Kernlochbohrer Skippy User manual

Operating instructions
Motor pile driver „Skippy“
PR-38/4T-PRO
Kernlochbohrer GmbH
Geigersbühlweg 52
72663 Großbettlingen
Tel. [phone]
Email: [e-mail] Version 1 2. Output 03/2023

Content
Introduction and description 3
About this guide 3
Thanks to the buyer 3
Explanation of symbols 4
Safety regulations 4
Technical data 6
Product description 7
Use and care 8
Precautions 8
Preparation 10
Structure of the unit 12
Commissioning 12
Operation 13
Switching off the machine 14
Air filter 14
Fuel filter 14
Carburettor 15
Spark plug 15
Silencer 15
Cylinder radiator 16
Lubrication of gearbox and impact cylinder 16
Engine oil 16
Cleaning and maintenance 17
Maintenance and inspection plan 18
Troubleshooting 20
Environmental protection 21
Warranty 21
Exploded view 22
EC Declaration of Conformity Attachment
2

Introduction and description
The motor pile driver "Skippy" PR-38/4T-PRO is intended for professional use and
may only be operated by instructed persons. Strictly adhere to the instructions in
the operating manual.
Our company declines all responsibility in the event of violations of the operating
instructions that may lead to injuries or machine damage. In addition, all currently
applicable regulations of the Accident Prevention Regulations (UVV) and the
Employer's Liability Insurance Association (BG) must be observed.
The machine may only be serviced by persons who have the appropriate
qualifications and certification.
About this guide
These operating instructions are for the model
PR-38/4T-PRO
Check the machine model against the type plate.
Thanks to the buyer
Thank you for purchasing a motor pile driver from Kernlochbohrer GmbH. Please
read the operating instructions carefully and observe the safety instructions. By
operating it correctly, you will fully appreciate the outstanding performance of our
products. Keep this manual in a safe place for future reference.
If you have any questions about the operation of the motor pile driver, please
contact Kernlochbohrer GmbH directly. We are available to answer your questions
at any time.
3

Note:
Kernlochbohrer GmbH reserves the right to change the design and appearance of
the products and their operating instructions. Future changes to the operating
instructions will be made without prior notice.
Explanation of symbols
Warning of general danger. Failure to comply with these safety precautions and
instructions may result in fire and/or serious injury.
Safety regulations
❖Read all precautions before commissioning and keep the operating
instructions. In addition, all currently applicable regulations of the Accident
Prevention Regulations (UVV) and the Employer's Liability Insurance
Association (BG) must be observed.
❖Please follow the operating instructions carefully, as failure to observe these
safety precautions and instructions may cause fire and/or serious injury.
1. Keep children and other people away while using the tool. If you are distracted,
you may lose control of the tool.
2. Be alert and use common sense when operating the tool, work with
concentration and pay attention to what you are doing. Do not use a tool when
you are tired or under the influence of drugs, alcohol or medicines. A moment of
carelessness can result in serious injury.
3. Do not overestimate your abilities.
4

4. Be sure to wear non-slip safety shoes and suitable protective equipment ear
protection and safety glasses. Wearing suitable protective equipment reduces
the risk of injury.
5. Avoid unusual postures. Make sure you stand securely and keep your balance
at all times. Stand in front of the air filter when operating.
6. After starting the machine, it must be held with both hands to avoid injury.
7. Make sure that you do not get any part of your body under the motor pile driver.
8. Keep unused tools out of reach of children. Do not allow persons to use the
appliance who are not familiar with it or have not read these instructions. Tools
are dangerous if used by inexperienced persons.
9. Non-approved spare parts and any modification are prohibited on our products.
10. Do not use the appliance in potentially explosive atmospheres, for example in
the presence of flammable liquids, gases or dust. Equipment may produce
sparks which may ignite dust or fumes.
11. In case of damage or malfunction, the unit should be switched off immediately
and this should be reported to an authorised person.
12. If you are not sure whether the unit is working properly, contact the
manufacturer's service department.
13. Use the unit in a well-ventilated area.
5

Technical data
Model
Motor pile driver „Skippy“
PR-38/4T-PRO
Art Nr.
6102
Dimensions
805mm x 275mm x 360mm
Fuel
Unleaded petrol min. 92 octane
Fuel tank capacity
0,65L
Weight
20,8kg
Engine Displacement
37.7 ccm
Max. Power and speed
1.000W / 6500 1/min
Max. Torque and speed
1,65Nm / 5.500 1/min
Max. Motor speed
8.500 1/min
Idle speed
3.000±250
Fuel consumption
≤480g/kWh
Oil consumption
≤1,2g/kWh
Beat frequency
700-1350 strokes/min.
Impact energy
20-55J
Spark plug type
CMR7H
Starter system
Manual starter hoist
Pile diameter
20-120mm
Engine oil
10W-30 (Universal Garden Tools Oil)
6

