Portek Post Driver Service manual

1
Read and fully understand the
instructions before operating
the Portek Post Driver
Operators Handbook
portek.co.uk
Post Driver

2
READ AND UNDERSTAND THIS MANUAL
FULLY BEFORE OPERATING THE POST DRIVER
The Post Driver is a high-speed, driving power tool, special safety precautions must be
observed to reduce risk of personal injury. Read this manual carefully. Be familiar with the
controls and the proper use of the unit. Know how to shut if off quickly.
This graphic accompanied by the words WARNING and DANGER
highlights an act or a condition which can lead to SERIOUS INJURY
ALWAYS WEAR EYE AND EAR PROTECTION.
Always TURN OFF ENGINE and make sure the Post Driver has stopped before cleaning,
removing or adjusting.
DISCONNECT spark plug lead before cleaning or essential maintenance to the Post Driver.
WARNING! Never modify the Post Driver in any way.
Improper use of any Post Driver can cause SERIOUS OR FATAL PERSONAL INJURY.
The engine exhaust from this product contains chemicals to cause cancer, birth defects,
or other reproductive harm.
Specifications, descriptions and illustrative material in this manual are as accurate as known
at the time of publication, but are subject to change without notice. Illustrations may include
optional equipment and accessories, and may not include all standard equipment.
Proper safety precautions must be observed. Like all equipment this unit must be handled
carefully DO NOT EXPOSE YOURSELF TO DANGER. Follow these general rules. Do not permit
others to use the Post Driver unless they are thoroughly responsible and have read, and
understand the machine manual and are trained in its operation.
Always wear hard hat, ear defenders and safety goggles for protection. Dress properly, do not
wear loose clothing or jewellery that could become caught in moving parts of the unit. Safe,
sturdy, steel toe cap non skid footwear should always be worn. Long hair should be tied back.
Legs and feet be covered to protect from flying debris during operation.
Before you start
!
ALWAYS WEAR SAFETY CLOTHING IN CONJUNCTION WITH HAND, EYE, HEARING
AND FOOT PROTECTION TO HSE/EN SPECIFICATIONS - SEE PAGE 6

3
Before use, inspect the entire machine for loose parts (nuts, bolts, screws, etc.) and any
damage. Repair or replace as necessary before using this machine. Serious injury to the
operator or bystanders could result as well as damage to the machine.
Keep the handles free from oil and fuel.
Do not smoke while mixing fuel or filling tank.
Do not mix fuel in an enclosed room or near open flames. Assure adequate
ventilation.
Always mix and store the fuel in a properly marked container that is approved by
local codes and ordinances for such usage.
Never remove the fuel tank cap while the engine is running.
Before transport, always empty the fuel tank to avoid leakage.
Never start or run the engine inside a closed room or building. When being used in
"closed areas" such as tunnels or trenches, make sure the area is well
ventilated. Fumes from the exhaust contain dangerous carbon monoxide.
Never attempt to make engine adjustments while the unit is running. Always make
engine adjustments with the unit resting on a flat, clear surface. REMOVE SPARK
PLUG LEAD TO PREVENT ACCIDENTAL STARTING
Do not use the unit if it is damaged or poorly adjusted.
Keep children away. Onlookers should be kept at a safe distance from the work area,
at least 15 metres/50 feet.
Never leave the machine unattended.
Do not use this unit for any job other than those for which it is intended as described
in this manual.
While operating the machine do not overreach. Keep proper footing and balance at
all times. Do not run the unit while standing on a ladder or on any other unstable
footing location. Do not operate one-handed. The operator should be stood in front
of the 'Air Filter' and operate the machine.
While lifting the machine, do not pull on the 'Throttle Switch', and carry out
idle-speed operation of the machine.
Do not use the unit when you are tired or under the influence of medication, drugs
or alcohol.
Important safety information
!
!
!
!
!
!

