Deer Fence Canada PP52 Maintenance and service guide

Post Pounder Safety and Operating
Instructions
Thank you for choosing our Honda gas powered Post Pounder. Certified by Honda Canada.
Deer Fence Canada Inc. assembles and services the driver for all of Canada. For more information
please visit www.deerfencecanada.ca or 1 866 914 3337
Warning: ONLY operate the throttle while the Post Pounder Driver is on a post and be-
tween 5-10kg (10 to 12 pounds) pull down force is exerted on handles. Failure to do so can
result in danger to the operator and damage to the machine. Further, never drive a post/
rod in to the ground until the barrel touches the ground as this can result damage to the post driver.
Read the Post Pounder Safety and Operating Instructions carefully and understand all
safety and operating instructions prior to using the machine. The Instructions contain es-
sential safety information and provide knowledge on how use and maintain the machine
in a safe and efficient

Table of contents
SAFETY 2
PERSONAL PROTECTIVE EQUIPMENT (PPE) 3
NOISE HAZARD 3
ELECTRICAL,GAS ,UTILITIES ,CONCEALED OBJECT HAZARDS 3
VIBRATION HAZARD 4
SERVICE AND MAINTENANCE 5
SMALLER POSTS - USE OF REDUCING BUSH 5
OPERATING INSTRUCTIONS 6
FUNCTION 6
APPLICATIONS 7
PRE-START CHECKLIST 7
SAFE STARTING 8
DRIVING POSTS 8
MAINTENANCE AND SERVICING 11
MANUFACTURER SERVICING 11
MAINTENANCE SCHEDULE 11
CRANK LUBRICATION 11
HAMMER SECTION SERVICE 13
STORAGE OF DRIVER 16
FREQUENTLY ASKED QUESTIONS (FAQ) 18
WARRANTY 19
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Safety
This section provides safety information and hazards of a general nature. Further safety warn-
ings and information are provided where relevant, in the Operating instructions, and Mainte-
nance and servicing sections of this document.
Warning: Sudden or unexpected movement of the machine may occur during op-
eration, which may result in injury to the operator and/or damage to the machine.
•Ensure the operator maintains a stable standing position with feet as far apart
as the width at shoulders. Keep body weight balanced.
• Stand firmly and always hold the Post Pounder with both hands.
• Quick start guide Never operate the Post Pounder unless both feet are in con-
tact with the ground, never stand on a ladder, chair, trailer, pickup, or any other
surface other than stable ground or approved working platform for safety at
heights.
• Ensure the handles are free from grease and oil.
•Do not start the engine while the Post Pounder is lying on the ground, start
when the Post Pounder is in a vertical position.
•Never allow children or persons who have not read the operating instructions to
operate the machine.
•Never let your post pounder run unattended.
•Start engine ,let engine tick over, warm up for 3-5 minutes
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Personal Protective Equipment (PPE)
Ensure the operator and all other persons nearby wear, at a minimum, the following PPE:
•Class 4 hearing protection, greater than 22dB attenuation CSA approved. http://
www.ccohs.ca/oshanswers/prevention/ppe/ear_prot.html
• Safety glasses to CSA medium impact rating (http://www.ccohs.ca/oshanswers/pre-
vention/ppe/glasses.html)
• Gloves suited to manual handling - leather or other abrasion resistant material, anti-vi-
bration gloves are recommended
• CSA approved Safety boots /shoes http://www.ccohs.ca/oshanswers/prevention/ppe/
footwear.html
Noise hazard
High sound levels may cause permanent hearing loss. Noise emitted from the tool
while working can reach above 100dB which can also harm others nearby, both the
operator and bystanders are to wear Class 4 hearing protection greater than 22dB
attenuation.
Electrical,Gas ,Utilities ,concealed object hazards
Whilst driving posts, concealed electrical services, wires and pipes constitute a dan-
ger that can result in serious injury or death. Before you start using the tool, check the
composition of the material you are to work on. Identify and avoid concealed ca-
bles and pipes e.g. electricity, telephone, water, gas and sewage lines etc.