Product description
Motor pile driver „Skippy“ PR-38/4T-PRO
1. Handle 11. Fuel filler cap
2. Positioning sleeve 12. Air filter
3. Stop switch 13. Fuel bladder
4. Combination switch 14. Air flap
5. Pile base holder 15. Starter
6. Sheet pile wall plinth 16. Support plate
7. Hammer housing 17. Damping spring
8. Throttle lever 18. Handle sleeve
9. Control switch 19. Lubricating oil filling hole
10. Fuel tank 20. Oil filter
7

Use and care
The device is designed for driving vertical piles into the ground (with a max. pile
diameter of 120mm).
The operator alone is liable for all damage caused by improper use.
Have your tool repaired only by qualified personnel and only with original spare
parts.
Precautions
1. ALWAYS wear ear protection! When using the machine, the loud noise in the
working area can cause hearing damage.
2. Do not overheat the unit. Only use suitable tools for the respective application.
Properly selected tools and careful handling lead to better work results.
3. Always keep the machine in perfect working order. Before each use, check for
damage to the machine and its moving parts (defective components or other
factors that could affect the safe operation of the machine). In the event of
damage, the machine must be taken in for repair before use
4. To ensure the functionality of the unit, the factory-fitted covers or screws must
not be removed.
5. Avoid situations where the unit stops while running under heavy load. This can
lead to overheating and thus damage to the unit.
6. Do not leave the unit unattended during operation.
8

7. The appliance must be cleaned regularly to prevent permanent dirt build-up.
Keep the handle dry, grease-free and clean.
8. The specified vibration emission value was determined using standard
measurement methods. It may change if the unit is used under different
environmental conditions.
9. Air inlet and air outlet must not be covered.
10. It is forbidden to interfere with the structure of the unit in order to change its
parameters or construction.
11. Do not pull the throttle switch when lifting the machine, the machine must
operate at idle.
12. Petrol is highly flammable. Therefore, refuel in a well-ventilated area. The
petrol engine must be switched off while filling with fuel.
13. Never remove the fuel filler cap or fill petrol while the engine is running or still
hot. Petrol hitting hot parts can cause an explosion!
14. Never start or use the machine if the fuel filler cap is not closed.
15. Do not smoke when filling the tank and during all handling of fuels and
lubricants.
16. Do not fill too much fuel. The fuel must not exceed the neck of the oil filter of
the fuel tank. If fuel is spilled, wait until the fuel has completely evaporated and
only then start the machine.
9

17. Tighten the fuel tank cap after refuelling. Before working, check whether the
fuel tank is damaged or leaking. If damage is detected, switch off the machine
immediately and have the defective part replaced at an authorised workshop.
18. Empty the fuel tank before transport to prevent leakage.
19. Inhaling the exhaust fumes from this engine can lead to carbon monoxide
poisoning, which in extreme cases is fatal. Carbon monoxide is odourless,
tasteless, invisible and therefore particularly dangerous. If symptoms of
poisoning occur (tiredness, drowsiness, clouding of consciousness, feeling
unwell), consult a doctor immediately. Stop work immediately and move away
to an area with fresh air.
Caution!
Although the appliance has been designed with safety in mind and has protective
mechanisms and additional safety features, there is a small risk of accident or injury
during operation. It is recommended that caution and common sense be exercised
during use.
Preparation
Do not use the unit in ambient temperatures above 45°C and relative humidity
above 85%. The unit may only be used in well-ventilated rooms. The ventilation
openings of the unit must not be covered. Keep the unit away from hot surfaces.
Always use the appliance on a stable, fireproof surface and out of the reach of
children and persons with impaired mental, sensory and executive functions.
Before first use (and also every 10 hours of operation), check the level of the
engine oil and adjust it if necessary. To reduce the level, pour the engine oil through
the hole from the oil plug. To top up the oil or check the level, place the unit in an
upright position. The unit should be cold or at least 15 minutes after the last
operation.
10

