Fayat Group DYNAPAC DFP7AX Operating Instruction Download Page 33

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3.10 Repair

Identify a defect machine with a warning sign.

Only operate the machine after it has been repaired.

When replacing safety relevant components, only original spare

parts must be used.

Repairs must only be performed by an expert/qualified person.

When performing welding work on the machine you should cover

the fuel tank with insulating material.

Concerning your safety – Repair

DFP7AX

Summary of Contents for DYNAPAC DFP7AX

Page 1: ...Operating Instruction Original Operating Instructions DFP7AX Single direction vibratory plate S N 101 924 23 1001 DL8 203 50 EN 04 2018 ...

Page 2: ...2 ...

Page 3: ...ions to the machine 22 3 3 4 Damage defects misuse of safety devices 22 3 4 Handling fuels and lubricants 23 3 4 1 Preliminary remarks 23 3 4 2 Safety regulations and environmental protection regulations for handling oil 24 3 4 3 Safety regulations and environmental protection regulations for handling gasoline 25 3 4 4 Safety regulations and environmental protection regulations for handling fuel s...

Page 4: ...he water level topping up 53 6 Operation 55 6 1 Mounting the guide handle 56 6 2 Starting the engine 57 6 3 Operation 61 6 4 Switching the water sprinkling system on off 63 6 5 Parking the machine in secured condition 64 7 Loading transporting the machine 67 7 1 Loading the machine 68 7 2 Lashing the machine to the transport vehicle 70 7 3 Transport wheels 71 7 3 1 Transport wheels with guide hand...

Page 5: ...ing the air filter 93 8 9 As required 95 8 9 1 Cleaning the cooling fins and the cooling air intake openings 95 8 9 2 Cleaning the machine 96 8 9 3 Cleaning the water spraying system 97 8 9 4 Servicing the V belt 97 8 9 5 Checking cleaning the spark plug 98 8 9 6 Measures for longer shut down periods 99 9 Troubleshooting 103 9 1 Preliminary remarks 104 9 2 Engine malfunctions 105 9 3 What to do if...

Page 6: ...Table of contents DFP7AX 6 ...

Page 7: ...1 Introduction Introduction DFP7AX 7 ...

Page 8: ...ing maintenance and repair measures to maintain the functional safety of your machine A description of all necessary maintenance work maintenance intervals as well as information on fuels and lubricants can be found in the chapter Maintenance Ä Chapter 8 Mainte nance on page 73 Do not service or repair your machine by yourself to avoid harming persons or damaging material or environment The machin...

Page 9: ...t constitute an extension of the warranty and liability conditions specified in the general sales and delivery conditions of Dynapac GmbH We wish you successful work with your Dynapac machine Introduction Foreword DFP7AX 9 ...

Page 10: ... Engine type Engine number Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No Made in Germany Ammerländer Str 93 D 26203 Wardenburg 1 2 B 924 0001 Fig 1 Machine type plate example Engine type and engine number Fig 2 Introduction Machine type plate and engine type plate DFP7AX 10 ...

Page 11: ...2 Technical data Technical data DFP7AX 11 ...

Page 12: ... 25 9 962 37 9 700 27 6 1084 42 7 545 21 5 500 19 7 Dimensions in millimetres Dimensions in inch Weights Operating weight CECE 82 181 kg lbs Basic weight 74 163 kg lbs Transport wheels optional equipment 5 11 kg lbs Dimensions Technical data DFP7AX 12 ...

Page 13: ...ders 1 Rated power SAE J 1349 2 6 3 5 kW hp Rated speed 3600 min 1 Drive system mechanical Exciter system Frequency 100 6000 Hz vpm Centrifugal force 12 2698 kN lbf Amplitude 1 10 0 043 mm in Water spraying system Type of spraying Gravity feed Filling capacities Fuel gasoline 2 0 0 5 each l gal us Water sprinkling system 13 5 3 6 each l gal us Technical data DFP7AX 13 ...

Page 14: ...ed acc to ISO 3744 and EN 500 2 1 2 Vibration data Vector total of the weighted effective acceleration in three orthog onal directions Total vibration value ahv 4 3 m s2 on crushed rock determined acc to ISO 5349 and EN 500 Associated uncertainty K 0 4 m s2 determined acc to EN 12096 Observe the daily vibration load work safety acc to 2002 44 EC Vector total of the weighted effective acceleration ...