If the tool seems to have hit a concealed object, switch off the machine immediately. Make
sure that there is no danger before continuing.
Dial Before You Dig if you are using the post pounder and are unsure of the location of ser-
vices.
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Vibration hazard
Hand-arm vibration (HAV)
Exposure to HAV can result in disrupted circulation in the hand and forearm and/or damage to
nerves and tendons, muscles, bones and joints of the hand and arm. It can cause a range of
conditions collectively known as hand–arm vibration syndrome (HAVS) and specific disorders
such as carpal tunnel syndrome, ‘tennis elbow’ and ‘vibration white finger’. Workers with expo-
sure to vibration while performing other hazardous manual tasks may also experience pain in
the hands and arms and diminished muscle strength.
See Canadian fact http://www.ccohs.ca/oshanswers/phys_agents/vibration/vibration_effect-
s.html
http://www.cchst.ca/oshanswers/phys_agents/vibration/vibration_effects.html
Reducing the risk of hand-arm vibration
Normal use of the Post Pounder exposes the operator to vibration. Vibrations from handheld
machines are transmitted into the hands via the handles. The spring dampened handles on
the Post Pounder are designed to dampen a large part of the initial vibrations. Further mea-
sures are required as vibrations are not eliminated completely.
• We recommend operators/employers implement a program of health surveillance to
detect early symptoms that may relate to vibration exposure, so that management
procedures can be modified to help prevent significant disability.
• If numbness, tingling, pain, clumsiness, weakened grip, whitening of the skin, or other
symptoms occur at any time, when operating the machine or when not operating the
machine, do not resume operating the machine and seek medical attention.
• Let the tool do the job. Use a firm, but minimum hand grip, consistent with proper con-
trol and safe operation.
• When the impact mechanism is activated, the only body contact with the Post Pounder
should be hands on the spring dampened handles. Avoid any other contact, e.g. sup-
porting any part of the body against the machine or leaning onto the machine trying to
increase the feed force.
• Never keep the throttle engaged while removing the Post Pounder from the post.
• Immediately stop working if the machine suddenly starts to vibrate strongly. Before re-
suming the work, find and remedy the cause of the increased vibrations.
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Service and maintenance
Read the Post Pounder Safety and Operating Instructions carefully and ensure main-
tenance and servicing are completed according with requirements. Perform en-
gine maintenance in accordance with the supplied Honda Owner’s Manual GX35.
• Regular maintenance is a prerequisite for keeping the machine safe and effective.
• If parts are damaged or worn, immediately cease using the Post Pounder until they
have been serviced or replaced.
• When servicing, if parts are cleaned with solvent, ensure there is satisfactory ventilation,
and PPE such as respiratory mask, gloves, and safety glasses are worn, and the manu-
facturer supplied Safety Data Sheet (SDS) for the solvent used is read and understood.
• Replace worn components in good time. When cleaning mechanical parts with sol-
vent, make sure to comply with occupational health and safety regulations, and make
sure that there is satisfactory ventilation.
Smaller posts - use of reducing bush
Warning: Pounding posts that are significantly smaller than the receiver barrel will
result in instability while operating the Post Pounder. This may result in injury to the
operator and will result in damage to Post Driver.
Ensure there is minimum clearance on either side of the post so it fits neatly in the
barrel. Where there is too much clearance on each side, use a reducing bush.
The bush can be locked in position on the PP83 with a retention device through
the tapped hole in the barrel. The reducers for the PP52 are held in place with O rings.
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Operating instructions
Function
The Post Pounder was designed for driving steel fence posts ,T Posts, rebar into the ground. A
range of other materials can be driven, however, success and performance will depend on
the quality of the material used and the ground conditions.
The Post Pounder operates a pneumatic hammer system powered by a Honda GX35 engine
to drive material into the ground with a hammering action.
