BAUMR-AG PTD4STBMRA4H0 Petrol Post Driver 4-Stroke Pile User Manual

User Manual

[Revision 5.0 October 2022]

READ THIS MANUAL CAREFULLY BEFORE USE – FAILURE TO DO SO MAY RESULT IN INJURY, PROPERTY DAMAGE AND MAY

VOID WARRANTY. • KEEP THIS MANUAL FOR FUTURE REFERENCE. • Products covered by this manual may vary in appearance,

assembly, inclusions, specifications, description, and packaging.

The product is NOT supplied with engine oil, although traces of oil from the manufacturing process may be present. It is essential to add

adequate engine oil of the correct type to the engine before use. Failure to add engine oil will void the product warranty.

BPX-600 Post Driver

Safety

Safety messages are designed to alert you to possible dangers or hazards that could cause death, injury or

equipment or property damage if not understood or followed. Safety messages have the following symbols:

You WILL be KILLED or

SERIOUSLY INJURED if you

do not follow instructions.

You CAN be KILLED or

SERIOUSLY INJURED if you

do not follow instructions.

You CAN be INJURED if you

do not follow instructions or

equipment damage may occur.

It is vital that you read and understand

this user manual before using the product,

including safety warnings, and any

assembly and operating instructions.

Keep the manual for future reference.

Safety precautions and recommendations

detailed here must be fully understood

and followed to reduce the risk of injury,

fire, explosion, electrical hazard, and/or

property damage.

Safety information presented here is

generic in nature – some advice may not

be applicable to every product. The term

"equipment" refers to the product, be it

electrical mains powered, battery powered

or combustion engine powered.

• Before Use - If you are not familiar with

the safe operation/handling of the

equipment, or are in any way unsure of

any aspect of suitability or correct use

for your application, you should

complete training conducted by a

person or organization qualified in safe

use and operation of this equipment,

including fuel/electrical handling and

safety.

• Do NOT operate the equipment in

flammable or explosive environments,

such as in the presence of flammable

liquids, gases or dust. The equipment

may create sparks or heat that may

ignite flammable substances.

• Keep clear of moving parts.

• Equipment may be a potential source of

electric shock or injury if misused.

• Do NOT operate the equipment if it is

damaged, malfunctioning or is in an

excessively worn state.

• Do NOT allow others to use the

equipment unless they have read this

manual and are adequately trained.

• Keep packaging away from children -

risk of suffocation! Operators must use

the equipment correctly. When using

the equipment, consider conditions and

pay due care to persons and property.

General Work Area Safety

• Work areas should be clean and well it.

• Do not operate the equipment if

bystanders, animals etc are within

operating range of the equipment or the

general work area.

• If devices are provided for connecting

dust extraction / collection facilities,

ensure these are connected and used

properly. Dust collection can reduce

dust-related hazards.

General Personal Safety

• Wear appropriate protective equipment

when operating, servicing, or when in

the operating area of the equipment to

help protect from eye and ear injury,

poisoning, burns, cutting and crush

injuries. Protective equipment such as

safety goggles, respirators, non-slip

safety footwear, hard hat, hearing

protection etc should be used for

appropriate equipment / conditions.

Other people nearby should also wear

appropriate personal protective

equipment. Do not wear loose clothing

or jewellery, which can be caught in

moving parts. Keep hair and clothing

away from the equipment.

• Stay alert and use common sense

when operating the equipment. Do not

over-reach. Always maintain secure

footing and balance.

• Do not use the equipment if tired or

under the influence of drugs, alcohol or

medication.

• This equipment is not intended for use

by persons with reduced physical,

sensory or mental capabilities.

General Fuel Safety

• Petrol/fuel/gasoline is extremely

flammable – keep clear of naked flames

or other ignition sources.

• Do not spill fuel. If you spill fuel, wipe it

off the equipment immediately – if fuel

gets on your clothing, change clothing.

• Do NOT smoke near fuel or when

refuelling.

• Always shut off the engine before

refuelling.

• Do NOT refuel a hot engine.

• Open the fuel cap carefully to allow any

pressure build-up in the tank to release

slowly.

• Always refuel in well ventilated areas.

• Always check for fuel leakage. If fuel

leakage is found, do not start or run the

engine until all leaks are fixed.

General Carbon-Monoxide Safety

• Using a combustion engine indoors

CAN KILL IN MINUTES. Engine

exhaust contains carbon-monoxide – a

poison you cannot smell or see.

• Use combustion engines OUTSIDE

only, and far away from windows, doors

and vents.

General Equipment Use and Care

• The equipment is designed for

domestic use only.

• Handle the equipment safely and

carefully.

• Before use, inspect the equipment for

misalignment or binding of moving

parts, loose components, damage or

any other condition that may affect its

operation. If damaged, have the

equipment repaired by an authorised

service centre or technician before use.