Page 15: ...3 Concerning your safety Concerning your safety DFP7AX 15 ...

Page 16: ...s n generally accepted safety and road traffic regulations n country state specific safety regulations It is the duty of the operator to be acquainted with the safety regu lations and to apply these accordingly This also applies for local regulations and regulations concerning different types of handling activities Should the recommendations in these instructions be dif ferent from the regulations...

Page 17: ...actices for safe and environment friendly disposal of fuels and lubricants as well as replacement parts 3 1 3 Personal protective equipment Depending on the work to be carried out personal protective equipment is required to be provided by the operating company Working clothes Tight fitting working clothes with low tear resistance tight sleeves and without any projecting parts protect against bein...

Page 18: ...use This machine must only be used for n Compaction of all types of soils n Repair work on all types of soil n Paving of walkways n Work in trenches n Underfilling and compaction of hard shoulders Intended use also includes compliance with the specified oper ating maintenance and repair measures 3 1 5 Improper use Dangers may arise from the machine when it is used for purposes other than the one i...

Page 19: ... to stand on the machine while working Lifting tackle must be removed before starting work Starting and operating the machine in explosive environments and in underground mining is prohibited The lifting and lashing points specified in these instructions must be used It is prohibited to use other lifting and lashing points e g guide handle steering rod Concerning your safety Basic prerequisites DF...

Page 20: ... regular safety inspections 3 2 2 Expert qualified person An expert qualified person is a person who based on his her pro fessional education and experience has profound knowledge in the field of construction equipment and the machine in question in particular This person is acquainted with the applicable governmental indus trial safety regulations accident prevention instructions guidelines and g...

Page 21: ...operate the machine Persons under the influence of alcohol medication or drugs are not allowed to operate service or repair the machine Maintenance and repair work requires specific knowledge and must therefore only be performed by trained specialists Concerning your safety Definition of responsible persons DFP7AX 21 ...

Page 22: ...t be informed about the dangers that arise from the operation of the machine 3 3 2 Regular safety inspections Have the machine inspected by an expert qualified person as required for the conditions the machine is working under but at least once every year 3 3 3 Modifications and alterations to the machine Unauthorized changes to the machine are prohibited for safety rea sons Original parts and acc...

Page 23: ... name of substance n possible dangers n composition information on constituents n first aid measures n fire fighting measures n measures in case of accidental release n handling and storage n limitation and monitoring of exposure personal protective equipment n physical and chemical properties n stability and reactivity n toxicological data n environmental data n notes on waste disposal n informat...

Page 24: ...caused by contact with oil Wear your personal protective equipment pro tective gloves protective clothing Do not inhale any oil vapours Avoid contact CAUTION Danger of slipping on spilled oil Immediately bind spilled oil with an oil binding agent ENVIRONMENT Oil is an environmentally hazardous substance Always keep oil in proper containers Immediately bind spilled oil with an oil binding agent Dis...

Page 25: ... Health hazard caused by contact with gasoline Wear your personal protective outfit protective gloves protective clothing Do not inhale any fuel fumes Do not swallow gasoline Avoid contact with gasoline ENVIRONMENT Gasoline is an environmentally hazardous sub stance Always keep gasoline in proper containers Immediately bind spilled gasoline with an oil binding agent and dispose of in accordance wi...

Page 26: ...with fuel sta bilizer Wear your personal protective outfit protective gloves protective clothing Do not inhale any fuel stabilizer fumes Do not swallow fuel stabilizer Avoid contact with fuel stabilizer ENVIRONMENT Fuel stabilizer is an environmentally hazardous substance Immediately bind spilled fuel stabilizer with an oil binding agent and dispose of according to regulations Dispose of fuel stab...

Page 27: ...ine components Secure the machine on the transport vehicle against rolling slip ping and turning over Loads must only be attached and hoisted by an expert capable person Use only lifting gear and lifting tackle with sufficient load bearing capacity for the weight to be loaded Fasten the lifting gear only at the specified lifting points Danger to the life of persons if they step or stand under a su...