Differences between PP52 and PP83
Post
PP52
PP83
Weight dry
Weight wet
13.5kg (29.7lb)
14kg (30.8lb)
17.4 kg (40 lb)
18kg (41.1lb)
Internal guide tube diameter
52mm
82mm
Reducing bush
optional
optional
Internal differences
53mm striker
83mm striker
Visual differences
ABS carrying handle
Pressed stainless steel
carrying handle
Engine
Honda GX35
What’s in the box
Post Pounder
Safety and Operating Instructions
Honda Owner’s Manual GX35
EP 0 Grease for servicing
Safety Glasses
Earplugs
Protective Case
Optional
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Applications
Types of posts
The Post Pounder will drive a variety of posts, tubing,pipe, rebar, ground rods directly into the
ground.
Wooden posts larger than 2 inch (50 mm) may require a pilot hole to be made depending on
the ground conditions.
Use the optional reducers/adaptors to keep the post being driven centred in the Post Pounder
barrel.
Ground conditions
The Post Pounder has excellent performance in most ground conditions. In aggregate soils
with stones small to medium stones will generally displace. If a larger stone is struck and the
post is not progressing, cease driving, remove the post and move along a short distance and
retry. The Post Pounders will drive steel posts through asphalt.
The Post Pounder will not drive a post through solid rock. This is beyond the limits of a small,
lightweight machine and most posts.
Pre-start checklist
Check point
Remedy
Check engine oil Honda
GX35
Check fuel level
• Fill with regular unleaded fuel only
Visually inspect striker
and barrel
• Look in the barrel of the Post Pounder to check for
damage to the striker or tube, repair/replace if damaged
• Dislodge any debris (such as tar, timber splinters with a WD
spray into the barrel
• Fill only to the top thread of the filler while the motor is in a
vertical position
•!Overfilling will damage the engine
• Refer to Honda Owner’s Manual GX35
• Use SAE10W 30 oil
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Safe starting
• Start and operate the Post Pounder unit outdoors, and in a ventilated area
•Place the Post pounder on a secure even surface
•Maintain a good safe stance.
•Press the priming bulb until fuel is seen in the return line.
•Close the choke.
•Slide the thumb switch on the throttle handle to “ON” position.
•Grasp the Honda GX35 engine pull starter grip and pull up and out. Excessive
force or speed is not required.
•Never wrap the Honda GX35 pull starter rope around the hand
•Do not quick release the Honda GX35 starter grip, guide the starter rope back
slowly to permit the rope to rewind properly
•Guide the starter rope back slowly to permit the rope to rewind properly.
•Failure to observe instructions regarding the pull starter may result in injury to the
operator’s hand and damage to the starter
•Let the engine warm up for 3-4 min. and then open the choke.
•Do not press the throttle lever until the Post Pounder is on a post.
•Should the engine not start easily, or the pull starter offer resistance, refer to the
Troubleshooting section.
Driving posts
•Ensure there is plenty of clearance behind and next to the Honda GX35 engine,
to allow for the escape of hot and toxic exhaust fumes.
Visually inspect all
fasteners
Tighten as necessary:( use Blue thread locker if screws were slack)
• Cover plate screws
• Carrying handle screws
• Screws in engine guard, and body castings
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•Maintain good balance and secure footing on both feet, with feet far apart.
•Only operate the Post Pounder in daylight conditions with good visibility
•Ensure the operator and all other persons nearby wear, at a minimum, the follow-
ing PPE
Stand the post in the required position and push into the ground. Ensure the post is stable
enough to take the weight of the Post Pounder.
• Where many posts are to be driven, doing this in batches will save time.
• A guide wire can be used to assist in maintaining a straight fence line.
• Lift the Post Pounder over and on to the post.
• Ensure the post is in a vertical position and the Post Pounder is on in a parallel plane
to the post.
!
•Pull down on the Post Driver with 5-10kg of downward force.
• This is mandatory to ensure the internal hammer mechanism is engaged in the cor-
rect operating position, and reduce unexpected movement while driving.
