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Fayat Dynapac DFP7, Operating And Maintenance Instructions Manual

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Fayat Dynapac DFP7 Operating And Maintenance Instructions Manual Download Page 76

8.4  Running-in instructions

8.4.1  General

The following maintenance work must be performed when running

in new machines or overhauled engines.

8.4.2  After 25 operating hours

1.

Change the engine oil

 

Ä

 Chapter 8.7.1 ‘Changing the engine

oil’ on page 81

.

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 96

.

6.

Check the oil level in the vibrator housing.

Maintenance – Running-in instructions

 

DFP7

 

76

Summary of Contents for Dynapac DFP7

Page 1: ...Operating Instruction Maintenance Instruction Original Operating Instructions DFP7 Forward plate S N 101 925 34 1001 DL8 204 80 EN 02 2020 ...

Page 2: ...uding toluene and benzene which are known to the State of California to cause cancer and birth defects or other reproductive harm WARNING Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Always start and operate the engine in a well ventilated area If in an enclosed area vent the exhaust to the ou...

Page 3: ...2 3 3 3 Modifications and alterations 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 gasoline 24 3 4 3 Safety regulations and environmental protection regulations for handling fuel stabiliser 25 3 4 4 Safety regulations and environment...

Page 4: ...rubber buffers 52 5 6 Checking the water level topping up 53 6 Operation 55 6 1 Mounting the guide handle 56 6 2 Starting the engine 57 6 3 Operation 60 6 4 Switching the water sprinkling system on off 62 6 5 Parking the machine in secured condition 63 7 Loading transporting the machine 65 7 1 Loading the machine 66 7 2 Lashing the machine to the transport vehicle 68 7 3 Transport wheels 69 8 Main...

Page 5: ...8 8 7 Replacing the air filter 92 8 9 As required 94 8 9 1 Cleaning the cooling fins and the cooling air intake openings 94 8 9 2 Cleaning the machine 95 8 9 3 Cleaning the water spraying system 96 8 9 4 Servicing the V belt 96 8 9 5 Checking cleaning the spark plug 97 8 9 6 Measures prior to extended shut down period 98 9 Troubleshooting 101 9 1 Preliminary remarks 102 9 2 Engine malfunctions 103...

Page 6: ...Table of contents DFP7 6 ...

Page 7: ...1 Introduction Introduction DFP7 7 ...

Page 8: ...ting 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 Maintenance on page 71 Do not service or repair your machine by yourself to avoid harming persons or damaging material or environment The machin...

Page 9: ...ot 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 DFP7 9 ...

Page 10: ...e 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 DFP7 10 ...

Page 11: ...2 Technical data Technical data DFP7 11 ...

Page 12: ...084 42 7 542 21 3 400 15 8 Dimensions in millimetres Dimensions in inch Weights Operating weight CECE 72 159 kg lbs Basic weight 71 157 kg lbs Water spraying system optional equipment 10 22 kg lbs Transport wheels optional equipment 4 8 8 kg lbs Dimensions Technical data DFP7 12 ...

Page 13: ...ed power SAE J 1349 2 6 3 5 kW hp Rated speed 3600 min 1 Drive system mechanical Exciter system Frequency 90 5400 Hz vpm Centrifugal force 12 2698 kN lbf Amplitude 1 42 0 056 mm in Water sprinkling system optional equipment Type of sprinkling 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 DFP7 13 ...

Page 14: ...ned 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 0 m s2 on crushed rock determined acc to ISO 5349 and EN 500 Associated uncertainty K 0 3 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 DFP7 15 ...

Page 16: ...ns 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 regulation...

Page 17: ...ractices 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 bei...

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 ...

Page 19: ...ing 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 3 1 6 Estimated service life of the machine If the following general conditions are met the service life of the machine is usually in the range of several thousand operating hours n Regular safety inspections by an expert qualified person n Perf...

Page 20: ...f 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 ...

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 DFP7 21 ...

Page 22: ...st 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 ac...

Page 23: ...n 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 informa...

Page 24: ...G 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 w...

Page 25: ... 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 sta...

Page 26: ... 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 Di...

Page 27: ...hine 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 s...

Page 28: ...r 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 a...

Page 29: ...Avoid operation in closed or partly closed rooms or ensure ade quate ventilation when working in trenches Concerning your safety Start up procedure DFP7 29 ...

Page 30: ...sual 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 ...

Page 31: ...nition and heat sources Apply measures against electrostatic charging Do not spill any fuel Collect leaking 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 cover if necessary replace immediately Concerning your safety Refuelling DFP7 31 ...