• Prevent unintentional starting of the

equipment - ensure equipment and

power switches are in the OFF position

before connecting or moving

equipment. Do not carry equipment

with hands or fingers touching any

controls. Remove any tools or other

items that are not a part of the

equipment from it before starting or

switching on.

• Do not force the equipment. Use the

correct equipment for your application.

Equipment will perform better and be

safer when used within its design and

usage parameters.

• Use the equipment and accessories

etc. in accordance with these

instructions, considering working

conditions and the work to be

performed. Using the equipment for

operations different from those

intended could result in hazardous

situations.

• Always keep equipment components

(engines, hoses, handles, controls,

frames, housings, guards etc) and

accessories (cutting tools, nozzles, bits

etc) properly maintained. Keep the

equipment clean and, where

applicable, properly lubricated.

• Store the equipment out of reach of

children or untrained persons. To avoid

burns or fire hazards, let the equipment

cool completely before transporting or

storing. Never place or store the

equipment near flammable materials,

combustible gases or liquids etc.

• The equipment is not weather-proof,

and should not be stored in direct

sunlight, at high ambient temperatures

or locations that are damp or humid.

• Do not clean equipment with solvents,

flammable liquids or harsh abrasives.

• For specific equipment safety use and

care, see Equipment Safety.

BPX-600 Post Driver

General Electrical Safety

• Inspect electrical equipment, extension

cords, power bars, and electrical fittings

for damage or wear before each use.

Repair or replace damaged equipment

immediately.

• Ensure all power sources conform to

equipment voltage requirements and

are disconnected before connecting or

disconnecting equipment.

• When wiring electrically powered

equipment, follow all electrical and

safety codes.

• Wherever possible, use a residual

current device (RCD).

• High voltage / high current power lines

may be present. Use extreme caution

to avoid contact or interference with

power lines. Electrical shock can be

fatal.

General Electrical Safety

• Electrically grounded equipment must

have an approved cord and plug and be

connected to a grounded electrical

outlet.

• Do NOT bypass the ON/OFF switch

and operate equipment by connecting

and disconnecting the electrical cord.

• Do NOT use equipment that has

exposed wiring, damaged switches,

covers or guards.

• Do NOT use electrical equipment in wet

conditions or in damp locations.

• Do NOT use electrical cords to lift,

move or carry equipment.

• Do NOT coil or knot electrical cords,

and ensure electrical cords are not trip

hazards.

General Service Information

• The equipment must be serviced or

repaired at authorised service centres

by qualified personnel only.

• Replacement parts must be original

equipment manufacturer (OEM) to

ensure equipment safety is maintained.

• Do NOT attempt any maintenance or

repair work not described in this

manual.

• After use, the equipment and

components may still be hot – allow the

equipment to cool and disconnect

spark plugs and/or electrical power

sources and/or batteries from it before

making adjustments, changing

accessories or performing repair or

maintenance.

• Do NOT make adjustments while the

equipment is running.

• Perform service related activities in

suitable conditions, such as a

workshop.

• Replace worn, damaged or missing

warning/safety labels immediately.

BPX-600 Post Driver

Safety Symbols

The product may have safety warning labels attached to it, explained below. Understand the symbols on

your product and their meanings. If any stickers become unreadable, unattached etc, replace them.

Flammable Material Hazard

Flammable liquids, gases or

substances etc may present.

Avoid ignition sources and

open flames. Danger of fire.

Read User Manual

Read and fully understand

product safety warnings,

operation, procedures etc

before using the product.

Use Hand Protection

Wear appropriate hand

protection and take due care

as the product or use of the

product may present hand

hazards.

Carbon-Monoxide Hazard

Do not use the product in

confined areas or without

adequate ventilation. Carbon-

monoxide poisoning can be

fatal.

Electrocution / Electrical

Shock Hazard

High voltage or high current

electricity may be present or

required by the product. Take

due care when handling

electrical products, cables,

plugs and leads. Electrical

shock can be fatal.

Toxic Fumes / Dust Hazard

Using the product or by-

products from use may

produce fumes, smoke or

particles that could be harmful

if inhaled. Wear appropriate

breathing protection and have

adequate ventilation.

Explosive Material Hazard

Combustible liquids, gases or

substances etc may be

present. Avoid ignition sources

and open flames. Danger of

explosion.

Cutting / Amputation Hazard

The product may have blades,

edges or mechanical devices

that can cause severe cut

injury to fingers, limbs etc.

Take due care when handling

and using the product.

Crush Hazard

The product may have blades,

edges or mechanical devices

that can cause severe crush

injury to fingers, limbs etc.

Take due care when handling

and using the product.

Single Operator Only

The product must be operated

by a single person only. More

than one person operating the

product may introduce

additional hazards.

Use Face Protection

Wear appropriate full-face

protection and take due care

as the product or use of the

product may present face and

eye hazards.

Use Foot Protection

Wear appropriate foot

protection and take due care

as the product or use of the

product may present foot

hazards.