Page 28: ... other faults the machine must not be operated until these deficiencies have been corrected Do not operate the machine with defective indicators and control elements 3 6 2 Spark protection The spark protection is optional In some areas of use operation of an engine without spark protec tion is not permitted Check the locally valid legislation and regulations 3 6 3 Starting the engine Do not use an...

Page 29: ... a depth of 3 metres and a length of 10 metres These test showed CO emissions below the occupational exposure limit OEL according to TRGS 900 when operating a maximum of 4 times 15 minutes per shift 8 hours For this reason take care to ensure sufficient ventilation when operating the vibratory tamper or vibratory plate in more than shoulder deep trenches which have a width of less than 1 5 metres ...

Page 30: ...ual noises and development of smoke Perform trouble shooting and have the fault corrected Always keep a safe distance to excavation pit borders embank ments and edges Refrain from any work that could adversely affect the stability of the machine Observe the daily vibration load work safety acc to 2002 44 EC 3 7 3 Parking the machine Park the machine on horizontal level firm ground Before leaving t...

Page 31: ...and heat sources Apply measures against electrostatic charging Do not spill any fuel Catch running out fuel do not let it seep into the ground Wipe off spilled fuel Keep dirt and water away from the fuel A leaking fuel tank can cause an explosion Ensure tight fit of the fuel tank cover if necessary replace immediately Concerning your safety Refuelling DFP7AX 31 ...

Page 32: ... operating temperature danger of scalding Wipe off spilled oil catch running out oil and dispose of environ mentally When working on the air filter no dirt should fall into the air duct Do not work on the hot exhaust danger of burning Store used filters and other oil contaminated materials in a sepa rate specially marked container and dispose of environmentally 3 9 3 Cleaning work Do not perform c...

Page 33: ... been repaired When replacing safety relevant components only original spare parts must be used Repairs must only be performed by an expert qualified person When performing welding work on the machine you should cover the fuel tank with insulating material Concerning your safety Repair DFP7AX 33 ...

Page 34: ... illegible stickers or signage immediately START OPERATION STOP MIN 1 3 MIN 1 2 MINUTEN STOP MAX 1 2 3 4 5 6 7 8 1 2 1 2 Water Gasoline Benzin Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No Patent Protection Made in Germany B 230 0113 Fig 6 Concerning your safety Signage DFP7AX 34 ...

Page 35: ...sticker Follow operating instructions Instruction sticker Wear ear defenders Information sticker Lifting point Information sticker Lashing point Fig 7 Fig 8 Fig 9 Fig 10 Concerning your safety Signage DFP7AX 35 ...

Page 36: ...ranteed sound capacity level Information sticker Filler opening for petrol Information sticker Filler opening for water Fig 11 B DEC 0216 Gasoline Benzin Fig 12 B DEC 0218 Water Fig 13 Concerning your safety Signage DFP7AX 36 ...

Page 37: ...Brief operating instructions Fig 14 Concerning your safety Signage DFP7AX 37 ...

Page 38: ...ne type plate example Fig 15 Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No Made in Germany Ammerländer Str 93 D 26203 Wardenburg B 924 0002 Fig 16 Concerning your safety Signage DFP7AX 38 ...

Page 39: ...4 Indicators and control elements Indicators and control elements DFP7AX 39 ...

Page 40: ...Overview Fig 17 1 Start switch 2 Throttle lever 3 Choke lever 4 Recoil starter 5 Fuel valve 4 1 2 Starter switch Position OFF Ignition off Position ON Ignition on Fig 18 Indicators and control elements Engine DFP7AX 40 ...

Page 41: ...ever Position MIN Idle speed Position MAX Maximum speed 4 1 4 Choke lever Position Left Choke closed Position Right Choke open 4 1 5 Recoil starter Fig 19 Fig 20 Fig 21 Indicators and control elements Engine DFP7AX 41 ...

Page 42: ...4 1 6 Fuel valve Position Left Fuel valve closed Position Right Fuel valve open Fig 22 Indicators and control elements Engine DFP7AX 42 ...

Page 43: ... 2 1 Rotary button for water sprinkling system Position 0 Water sprinkling system off turn anticlockwise Water sprinkling system on infinite adjustment of the sprinkling quantity up to position MAX 1 2 B 230 0114 Fig 23 Fig 24 Indicators and control elements Water spraying system DFP7AX 43 ...

