Introduction – Foreword 1.1 Foreword These operating and maintenance instructions are part of your machine. They provide necessary information to operate your machine safely and properly. They also contain information on required operating, maintenance and repair measures. Carefully read the operating and maintenance instructions before taking your machine into operation.
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Introduction – Foreword The above notes do not 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. DFP7AX...
Introduction – Machine type plate and engine type plate 1.2 Machine type plate and engine type plate Please enter here: Machine type (1): Made by Designation Type Serial number (2): Nominal Power Operating Mass Year of Construction Serial-No. Ammerländer Str. 93 D-26203 Wardenburg Made in Germany B-924-0001...
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Technical data Dimensions B-230-0101 Fig. 3 1084 (25.9) (37.9) (27.6) (42.7) (21.5) (19.7) Dimensions in millimetres (Dimensions in inch) Weights Operating weight (CECE) (181) (lbs) Basic weight (163) (lbs) Transport wheels (optional equipment) (+ 11) (lbs) DFP7AX...
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Technical data Travel characteristics Max. working speed m/min (98) (ft/min) Max. gradability (depending on soil) Drive Engine manufacturer Honda Type GX 120 Cooling Number of cylinders Rated power SAE J 1349 (3.5) (hp) Rated speed 3600 Drive system mechanical Exciter system Frequency (6000) (vpm)
Technical data – Noise and vibration data 2.1 Noise and vibration data The following noise and vibration data were determined in accord- ance with the following guidelines under equipment specific condi- tions and by using harmonized standards: EU Machine Directive edition 2006/42/EU Noise Emission Directive 2000/14/EU, Noise Protection Direc- tive 2003/10/EU Vibration Protection Directive 2002/44/EU...
Concerning your safety – Basic prerequisites 3.1 Basic prerequisites 3.1.1 General This machine has been built in compliance with the latest technical standard and complies with the applicable regulations and tech- nical rules. However, dangers for persons and property may arise from this machine, if: it is used for purposes other than the ones it is intended for, it is operated by untrained personnel,...
Concerning your safety – Basic prerequisites CAUTION! Danger of injury if failing to comply! Sections marked accordingly indicate a dangerous situation that could lead to fatal or severe injuries, if this warning is disregarded. NOTICE! Danger of material damage if failing to comply! Sections marked accordingly indicate possible dangers for machines or components.
Concerning your safety – Basic prerequisites Safety goggles To protect the eyes against airborne particles and squirting fluids. Face protection To protect the face against airborne particles and squirting fluids. Hard hat To protect the head against falling parts and to protect against injuries.
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Concerning your safety – Basic prerequisites Examples for improper use are: dragging the machine along as a measure of transportation throwing the machine off the transport vehicle attaching an additional weight to the machine It is not permitted to stand on the machine while working. Lifting tackle must be removed before starting work.
Concerning your safety – Definition of responsible persons 3.2 Definition of responsible persons 3.2.1 Operating company The operating company is the natural or juridical person who uses the machine or in who's name the machine is used. The operating company must make sure that the machine is only used for the purpose it is intended for and in strict compliance with the safety regulations mentioned in these operating and mainte- nance instructions.
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Concerning your safety – Definition of responsible persons have made himself familiar with the operation of the machine, be physically and psychologically able to drive and operate the machine. Persons under the influence of alcohol, medication or drugs are not allowed to operate, service or repair the machine.
Concerning your safety – Basic safety regulations for safe operation 3.3 Basic safety regulations for safe operation 3.3.1 Remaining dangers, remaining risks Despite careful work and compliance with standards and regula- tions it cannot be ruled out that further dangers may arise when working with and handling the machine.
Concerning your safety – Handling fuels and lubricants 3.4 Handling fuels and lubricants 3.4.1 Preliminary remarks The operating company must ensure that all professional users have read and follow the corresponding safety data sheets for the individual fuels and lubricants. Safety data sheets provide valuable information about the following characteristics: name of substance...
Concerning your safety – Handling fuels and lubricants 3.4.2 Safety regulations and environmental protection regulations for handling oil WARNING! Danger of burning by ignited oil! – Do not allow oil to come into contact with hot components. – Smoking and open fire is prohibited! –...
Concerning your safety – Handling fuels and lubricants 3.4.3 Safety regulations and environmental protection regulations for handling gas- oline DANGER! Danger to life caused by explosive gas-air mixes! – Do not allow gasoline to come into contact with hot components. –...
Concerning your safety – Handling fuels and lubricants 3.4.4 Safety regulations and environmental protection regulations for handling fuel stabiliser WARNING! Danger of burning by ignited fuel stabilizer! – Do not allow fuel stabilizer to come into contact with hot components. –...