• Gently pull the throttle trigger until the hammer action is felt.
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Correct
Incorrect

• Once the post has been observed as being driven in to the ground, then fully de-
press the throttle trigger and drive the post to the desired depth.
• If the post does NOT drive into the ground cease driving, remove the post and
move along a short distance and retry.
•Never drive a post until the barrel touches the ground.
• Once the desired depth is reached, release the throttle fully so the Honda GX35 En-
gine is idling, and the hammer action has stopped.
•Never operate the throttle unless the Post Driver is on a post, and between 5-10kg
downward force is exerted on the handles.
• Move to the next post and repeat.
•TIP to prevent “Dry Fire” hammer sticking on stops lift Post Pounder off the post and
bring firmly back down on the post. This will ensure the hammer is off the end stops
ready for next post.
Refuelling
Warning: Fuel vapours are extremely flammable and can cause severe injury or
death, if ignited by a spark or excessive heat from a hot motor.
• Always switch off the Honda GX35 engine, and allow adequate time for it to cool down
before refuelling.
• Use regular unleaded fuel only.
• Fill the tank on level ground avoiding spilling fuel on the motor. Allow any spilt fuel to
evaporate before restarting the motor.
•Ensure fuel cap is tightened adequately before restarting the motor.
•Check the grease level behind the crank cover after 8 hours use and top up as neces-
sary.
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Maintenance and servicing
Read the supplied Honda Owner’s Manual GX35 and perform engine maintenance
as recommended by Honda.
Failure to follow the maintenance schedules for the Post Pounder, and Honda
GX35 engine, may result in non-warranty machine failures.
Manufacturer servicing
Should assistance be required, Deer Fence Canada Inc. can perform servicing at a cost. For
technical advice, please contact Deer Fence Canada Inc..
Maintenance schedule
Crank lubrication
Easy Lubrication.
No tools required just 1 pump of EP0 grease each use via the grease nipple on the crank case
cover.
Service
Domestic/farm/light use
Commercial use
Crank lubrication
Annually or EP0 grease gun
1 pump each use
5 hours or 3 months
Whichever occurs first or
EP0 grease gun 1 pump
each use.
Hammer section
Bi-annually
50 hours or 6 months
Whichever occurs first
Gearbox Section
Every 2 years
Annually
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Tools/materials required for full Lubrication
• M3 Allen key, provided with service kit.
• Blue Thread locking compound medium strength
•Degreaser solvent
•EP 0 grease.
Performing the crank lubrication.
1. Remove the 4 screws from the crank cover plate, using an M3 Allen key.
2. Inspect the amount and colour of grease in the crank area. There should be a liberal
amount of grease coated around the outside of the crank about 6-8mm thick.
• If the grease looks to be low, add a small amount of EP 0 grease. 20-30 ml is gener-
ally sufficient.
• The colour of the grease can be yellow to brown or purple depending on suppliers.
• If the grease is black, this may be due to residue entering the machine and
contaminating the grease. The Post Pounder will need further stripping as described
at Hammer Section(P14), and is recommended if reduced performance has been
noted.
3. Clean the cover plate screws with degreaser solvent. Apply Blue thread locking com-
pound medium strength to screws.
4. Tighten the cover plate screws in an even pattern, to prevent pinching the cover plate
o ring.
The amount and type of grease used is critical for the performance and service life
of the Post Driver. Not enough grease will cause failure and too much grease will af-
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fect the striking power of the tool.
Do not over or under grease or the air holes will become blocked.
If the ring of grease around the crank case wall measures less than 6-8 mm ( 1⁄4”), this is an in-
dication the grease level is low. Add no more than a few tablespoons of EP 0 grease,
you never want to exceed 12-13 mm (1⁄2” )of grease ring around the crank case walls.
Hammer section service
Tools/materials required
• M3 and M6 Allen key, of good quality
• 13/16 (21mm) socket and ratchet
• Thread locking compound medium strength
•Degreaser solvent
•EP 0 grease.