Page 32: ...ters and other oil contaminated materials in a sepa rate specially marked container and dispose of environmentally 3 9 3 Cleaning work Do not perform cleaning work while the motor is running Allow the engine to cool down before starting cleaning work Do not use gasoline or other easily inflammable substances for cleaning 3 9 4 Measures for longer shut down periods If the machine is taken out of op...

Page 33: ...s 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 DFP7 33 ...

Page 34: ...ARNING California Proposition 65 Warning This product contains chemicals that cause cancer chemicals that are reproductive toxicants before taking into operation vor Inbetriebnahme avant la mise en service anterior a la puesta en servicio weekly wöchentlich hebdomadairement cada semana twice annual halbjährlich tous les 6 mois cada 6 meses annual jährlich annuellement anualmente BENZIN GASOLINE ST...

Page 35: ... 65 Instruction sticker Wear ear defenders Information sticker Lifting point Fig 7 WARNING California Proposition 65 Warning This product contains chemicals that cause cancer chemicals that are reproductive toxicants B DEC 0316 Fig 8 Fig 9 Fig 10 Concerning your safety Signage DFP7 35 ...

Page 36: ...on sticker Guaranteed sound capacity level Information sticker Filler opening for petrol Information sticker Filler opening for water Fig 11 Fig 12 B DEC 0216 Gasoline Benzin Fig 13 B DEC 0218 Water Fig 14 Concerning your safety Signage DFP7 36 ...

Page 37: ...efore taking into operation vor Inbetriebnahme avant la mise en service anterior a la puesta en servicio weekly wöchentlich hebdomadairement cada semana twice annual halbjährlich tous les 6 mois cada 6 meses annual jährlich annuellement anualmente BENZIN GASOLINE B DEC 0321 Fig 16 Concerning your safety Signage DFP7 37 ...

Page 38: ...pe plate example 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 17 Concerning your safety Signage DFP7 38 ...

Page 39: ...3 12 Safety Components 1 2 B 925 0006 Fig 18 1 Heat protection cover 2 Belt guard Concerning your safety Safety Components DFP7 39 ...

Page 40: ...Concerning your safety Safety Components DFP7 40 ...

Page 41: ...4 Indicators and control elements Indicators and control elements DFP7 41 ...

Page 42: ...view Fig 19 1 Engine stop switch 2 Throttle lever 3 Choke lever 4 Recoil starter 5 Fuel valve 4 1 2 Engine stop switch Position OFF Ignition off Position ON Ignition on Fig 20 Indicators and control elements Engine DFP7 42 ...

Page 43: ...IN Idle speed Position MAX Maximum speed 4 1 4 Choke lever Position Left Choke closed Position Right Choke open 4 1 5 Recoil starter B HON 0041 Fig 21 B HON 0042 Fig 22 B GEN 0084 Fig 23 Indicators and control elements Engine DFP7 43 ...

Page 44: ...4 1 6 Fuel valve Position Left Fuel valve closed Position Right Fuel valve open B HON 0043 Fig 24 Indicators and control elements Engine DFP7 44 ...

Page 45: ...4 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 25 Fig 26 Indicators and control elements Water spraying system DFP7 45 ...

Page 46: ...4 3 Transport wheels 1 2 B 230 0023 Fig 27 1 Locking of guide handle 2 Locking of transport wheels Indicators and control elements Transport wheels DFP7 46 ...

Page 47: ...5 Checks prior to start up Checks prior to start up DFP7 47 ...

Page 48: ...ixed 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 Chap...

Page 49: ...k and fuel lines and for leaks 2 Check the bolted connections are tight and secure 3 Check the machine for contamination and damage 4 Check the hydraulic oil cooler for dirt 5 Check the starter rope for chafing Checks prior to start up Visual inspections and function tests DFP7 49 ...

Page 50: ...ipstick 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 B SYM 1068 Fig 28 B 834 002...

Page 51: ...on 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 73 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 63 2 Clean the area around the filling port 3 Remove the cap and check the fil...

Page 52: ...es n Protective gloves 1 Check the rubber buffer pairs left and right for tight fit cracks and tear offs ð Have damaged rubber buffers replaced by authorised service personnel immediately B SYM 1073 Fig 32 B 230 0066 Fig 33 Checks prior to start up Checking the rubber buffers DFP7 52 ...

Page 53: ...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 3 Insert the bolt through the guides on the water tank and insert the split pin to lock ð The water tank can now be carried ...