Use Eye / Ear / Head

Protection

Wear appropriate eye and / or

ear and / or head protection

and take due care as the

product or use of the product

may present eye, hearing and

head hazards.

Running Hazard

Do not run on or near the

product as doing so may

present a fall hazard.

Diving Hazard

Do not dive into the product as

doing so may present a neck /

head injury hazard.

Adult Supervision Required

Always supervise children and

other users of a product to

prevent drowning or injury.

Skin Penetration / Puncture

Hazard

The product may produce

pressure, emit liquids or

objects that can cause severe

injury to fingers, limbs, blood

etc. Take due care when

handling and using the

product.

Hot Surface Hazard

Be aware that the product may

produce high temperatures

and hot surfaces that can

cause burn injuries.

Flying Debris Hazard

Be aware that the product or

use of the product may

present hazards produced by

flying debris. Wear appropriate

clothing and protectiove

devices.

Moving Parts Hazard

Be aware that the product

contains or uses mechanical

devices that move or rotate.

Always wait for moving parts

to stop fully before handling

the product, adjusting,

maintenence etc.

BPX-600 Post Driver

Carbon-Monoxide Hazard

Do not use the product in

confined areas or without

adequate ventilation. Carbon-

monoxide poisoning can be

fatal.

Pull Hazard

Be aware that the product

contains or uses mechanical

devices that can pull in objects

and can cause severe injury to

fingers, limbs etc. Take due

care when handling and using

the product.

Slope / Fall Injury Hazard

Be aware that using the

product on sloping surfaces or

in slippery conditions may

present additional dangers

from falls and contact with

blades, moving parts, hot

surfaces etc.

"Slam Dunk" Warning

Do NOT attempt "slam dunk"

maneouvres as this may result

in severe injury due to falling,

product breakage or collapse

etc.

Electrocution / Electrical

Shock Hazard - Outdoor

High voltage or high current

electricity may be present or

required by the product. Do

NOT use in rain, damp or wet

conditions. Electrical shock

can be fatal.

Electrocution / Electrical

Shock Hazard - Disconnect

High voltage or high current

electricity may be present or

required by the product.

Always disconnect the product

from the electrical supply

before handling the product,

adjusting, maintenence etc.

Power Line Electrocution

Hazard

High voltage / high current

power lines may be present.

Use extreme caution to avoid

contact or interference with

power lines. Electrical shock

can be fatal.

"Kick-Back" Hazard

High level of "kick-back"

hazard that can cause the

machine to suddenly rotate

towards operator. Kick-back

injury can be fatal.

Winch Operator Position

Hazard

Do NOT stand between winch

and load. Do NOT use winch

to move people.

Winch Lift Hazard

Do NOT LIFT load vertically.

Use machine to PULL only.

Cable Hazard

Ensure that load bearing cable

is not kinked or knotted.

Winch Cable Hazard

Ensure that there is a

minimum number of cable

coils on winching mechanism.

Winch Hook Hazard

Carry hook to load – do NOT

throw or run.

BPX-600 Post Driver

Equipment Safety

Post drivers are high-speed, impact equipment that can cause serious or fatal injury if not

used correctly or without taking proper safety precautions. It is extremely important that

you read and fully understand the information in this section and all other safety warnings /

recommendations and usage instructions before using the equipment.

Operator

• If you are untrained in the use of a post driver or a particular accessory, it is highly recommended that

you be trained/instructed by a suitably qualified or experienced user before using the machine.

• You must be in good physical condition to use a post driver. NEVER operate the machine when tired, or

under the influence of any substance (medication, alcohol, drugs etc) that may impair your judgement,

alertness, physical strength, vision or dexterity.

• Maintain sure-footing and balance always when using or handling the machine and have full awareness

of your surroundings and any possible hazards.

• Prolonged use may lead to health complications, such as carpal tunnel syndrome, due to vibration. To

help reduce the possibility of such conditions, wear gloves, take breaks frequently, keep fingers and

hands warm, and maintain the equipment for optimal operation and minimal vibration. It is recommended

to seek medical advice if you feel numbness or burning sensations in fingers/hands.

Clothing and Protective Equipment – All Operators and Assistants

• Wear approved safety goggles, or safety glasses with adequate top and side protection. In addition to

eye protection, wearing a full-face shield is highly recommended.

• Wear suitable hearing protection.

• Wear an approved safety hard-hat.

• Wear heavy-duty, non-slip leather or protective gloves.

• Wear suitable overalls or work clothing that fits snugly, but does not restrict movement. Avoid loose

fitting clothing, scarves, jewellery etc and keep long hair contained to avoid getting caught or pulled by

the chainsaw or by tree branches etc.

Work Area Safety

• Use EXTREME CAUTION to avoid power cables – contact can be fatal. Also be aware of plumbing,

water and gas pipes etc. If in any doubt, do NOT dig – contact the appropriate organisation or authority

for information before digging.