•O Rings
Hammer section service procedure
1. Remove the 6 Allen head bolts from the bottom cast handle support section, using an
M6 Allen key, and carefully slide the bottom barrel section from the top housing.
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Bottom assembly
with bolts and seal
Anvil assembly parts

2. Remove the damper section , and inspect for wearing in the rubber dampers and steel
components.
3. Remove the bottom anvil and inspect the Viton O ring for wear or damage, and re-
place if necessary. The anvil component is made from high quality tool steel and should
not be a wearing component,clean off old grease.
4. To remove the top hammer, gently tap the main cast housing vertically down on a soft
bench top and it should slide out of the inner cylinder liner.
• Take note of the orientation of the components as in the parts diagram
5. Check the crank pin bearing for wear, if it is worn replace both crank pin and piston
assembly.
6. The top piston can be removed from the crank by:
•Removing the Left Hand thread crank pin from the crank. Jam the connecting rod
with a round metal bar to release the crank pin. DO NOT USE A SQUARE OR SHARP
OBJECT TO JAM THE CONNECtING ROD.
•Gently push the piston through the bottom of the housing.
!
• Check the piston and Viton O ring for obvious signs of wear, and replace along
with top hammer O ring if necessary.
• Wash all grease from the housing and components using a degreaser solvent and
inspect the inner barrels for wear.
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Top Hammer with Viton O Ring

Reassembling the bottom assembly
After thoroughly cleaning and drying the components and checking for excessive wear, re-
assembly can occur.
1. Apply a coating of EP0 grease around the O ring and outside of the piston, and gently
push back into the housing using a soft dolly.
2. Add a small amount of grease to the crank pin and reassemble remembering it is Left
Hand thread. Do not over tighten this pin, not more than 30Nm.
3. Add a coating of EP 0 grease to the outside of top hammer, and gently push into the
housing. The O ring will be at the top.
4. Add a coating of EP0 grease to the bottom anvil parts, then push the bottom striker
into the guide tube.
5. Reassemble the damper cup with a small amount of EP 0 grease to all components.
NOTE! The hammer “GUIDE RING” should be oriented correctly so the side with
the large chamfer (slightly rounded edge) is facing down towards the bottom hammer.
Remember: round to the ground!
6. Install the bottom guide section back into the main housing ensuring the O ring is not
damaged between the housings.
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7. Insert the handles and springs back into the bottom housing. Apply medium strength
thread locking compound to the 6 socket screws with lock washers in the bottom han-
dle casting and tighten to 20Nm.
8. Apply 75ml of EP 0 grease to the crank area, and reinstall the socket screws using
medium strength blue thread locking compound.
All screws must be correctly tightened in an alternate pattern, as machine damage can
occur from loose or lost bolts.
Storage of Driver
The driver should be stored in a vertical position to allow the engine oil to drain into the sump
of the engine. If the unit is stored horizontally oil can seep into the combustion chamber and
cause damage to the engine.
The post Pounder transit and storage case is designed to stand vertically with the Post Pounder
inside.
Troubleshooting
Recoil starter offering resistance
• Engine overfilled with oil. Drain out and see fill instructions in the Honda GX35 manual.
Place unit on a post so it is upright and level. Fill oil to correct level.
Pull starter rope pulling but engine is not cranking
• Damaged recoil starter or starter drive dog
• Requires replacement part, either whole recoil starter or starter drive dog.
Engine does not start
• Check fuel level and quality
• Check fuel cap is not to tight and starving fuel tank of air.
• Check On/Off switch
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• Prime fuel bulb and engage choke
• Check spark plug and spark present.
Post driver not hammering
•If your driver sounds like it is running fine, however the striker is not hammering as it
should; make sure your striker is fully engaged. There is a safety feature which will disen-
gage the striker if it is dry fired or misfired. To re-engage the striker, simply pick the driver
up off the post and then place it back down on the post with a bit of force to hit the
striker against the post.
