careful not to damage the gear 5 ...

Page 59: ...fer to 3 2 2 When installing the cover 12 apply liquid packing to the cover mounting surface After installing the vibrator pour in the prescribed amount of oil Refer to P 3 001 3 2 1 Bleeding Air from the Cylinder The lead line numbers shown in the illustration below are consistent with the part numbers of the vibrator shown on page 5 007 1 Take the plug out of the cylinder 2 and pour in the oil A...

Page 60: ...ight on the variable side Rotate the shaft on the fixed weight side Set the position of the fixed weight perpendicular as shown in the figure on the right 4 While maintaining the position from Step 3 install the gear 7 on the fixed weight side by aligning it with the shaft key Notice Confirm that the position of each weight is correct PF120 05016 7 Key PF120 05018 Variable weight side Fixed weight...

Page 61: ...120 05017 8 5 Install the retaining ring 8 After installing the retaining ring turn the gear on the variable weight side and check to see whether or not the pin 14 and gear 13 move smoothly 5 012 VIBRATOR ...

Page 62: ...4 8 Shibadaimon 1 chome Minato ku Tokyo Japan Telephone 81 3 3434 3401 Global Service Division 2500 Takayanagi Kuki shi Saitama Japan Telephone 81 480 52 1111 Copy right 2010 SAKAI HEAVY INDUSTRIES LTD All Right Reserved Printed in Japan 2010 8 0 0 CD ...

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