To check the level, wait a while if you have previously added oil, then unscrew the
oil plug and check the level using the scale. The correct level should reach at least
the lower edge of the scale at the top of the filler plug. If the oil is not sufficient, add
oil so that the level is within the range at the plug.
If the oil has a distinct dark colour or is less transparent, be sure to change it.
Caution!
Oil tank opening
Min. engine oil level
Oil plug with level indicatorThe max. engine oil level should not
exceed the lower edge of the end of the filler opening (see
illustration). In case of overflow, the excess can be sucked out
through the filler opening. Never suck up engine oil or petrol by
mouth. This can lead to poisoning.
Use oil with the following viscosity class
Ambient temperature
Note:
To power the unit, use only unleaded petrol (min. 92 octane) without oil admixture!
11
Oil plug with level indicator
Min. engine oil level
Oil tank opening
Max. engine oil level
Max. Engine oil level

Before operation, install the correct pile base holder of
the required size by unscrewing or screwing it on.
Structure of the unit
This is a hand-held petrol pile driver, which is characterised by its light weight and
low petrol consumption.
The product can regulate the impact energy and impact frequency and can be used
for a variety of piles with a diameter of more than 20 mm (inclusive) and less than
120 mm (inclusive).
The operating handle of the machine is made of foam rubber, which can greatly
reduce the recoil force of the machine. The machine is equipped with a two-way
damping spring.
Commissioning
After pouring fuel into the tank and making sure there is enough oil in the engine,
press the transparent semicircular fuel bubble on the unit (next to the suction lever)
several times until the carburettor is filled with fuel before starting.
When the engine is cold, close the air flap. Open the air flap after starting.
Stand the machine upright. Hold the upper part of the handle with one hand while
quickly pulling the starter's pull handle over 50cm with the other hand. Do not let the
pull handle snap back freely during repeated pulls, but hold it firmly to avoid injury
from rapid springback.
12

Attention!
Sometimes it may take a few strokes or pulls before the engine starts. In extremely
cold conditions, it may take longer for the engine to reach operating temperature.
Operation
Do not let go of the engine pile driver immediately after starting the engine, but hold
it firmly. After starting, open the air flap completely. Let the engine idle for approx. 5
minutes to bring it to operating temperature, then you can start working. Adjust the
engine speed with the control switch depending on the desired impact force. It is
recommended to work at medium engine speed
Air flap open Air flap closed
Attention!
When operating the motor pile driver for the first time, it is recommended to work at
low or max. medium speed for the first 20 hours of operation and not at full throttle,
so that the motor can run in. This will extend its service life.
13

Switching off the machine
Stop the impalement procedure, release the throttle and
let the machine idle for 3-5 minutes. Then press the
stop button latch to unlock it and move the stop button
up yourself.
Attention!
If the unit is not going to be used in the near future, let it cool down completely and
drain the remaining fuel from the tank.
Air filter
The condition of the air filter should be checked regularly for contamination.
Contamination can cause the air filter to become clogged. A clogged air filter affects
engine performance and service life. If the filter is dirty, disassemble it and wash it
in warm water with a mild detergent (e.g. washing-up liquid). Wipe all parts well and
dry them completely before reassembly. If the filter is damaged, replace it with a
new one. Especially if it has been in an environment with a lot of dust, the
maintenance cycle should be shortened accordingly.
Fuel filter
If a fuel filter is clogged, the ram will have reduced engine speed and weaker
impact energy. To clean the fuel filter, unscrew the fuel cap from the tank and pull
the fuel filter out of the opening with a metal hook and clean it. When you clean the
fuel filter, you also clean the fuel tank.
14

Carburettor
There is usually residual fuel in the fuel tank and carburettor. If the machine is not
used for more than 3 months, remove the fuel completely.
To do this, pull out the fuel inlet line, press repeatedly on the rubber bladder of the
carburettor to drain the fuel. Push the fuel inlet line back into position when the fuel
in the fuel bladder and fuel inlet line is drained.
Spark plug
To ensure proper engine operation, the spark plug
gap must be set correctly (0.5-07mm). Remove
deposits with a wire brush.
Please use spark plugs of the type CMR7H.
Silencer
Regularly remove dirt from the inlet and outlet of the muffler or clean it with suitable
cleaning agents.
Attention!
Clean the muffler only when it is cold.
15