Page 54: ...Checks prior to start up Checking the water level topping up DFP7 54 ...

Page 55: ...6 Operation Operation DFP7 55 ...

Page 56: ...ipment 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 36 Operation Mounting the guide handle DFP7 56 ...

Page 57: ...ng 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 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 ...

Page 58: ...pera 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 Switch the engine stop switch to ON position B HON 0035 Fig 37 B HON 0037 Fig 38 B 230 0096 MAX MIN Fig 39 B 834 0079 ON OFF I 0 Fig 40 Operation Starting the engine DFP7 58 ...

Page 59: ...uring 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 immediately under full load 14 If the engine stops again after approx 3 to 5 seconds n Close the choke again n Repeat ...

Page 60: ...ng 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 Th...

Page 61: ...he 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 45 Fig 46 Operation Operation DFP7 61 ...

Page 62: ...prinkling 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 47 Operation Switching the water sprinkling system on off DFP7 62 ...

Page 63: ...ng 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 Switch the engine stop switch to OFF position ð The engine is shut down B 834 0017 MAX MIN 1 2 Min Fi...

Page 64: ...4 Close the fuel valve completely 5 Secure the machine against unauthorised use B HON 0036 Fig 50 Operation Parking the machine in secured condition DFP7 64 ...

Page 65: ...7 Loading transporting the machine Loading transporting the machine DFP7 65 ...

Page 66: ...ting 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 63 2 Allow the engine to cool down 3 Fold the...

Page 67: ...6 If necessary pull the machine by the handles or loops 1 on an even surface 1 B 230 0070 Fig 52 Loading transporting the machine Loading the machine DFP7 67 ...

Page 68: ...irection 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 53 B 230 0092 Fig 54 Loading transporting the mac...

Page 69: ...ndle 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 55 2 B 230 0028 Fig 56 B 230 0005 Fig 57 Loading transporting the machine Transport wheels DFP7 69 ...

Page 70: ...Loading transporting the machine Transport wheels DFP7 70 ...

Page 71: ...8 Maintenance Maintenance DFP7 71 ...

Page 72: ...ive 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 dama...

Page 73: ...ine 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 74: ...e 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 h...

Page 75: ...tion Ä Chapter 8 2 2 Fuel on page 73 2 0 l 0 5 gal us Fuel stabilizer Specification Ä Chapter 8 2 2 2 Fuel stabil izer on page 74 DL 009 940 20 as required Exciter shaft housing SAE 10W 40 Specification Ä Chapter 8 2 3 Oil for exciter shaft housing on page 74 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 ...

Page 76: ... engine oil Ä Chapter 8 7 1 Changing the engine oil on page 81 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 96 6 Check the oil level in the vibrator housing Maintenance Running in instructions DFP7 76 ...

Page 77: ...trainer 84 8 8 4 Replacing the V belt 87 8 8 5 Replacing the starter rope 89 8 8 6 Changing the oil in the exciter housing 91 8 8 7 Replacing the air filter 92 As required 8 9 1 Cleaning the cooling fins and the cooling air intake openings 94 8 9 2 Cleaning the machine 95 8 9 3 Cleaning the water spraying system 96 8 9 4 Servicing the V belt 96 8 9 5 Checking cleaning the spark plug 97 8 9 6 Measu...

Page 78: ...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 Safety shoes n Protective gloves n Safety goggles 1 Park the machine safely Ä Chapter 6 5 Parking the machine in secured condition on page 63 2 Allow the engine to cool down 3 Unscrew wing nut 1 and remove cover 2 4 Clean the cover 5 Unscrew wing nut 3 and remove fil...

Page 79: ... 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 ...

Page 80: ...r 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 B HON 0033 1 2 3 4 5 Fig 63 Maintenance Weekly DFP7 80 ...

Page 81: ...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 edge of the filler bore 7 Pu...

Page 82: ...park 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 clearance P...

Page 83: ...th 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 68 Fig 69 ...

Page 84: ...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 Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 5 Parking the machine in secured c...

Page 85: ...d filter 1 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 B HON 0036 Fig 73 1 2 3 B HON 0040 Fig 74 B HON 0035 Fig 75 Maintenance Annually DFP7 85 ...

Page 86: ...l tank 12 Loosen the hose clamp 1 and pull off the fuel hose 13 Unscrew 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 1 2 3 A 1 B HON 0039 Fig 76 A View from below Alignment of filter during installation 1 2 B 834 0038 Fig 77 2...