Page 44: ...4 3 Transport wheels 1 2 B 230 0023 Fig 25 1 Locking of guide handle 2 Locking of transport wheels Indicators and control elements Transport wheels DFP7AX 44 ...

Page 45: ...4 3 1 Transport wheels with guide handle in middle position B 230 0031 1 2 Fig 26 1 Locking of guide handle 2 Locking of transport wheels Indicators and control elements Transport wheels DFP7AX 45 ...

Page 46: ...Indicators and control elements Transport wheels DFP7AX 46 ...

Page 47: ...5 Checks prior to start up Checks prior to start up DFP7AX 47 ...

Page 48: ...xed settings WARNING Health hazard caused by fuels and lubricants Safety regulations and environmental protec tion regulations must be followed when han dling fuels and lubricants Ä Chapter 3 4 Han dling fuels and lubricants on page 23 WARNING Danger of injury caused by rotating parts Before starting work on the machine make sure that the engine can not be started 1 Park the machine safely Ä Chapt...

Page 49: ... lines for condition and leaks 2 Check bolted connections for tight fit 3 Check machine for contamination and damage 4 Check the hydraulic oil cooler for dirt 5 Check starter rope for chafing Checks prior to start up Visual inspections and function tests DFP7AX 49 ...

Page 50: ...screw the dipstick and wipe it clean with a lint free clean cloth 3 Insert the dipstick into the oil filler socket do not screw it in but pull it out again to check the oil level ð The oil level must be between the MIN and MAX marks 4 NOTICE Danger of engine damage Do not fill in too much engine oil If the oil level is too low top up oil to the MAX mark 5 Screw the oil dipstick in Fig 27 Checks pr...

Page 51: ...alfunction or even damage of the engine If necessary fill in fuel through a screen filter Use only fuel of the permitted specification Ä Chapter 8 2 2 Fuel on page 75 Protective equipment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 5 Parking the machine in secured condition on page 64 2 Clean the area around the filler opening 3 Remove the cap and chec...

Page 52: ...the rubber buffers 1 Check the rubber buffer pairs left and right for tight fit cracks and tear offs ð Replace damaged rubber buffers immediately Fig 29 Checks prior to start up Checking the rubber buffers DFP7AX 52 ...

Page 53: ...loves 1 Clean the area around the filling port 2 Remove the cap and check the water supply in the water tank NOTICE Dirty or contaminated water can block the bore holes Fill only with clean water 3 If necessary fill in clean water 4 Close the cap Alternatively the water tank can also be removed and transported for filling 1 Pull out the split pin 1 2 Pull out the bolt 2 and take off the water tank...

Page 54: ...Checks prior to start up Checking the water level topping up DFP7AX 54 ...

Page 55: ...6 Operation Operation DFP7AX 55 ...

Page 56: ...pment n Working clothes n Safety shoes n Protective gloves 1 Force the guide handle apart and plug it onto the brackets 2 Lock and secure the guide handle on both sides with clip pins B 230 0064 Fig 32 Operation Mounting the guide handle DFP7AX 56 ...

Page 57: ...n hot components Wear your personal protective equipment pro tective gloves protective clothing Avoid touching hot components WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection Operate the machine only with the guide handle mounted and low ered Protective equipment n Hearing protection n Working clothes n Protective gloves n Safety shoe...

Page 58: ...engine is warm or the outside tempera tures are high the choke must remain open to prevent the engine from stalling Close the choke 5 Set the throttle lever to MIN position 6 Turn the starter switch to ON position Fig 33 Fig 34 Fig 35 Fig 36 Operation Starting the engine DFP7AX 58 ...

Page 59: ... and with power 10 Manually guide the starter handle back to initial position 11 If the engine does not start during the first attempt repeat the starting process 12 Open the choke bit by bit when the engine is running 13 Run the engine warm for approx 1 to 2 minutes in idle speed NOTICE Danger of engine damage Warm up engine for a short while before starting work Do not operate the engine immedia...

Page 60: ...starter is frequently operated with the choke closed the engine will draw in too much fuel and is unable to start Ä Chapter 9 3 What to do if the engine has flooded on page 107 Operation Starting the engine DFP7AX 60 ...