4Important safety information
FOLLOW INSTRUCTIONS FOR CHANGING ACCESSORIES.
Do not store in a closed area where fuel vapours can reach an open flame from hot
water heaters, furnaces etc. Store in a locked, well ventilated area only.
Use only PORTEK equipment parts when servicing the unit, this will ensure safe and proper
performance of your product. These parts are available from your dealer. The use of any other
accessories or attachments may cause a potential hazard to the user, damage to the machine
and void this warranty.
When refuelling, be sure to stop the engine. NEVER refuel when the engine is running or has
overheated. When gasoline spills, be sure to wipe it up completely and properly dispose of
those materials before starting the engine.
Stay clear of other workers or bystanders by at least 15 metres/50 feet.
Whenever approaching an operator of the machine, carefully call his attention and confirm the
operator stops the engine. Be careful not to startle or distract the operator which can cause an
unsafe situation.
Pay attention to loosening and overheating of parts. If there is any abnormality of the machine,
stop operation immediately and check that machine carefully. If necessary, have the machine
serviced by an authorised dealer. Never continue to operate a machine which may be
malfunctioning.
In start-up or during operation of the engine, never touch hot parts such as the muffler, the
high voltage wire or the spark plug.
After the engine has stopped, the muffler is still hot. Never place the machine in any places
where there are flammable materials (dry grass etc.) combustible gasses or combustible
liquids.
AFTER USE
Clean the machine completely, especially the fuel tank, its surroundings and the air cleaner.
!

5
Safety and contents
Pay special attention to operation in the rain or just after the rain as the ground may
be slippery.
If you slip or fall to the ground, release the throttle lever immediately.
Be careful not to drop the machine or hit it against obstacles.
Before proceeding to adjust or repair the machine, be sure to stop the engine and detach the
spark plug cap from the spark plug.
When the machine is placed in storage for a long time, drain fuel from the fuel tank and
carburettor, clean the parts, move the machine to a safe place and confirm that the engine is
cooled down.
Make periodic inspections to assure safe and efficient operation. For a thorough inspection of
your machine, please contact a dealer.
Keep the machine away from fire or sparks.
CONTENTS
Important Safety Instructions 2 - 6
Specifications 7
Setting Up 8
Operation 9
Maintenance 11
Troubleshooting & Spare Parts 15
Exploded Drawings 16
Certificate of Conformity 20

6Safety Equipment Requirements
Essential Equipment for Your Protection
The Portek Post Driver complies with all current safety standards.
For your safety You must wear full protection as specified below.
Head, eye and hearing protection
Eye protection to EN166 – B
Hearing protection to EN 352-1: 2002
Face protection visor recommended
Hand protection
Gloves to EN 12477:2001
Foot protection
Boots to EN 20345:2011
Leg protection
Sturdy full length trousers - ideally to EN381 standard

7
Specifications
Max power and speed: 1500W / 9,000rpm
Max torque and speed: 2.5N.m / 5,000rpm
Impact frequency: 700 ~ 1,350rpm
Impact energy: 20 ~ 55J
Noise level: LpA: 104dB / LwA: 115dB
Vibration level: 13.891m/s2/ K=1.5m/s2
Engine: Single cylinder, air-cooled,
2 stroke petrol
Cylinder diameter × stroke: 44mm × 34mm
Capacity: 52cc
Max power output: <1.42kW
Carburettor: MZA 102H
Ignition: Non-contact electronic ignition
Spark plug type: L8RTC
Starting method: Recoil type ‘pull’ starter
Fuel mixture: 25:1 - petrol:oil mixture
Fuel tank capacity: 1.3l
Fuel consumption rate: ≤0.60l/h
Weight of complete unit: 21kg
Length × width × height: 805mm × 305mm × 270mm
Post Driver box contents
Post Driver with main 4" capacity post holder fitted.
Reducing adaptor for using plastic post holders.
x3 plastic piling sizing rings: 20-49mm, 50-69mm and 70-100mm.
Lubricating grease (60g).
Instruction booklet.
Tool kit - comprising of: spark plug, spark plug handle, 4mm inner hexagon spanner,
5mm inner hexagon spanner, inner hexagon spanner 6mm, T-shaped inner hexagon
spanner, straight screw-driver and 8-10mm open spanner.