• Inspect the work area and remove any objects that may obstruct posts.

• Be aware of fire risks resulting from machine use. Ensure that the machine exhaust and spark arrestor (if

equipped) is well maintained and that engine is tuned correctly.

• Refuel outdoors only. Avoid fuel spillage. Start the machine at least 3m (10') away from the fuelling

location.

Operational Safety

• Do NOT use the machine if the throttle or any safety guard or mechanism is not installed or is not

operating correctly – have the machine inspected and repaired at an authorised service centre before

using it again.

• Always hold the machine firmly with both hands during operation. Always use the machine handles.

• Use CAUTION when using the machine on sloping surfaces.

• Do NOT use any attachment that is cracked or damaged in any way – replace it.

• Ensure the piling socket is not obstructed before post driving.

• Do NOT use the equipment for purposes it is not designed for, such as breaking concrete.

• Do not attach the machine to fixed supports.

BPX-600 Post Driver

Transportation Safety

• Always STOP the engine before transporting or working on it (refuelling, adjusting etc).

• When transporting the machine in a vehicle, ensure the engine is OFF, the tillers and digging

attachments are disconnected, and the machine is secured in an upright position to prevent tip-over,

machine damage or fuel spills.

BPX-600 Post Driver

Table of Contents

Safety ................................................................................................................................................................. 2

Safety Symbols ............................................................................................................................................ 4

Equipment Safety ............................................................................................................................................. 6

Parts Identification ........................................................................................................................................... 9

Engine and Machine Components ............................................................................................................. 10

Before Use Checklist ...................................................................................................................................... 11

Air Filter ...................................................................................................................................................... 11

Fuel ............................................................................................................................................................ 11

Priming the Fuel System ..................................................................................................................... 11

Attaching the Piling Socket Adaptor ........................................................................................................... 12

Engine Starting and Stopping ....................................................................................................................... 13

Starting the Engine ..................................................................................................................................... 13

Stopping the Engine ................................................................................................................................... 13

Environmental Considerations ................................................................................................................... 13

Post Driver Operation..................................................................................................................................... 14

Using the Throttle and Adjusting Hammer Speed ............................................................................... 14

Maintenance .................................................................................................................................................... 15

Maintenance Schedule – 4-Stroke Engine / Machine ................................................................................ 16

Engine Oil ................................................................................................................................................... 17

Air Filter ...................................................................................................................................................... 19

Inspection and Cleaning ...................................................................................................................... 19

Removal/Installation ............................................................................................................................ 19

Spark Plug .................................................................................................................................................. 20

Cleaning and Gap Checking ................................................................................................................ 20

Removal/Installation ............................................................................................................................ 20

Fuel Strainer ............................................................................................................................................... 22

Inspection and Cleaning ...................................................................................................................... 22

Removal/Installation ............................................................................................................................ 22

Pinion ......................................................................................................................................................... 23

Cleaning Guidelines ................................................................................................................................... 23

Engine Tuning Guidelines ............................................................................................................................. 24

Carburettor Adjustments ...................................................................................................................... 24

Factory Settings ................................................................................................................................... 24

Tuning .................................................................................................................................................. 25

Transportation and Storage .......................................................................................................................... 26

Troubleshooting ............................................................................................................................................. 27

Specifications ................................................................................................................................................. 28

Engine Service and Maintenance Record .................................................................................................... 29

BPX-600 Post Driver

Parts Identification

No. Name No. Name

1 Engine / Hammer / Handle Assembly 5 Tools / Accessories:

4 / 5 / 6mm Allen Key

4 / 5 / 6mm Multi-Allen Key

8 / 10mm Spanner

Flat-Blade Screwdriver

Spark Plug Tool / Screwdriver

Spark Plug (spare, may be included)

Grease (for hammer pin)

2 55 to 80mm Piling Socket Adaptor

3 45 to 55mm Piling Socket Adaptor

4 20 to 45mm Piling Socket Adaptor

2

1

3

5

4

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BPX-600 Post Driver

Engine and Machine Components

No. Name No. Name

1 Engine ON / OFF Switch 8 Exhaust

2 Throttle Control 9 Air Filter Assembly (air filter inside)

3 Choke Lever (obscured) 10 Spark Plug Cover (spark plug inside)

4 Starter Cord 11 Handle

5 Fuel Tank 12 Hammer Case

6 Fuel Primer (obscured) 13 Pinion Housing

7 Throttle Limiter 14 Pinion Access Cover

Spare parts available for purchase, scan QR code below:

1

2

3

4

5

6

7

8

9

10

11

12

13

14

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BPX-600 Post Driver

Before Use Checklist

Ensure that you carry out all procedures below before starting the engine or operating the

equipment. All procedures described are generic in nature and slight variations between different

models may exist. Failure to follow the checklist and carry out the procedures correctly may result in

making the product warranty void.