Concerning your safety – Loading/transporting the machine 3.5 Loading/transporting the machine Make sure that persons are not endangered by the machine tipping or sliding off. Do not use damaged or in any other way impaired lashing points. Always use appropriate lifting and lashing means on the lifting and lashing points.
Concerning your safety – Start-up procedure 3.6 Start-up procedure 3.6.1 Prior to starting up Use only machines which are serviced at regular intervals. Become acquainted with the equipment, the indicators and control elements, the working principle of the machine and the working area.
Concerning your safety – Start-up procedure Avoid operation in closed or partly closed rooms, or ensure ade- quate ventilation when working in trenches. 3.6.4 Operation in trenches Applies only to Germany. The vibratory tamper or the vibratory plate were tested outdoors by BG Bau (Germany) regarding CO emissions.
Concerning your safety – Operation 3.7 Operation 3.7.1 Persons in the danger area Before taking up work, also after breaks, you should always con- vince yourself that the danger zone is free of persons or obstruc- tions. Give warning signals, if necessary. Stop work immediately if per- sons remain in the danger zone, despite the warning.
Concerning your safety – Refuelling 3.8 Refuelling Do not inhale any fuel fumes. Refuel only with the engine shut down. Do not refuel in closed rooms. No open fire, do not smoke. Keep away from ignition and heat sources. Apply measures against electrostatic charging. Do not spill any fuel.
Concerning your safety – Maintenance work 3.9 Maintenance work 3.9.1 Preliminary remarks Adhere to the specified operating, maintenance and repair meas- ures. The machine must only be serviced by qualified personnel author- ised by the operating company. Keep unauthorised persons away from the machine. Perform maintenance work only with the engine shut down and the spark plug connector disconnected.
Concerning your safety – Repair 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 – Signage 3.11 Signage Keep stickers and signage in good and legible condition and comply with their meaning. Replace damaged and illegible stickers or signage immediately. Made by Designation Type Nominal Power Operating Mass Year of Construction Serial-No.
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Concerning your safety – Signage Warning sticker - Follow operating instructions Fig. 7 Instruction sticker - Wear ear defenders Fig. 8 Information sticker - Lifting point Fig. 9 Information sticker - Lashing point Fig. 10 DFP7AX...
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Concerning your safety – Signage Information sticker - Guaranteed sound capacity level Fig. 11 Information sticker - Filler opening for petrol Gasoline/Benzin B-DEC-0216 Fig. 12 Information sticker - Filler opening for water Water B-DEC-0218 Fig. 13 DFP7AX...
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Concerning your safety – Signage Maintenance sticker Fig. 15 Machine type plate (example) Made by Designation Type Nominal Power Operating Mass Year of Construction Serial-No. Ammerländer Str. 93 D-26203 Wardenburg Made in Germany B-924-0002 Fig. 16 DFP7AX...
Indicators and control elements – Engine 4.1 Engine 4.1.1 Overview Fig. 17 Start switch Throttle lever Choke lever Recoil starter Fuel valve 4.1.2 Starter switch Position “OFF” Ignition off Position “ON” Ignition on Fig. 18 DFP7AX...
Indicators and control elements – Engine 4.1.3 Throttle lever Position "MIN" Idle speed Position "MAX" Maximum speed Fig. 19 4.1.4 Choke lever Position "Left" Choke closed Position "Right" Choke open Fig. 20 4.1.5 Recoil starter Fig. 21 DFP7AX...
Indicators and control elements – Water spraying system 4.2 Water spraying system Rotary button for water spraying system Water level gauge B-230-0114 Fig. 23 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”...
Indicators and control elements – Transport wheels 4.3 Transport wheels B-230-0023 Fig. 25 Locking of guide handle Locking of transport wheels DFP7AX...
Indicators and control elements – Transport wheels 4.3.1 Transport wheels with guide handle in middle position B-230-0031 Fig. 26 Locking of guide handle Locking of transport wheels DFP7AX...
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Indicators and control elements – Transport wheels DFP7AX...
Checks prior to start up – Notes on safety 5.1 Notes on safety If the following tests reveal damages or other defects, the machine must not be operated, until these deficiencies have been corrected. Do not operate the machine with defective indicators and control elements.
Checks prior to start up – Visual inspections and function tests 5.2 Visual inspections and function tests Check fuel tank and lines for condition and leaks. Check bolted connections for tight fit. Check machine for contamination and damage. Check the hydraulic oil cooler for dirt. Check starter rope for chafing.
