Sakai PF120 Install guide

PF120/150
SHOP MANUAL
3498-64884-0

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.

PF120/150○
0
CONTENTS
1. SAFETY
1. GENERAL SAFETY  1-001
1-1. Understanding the Safety Symbols and Words  1-001
1-2. General  1-001
1-3. Qualifications of Operators and Maintenance Personnel  1-002
1-4. Safety Practices and Policies 1-002
1-5. Pre Start Inspection  1-003
1-6. Safety Instructions  1-003
1-7. Starting  1-004
1-8. 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
1-4. Vibrator  3-001
1-5. Air Cleaner  3-002
1-6. Spark Plug  3-003
1-7. Hydraulic Oil  3-003
2. BASIC TROUBLESHOOTING  3-004

PF120/150○
0
4. PARTS CATALOGUE
1. GUIDE FOR USE OF PARTS CATALOGUE  4-001
2. FRAME (PF120)  4-002
3. HANDLE (PF120)  4-004
4. VIBRATOR (PF120)  4-006
5. NAME PLATE (PF120)  4-008
6. FRAME (PF150)  4-010
7. HANDLE (PF150)  4-012
8. VIBRATOR (PF150)  4-014
9. NAME PLATE (PF150)  4-016
5. VIBRATOR
1. PRECAUTIONS 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. Bleeding Air from the Cylinder  5-010
3-2-2. Weight Phase Focusing  5-010

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.
: 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.
1-2. 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 the compaction of asphalt or soil road construction
materials. Use of the machine for other purposes such as towing other equipment is
considered contrary to the designated use. The manufacturer cannot be responsible or held
liable for any damage resulting from such use. 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 perform service or maintenance on the machine unless the drums or tires are
adequately blocked, articulation lock bar and pin is in the locked position.
• 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.
• Check that steering and lights are fully functional before starting work or traveling with the
machine.

1-004
SAFETY
1-8. Operating
• Always make sure that there are no obstructions or persons in your line of travel before
starting the compactor in motion.
• Use caution and be very observant when operating in close quarters and congested areas.
• Obey all traffic regulations when working on public roads and make sure machine is
compatible with these regulations.
• Know and use the hand signals for particular jobs and who has the responsibility for
signaling.
• Do not work close to edges or in the vicinity of overhanging banks or on grades that could
cause the compactor to slide or roll over. Avoid any areas that may be a risk to machine
stability.
• Avoid side hill travel. Always operate up and down the slope. Always keep the propulsion
(travel control) lever in low speed range when climbing or descending hills or steep grades.
• Never allow anyone to stand in the articulation area of the machine when the engine is
running.
• Always look in all directions before reversing the direction of travel.
• Always switch on the lighting system (if equipped) during poor visibility conditions and after dark.
• Do not attempt to control the compactor travel speed 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.
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 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 by removing
the starter key and attaching a warning sign to the starter
switch.
• The machine must be parked on stable and level ground
with the drums or tires blocked to prevent inadvertent
movement.
• 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.
• Whenever possible, avoid servicing or maintenance when the engine is running unless the
drums or tires are adequately blocked, the articulation lock bar is in the locked position.
• 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 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 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.
• Inspect hydraulic hoses at regular intervals and immediately replace if they show signs of
chafing, cracking, brittleness, deformation, blistering, fitting separation, leakage, corrosion
or other damage which may affect their function or strength.
• Do not work on hydraulic system while the engine is running and the system is under
pressure. The hydraulic system remains pressurized even after the engine has stopped.
• Do not disconnect hydraulic hoses or fittings until the pressure has been properly relieved.

1-006
SAFETY
• Wait until the systems and fluid have cooled down before disconnecting.
• Never use your hands to check for leaks when inspecting a hydraulic system. Use a piece
of cardboard and always wear gloves and safety glasses.
• Get immediate medical attention if fluid has been injected under your skin. Fluid penetration
from a pin hole leak can cause severe injury or death.
• Ensure that hydraulic lines and hoses are routed and fitted properly. Ensure that no
connections are interchanged. All fittings, lengths and specifications of hoses must comply
with the technical requirements.
• 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.
1-11. 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 unloading the machine. Ramps must be the
proper strength, low angle and the proper height and width.
• Block the drums or tires (front and rear) of the hauling vehicle when loading and unloading
the compactor. Ensure that the haul vehicle is on level ground and approach the loading
ramps squarely to make sure that the compactor does not slide off the edge of the ramp.
• Position the compactor on the trailer or transport vehicle centered from side to side. Shut off
the engine and lock all lockable compartments.
• Block the drums or tires and lock the articulation lock bar. Chain the machine down properly
using the appropriate tackle.
• Know the overall height of the compactor and hauling vehicle. Observe height and weight
regulations and be sure you can pass safely at overhead obstructions.

SPECIFICATIONS

2-001
SPECIFICATIONS
1. SPECIFICATION DATA
1-1. PF120
600
1080
400
370
995
690
1085
PF120-02001
Model SAKAI PF120 PLATE COMPACTOR
Physical
Machine Weight 120 kg (265 lbs.)
Total Length 1,080 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

2-002
SPECIFICATIONS
1-2. PF150
700
1130
500
370
995
690
1085
PF120-02002
Model SAKAI PF150 PLATE COMPACTOR
Physical
Machine Weight 150 kg (330 lbs.)
Total Length 1,130 mm (44 in.)
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

2-003
SPECIFICATIONS
2. FUEL AND LUBRICANT
2-1. Fuel
Fuel to be employed: Regular gasoline for automobile
Fuel tank capacity: 3.6 liters
2-2. 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

2-004
SPECIFICATIONS
3. TIGHTENING TORQUE CHART
N·m (lbf·ft)
Nominal
Dia. Pitch Strength Classification
6.8 8.8 10.9 12.9
Metric coarse screw
5 0.8 4.9 (3.6) 5.9 (4.4) 7.8 (5.8) 7.8 (5.8)
6 1.0 7.8 (5.8) 9.8 (7.2) 13 (9.6) 13 (9.6)
8 1.25 17 (13) 23 (17) 31 (23) 31 (23)
10 1.5 39 (29) 49 (36) 59 (44) 59 (44)
12 1.75 69 (51) 78 (58) 108 (80) 108 (80)
14 2.0 98 (72) 127 (94) 167 (123) 167 (123)
16 2.0 157 (116) 196 (145) 265 (195) 265 (195)
18 2.5 196 (145) 245 (181) 343 (253) 343 (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 (289) 392 (289)
20 1.5 343 (253) 441 (325) 588 (434) 588 (434)
22 1.5 490 (361) 588 (434) 785 (579) 785 (579)
24 2.0 588 (434) 735 (542) 981 (724) 981 (724)
27 2.0 834 (615) 1030 (760) 1422 (1049) 1422 (1049)
30 2.0 1177 (868) 1422 (1049) 1961 (1446) 1961 (1446)