Air Filter

The air filter is used to prevent dirt and other particles from possibly entering the engine and causing internal

damage to it. The air filter requires regular maintenance.

Always check the air filter before starting the engine. See Air Filter.

Fuel

Petrol/fuel/gasoline is extremely flammable – keep clear of naked flames or other ignition

sources. • The engine must be cool before refuelling. • Always pre-mix the fuel before

placing it in the fuel tank.

Adequately fill the fuel tank with the correct fuel type.

• Use non-ethanol unleaded petrol (higher RON values will provide best engine performance). Do not use

old or contaminated fuel/oil. Fuel/oil mix ratio examples are shown below.

To fill or top up fuel:

1. Place the machine in a horizontal position on a flat and level surface with the fuel filler cap facing up.

2. Clean the machine around the fuel filler so that no dirt or other material enters the engine when the cap

is removed.

3. Remove (rotate left) the fuel filler cap.

4. Using a funnel, carefully fill the tank with fuel. Do not fill above the top of the strainer (if equipped) or

otherwise overfill the tank.

5. When finished, reinstall (rotate right) the fuel filler cap until firm. Wipe away any residual fuel from the

machine. If fuel has been spilt, move the machine away from the spillage before starting the engine.

Priming the Fuel System

When an engine is new or has been completely run out of fuel it may

be necessary to "prime" the fuel system before attempting to start the

engine. This means removing any air from the fuel line. To prime:

1. Ensure the fuel tank is filled with fuel.

2. Press the fuel primer (A) bulb repeatedly until you feel resistance

or pressure in the bulb – this indicates that it is full of fuel. Fuel will

also be visible in the fuel intake tube.

A

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BPX-600 Post Driver

Attaching the Piling Socket Adaptor

Do not use the machine without a piling socket adaptor attached.

Screw the required piling socket adaptor (1) to the thread on the end of the hammer case (B) (rotate right )

and firmly tighten by hand.

1

B

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BPX-600 Post Driver

Engine Starting and Stopping

Starting the Engine

1. PRIME – If necessary, "prime" the fuel system.

2. CHOKE – If the engine is cold, place the choke (E) in the "COLD" position. If the engine is warm or the

ambient temperature is high, place the choke in the "RUN" position.

3. IGNITION – Place the engine ON/OFF switch (F) in the "ON" ("I") position.

4. START – Slowly pull out the starter cord (G) until you feel it engage with the engine, then pull it out

rapidly. The engine should start. Allow the starter cord to rewind slowly – do not let it "snap" back.

5. WARM-UP – Allow the engine to warm-up and run smoothly. If choke is being applied, gradually move

the choke (E) to the "RUN" position.

If the engine does not start, repeat step 4 onward. If the engine fails to start after several attempts, refer to

Troubleshooting.

Stopping the Engine

To stop the engine, release the throttle and place the engine ON/OFF switch in the "OFF" position.

Environmental Considerations

Altitude – If the engine is being used in altitudes at or above 1500m (approximately 5000'), adjustments to

the carburettor may be required. This is because there is less oxygen in the air as altitude increases, which

effectively "enriches" the ratio of fuel to air going into the engine and the higher the altitude, the richer the

fuel mixture becomes. If the engine is being permanently operated at high altitude, it is recommended to

have an authorized service centre make the necessary carburettor adjustments. If the engine is used

occasionally at altitude (not extreme altitudes), no adjustments should be required, however, a slight

decrease in engine performance can be expected.

Temperature (4-Stroke Engines) – If the engine is being used

in extremely cold or hot environments; for example, desert or

snow conditions, the type of engine oil may need to be changed

to suit environmental temperatures. Oil thickens as the

temperature decreases and thins as temperature increases,

which means that if the engine oil is not suited to the

temperature its ability to properly lubricate the engine may be

affected. Use the chart to determine the correct engine oil.

E

F

G

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BPX-600 Post Driver

Post Driver Operation

Post drivers are high-speed, impact equipment that can

cause serious or fatal injury if not used correctly or

without taking proper safety precautions. It is extremely important that you

read and fully understand the information in this section and all other

safety warnings / recommendations and usage instructions before using

the equipment. • Before use, ensure that there are no electrical cables, gas or

water pipes etc or other buried or unseen hazards in the work area. Contact the

applicable utility providers for assistance. • The machine should be operated on

ground that is suitable for driving posts. Do not attempt to drive posts into set

concrete, rock, tree roots, or other extremely hard surfaces. • Do not use the

machine without a piling socket attached.

The machine is used for driving "star pickets" and hollow metal posts etc into

the ground. For example, to erect simple fencing etc. The machine operates by

driving a "hammer" against the top of the post many times per second,

effectively forcing it into the ground. The machine is designed for manual

operation, where the operator both holds and controls it. Note the following:

• Place the post/star picket into the required position before driving it.

• Adjust the throttle, which controls the hammer action, only when ready to

begin driving the post.

• Hold the machine as straight as possible when in use to ensure that posts

are driven in vertically.