8Setting up
Post Holders and Sizing Rings
The pre-fitted post holder (part no.
075/02) on the machine can be used
without further attachments for 4"
diameter posts.
For smaller posts the reducing adaptor is
screwed onto the end of the post holder,
followed by a plastic sizing ring screwed
on to the adaptor. You should choose
the ring with the closest diameter to the
post being driven.
The rings can easily changed by screwing
them off/on at the threaded end of the
adaptor.
Important!
Care should always be taken to avoid
damage to the threads of the post holder
adaptor and sizing rings.
Optional Square Post Holder
An additional post holder (part no.
075/01) can be purchased which can be
fitted to the machine as an alternative
to the standard post holder. This can be
used for square and rectangular posts of
4" square, 4x3" and 3" square sizes.
Changing the Post Holder
Using an allen key undo the 4 retaining
bolts securing the 'Post Holder' to the
machine, firmly slide the old holder off
and push the new holder onto the end.
Secure the new holder in place with the
4 retaining bolts and tighten firmly to
make sure they do not loosen while the
machine is in use.
70mm - 100mm
(2.75” - 4”)
50mm - 69mm
(2” - 2.75”)
20mm - 49mm
(0.75” - 2”)
Post
Holder
Reducing
Adaptor
Plastic
Sizing Rings
!

9
Operation
Preparing the Fuel
Always refuel the Post Driver in a well
ventilated area. Use the mixing container
supplied to mix the petrol and 2 stroke
oil (see specifications) in the ratio of
25:1. Fill the fuel tank of the Post Driver
(do not overfill). The fuel level should
not exceed the neck of 'Fuel Tank Filling
Port'.
If you spill fuel during refill, clean
up and then wait until the fuel has
evaporated completely before restarting
the machine. After refuelling, tighten
and check the lid of Fuel tank before
operation.
Recommended mixing ratios:
Operating Hours Petrol:Engine Oil
Operation within 20 hours 20:1
Operation of over 20 hours 25:1
Starting
Before starting the Post Driver, prime the
engine with fuel by pressing the flexible
plastic bulb several times to pump the
fuel into the carburettor. If the engine is
cool, close the choke, but make sure you
open it after starting.
With the Post Driver upright. Hold the
upper part of handle tightly with one
hand while the other pulls the pulling
handle of starter for over 50cm quickly.
Do not let the pulling handle go back
freely in repeated pulling but hold it
tightly to avoid injury resulting from
quick recoil.
Start the engine and then open the
choke completely. After idle operation
of 5 minutes, start normal work.
Choke
Starter
Handle
Fuel
Bubble

10
Once you have started the engine, allow
the engine to carry out 'Idle Operation'
of 5 minutes to give the Post Driver time
to reach correct operating temperature.
When the engine is warm, press the
'Throttle Switch' to the appropriate
operating position according to the
required impact power.
The Post Driver should be run at low or
medium-speed in the first 20 hours of
operation and in order to extend the
service life of the machine.
The Post Driver should not be run at
high-speed during operation.
Operation
Stopping
To stop the Post Driver, release the
'Throttle Switch' and carry out idle
running of the machine for 3-5 minutes.
Then pull the 'Stop Switch' to the stop
position.
Combination
Switch
Throttle
Switch
Stop
Switch
STOP

11
No. Description
1 Combination Switch
2 Stop Switch
3 Handle
4 Spark Plug
5 Choke Lever
6 Fuel Bubble
7 Fuel Tank
8 Throttle Cable Adjuster
9 Throttle Switch
10 Hammer Case
11 Standard Post Holder (Part No. 075/02)
12 Reducing Adaptor
No. Description
13 Plastic Sizing Rings
14 Support Plate
15 Throttle Cable
16 Lubricating Grease Filling Port
17 Fuel Tank Lid
18 Pull Cord
19 Air Filter
20 Positioning Sleeve
21 Grip
22 Damping Spring
23 Optional Post Holder (Part No. 075/01)
20
17
12
11
10
16
18
5
14
3
21
22
4
9
1
2
15
19
7
6
8
Maintenance
13
23