Page 61: ...g on hot components Wear your personal protective equipment pro tective gloves protective clothing Avoid touching hot components WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection Protective equipment n Hearing protection n Working clothes n Protective gloves n Safety shoes 1 Make sure that no persons are in the danger zone 2 NOTICE The...

Page 62: ...e machine by means of the guide handle 4 For short work interruptions you should always return the throttle lever to MIN position idle speed ð Vibration is switched off Fig 41 Fig 42 Operation Operation DFP7AX 62 ...

Page 63: ...rinkling system on or off with the rotary button Position 0 Water sprinkling system off turn anticlockwise Water sprinkling system on infinite adjustment of the sprinkling quantity up to position MAX Fig 43 Operation Switching the water sprinkling system on off DFP7AX 63 ...

Page 64: ...rotective equipment n Hearing protection n Working clothes n Protective gloves n Safety shoes 1 Park the machine on level and firm ground 2 Set the throttle lever to MIN position idle speed 3 NOTICE Danger of engine damage Do not shut down the engine all of a sudden from full load speed but let it idle for about two minutes Turn the starter switch to OFF position ð The engine is shut down Fig 44 F...

Page 65: ...4 Close the fuel valve completely 5 secure the machine against unauthorized use Fig 46 Operation Parking the machine in secured condition DFP7AX 65 ...

Page 66: ...Operation Parking the machine in secured condition DFP7AX 66 ...

Page 67: ...7 Loading transporting the machine Loading transporting the machine DFP7AX 67 ...

Page 68: ...ing tackle must not be damaged by machine parts When lifting the machine make sure the load does not move in an uncontrolled way If necessary hold the load steady with guide ropes Protective equipment n Working clothes n Hard hat n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 5 Parking the machine in secured condition on page 64 2 Allow the engine to cool down 3 Fold the ...

Page 69: ...6 If necessary pull the machine by the handles or loops 1 on an even surface 1 B 230 0070 Fig 48 Loading transporting the machine Loading the machine DFP7AX 69 ...

Page 70: ...rection Lifting tackle must not be damaged by machine parts Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Fasten the lashing tackle to the marked lashing point 2 Lash the machine securely to the transport vehicle as shown 3 Use suitable gear to prevent the guide handle from swinging over unintentionally B 230 0071 Fig 49 B 230 0092 Fig 50 Loading transporting the mach...

Page 71: ...dle with the locking bolts 1 3 Unlock the locking bolts 2 and fold down the transport wheels 4 Push the machine up by the guide handle and fold the trans port wheels under the base plate ð The machine can now be moved 1 B 230 0027 Fig 51 2 B 230 0028 Fig 52 B 230 0005 Fig 53 Loading transporting the machine Transport wheels DFP7AX 71 ...

Page 72: ...n on page 64 2 Lock the guide handle with the hook 1 3 Unlock the locking bolts 2 and fold down the transport wheels 4 Push the machine up by the guide handle and fold the trans port wheels under the base plate ð The machine can now be moved 1 2 B 230 0032 Fig 54 B 230 0005 Fig 55 Loading transporting the machine Transport wheels DFP7AX 72 ...

Page 73: ...8 Maintenance Maintenance DFP7AX 73 ...

Page 74: ...ve equipment Do not touch hot components Park the machine on horizontal level firm ground Perform maintenance work only with the engine shut down and the spark plug connector disconnected Make sure that the engine cannot be accidentally started during maintenance work Thoroughly clean machine and engine before starting maintenance work Do not leave any tools or other objects that could cause damag...

Page 75: ...ne oil espe cially under low ambient temperatures SAE 10W 30 is recommended for general use You may alternatively use 15W 40 except under low tempera tures 8 2 1 3 Oil change intervals Oil change interval semi annually or every 100 operating hours 8 2 2 Fuel 8 2 2 1 Fuel quality Use unleaded gasoline with a research octane number of 91 or higher or octane number 86 or higher Use unleaded standard ...

Page 76: ... Please follow the instructions of the manufacturer concerning the correct mixing ratio and shelf life Mixing in fuel stabilizer does not regenerate old fuel 8 2 3 Oil for exciter shaft housing Use only engine oils according to the following specifications n API CI 4 or higher quality Avoid mixing engine oils NOTICE Components may get damaged Do not use low ash engine oils for the exciter shaft ho...