To drive a post:

1. Start the machine and allow it to warm up.

2. Position the post in the required location.

3. Place the machine over the post so that it rests on it.

4. Adjust the throttle for the desired hammering speed.

5. Drive the post into the ground as required – there is no need to push down on the machine.

6. Release the throttle – this disengages the hammer action.

7. Lift the machine from the post.

Using the Throttle and Adjusting Hammer Speed

The throttle (A) is used to adjust the engine speed, which in turns

controls speed of the hammer action. To adjust the throttle, grip the

throttle handle (B) so that the throttle safety switch (C) is pushed in –

this allows the throttle to be adjusted – squeeze to increase engine

speed. The throttle features a limiting screw (D) that stops it from being

opened further. Note the following:

• The throttle safety switch must be pushed in, in order to adjust the

throttle. When the throttle safety switch is released it is no longer

possible to adjust the throttle.

• It is recommended to set the limiting screw when an effective

engine/hammer speed is attained. Turn the screw right to reduce

the throttle opening limit (slower speed). Turn the screw left to

increase the throttle opening limit (faster speed). The hardness of

the material that the posts are being driven into may require

adjustment of engine/hammer speed for best performance.

A

C

B

D

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BPX-600 Post Driver

Maintenance

Running combustion engines in confined areas CAN KILL IN MINUTES. Engine exhaust

fumes contain carbon-monoxide – a deadly gas that you cannot smell or see. NEVER run

a combustion engine in confined areas EVEN IF windows and doors are open. ONLY run

combustion engines OUTDOORS and away from doors, windows and vents. • Petrol / fuel

/ gasoline is extremely flammable – keep clear of naked flames or other ignition sources. •

Do not have the engine running during inspection and maintenance unless specifically required. • The engine

should be cool enough to touch before performing maintenance activities. • Some maintenance activities

may be beyond the scope of some users. Do NOT attempt procedures that you are not comfortable with, or

do not have the necessary tools, experience or knowledge for – take the unit to an authorised service centre

or qualified technician for servicing. • Harsh operating environments such as extreme temperatures, dust etc

may necessitate more frequent maintenance. • Failure to follow the maintenance schedule, using

incorrect or non-compatible accessories or replacements parts, or general negligence may result in

making the product warranty void.

1. To keep the machine performing at optimal efficiency, regular checks and maintenance is required.

The maintenance schedule below specifies preventative maintenance checks and necessary maintenance

tasks and how often they should be performed. The schedule applies to multiple engines; some engines may

not include some components, so maintenance on those components is not applicable.

Maintenance Schedule

Use the following maintenance schedule for a list of regular maintenance tasks and how often they need to

be performed. Maintenance frequency is based on average usage. Be aware of how much the machine is

used and be sure to follow the schedule according to time or usage, whichever comes first.

Towards the end of this document is a form you can use for maintenance record keeping. It is recommended

that you keep a reference of all maintenance.

Major Servicing and "Heavy-Duty" Usage - For engines that are subject to "heavy-duty" use,

which can be defined as being used under loads of 85% or more and / or in use more than

approximately 300 hours per year (for example, generators and water pumps), more frequent "Major

Service" maintenance is required. In addition to normal service requirements, and as with many smaller

machine and off-road bike engines, the following parts (as applicable for petrol, diesel or 2-stroke engines)

may require replacement during a major service:

• Piston rings.

• Big-end bearings.

• Small-end bearings.

• Gudgeon pin.

• Oil rings.

• Gaskets and seals.

• Valve seats.

Inspection of the following items is required:

• Piston for cracks and stress fractures.

• Bore for wear requiring reconditioning.

• Full machine for broken, worn or loose parts.

Failure to follow the maintenance schedule, using incorrect or non-compatible accessories or

replacements parts, or general negligence may result in making the product warranty void.

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Maintenance Schedule – 4-Stroke Engine / Machine

Major Service

–

Heavy

-Duty Use

Every 200

Hours Use

Replace

Check. Tighten as necessary

Replace

Clean

Replace as necessary

Check. Clean

Flush and clean

Check. Adjust as necessary

Check.

Tighten as necessary

Check. Clean / de

-coke as necessary

Check level. Adjust as necessary

Perform

Sharpen. Replace as necessary

Replace

Check. Replace as necessary

Grease

Major Service

–

Normal Use

24 Months / 200

Hours Use

12 Months /

100 Hours

Use

Clean. Replace as necessary

6 Months / 50

Hours Use

3 Months / 25

Hours Use

Check

After First 5

Hours Use

Every Use

Check level. Adjust

as necessary

Check

Check level. Adjust

as necessary

Check level. Adjust

as necessary

Check tension.

