Fairport PP193 Guide

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Blagden Street
Sheffield
S2 5QS
ENGLAND
Tel: [phone]
Fax: [phone]
Email: [email protected]
Website: www.fairport.uk.com
OPERATOR'S
SPARE PARTS &
SERVICE MANUAL
!
Unit 32,
The Bell Centre,
Newton Road,
Manor Royal,
Crawley,
West Sussex,
RH10 9FZ
Tell [phone]
Fax [phone]
FAIRPORT
CONSTRUCTION EQUIPMENT LTD
Plate Compactor
Models PP193 & PD193

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CONTENTS
1. SAFETY PRECAUTIONS 2
SAFETY PICTOGRAMS USED ON FAIRPORT EQUIPMENT 3
2. TECHNICAL DATA 4
3. STARTING THE ENGINE 5
4. OPERATOR INSTRUCTIONS 5
5. GENERAL MAINTENANCE 6
6. ENGINE 6
7. VEE BELT ADJUSTMENT 6
8. CENTRIFUGAL CLUTCH 6
8.1. M TYPE CLUTCH 6
8.2. B TYPE CLUTCH 7
9. ENGINE MOUNTING PLATE AND ANTI-VIBRATION MOUNTS 8
10. HANDLE, BRACKETS AND ANTI-VIBRATION MOUNTS 8
11. WHEEL ARM ASSEMBLY 8
12. VIBRATOR UNIT 8
13. BLOCK COMPACTING ATTACHMENT PLATE 9
14. PARTS LIST - BASE PLATE, ENGINE PLATE, BELT GUARD AND ENGINES
12
15. PARTS LIST WHEEL ARM AND HANDLE BRACKET 16
16. PARTS LIST CLUTCH PULLEY ASSEMBLY 18
16.1. M TYPE CLUTCH 18
16.2. B TYPE CLUTCH 18
17. PARTS LIST BLOCK COMPACTING ATTACHMENT PLATES 19
18. WATER SPRINKLER KIT 19
19. WARRANTY CONDITIONS AND CLAIMS PROCEDURE 20
CONDITIONS 20
CLAIMS PROCEDURE 21
20. REPAIRS AND ESTIMATES 21

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1. SAFETY PRECAUTIONS
Do not operate this machine 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.

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SAFETY PICTOGRAMS USED ON FAIRPORT EQUIPMENT

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2. TECHNICAL DATA
Engines
Type Net BHP at Operating
operating speed speed
Honda GX160 4.7 3300 RPM
Robin EY20 3.7 3300 RPM
B&S 5HP 4.0 3300 RPM
Yanmar L40AE 3.6 3300 RPM
Dimensions
Base plate width: 460mm
Overall length 960mm
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 GX160 13.8m/Sec2
Test condition: To BS 500-4 2001
Performance
Vibration frequency 5500 V.P.M.
Centrifugal force 1570 kg

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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 open 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 the 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 depth.
Uniformly graded granular material compacts far more efficiently than wet cohesive
material.
When compacting block paving always use a rubber attachment 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 conditions, 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, refer 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 mounting 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 together. 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 order.
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 until
they have moved about 3mm 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 onto 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 recessed
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 off shaft.
To remove clutch from an 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 happens 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 nuts (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) remembering 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 case 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 as 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 bearing by striking it with a
suitable drift inserted from the far end.
Reassembly
Grease the bearings as described above
First place a bearing shield (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 over the end of the shaft. Lightly grease the inner and outer
surfaces of the second bearing and also the shaft and housing. Force the bearing
onto the shaft and into the housing using a suitable tubular drift and 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 bearing. If they are not available, pre lubricated
bearings; Part No. W81020 with shields may be fitted. For housings that do have 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 face of the
attachment plate. Mark the edge of the base plate where the front holes and studs 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 and 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 diameter 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
AND ENGINES
Item No. Part No. Description Qty
19 435/8/16 M8 x 16 Hex. hd. bolt 5
20a W51819 Belt guard (petrol engines) 1
20b W51765 Belt guard (Yanmar engine) 1
21 435/8/40 M8 x 40 hex. hd. eng. mt. bolt 3
22 420/8/25 M8 Washer 3
23 W526/8 M8 large. dia. washer 3
24 480/8 M8 Nyloc nut 13
25a W51811 Engine plate (petrol engines) 1
25b W51772 Engine plate (Yanmar L40 engine) 1
26 439/10 M10 Star washer 28
27 469/10/16 M10 x 16 Csk. Skt. Screw 4
28 W51809 Eccentric weight and shaft 1
29 W81054 Ball bearing (for use with ring item 64) 2
29 W81020 Ball bearing (with out ring item 64 ) 2
30 W50243 Front cover 1
31 W80098 Taper sleeve 1
32a W51810 Lower pulley for use with M type clutch 1
32b W55036 Lower pulley for use with B type clutch 1
33 455/6/22 M6 x 22 cap. hd. screw 8
34 435/10/30 M10 x 30 hex. hd. bolt 4
35 480/10 M10 Nyloc nut 4
36 W50240 Rear cover 1
37 W80466 A.V. mount 4
W88909 A.V. mount after Oct 2002 4
38 W51812 Front bracket 2
39 W51808 Base plate 1
51 439/8 M8 star washer 7
63 480/10 M10 nut 4
64 W51788 Bearing shield (for shouldered brg hsg) 2
64 W81053 Nilos ring (for straight through brg. hsg) 2
65 W81246 Lip seal 1
Additional requirements for diesel version (not illustrated)
W51773 Rear buffer bracket 2
W51774 Rear buffer 2
Engine Part Numbers
Honda GX160 screwed shaft W81732
Honda GX160 keywayed shaft W81731
Robin EY20 screwed shaft W81798
Robin EY20 keywayed shaft W81776