Page 77: ... Ä Chapter 8 2 2 Fuel on page 75 2 0 l 0 5 gal us Fuel stabilizer Specification Ä Chapter 8 2 2 2 Fuel stabil izer on page 76 as required Exciter shaft housing SAE 10W 40 Specification Ä Chapter 8 2 3 Oil for exciter shaft housing on page 76 Components may get damaged Do not use low ash engine oils for the exciter shaft housing 0 15 l 0 04 gal us SAE 15W 40 SAE 10W 30 Water tank Water Anti freeze ...

Page 78: ...engine oil Ä Chapter 8 7 1 Changing the engine oil on page 83 2 Check engine and machine for leaks 3 Retighten the fastening screws on air filter exhaust and other attachments 4 Retighten the bolted connections on the machine 5 Checking the V belt Ä Chapter 8 9 4 Servicing the V belt on page 97 6 Check the oil level in the vibrator housing Maintenance Running in instructions DFP7AX 78 ...

Page 79: ... strainer 86 8 8 4 Replacing the V belt 89 8 8 5 Replacing the starter rope 91 8 8 6 Changing the oil in the exciter housing 92 8 8 7 Replacing the air filter 93 As required 8 9 1 Cleaning the cooling fins and the cooling air intake openings 95 8 9 2 Cleaning the machine 96 8 9 3 Cleaning the water spraying system 97 8 9 4 Servicing the V belt 97 8 9 5 Checking cleaning the spark plug 98 8 9 6 Mea...

Page 80: ...d for damage using a torch Do not continue to use a damaged air filter ele ment If in doubt use a new air filter Protective equipment n Working clothes n Protective gloves n Safety goggles 1 Park the machine in secured condition Ä Chapter 6 5 Parking the machine in secured condition on page 64 2 Allow the engine to cool down 3 Unscrew wing nut 1 and remove cover 2 4 Clean the cover 5 Unscrew wing ...

Page 81: ...by moving the gun up and down inside the element until it is free of dust 9 In case of excessive dirt replace the paper element 10 Clean the foam element 5 in warm soapy water rinse it and let it dry thoroughly 11 Soak the foam element in clean engine oil and press exces sive oil out 12 Check both elements thoroughly for holes and cracks 13 Replace if damaged 14 Pull the foam rubber element over t...

Page 82: ...the rubber seal 5 16 Insert the filter element 4 correctly and tighten it with the wing nut 3 17 Tighten the cover 2 with the wing nut 1 18 Dispose of the filter element if replaced in an environmen tally friendly way Assembling the air filter Fig 60 Maintenance Weekly DFP7AX 82 ...

Page 83: ...2 WARNING Danger of burning on hot components Wear your personal protective equipment protective gloves protective clothing Avoid touching hot components Clean the area around oil dipstick 1 and drain plug 3 3 Unscrew the oil dipstick 4 Unscrew the drain plug and collect any oil running out 5 Clean the oil drain plug and screw it back in with a new seal ring 2 6 Fill in fresh oil up to the bottom ...

Page 84: ...e spark plug using a 13 16 inch spark plug spanner 5 Check the electrode gap of the new spark plug with a feeler gauge if necessary adjust the gap ð Nominal value 0 7 0 8 mm 0 028 0 032 in 6 Screw in the new spark plug carefully by hand 7 Once the sealing surface of the new spark plug is in contact tighten for another 1 2 turn with the spark plug spanner 8 8 2 Checking adjusting the valve clearanc...

Page 85: ...h seal 3 5 Set the piston to the top dead centre position of the compres sion stroke For this purpose align the alignment mark 2 on the starter disc to the top bore 1 Valve clearance Intake valve IN 0 15 mm 0 006 in Exhaust valve EX 0 20 mm 0 008 in 1 Check the valve clearance with a feeler gauge between rocker arm 2 and valve shaft 1 on both valves adjust if necessary Preparations Fig 64 Fig 65 C...

Page 86: ...trainer DANGER Danger to life caused by explosive gas air mixes Do not allow gasoline to come into contact with hot components Smoking and open fire is prohibited Keep away from heat sources sparks and other sources of ignition Do not spill any gasoline Protective equipment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 5 Parking the machine in secured co...