Checks prior to start up – Checking the engine oil level 5.3 Checking the engine oil level NOTICE! Danger of engine damage! – +Use only oil of the permitted specification Ä Chapter 8.2.1 „Engine oil“ on page 75. Protective equipment: Working clothes Protective gloves Clean the area around the oil dipstick (1).
Checks prior to start up – Checking the fuel level, topping up fuel 5.4 Checking the fuel level, topping up fuel DANGER! Danger to life caused by explosive gas-air mixes! – Do not allow gasoline to come into contact with hot components.
Checks prior to start up – Checking the rubber buffers 5.5 Checking the rubber buffers Check the rubber buffer pairs, left and right, for tight fit, cracks and tear-offs. ð Replace damaged rubber buffers immediately. Fig. 29 DFP7AX...
Checks prior to start up – Checking the water level, topping up 5.6 Checking the water level, topping up NOTICE! Components may get damaged by frost! – Drain all water off if there is a risk of frost. – The water system can alternatively be filled with an anti-freeze mixture.
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Checks prior to start up – Checking the water level, topping up DFP7AX...
Operation – Mounting the guide handle 6.1 Mounting the guide handle Protective equipment: Working clothes Safety shoes Protective gloves Force the guide handle apart and plug it onto the brackets. Lock and secure the guide handle on both sides with clip pins.
Operation – Starting the engine 6.2 Starting the engine Exhaust fumes contain toxic substances and can damage your health, cause unconsciousness or even death. WARNING! Danger of poisoning by exhaust gases! – Do not inhale exhaust gases. – Avoid operation in closed or partly closed rooms, or ensure adequate ventilation when working in trenches.
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Operation – Starting the engine Fully open the fuel tap. Fig. 33 Close the choke only when the engine is cold. If the engine is warm or the outside tempera- tures are high, the choke must remain open to prevent the engine from stalling. Close the choke.
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Operation – Starting the engine Pull the rope by the starter handle, until resistance can be felt. Guide the starter handle back to initial position. Fig. 37 CAUTION! Danger of injury caused by uncontrolled machine movement! – Always hold on to a running machine. –...
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Operation – Starting the engine If the recoil 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. DFP7AX...
Operation – Operation 6.3 Operation Guide the machine only by the guide handle. Guide the machine so that your hands do not hit against solid objects. Keep feet clear of the vibrating base plate. CAUTION! Danger of injury caused by uncontrolled machine movement! –...
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Operation – Operation Guide the machine by means of the guide handle. Fig. 41 For short work interruptions you should always return the throttle lever to “MIN” position (idle speed). ð Vibration is switched off. Fig. 42 DFP7AX...
Operation – Switching the water sprinkling system on/off 6.4 Switching the water sprinkling system on/off Switch the water sprinkling 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”...
Operation – Parking the machine in secured condition 6.5 Parking the machine in secured condition Components can be very hot during or immediately after operation. WARNING! Danger of burning on hot components! – Wear your personal protective equipment (pro- tective gloves, protective clothing). –...
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Operation – Parking the machine in secured condition Close the fuel valve completely. secure the machine against unauthorized use. Fig. 46 DFP7AX...
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Operation – Parking the machine in secured condition DFP7AX...
Loading / transporting the machine – Loading the machine 7.1 Loading the machine Loads may only be attached and hoisted by an expert/qualified person. Do not use lifting points that are damaged or impaired in any other way. Only use lifting and lashing tackle with sufficient load bearing capacity for the weight to be loaded.
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Loading / transporting the machine – Loading the machine If necessary, pull the machine by the handles or loops (1) on an even surface. B-230-0070 Fig. 48 DFP7AX...
Loading / transporting the machine – Lashing the machine to the transport vehicle 7.2 Lashing the machine to the transport vehicle Do not use lifting points that are damaged or impaired in any other way. Always use appropriate lifting and lashing tackle at the lifting and lifting points.
Loading / transporting the machine – Transport wheels 7.3 Transport wheels Park the machine safely Ä Chapter 6.5 „Parking the machine in secured condition“ on page 64. Lock the guide handle with the locking bolts (1). B-230-0027 Fig. 51 Unlock the locking bolts (2) and fold down the transport wheels.
Loading / transporting the machine – Transport wheels 7.3.1 Transport wheels with guide handle in middle position Ä Chapter 6.5 „Parking the machine Park the machine safely in secured condition“ on page 64. Lock the guide handle with the hook (1). Unlock the locking bolts (2) and fold down the transport wheels.
Maintenance – Preliminary remarks and safety notes 8.1 Preliminary remarks and safety notes DANGER! Danger to life caused by an operationally unsafe machine! – The machine must only be serviced by quali- fied and authorized personnel. – Follow the safety regulations for maintenance Ä...