•AVOID REPEATED DRY FIRE by maintaining 10 to 12 pounds of down pressure at all
times!
•Check the type of grease in the crank; ONLY use the EP 0 grease which we recom-
mend! EP 0 isa low viscosity grease for machinery with rapid moving parts which pro-
duce a lot of friction. If you use a different type of grease, you will inhibit the perfor-
mance of your driver and possibly cause damage to your driver or your engine. If you
have greased your driver with the wrong grease, you will need to follow the instructions
in the maintenance section for replacing grease in the crank housing area.
•If you feel that the striker or hammer of the machine is not moving as freely as it should,
you can spray WD-40 up into the barrel to lubricate and cleanse this area. Occasionally
you will get bits of debris which chip off the posts and then make their way up into the
striker area.
• If the hammer will not engage after trying WD spray procedure, further servicing of the
machine may be required as in previous chapters.
•If your engine seems to be overheating and not wanting to operate as it should; it may
be starving for air or have too much pressure built up. You can remedy this by unscrew-
ing the gas cap and make sure air is getting into the tank, The gas cap may need to be
cleaned if the breather holes are blocked.
•Other wise consult the Honda service manual to remedy the engine issue.
•In the unlikely event that a driven posts badly flared and becomes lodged within the
barrel follow these steps:
-Remove the six lower body bolts to separate the lower driver body from the upper driver
body.
-Slide the lower driver body down the post to expose the flared top of the post. With a prop-
er cutting tool for the type of post, cut the post off just below the flared top.
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-Once the flared top is removed, slide the lower driver body off the post and re-assemble it
to the upper driver body. Follow the bolt tightening and thread locking guidelines explained
in the “servicing” section.
Frequently asked questions (FAQ)
Servicing
Q: Will servicing void warranty?
A: Warranty will be covered when service is performed in accordance with the instructions
contained in this service manual.
Q: What type of fuel is recommended?
A: Regular unleaded petrol. Refer to the Honda GX35 manual.
Q: What type of Engine oil is recommended?
A: 10W30 engine oil. Refer to the Honda GX35 manual
Q: What type and quantity of grease is recommended for the post driver?
A: EP 0 grease. Approximately 75ml is sufficient for a total strip and rebuild of the machine as
per instructions in this manual.
Q: How often does the machine need stripping and rebuilding?
A: As per the servicing recommendations in this manual or if there is notice of performance
reduction and determined not to be an engine problem.
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Warranty
The Post Pounder has a one year warranty limited to defects in workmanship or parts, from the
date of supply (by the distributor) when used in accordance with reasonable use and care.
Please keep your proof of purchase to assist with any warranty claims.
Defects that occur within the stated warranty period other than those components excluded
below shall be repaired or replaced.
Any parts or goods repaired under this warranty is only warranted for the remainder of the war-
ranty period commencing the original date of supply by the distributor.
Exclusions
This warranty does not cover:
•normal wear and tear,
•damage caused by the Customer failing to follow the Safety and Operating Instructions,
including but not limited to seizures due to lack of maintenance and cleaning;
•components that may need replacement or repair due to normal wear and tear or lack of
maintenance upkeep, including but not limited to:
oO rings and seals,
olost, stripped or broken fasteners,
oBroken throttle controls
oLubrication and grease.
•physical damage caused by accident, misuse, negligence, abuse or fire;
•unauthorized alteration, modification or substitution of any parts of the Post Pounder instal-
lation or use of the Post Pounder not in accordance with instructions supplied;
•damage due to faulty installation or operation or maintenance;
•overloading or transport damage; or damage as a result of improper packaging,
•Post Pounders that have their serial number or model number label removed or defaced;
•failures or defects cause by or associated with use of the Post Pounder in unsuitable physi-
cal or operating environment;
•damage caused by force majeure events such as acts of God and factors beyond rea-
sonable human control;
•Post Pounder that have been used for a purpose other than for what was reasonably in-
tended for the Post Pounder.
•The original Honda engine is not fitted to the machine.
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