Page 87: ...5 Clean filter bowl and filter in a non inflammable solvent dry them thoroughly afterwards 6 Open the fuel valve and collect running out fuel 7 Close the fuel valve Fig 69 Fig 70 A View from below Alignment of filter during installation Fig 71 Maintenance Annually DFP7AX 87 ...

Page 88: ...rew the fuel strainer 3 with the seal 2 14 Clean the fuel strainer check the condition of the screen replace if necessary 15 Turn the fuel strainer tightly in with the new seal 16 Assemble the fuel hose with the hose clamp 17 Assemble the fuel tank with hexagon nuts 2 and hexagon screw 1 18 Check the fuel system for leaks 19 Dispose of fuel and replaced components in an environmen tally friendly w...

Page 89: ...the engine to cool down 3 Loosen the fastening screws 2 and remove the V belt guard 1 4 Slightly loosen the fastening screws 1 on both sides 5 Pull the engine carrier forward remove and replace the V belt 6 Install the new V belt and pull the engine carrier back 7 Tighten the fastening screws 1 on both sides 2 1 B 230 0072 Fig 76 1 B 230 0029 Fig 77 1 B 230 0030 Fig 78 Maintenance Annually DFP7AX ...

Page 90: ...d on to a running machine Always keep an eye on a running machine Protective equipment n Working clothes n Hearing protection n Safety shoes Special tool n Sirometer 1 Park the machine on a rubber mat 2 Start the engine Ä Chapter 6 2 Starting the engine on page 57 3 Run the machine at maximum speed for one minute 4 Check the base plate s frequency with a suitable measuring instrument e g Sirometer...

Page 91: ...Parking the machine in secured condition on page 64 2 Allow the engine to cool down 3 Disassembling the recoil starter 4 Pull the starter rope with the starter handle out completely 5 If the starter rope has been torn or the coil has recoiled com pletely n Before assembling the rope turn the coil 2 5 revolutions in anti clockwise direction and align the rope openings in coil and housing 5 to one a...

Page 92: ...andle hitting against your body Do not let the starter handle hit back Remove the fixing of the coil and run the starter handle slowly back to initial position 10 Pull the starter handle to check the function and light move ment of the recoil starter 11 Assemble the recoil starter 8 8 6 Changing the oil in the exciter housing NOTICE Components may get damaged Use only oil of the permitted specific...

Page 93: ...damaged Do not use low ash engine oils for the exciter shaft housing 6 Fill in fresh oil up to the bottom edge of the opening 7 Screw in the plug 1 8 Dispose of oil in line with environmental regulations 8 8 7 Replacing the air filter NOTICE Danger of engine damage Do not start the engine after having removed the air filter Protective equipment n Working clothes n Safety shoes n Protective gloves ...

Page 94: ...ment 7 Replace the filter element consisting of paper and foam insert NOTICE Danger of engine damage Insert the filter element correctly 8 Install the rubber seal 5 9 Insert the filter element 4 correctly and tighten it with the wing nut 3 10 Tighten the cover 2 with the wing nut 1 11 Dispose of the old filter element in an environmentally friendly way Fig 89 Fig 90 Fig 91 Maintenance Annually DFP...

Page 95: ...ing clothes n Protective gloves n Safety goggles 1 Park the machine in secured condition Ä Chapter 6 5 Parking the machine in secured condition on page 64 2 Allow the engine to cool down 3 Remove dried dirt with a suitable brush from all cooling fins and cooling air intake openings 4 CAUTION Danger of eye injuries caused by particles flying around Wear your personal protective equipment safety glo...

Page 96: ...osion 3 Look for the cause of oily contamination and have any leaks sealed by our customer service 8 9 2 Cleaning the machine NOTICE Danger of engine damage caused by reduced cooling Immediately seal any oil or fuel leaks near fuel tank cylinder or cooling air intake 1 Park the machine in secured condition Ä Chapter 6 5 Parking the machine in secured condition on page 64 2 Allow the engine to cool...

Page 97: ... tank with a strong water jet until all dirt has run out 4 Fill the water tank with clean water and close the cap 8 9 4 Servicing the V belt Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 5 Parking the machine in secured condition on page 64 2 Allow the engine to cool down 3 Loosen the fastening screws 2 and remove the V belt guard 1...