Adjust as necessary

Component / Task

Engine Oil

****

Engine Oil Filter

*

Engine / Machine Fasteners

Air Filter

Spark Plug

Spark Arrestor

*

Fuel Filter

*

Fuel Strainer

*

Float Bowl

*

Fuel Lines / Hoses

Fuel injector

*

Fuel Pump

*

Fuel Tank

Idle Speed

Valve Clearance

Cylinder Head Fasteners

Combustion Chamber

Battery Electrolyte

*

Major Service

Cutting Blade / Chain

*

Water Pump Oil

**

Hydraulic Fluid

***

Drive Belt

*

Gearbox / Joints

*

* Where applicable. ** Pressure washers with non-sealed water pumps. *** Log splitters only.

**** Briggs & Stratton "EXi" engines do NOT require engine oil changes; just ensure that oil level is correct.

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Engine Oil

Engines are NOT supplied with engine oil, although traces of oil from the manufacturing

process may be present. It is essential to add adequate engine oil of the correct type to the

engine before use. Failure to add engine oil will void the product warranty. • Always check engine oil

level when the machine is in an upright position on a flat and level surface. • Do not use used or

contaminated engine oils. • Use only engine oils of the correct type (see Specifications). • Perform the first oil

change within the first 10 hours of use. Subsequently, change the oil every 20 hours of use. • It is

recommended that the engine be warm, but not hot, when performing oil changes. When the oil is warm it

drains faster. • Using dirty or incorrect engine oil may cause engine damage and void any warranty • Always

use suitable tools. • Always dispose of used oil in an environmentally responsible manner and according to

regulations. • Some engines feature oil level detection, which will prevent the engine being started or

automatically stop a running engine if there is insufficient oil. • Always check the oil level and ensure is at

or near the "MAX" indicator before using the machine.

4-stroke engines require engine oil in the crankcase for lubrication of internal components. Severe or

irreparable damage may occur if the engine is allowed to run without engine oil. The engine oil level requires

regular maintenance as per the maintenance schedule.

To check engine oil level:

1. Place the machine on a flat and level surface.

2. Clean the machine around the oil filler cap (A) so that no dirt or other material enters the engine when

the cap is removed.

3. Remove the oil filler cap (rotate left) until fully unscrewed. For machines without a dipstick, the oil level is

determined by how close the oil is to the edge of the filler hole (B). For machines equipped with an oil

level dipstick:

a. Remove the dipstick (C) and wipe clean with a piece of cloth or paper.

b. Insert the dipstick into the oil filler but do not screw it in.

c. Remove and inspect the dipstick – the oil level is determined by where oil can be seen on it.

4. Ensure that the oil level is at or just under the "maximum". If the oil level is low, add additional oil until the

correct level is reached. If the oil level is too high, drain some oil until the correct level is reached.

5. When finished, re-install (rotate right) the oil filler cap until firm. Wipe off any residual oil from the

machine.

IMPORTANT! Oil capacity is 65ml do not overfill.

A

B

C

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To change the engine oil:

1. Place the machine on a suitable work surface that is flat and level and have a container ready to catch

drained oil.

2. Clean the machine around the oil filler cap (A) and oil filler cap/dipstick so that no dirt or other material

enters the engine when the plug or cap is removed.

3. Unscrew (rotate left) and remove the oil filler cap/dipstick.

4. Tilt the machine and drain all oil from the engine. Once drained, allow the machine to sit level again.

5. Clean away any residual oil from the engine.

6. Using a funnel, carefully add oil to the engine until the "maximum" level is reached. Double-check the oil

level (described above).

7. When finished, re-install (rotate right) the oil filler cap/dipstick until firm. Wipe off any residual oil from the

machine.

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Air Filter

Operating the machine without a functional air filter may cause severe engine damage and will void

any warranty. • A dirty or oil saturated air filter will restrict air flow, which can reduce performance

and be mistaken as fuel system problems. Check the condition of the air filter before adjusting engine idle

speed, where applicable. • If the air filter is damaged (torn, broken, disintegrating), replace it.

The air filter is used to prevent dirt and other particles from possibly entering the engine and causing internal

damage to it. The engine breather may be connected to the air intake assembly – this may lead to a build-up

of oil in the air filter over extended use and is normal. The air filter requires regular maintenance as per the

maintenance schedule.

Inspection and Cleaning

Inspect the air filter for dirtiness and debris, damage etc. Clean or replace the filter element as necessary. To

clean air filters:

• For foam filters, wash the filter in warm water and mild detergent, then rinse and allow to dry.

• For paper filters, use compressed air to blow particles from it, if possible. The air should be blown from

the engine side of the filter. Tapping the filter element against a hard surface and brushing the pleats

using a soft brush may also help remove debris from the filter.

• For foam filters, place a few drops of clean engine oil on the filter then squeeze it a few times to spread

the oil through the filter material and remove any excess oil.

• It is recommended to clean the air filter cover and air intake assembly of any dirt, cuttings etc.

Removal/Installation

To remove the air filter:

1. Squeeze in and hold the tabs (B) at the top of the air filter cover (A) then, rotate the top of the air filter

cover downward until it can be released from the engine.