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Briggs & Stratton keywayed shaft W81924
Yanmar L40 keywayed shaft W81843

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PARTS DIAGRAM - WHEEL ARM AND HANDLE BRACKET

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Items Fitted to Engines (not illustrated)
W51784 Throttle stop (for Honda engines) 1
433/6 Ext. star washer (for throttle stop) 1
437/6/16 M6 x 16 screw " 1
418/6 M6 washer " 1
480/6 M6 nyloc nut " 1
W81805 Exhaust deflector (for Honda engine) 1
W81846 Deflector screws " 2
W81860 Exhaust deflector (for B & S.engine) 1
15. PARTS LIST WHEEL ARM AND HANDLE BRACKET
Item No. Part No. Description Qty
24 480/8 M8 Nyloc nut 13
25 W51811 Engine plate 1
26 439/10 M10 star washer 28
40 437/8/20 M8 x 20 hex. hd. screw 40
41 W51814 Handle bracket LHS 1
41 W51815 Handle bracket RHS 1
42 W80467 8.2 i/d disc spring 2
43 435/8/25 M8 x 25 hex. hd. bolt 2
44 W83011 Anti-vibration mount 4
45 W51816 Locking lever 2
46 W51813 Handle (U type) 1
47 W51823 Handle bolt 4
48 W80468 Disc spring 18 x 35.5 2
50 W51817 Pivot washer 2
51 439/8 M8 star washer 7
52 435/8/16 M8 x 16 hex. hd. bolt 2
54 418/20 M20 washer 6
55 W80322 Wheel 2
67 W51827 Catch plate 2
68 433/6 M6 star washer 4
69 437/6/14 M6 x 14 hex. hd. screw 4
70 485/12 M12 thin nut 2
71 433/12 M12 star washer 2
72 W51825 Wheel arm 2
73 W51826 Wheel axle 2
74 420/12 M12 washer 2
75 435/12/90 M12 x 90 hex. hd. bolt 2
76 W51820 Wheel Arm Pivot (Welded to eng. plate) 2

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PARTS DIAGRAM - CLUTCH PULLEY ASSEMBLY
M TYPE CLUTCH
B TYPE CLUTCH

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16. PARTS LIST CLUTCH PULLEY ASSEMBLY
16.1. M TYPE CLUTCH
Item No. Part No. Description Qty
1 W84040 Key (3/4" shaft) 1
2 W51719 Shaft adaptor (3/4" shaft) 1
2 W51160 Shaft adaptor (5/8" UNF) 1
3 417/10 Csk star washer for 3/8" UNF screw * 1
3 417/8 Csk star washer for 5/16" UNF screw* 1
4 466/6/30 3/8 UNF csk skt screw x 3/4" long* 1
4 466/5/16 5/16 UNF csk skt screw x 5/8" long* 1
5 W50102 Rear cover 1
6 W81007 Ball bearing 2
7 W50106 Distance ring 1
8 92468 Clutch assembly 1
9 W81929 Clutch shoe 2
10 W81933 Clutch spring 2
11 W52341 Clutch hub 1
11a W87401 Drive pin (not shown) ** 2
12 W50107 Clutch pulley 1
13 W50101 Spacer 1
14 W50103 End cover 1
15 435/6/40 M6 Hex. Hd bolt x 40 long 4
16a W80223 Vee belt A36 (diesel engines) 1
16b W80465 Vee belt A33 (petrol engines) 1
17 W80097 Taper sleeve 1
18 480/6 M6 Nyloc nut 4
92351 Clutch assembly (5/8” UNF shaft)
91026 Clutch 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.
16.2. B TYPE CLUTCH
21a W84040 Key (3/4" shaft) 1
21b W14565 Adaptor key (5/8" shaft) 1
22 BT-01200035 Shoe 2*
23 BT-01000178 Spring 2*
24 BT-11300026 Hub 1*
25 BT-11600320 Drum/Pulley 1*
26 W81048 Ball bearing 1*
27 W81254 Circlip 1*
28 W81303 Circlip 1*

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29 W14562 Clutch spacer 1
30** W51817 Washer (3/4" shaft) 1
30** W525/6/16 3/8" large dia washer (3/4" shaft) 1
31** 439/8 M8 Shakeproof washer (3/4" shaft) 1
31** 425/6 3/8" Shakeproof washer (3/4" Shaft) 1
32a W87276 Vee belt (petrol engines) 1
32b W80036 Vee belt (Yanmar engine) 1
33** 408/5/10 5/16" UNF x 5/8" hex screw (3/4" shaft) 1
33** 525/6/10 3/8" UNF x 5/8" hex screw (3/4" shaft) 1
34 W14571 Locknut 1
35 425/12 3/4" Shakeproof washer 1
37 W55037 Shaft adaptor 1
Items marked * comprise 93024 Clutch Pulley Assembly.
** Check size required.
17. PARTS LIST BLOCK COMPACTING ATTACHMENT PLATES
(not illustrated)
For Cast Base Plate
Part No. Description Qty required
92650 Block compacting attachment plate kit comprising parts listed below:
W51780 Attachment plate 1
W50165 Rear washer 2
W51787 Front washer 2
435/12/50 M12 x 50 bolt 2
439/12 M12 Shakeproof washer 4
418/12 M12 plain washer 2
480/12 M12 Nyloc nut 4
For Fabricated Base Plate
92333 Block compacting attachment plate kit comprising parts listed below:
W51822 Attachment plate 1
435/10/40 M10 x 40 hex. bolt 3
480/10 M10 Nyloc nut 5
420/10 M10 washer 8
18. WATER SPRINKLER KIT
(not illustrated)
92332 Water sprinkler kit comprising parts listed below
W51670 Strap 1
W51671 Bracket 1