12 Maintenance
Air Filter
Check and clean the air filter on a regular basis. Soot deposits blocking the filter
element will reduce the engine power and the service life of your Post Driver. If the
filter has a high level of soot deposits, carefully remove it, and clean it with warm
water and detergent. Leave to dry before refitting. The air filter should be replaced if
damaged in any way.
Fuel Filter
If the fuel filter becomes blocked, the Post Driver engine power will become greatly
reduced and you will find the impact energy will become weak. To check and clean
the filter open the fuel tank lid and remover the fuel filter from tank, using a metal
hook. While the fuel filter is removed, inspect the fuel tank at same time.
Carburettor
Over time oil residue may build up around the carburettor and the fuel tank, this is
normal but you should take care that the greasy oil does not block the oil line to the
engine and cause problems when starting. It is highly recommended that when the
Post Driver is non-operational for long periods that the fuel is properly drained. To
drain the carburettor of fuel, carefully pull out the oil inlet pipe and firmly press the
rubber bubble of the carburettor repeatedly to discharge the fuel into a container.
Continue to press the fuel bubble until the oil return pipe is empty. Replace the oil
inlet pipe and clean off any spillage and oil residue from the Post Driver.
Spark Plug
To ensure normal operation of the engine,
the spark plug gap must be properly
maintained. Remove any sediment with
a wire brush. The proper gap of the spark
plug is 0.5 - 0.7mm.

13
Muffler
Regularly remove any dirt build up with warm water and detergent from both the
inlet and outlet of the muffler of the Post Driver.
The Cylinder Heat Sink
The Post Driver is air-cooled so regularly remove dust to ensure cylinder cooling. If
dust accumulates on the cylinder heat sink, the cooling effect will be reduced, which
may lead to failure of the cylinder.
Gearbox Lubrication
Open the gearbox cover and regularly inspect to make sure the gearbox drive gears
are well lubricated.
Impact Cylinder Lubrication
The impact cylinder should be re-lubricated after every 50 hours of operation.
Remove the screw "plug" with an allen key, before carefully adding 50g of lubricating
grease.
Maintenance

14 Maintenance
The Post Driver will provide reliable performance
and service if maintained regularly.
The following intervals apply to normal operating
conditions. If you are using the Post Driver in very
dusty conditions or for long operating periods, adjust
accordingly.
Please contact your Portek Dealer if in any doubt.
Complete Post
Driver machine
Check X X
Clean X
Controls Check X X
Air Filter Clean X X
Replace X
Fuel Filter Check X
Replace X
Fuel Tank & Cover Clean X X
Check X X
Tighten X
Gearbox/Cylinder Check X
Add Oil X
Silencer Check X
Clean X
Cooling Fan Check X
Clean X
Spark Plug Electrode gap (0.025” / 0.635mm) X
Replace (every 100 operating hours) X
All screws/nuts and
fixings for tightness Check X X
before starting work after finishing work or daily after each refuelling stop every week every month if problem or damaged if required
Warranty
Warranty for your Post Driver is 12 months for domestic use and 3 months for any
commercial or contractor use. Please retain your proof of purchase for any
warranty claim.