Page 87: ...clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 5 Parking the machine in secured condition on page 63 2 Allow 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 1 2 B 834 0038 Fig 79 2 1 B 230 0072 Fig 80 1 B 230 ...

Page 88: ...1 with fastening screws 2 10 Check the V belt tension again after 25 operating hours tighten if necessary 8 8 4 1 Checking the frequency of the base plate Keep feet and hands clear of the vibrating base plate CAUTION Danger of injury caused by uncontrolled machine movement Always hold on to a running machine Always keep an eye on a running machine 1 B 230 0030 Fig 82 Fig 83 2 1 B 230 0072 Fig 84 M...

Page 89: ... Ä Chapter 2 Technical data on page 11 5 Park the machine safely Ä Chapter 6 5 Parking the machine in secured condition on page 63 6 If frequency incorrect n Check the engine speed n Check the V belt n If necessary contact our customer service 8 8 5 Replacing the starter rope Protective equipment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 5 Parking th...

Page 90: ...oil 2 to the housing 5 with a cable strap 1 7 Untie the knots of the starter rope at both ends and remove the old starter rope 8 Thread in the new starter rope 3 and fix it with knots on both ends 9 CAUTION Danger of injury caused by the starter handle 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 po...

Page 91: ... page 75 Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine on level ground 2 Park the machine safely Ä Chapter 6 5 Parking the machine in secured condition on page 63 3 Tilt the machine slightly towards the oil drain side and secure it properly 4 Unscrew the oil drain plug 1 and collect running out oil Fig 90 B 834 0041 1 Fig 91 Maintenance Annually DFP7 ...

Page 92: ...o not start the engine after having removed the air filter 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 63 2 Allow the engine to cool down 3 Unscrew wing nut 1 and remove cover 2 4 Clean the cover 5 Unscrew wing nut 3 and remove filter element 4 6 Check the rubber seal 5 replace if...

Page 93: ... 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 94 Fig 95 Maintenance Annually DFP7 93 ...

Page 94: ...t n Working clothes n Protective gloves n Safety goggles 1 Park the machine safely Ä Chapter 6 5 Parking the machine in secured condition on page 63 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 gloves pr...

Page 95: ...id corrosion 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 remove any oil or fuel leaks near fuel tank cylinders or cooling air intake 1 Park the machine safely Ä Chapter 6 5 Parking the machine in secured condition on page 63 2 Allow the engine to cool dow...

Page 96: ...r 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 63 2 Allow the engine to cool down 3 Loosen the fastening screws 2 and remove the V belt guard ...

Page 97: ...lug NOTICE Danger of engine damage Do not use spark plugs with incorrect heat value Protective equipment n Working clothes n Protective gloves 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 63 2 Allow the engine to cool down for at least 15 minutes 3 Clean the area around the spark plug 4 Unscrew the spark...

Page 98: ...d 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 hot components Smoking and open fire is prohibited Keep away from heat sources sparks and other sources of ignition Do not spill any gasoline If the machine is shut down for a longer period of time e g winter season the following work must be carried out D...

Page 99: ...bowl 2 and the O ring 1 4 Open the fuel valve and collect running out fuel 5 Close the fuel valve 6 Install the drain plug with the seal on the carburettor 7 Assemble the filter bowl with the O ring 8 Dispose of fuel in line with environmental regulations Tool n 13 16 inch spark plug spanner 1 Unscrew the spark plug using a 13 16 inch spark plug spanner 2 Fill in several drops of fresh engine oil ...

Page 100: ...er the engine to protect it against dust and moisture 4 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 and open fire is prohibited Keep away from heat sources sparks and other sources of ignition D...

Page 101: ...9 Troubleshooting Troubleshooting DFP7 101 ...

Page 102: ...nce 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 DFP7 102 ...

Page 103: ...oil 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 pretension of the spring Check the pretension 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 defecti...

Page 104: ...ange the fuel Engine oil level too low Check the engine oil level top up if nec essary Engine runs with high speed but no vibration Centrifugal clutch defective Have it checked by qualified expert per sonnel V belt torn Replacing the V belt Troubleshooting Engine malfunctions DFP7 104 ...

Page 105: ...ignition Do not spill any gasoline Protective equipment n Working clothes n Safety shoes n Protective gloves n Safety goggles 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 B HON 0036 Fig 107 B 834 0029 Fig 108 Trouble...

Page 106: ...ssary 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 engine damage ca...

Page 107: ...10 Disposal Disposal DFP7 107 ...

Page 108: ... is prohibited Keep gasoline away 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 ...

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