Page 98: ...tening screws 2 8 9 5 Checking cleaning the spark plug NOTICE Danger of engine damage Do not use spark plugs with incorrect heat value Protective equipment n Working clothes n Protective gloves Special tool n 13 16 inch spark plug spanner 1 Park the machine in secured condition Ä Chapter 6 5 Parking the machine in secured condition on page 64 2 Allow the engine to cool down for at least 15 minutes...

Page 99: ...ng surface of the used spark plug is in contact tighten for another 1 8 to 1 4 turn with the spark plug spanner NOTICE Danger of engine damage caused by a loose spark plug Always screw the spark plug in correctly 8 9 6 Measures for longer shut down periods 8 9 6 1 Measures before shutting down DANGER Danger to life caused by explosive gas air mixes Do not allow gasoline to come into contact with h...

Page 100: ...ow the instructions of the manufacturer 2 Empty the fuel tank and fill it with the prepared fuel mix 3 Start the engine and run the machine for approx 10 minutes in the open 4 Park the machine in secured condition 1 Close the fuel valve 2 Disassemble the drain plug 3 and the seal 4 from the car burettor and catch running out fuel 3 Disassemble filter bowl 2 and O ring 1 4 Open the fuel valve and c...

Page 101: ...ck 1 After shutting down store the machine under cover in a dry and well ventilated room 2 Cover the engine to protect it against dust and moisture 3 A machine with conserved engine must be clearly marked by attaching an information sign 8 9 6 2 Measures before restarting DANGER Danger to life caused by explosive gas air mixes Do not allow gasoline to come into contact with hot components Smoking ...

Page 102: ...4 Clean the machine thoroughly 5 Start the engine and run it for 15 to 30 minutes with idle speed Maintenance As required DFP7AX 102 ...

Page 103: ...9 Troubleshooting Troubleshooting DFP7AX 103 ...

Page 104: ...ce Whenever a fault occurs you should therefore thoroughly read these instructions on correct operation and maintenance If you cannot locate the cause of a fault or rectify it yourself by fol lowing the trouble shooting chart you should contact our customer service department Troubleshooting Preliminary remarks DFP7AX 104 ...

Page 105: ...e recoil starter Spring broken Replace the recoil starter Starter rope of recoil starter does not return to initial position Recoil starter dirty Clean the recoil starter Insufficient pre tension of the spring Check the pre tension of the spring adjust if necessary Spring broken Replace the recoil starter Low engine power Air filter clogged Clean the air filter replace if necessary Throttle cable ...

Page 106: ...change the fuel Engine oil level too low Check the engine oil level correct if nec essary Engine runs with high speed but no vibration Centrifugal clutch defective Have checked by qualified expert per sonnel V belt broken Replacing the V belt Troubleshooting Engine malfunctions DFP7AX 106 ...

Page 107: ...r sources of ignition Do not spill any gasoline Protective equipment n Working clothes n Protective gloves n Safety goggles Special tool n 13 16 inch spark plug spanner 1 Allow the engine to cool down 2 Close the fuel valve 3 Pull off the spark plug socket 4 Unscrew the spark plug using a 13 16 inch spark plug spanner 5 Have a cloth ready to soak up the fuel Fig 103 Fig 104 Troubleshooting What to...

Page 108: ...er gauge if necessary adjust the gap ð Nominal value 0 7 0 8 mm 0 028 0 032 in 12 Screw the used spark plug carefully in by hand and once the sealing surface of the used spark plug is in contact tighten it for another 1 8 to 1 4 turn with the spark plug spanner 13 Once the sealing surface of the new spark plug is in contact tighten for another 1 2 turn with the spark plug spanner NOTICE Danger of ...

Page 109: ...10 Disposal Disposal DFP7AX 109 ...

Page 110: ...from heat sources sparks and other sources of ignition Do not spill any gasoline Components that previously contained gaso line must not be cut with a cutting torch WARNING Health hazard caused by fuels and lubricants Safety regulations and environmental protec tion regulations must be followed when han dling fuels and lubricants Ä Chapter 3 4 Han dling fuels and lubricants on page 23 Protective e...

Page 111: ...11 List of special tools List of special tools DFP7AX 111 ...

Page 112: ...13 16 inch spark plug spanner Fig Sirometer Measuring instrument for speed and frequency Fig List of special tools DFP7AX 112 ...

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