15
Spare Parts
A full range of spares are available. Please contact your Portek Dealer to request
replacement parts.
Problem Possible Cause Remedy
Difficulties in starting
engine in cooling state.
Not enough fuel in fuel tank Add fuel
Spark plug is wet Remove spark plug and dry
Spark plug is damaged Replace spark plug
Spark plug connector lose Check and secure
Spark plug gap incorrect Set gap to 0.025” (0.635mm)
Difficulties in restarting
after a sudden stop.
Not enough fuel in fuel tank Add fuel
Carburettor is blocked Check and clean
Fuel filter is blocked Replace fuel filter
High carbon deposits found
on spark plug
Remove carbon deposits
from spark plug, clean filter
Slow speed
or weak power.
Air filter is blocked Replace air filter
Fuel tank feed pipe
or air vent blocked
Check and clean
High carbon deposits found
in combustion chamber
Remove carbon deposits
Abnormal sound
Damage or abrasion
to active components
Replace worn parts
High carbon deposits found
in combustion chamber
Remove carbon deposits
Post Driver works
but not efficiently
Rubber impact piston ring is
aged or worn
Replace worn parts
Excessive smoke Wrong fuel mixture Drain fuel and replace
WARNING! Operating problems are often due to causes that the user
can fix. Therefore check the product using this section to eliminate
these simple issues. In most cases the problem can be solved quickly.
!
WARNING! Only perform the steps described below! All further
inspection, maintenance and repair work must be performed by an
authorised service centre or a similarly qualified specialist if you cannot
solve the problem yourself! IF IN DOUBT SEEK EXPERT ADVICE
!
Troubleshooting & spare parts

16 Exploded drawings

17
No. Description Qty
1 95A Gasoline Engine 1
2 Inner Hexagon
Cheese-head Screw M6×25 3
3 Inner Hexagon
Cheese-head Screw M6×20 2
4 Gearbox 1
5 Deep Groove Ball
Bearings 6202-2RZ 1
6 Driven Disk 1
7 Deep Groove Ball
Bearings 6205-2RZ 1
8 Impact Crankshaft 1
9 Crankshaft Retainer 1
10 Elastic Washer 8×2.1 15
11 Inner Hexagon
Cheese-head Screw M8×20 5
12 Oil Storage Box Seal 1
13 Inner Hexagon
Cheese-head Screw M5×20 2
14 Oil Storage Box Lid 1
15 Inner Hexagon
Cheese-head Screw M5×16 1
16 O-ring 18×2.65 1
17 Oil Plug M20×1.5 1
18 Impact Connecting Rod 1
19 Lip-shaped Ring
35.5×45.5×6 1
20 Impact Piston 1
21 Impact Piston Pin 1
22 O-ring 35.5×5 1
23 Impact Cylinder 1
24 Aluminium Hammer Case 1
25 Inner Hexagon
Cheese-head Screw M8×35 4
26 Iron Ring 2
27 Small Vibration Absorption Ring 1
28 Opening Ring Rubber Circle 1
29 Opening Ring 1
30 Iron Handle Sleeve 1
31 Big Vibration Absorption Ring 1
32 O-ring 33×4 1
No. Description Qty
33 Shock 1
34 Support Plate 1
35 Hexagon Flange Nut M18×1.5 2
36 Shock Guide Sleeve 1
37 Inner Hexagon
Cheese-head Screw M8×40 6
38 Inner Pile Head 1
39 Standard Piling Socket 1
40 Reducing Adaptor 1
41 Plastic Sizing Ring 3
42 Positioning Sleeve 2
43 Compression Spring
22.5×27.5×60 2
44 Switch Handle Guide Sleeve 2
45 Combination Switch 1
46 Connecting Thread Head 2
47 Compression Spring
22.5×27.5×123 2
48 Step Nut 2
49 Handle Sleeve 1
50 Inner Hexagon
Cheese-head Screw M6×40 2
51 Steel tube handle 1
52 Handle hose 1
53 Big Gear 1
54 Cross Recessed Countersunk
Head Screw M5×10 4
55 Bearing Holder 1
56 Deep Groove Ball
Bearings 6204-2RZ 1
57 Gear Shaft 1
58 Middle Gear 1
59 Deep Groove Ball
Bearings 6203-2RZ 2
60 Shaft Retainer 17 1
61 Hole Retainer 40 1
62 Gearbox Cover Seal 1
63 Gearbox Cover 1
64 Inner Hexagon
Cheese-head Screw M6×16 6
65 Hole Retainer 35 1
66 Small Gear 1
Exploded drawings