Cylinder radiator
Regularly remove accumulated dust and other contaminants from the cylinder
cooling fins. The unit has an air-cooled motor, so the permeability of the cylinder
fins is crucial for trouble-free long-term operation.
Lubrication of gearbox and impact cylinder
Open the gearbox cover and lubricate the drive gearbox regularly with lubricating oil
to ensure complete lubrication of the gearbox.
Lubricate the impact cylinder after 40 hours of operation. To do this, unscrew the
filler plug and pour approx. 40g of gear grease (Mobil SHC 32) into the gear.
Engine oil
The condition of the oil has a significant effect on the
operation and life of the engine. The engine oil must be
changed after first use, then after 10 hours of operation
and then every 50 hours of operation or every six months,
whichever comes first.
To change the oil, prepare a special oil container with a
suitable capacity, then unscrew the engine oil filler cap on
the vertically positioned unit and tilt the unit so that all the
oil comes out through the filler hole.
16
Oil filler opening
Fuel filler cap

Attention!
Warm oil is thinner and easier to drain. However, be careful not to burn yourself on
the hot parts of the appliance and on the oil itself.
Cleaning and maintenance
1. Cool the appliance completely before any cleaning, adjustment, replacement
of accessories and also when the appliance is not in use.
2. Only use agents without corrosive ingredients to clean the surface.
3. Store the unit in a dry, cool place protected from moisture and direct sunlight.
4. It is forbidden to spray the appliance with a water jet or to immerse it in water.
5. Water must not be allowed to enter the interior of the unit through the
ventilation openings on the housing.
6. The ventilation openings are to be cleaned with a brush and compressed air.
7. For technical efficiency and to prevent damage, the unit should be checked
regularly.
8. Use a soft cloth for cleaning.
9. Do not use sharp sponges and/or metallic objects such as steel wool, wire
brushes or metal spatulas for cleaning, as these may damage the surface of
the material from which the appliance is made.
17

Maintenance and inspection plan
This table shows the standard operating and maintenance intervals for the unit
under normal conditions of use. When working under severe conditions, e.g. in
dusty environments, long continuous operation, etc., the maintenance intervals are
shortened.
Maintenance points
(regular inspection
required)
Before
operati
on
After
operation or
daily
After
adding oil
Every
week
Every
mont
h
In case
of wear
If
necessar
y
Visual inspection of
the unit (general
condition, tightening
of screws)
√
√
Cleaning the
complete unit
√
Control handle/
switch Function test
√
√
Air filter - Cleaning
√
√
Air filter - exchange
√
Fuel filter -
inspection
√
Fuel filter - exchange
√
Fuel Tank / Fuel
Tank Cap - Cleaning
√
√
Fuel Tank / Fuel
Tank Cap -
Inspection
√
√
Fuel Tank / Fuel
Tank Cap -
Retighten
√
Gearbox / Cylinder -
Cleaning
√
Gearbox / Cylinder -
Adding oil
√
Inspection of the
silencers
√
Removing
accumulated soot
from the silencer
√
18

Maintenance points
(regular inspection
required)
Before
operati
on
After
operation
or daily
After
adding oil
Every
week
Every
month
In the
event of
wear and
tear
If
necessar
y
Removing
accumulated soot
from the silencer
√
Inspection of the
cylinder heat sink
√
Cleaning the cylinder
heat sinks
√
Inspection /
adjustment of the
distance between
the electrodes of the
spark plug
√
Replacing the spark
plug
√
Inspection of all bolts
and nuts
√
√
Tightening the bolts
and nuts
√
19

Troubleshooting
If a defect occurs during operation of the motor pile driver, contact a nearby service
station or Kernlochbohrer GmbH immediately. Do not disassemble the tool yourself
under any circumstances.
Malfunction
Possible cause
Troubleshooting
Difficulty starting the
engine when cooled
down
Check if the spark plug is wet
Check if the spark plug
produces an electric spark
Check if too much fuel is
absorbed
Wipe spark plug dry
Replace spark plug
Reduce the fuel supply
Difficulties in restarting
after a sudden stop
Check if the fuel is used up or
the carburettor is clogged
Check if the fuel filter is
clogged
Check if there is too much
carbon deposit on the spark
plug
Fill fuel tank or clean
carburettor
Clean fuel filter
Remove carbon deposit from
spark plug and clean filter
element.
Slow speed and weak
performance
Check for carbon deposits in
the cylinder or muffler
Check whether the oil hose
and the fuel tank vent are
blocked.
Check if the air filter is
clogged.
Remove carbon deposits
Clean
Clean filter
Abnormal sound
Check whether there are
carbon deposits in the
combustion chamber
Check if there is heavy
abrasion of active components
Remove carbon deposits
Replace the affected parts
Die Maschine arbeitet
normal, aber die
Arbeitseffizienz ist sehr
gering
Check if the rubber ring of the
impact piston is aged and
worn out
Replace the rubber ring
20