Maintenance – Fuels and lubricants 8.2 Fuels and lubricants 8.2.1 Engine oil 8.2.1.1 Oil quality The following engine oil specifications are permitted: Engine oils for four-stroke engines acc. to API-classification SJ or higher Avoid mixing of engine oils. 8.2.1.2 Oil viscosity Since engine oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAE-class).
Maintenance – Fuels and lubricants 8.2.2.2 Fuel stabilizer If the machine is only occasionally used (if it is out of use for longer than four weeks), mix in the correct amount of fuel stabilizer directly after you have purchased fresh fuel. The fuel stabilizer has a limited shelf life.
Maintenance – List of fuels and lubricants 8.3 List of fuels and lubricants Assembly group Fuel or lubricant Spare parts Filling quantity number Summer Winter Observe the level mark! Engine oil SAE 10W-30 0.6 l Ä Chapter 8.2.1 „Engine Specification: (0.16 gal us) oil“...
Maintenance – Running-in instructions 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 Ä Chapter 8.7.1 „Changing the engine Change the engine oil oil“ on page 83. Check engine and machine for leaks.
Maintenance – Weekly 8.6 Weekly 8.6.1 Checking, cleaning the air filter NOTICE! Danger of engine damage! – Do not start the engine after having removed the air filter. – If necessary, the air filter may be cleaned up to six times. –...
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Maintenance – Weekly Checking, cleaning the air filter Separate paper element and foam element. Fig. 58 CAUTION! Danger of eye injuries caused by particles flying around! – Wear your personal protective equipment (safety gloves, protective working clothes, goggles). Blow the paper element (4) out with dry compressed air (max.
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Maintenance – Weekly Assembling the air filter NOTICE! Danger of engine damage! – Insert the filter element correctly. Install the rubber seal (5). Insert the filter element (4) correctly and tighten it with the wing nut (3). Tighten the cover (2) with the wing nut (1). Dispose of the filter element (if replaced) in an environmen- tally friendly way.
Maintenance – Semi-annually 8.7 Semi-annually 8.7.1 Changing the engine oil NOTICE! Danger of engine damage! – Change the oil only with the engine at oper- ating temperature. – Use only oil of the permitted specification Ä Chapter 8.2.1 „Engine oil“ on page 75. Ä...
Maintenance – Annually 8.8 Annually 8.8.1 Replacing the spark plug NOTICE! Danger of engine damage! – Do not use spark plugs with incorrect heat value. Recommended spark plugs: BPR6ES DENSO W20EPR-U Protective equipment: Working clothes Protective gloves Special tool: 13/16 inch spark plug spanner Ä...
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Maintenance – Annually Preparations Protective equipment: Working clothes Protective gloves Ä Chapter 6.5 Park the machine in secured condition „Parking the machine in secured condition“ on page 64. Let the engine cool down to 20 °C (68 °F). Unscrew the fastening screws (1). Remove valve cover (2) with seal (3).
Maintenance – Annually Adjusting the valve clearance Hold the hexagon nut (1) on the rocker arm and loosen counter nut (2). Adjust the hexagon nut, until the feeler gauge can be inserted and pulled out with little resistance after retightening the counter nut.
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Maintenance – Annually Close the fuel valve. Fig. 69 Disassemble filter bowl (3), O-ring (2) and filter (1). Clean filter bowl and filter in a non-inflammable solvent, dry them thoroughly afterwards. Fig. 70 A View from below: Alignment of filter during installation Open the fuel valve and collect running out fuel.
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Maintenance – Annually Check the O-ring (2) for damage, replace if necessary. Install the filter (1). Observe the alignment (A) of the filter on the housing. Assemble the filter bowl (3) with the O-ring. Fig. 72 A View from below: Alignment of filter during installation Unscrew the hexagon nuts (2) and the hexagon screw (1) and take off the fuel tank.
Maintenance – Annually 8.8.4 Replacing the V-belt Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.5 „Parking the machine Park the machine safely in secured condition“ on page 64. Allow the engine to cool down. Loosen the fastening screws (2) and remove the V-belt guard (1).
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Maintenance – Annually Check tension of V-belt, tighten if necessary. ð Compression measurement: 5 - 10 mm (0.2 - 0.4 in). Fig. 79 Assemble the V-belt guard (1) with fastening screws (2). Check the V-belt tension again after 25 operating hours, tighten if necessary.