2. Carefully remove the filter element (D).

To install the air filter:

1. Insert the air filter element, and ensure it is correctly positioned in relation to the air intake assembly as it

will seat properly in one position only.

2. Locate the bottom of the cover in the hooks at the bottom of the air intake, then rotate the top of the

cover up until it "clicks" into position.

B

A

D

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Spark Plug

If the spark plug is damaged (cracked insulator, broken or eroded electrodes etc), replace it. •

Always use spark plugs of the correct "heat range" - see Specifications. • Depending on model, the

spark plug may be accessible directly, or may be located underneath the air filter cover.

The spark plug is used to ignite the air/fuel mixture inside the engine. The spark plug has electrodes on one

end and an electrical terminal on the other. The spark plug requires regular maintenance.

Cleaning and Gap Checking

The spark plug should be checked and cleaned as per the maintenance schedule.

1. Remove any carbon deposits on the spark plug (A) electrodes (B) with a wire

brush.

2. Clean the spark plug threads and the electrical terminal (C) on the top.

To check and adjust the spark plug "gap":

1. Use "feeler" or "thickness" gauges (X) to measure the existing gap. The gauge

must drag a little when being slid between the electrodes (2) – this means the

measurement is fairly accurate.

2. Adjust the gap to within specification (see Specifications). If the gap needs to be

reduced, gently tap the electrode as required. If the gap needs to be increased,

use pliers to gently pull the electrode as required.

3. Measure the gap again and ensure it is within the specified range before re-installing the spark plug.

Removal/Installation

1. Loosen the screw (B) securing the top engine cover (A), then remove the cover to access the engine

and spark plug.

2. Pull the electrical lead / rubber boot (C) from the terminal on top of the spark plug (D).

3. Clean the area around the spark plug so that no dirt or other material can enter the engine when the

spark plug is removed.

4. Use the spark plug tool (E) to remove the spark plug (rotate left).

To re-install the spark plug:

1. Place the spark plug in its hole and screw it in (rotate right) until "finger tight".

2. Use the spark plug tool to tighten the spark plug approximately one quarter turn (do not over-tighten).

3. Place the electrical lead over the spark plug terminal and push it down so that it connects firmly and the

rubber boot is seated firmly against the engine.

4. Re-install the top engine cover, then tighten the screw to secure it.

A

B

X

C

A

B

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C

D

E

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Fuel Strainer

A dirty or blocked fuel strainer will restrict fuel flow, which can reduce performance and be mistaken

as fuel system problems. Check the condition of the fuel strainer before adjusting engine idle speed,

where applicable. • If the fuel strainer is no longer serviceable, replace it.

The fuel strainer is used to prevent dirt and other particles from possibly entering the fuel system and engine

and causing internal damage to it. The fuel strainer requires regular maintenance as per the maintenance

schedule.

Inspection and Cleaning

Inspect the fuel strainer for dirtiness and debris etc. Clean or replace the strainer as necessary. To clean fuel

strainers:

• Wash the strainer in clean solvent.

• If possible, use compressed air to assist in removing any blockages. Blow air into the strainer from

where it connects to the tube.

Removal/Installation

To remove the fuel strainer:

1. Place the machine in a horizontal position on a flat and level surface with the fuel filler cap facing up.

2. Remove the fuel tank cap (rotate left) and empty the fuel tank (A).

3. Use a hooked object to capture the fuel intake tube (B) inside the fuel tank and gently pull it from the

tank.

4. The strainer (C) is installed on the end of the tube – to remove it, twist and pull it from the end of the tube

To install the strainer:

1. Firmly push the strainer onto the fuel intake tube.

2. Place the tube back inside the fuel tank – it should rest along the bottom of the tank.

C

A

B

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Pinion

The pinion is used to activate the hammer. The pinion operates at high speed and requires lubrication. To

grease the pinion:

1. Place the machine in a horizontal position with the fuel filler cap facing up on a flat and level surface.

2. Remove the pinion access cover (A) (rotate left).

3. Liberally coat the pinion and drive components with automotive bearing grease.

4. Re-install the pinion access cover (rotate right) and tighten firmly by hand.

Cleaning Guidelines

Do not use solvents, chemicals or abrasives when cleaning the machine, as some surfaces

may be damaged. • Wear gloves or use suitable tools to assist in cleaning – do not use bare

hands. • Clean the machine after every use to ensure best performance and longest service life.

• Use a slightly damp cloth and mild detergent for cleaning.

• Use a brush for parts that are difficult to reach.

• Ensure air vents and surfaces designed for heat dissipation are clean and free of obstructions or debris.

• Ensure all guards and safety devices are clean and functioning correctly.

• Ensure that spring-loaded parts, such as the throttle, return to the normal position when released.

• Ensure that all control cables, levers, switches etc are clean and operate normally and smoothly.

A

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Engine Tuning Guidelines