18 Exploded drawings

19
No. Description Qty
1-1 Oiler rubber assembly 1
1-2 Fuel Tank Lid
Assembly Screw M5×20 1
1-3 Start Handle 1
1-4 Inner six angle cylinder head
combined screw M5×20 4
1-5 Cross recessed countersunk
head tapping screws ST4.8×13 2
1-6 starter 1
1-7 Oil Mirror 1
1-8 Fuel Tank 1
1-9 Start Disc Spring 1
1-10 Rope 1
1-11 Start Rope Wheel 1
1-12 Washer 10×14×0.5 1
1-13 Start Spring 1
1-14 Start Paw Assembly 1
1-15 Washer 9.5×12.5×0.8 2
1-16 Start jaw screw 1
1-17 Start Dial Disc 1
1-18 Starter Gasket 1
1-19 Cylinder 1
1-20 Cylinder Gasket 1
1-21 Piston Ring 2
1-22 Piston 1
1-23 Piston Pin 1
1-24 Clamp Spring 2
1-25 Needle Roller Bearing
HK101316 1
1-26 Left and right crankcase 1
1-27 Case Sealing Paper Pad 1
1-28 Oil Seal 12×22×7 1
1-29 Bearing 6202 2
1-30 Crankshaft Assembly 1
1-31 Woodruff Key 3×5×13 1
1-32 Oil Seal 15×30×7 1
1-33 Inner six angle cylinder
head combined screw M5×35 4
1-34 Magnetic Flywheels 1
1-35 Hexagon flange nuts 1
No. Description Qty
1-36 Small washer 8.5×15×1.6 2
1-37 Clutch inner 1
1-38 Wave washer 10.5×15×0.5 2
1-39 Shaft Screw M8×10 2
1-40 Positioning Pin 5×10 2
1-41 Wind Scooper 1
1-42 Inner six angle cylinder
head combined screw M6×25 4
1-43 Inner six angle cylinder
head combined screw M5×14 1
1-44 Internal six angle cylinder
head screws M6×55 2
1-45 Elastic washer 6×1.6 2
1-46 Plain washer C level 6×1.6 2
1-47 Silencer 1
1-48 Silencer Paper Pad 1
1-49 Inner six angle cylinder head
combined screw M5×16 2
1-50 Igniter Assembly 1
1-51 Stop Wire 1
1-52 Cover Plate 1
1-53 Cover 1
1-54 Inner six angle cylinder head
combined screw M5×25 10
1-55 Spark Plug 1
1-56 Inlet Pipe Gasket 1
1-57 Inlet Pipe 1
1-58 Carburettor Gasket 1
1-59 Carburettor 1
1-60 Plain washer C level 5×12×1 2
1-61 Internal six angle cylinder
head screws M5×50 2
1-62 Throttle switch 1
1-63 Air Filter Seat 1
1-64 Door stopper 1
1-65 Countersunk head
screws C ST4×8 1
1-66 Filter Screen 1
1-67 Air Filter Cover 1
Exploded drawings

20
Portek Ltd.
Bryn Hall, Knolton Bryn
Overton-on-Dee
Wrexham, LL13 0LF
Tel: [phone]
Fax: [phone]
General enquiries
Email: [email protected] 1019 ©2019 Portek Ltd
EC Declaration of Conformity
Portek Ltd, Bryn Hall, Knolton Bryn, Overton on Dee,Wrexham, LL13 0LF
declare that the machinery named below conforms to the requirements of
EC Council Machinery Directive, Annex II
Designation of Machinery: Portek Post Driver
Relevant EC Council Directives:
2006/42/EC (Machinery Directive)
2014/30/EU (Electromagnetic Compatibility Directive)
Applied Harmonised Standards:
BS EN ISO 12100:2010
BS EN 60745-1:2009+A11:2010
BS EN 55012:2007+A1:2009
Signature of Manufacturer's Representative:
Declaration made by Steve Morris
Design Engineer on 02/07/2018.
Declaration of Conformity