Maintenance – Annually If frequency incorrect: Check the engine speed. Check the V-belt. If necessary, contact our customer service. 8.8.5 Replacing the starter rope Protective equipment: Working clothes Protective gloves Ä Chapter 6.5 Park the machine in secured condition „Parking the machine in secured condition“ on page 64. Allow the engine to cool down.
Maintenance – Annually Secure the coil against winding up. For this purpose tie the coil (2) to the housing (5) with a cable strap (1). Untie the knots of the starter rope at both ends and remove the old starter rope. Thread in the new starter rope (3) and fix it with knots on both ends.
Maintenance – Annually Protective equipment: Working clothes Safety shoes Protective gloves Park the machine on level ground. Ä Chapter 6.5 „Parking the machine Park the machine safely in secured condition“ on page 64. Tilt the machine slightly towards the oil drain side and secure it properly.
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Maintenance – Annually Unscrew wing nut (1) and remove cover (2). Clean the cover. Unscrew wing nut (3) and remove filter element (4). Check the rubber seal (5), replace if necessary. The rubber seal frequently sticks to the filter element. Fig.
Maintenance – As required 8.9 As required 8.9.1 Cleaning the cooling fins and the cooling air intake openings How dirty the cooling fins and cooling air intake openings are depends very much on the daily operating conditions; clean daily if necessary. NOTICE! Danger of engine damage caused by reduced cooling!
Maintenance – As required NOTICE! Components can be damaged by water entering into the system! – Do not direct the water jet directly into the air filter, carburettor, recoil starter, air intake or starter switch. CAUTION! Danger of eye injuries caused by particles flying around! –...
Maintenance – As required 8.9.3 Cleaning the water spraying system Protective equipment: Working clothes Safety shoes Protective gloves Remove the cap (2). Open the rotary button (1) completely and let all water run out. Alternatively you may also remove the water tank for cleaning.
Maintenance – As required Check condition and tension of the V-belt, tighten if neces- sary. ð Compression measurement: 5 - 10 mm (0.2 - 0.4 in). If necessary, tighten the V-belt; if damaged, replace the V- Ä Chapter 8.8.4 „Replacing the V-belt“ on page 89. belt Fig.
Maintenance – As required Clean the area around the spark plug. Unscrew the spark plug using a 13/16 inch spark plug spanner. Fig. 97 Check the condition of the spark plug, clean if necessary. In case of excessive combustion residues or burned off elec- Ä...
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Maintenance – As required Depending on weather conditions these conservation measures will protect the machine for approx. 6 to 12 months. Ä Chapter 6.5 Park the machine in secured condition „Parking the machine in secured condition“ on page 64. Allow the engine to cool down for at least 30 minutes. Clean the machine thoroughly.
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Maintenance – As required Protecting the cylinder Special tool: 13/16 inch spark plug spanner Unscrew the spark plug using a 13/16 inch spark plug spanner. Fill in several drops of fresh engine oil through the ignition plug opening. Fig. 101 Crank the engine several times with the recoil starter to dis- tribute the oil in the cylinder.
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Maintenance – As required Clean the machine thoroughly. Start the engine and run it for 15 to 30 minutes with idle speed. DFP7AX...
Troubleshooting – Preliminary remarks 9.1 Preliminary remarks Malfunctions are frequently caused by incorrect operation of the machine or insufficient maintenance. 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 – Engine malfunctions 9.2 Engine malfunctions Malfunction Possible cause Remedy Engine does not Fuel tank empty Check, fill up if necessary start Fuel valve closed Open the fuel valve Fuel system clogged Clean the fuel screen Check the fuel screen in the carburettor Have checked by qualified expert per- sonnel Set the starter switch to “OFF”...
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Troubleshooting – Engine malfunctions Malfunction Possible cause Remedy Poor fuel quality Check the fuel quality, if necessary change the fuel Engine oil level too low Check the engine oil level, correct if nec- essary Engine runs with Centrifugal clutch defective Have checked by qualified expert per- high speed, but no sonnel...
Troubleshooting – What to do if the engine has flooded 9.3 What to do if the engine has flooded DANGER! Danger to life caused by explosive gas-air mixes! – Do not allow gasoline to come into contact with hot components. –...
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Troubleshooting – What to do if the engine has flooded Open the choke. Fig. 105 CAUTION! Danger of eye injuries caused by particles flying around! – Wear your personal protective equipment (safety gloves, protective working clothes, goggles). Crank the engine several times with the recoil starter to remove excessive fuel from the combustion chamber.
Disposal – Final shut-down of machine 10.1 Final shut-down of machine If the machine can no longer be used and needs to be finally shut down you must carry out the following work and have the machine disassembled by an officially recognized specialist workshop. DANGER! Danger to life caused by explosive gas-air mixes!