Grizzly T27710 Owner's Manual

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Page 1

MODEL T27710

22-TON LOG SPLITTER

w/KOHLER ENGINE

OWNER'S MANUAL

(For models manufactured since 04/16)

WARNING : NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE

OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.

#BLWK18211 PRINTED IN CHINA

V1. 06.16

Page 2

This manual provides critical safety instructions on the proper setup, operation, maintenance, and service of this machine/tool. Save this document, refer to it often, and use it to instruct other operators.

Failure to read, understand and follow the instructions in this manual may result in fire or serious personal injury—including amputation, electrocution, or death.

The owner of this machine/tool is solely responsible for its safe use. This responsibility includes but is not limited to proper installation in a safe environment, personnel training and usage authorization, proper inspection and maintenance, manual availability and comprehension, application of safety devices, cutting/sanding/grinding tool integrity, and the usage of personal protective equipment.

The manufacturer will not be held liable for injury or property damage from negligence, improper training, machine modifications or misuse.

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• Lead from lead-based paints.

• Crystalline silica from bricks, cement and other masonry products.

• Arsenic and chromium from chemically-treated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: Work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

Page 3

Table of Contents

INTRODUCTION ............................................................................................................................... 2

Contact Info ................................................................................................................................ 2

Manual Accuracy ........................................................................................................................ 2

Identification ............................................................................................................................... 3

Controls & Components ............................................................................................................. 4

Machine Data Sheet ................................................................................................................... 6

SECTION 1: SAFETY ....................................................................................................................... 8

Safety Instructions for Machinery ............................................................................................... 8

Additional Safety for Log Splitters ............................................................................................ 10

SECTION 2: SETUP ....................................................................................................................... 11

Needed for Setup ..................................................................................................................... 11

Unpacking ................................................................................................................................ 11

Inventory ................................................................................................................................... 12

Site Considerations .................................................................................................................. 14

Assembly .................................................................................................................................. 15

Test Run/Break-In .................................................................................................................... 19

SECTION 3: OPERATIONS ........................................................................................................... 21

Operation Overview.................................................................................................................. 21

Job Site Considerations ........................................................................................................... 22

Transporting ............................................................................................................................. 22

Control Lever ............................................................................................................................ 23

Splitting Logs ............................................................................................................................ 24

Removing Stuck Logs .............................................................................................................. 25

SECTION 4: ACCESSORIES ......................................................................................................... 26

SECTION 5: MAINTENANCE......................................................................................................... 28

Schedule .................................................................................................................................. 28

Cleaning ................................................................................................................................... 28

Lubrication ................................................................................................................................ 28

Checking/Adding Hydraulic Fluid ............................................................................................. 29

Changing Hydraulic Fluid ........................................................................................................ 30

Changing Hydraulic Tank Filter ................................................................................................ 31

Storage ..................................................................................................................................... 31

Sharpening Splitting Wedge ..................................................................................................... 32

SECTION 6: SERVICE ................................................................................................................... 33

Troubleshooting ........................................................................................................................ 33

SECTION 7: HYDRAULIC SYSTEM .............................................................................................. 35

SECTION 8: PARTS ....................................................................................................................... 36

Main .......................................................................................................................................... 36

Labels ....................................................................................................................................... 38

WARRANTY & RETURNS ............................................................................................................. 41

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Model T27710 (Mfd. Since 04/16)

We stand behind our machines! If you have questions or need help, contact us with the information below. Before contacting, make sure you get the

serial number

machine ID label. This will help us help you faster.

We want your feedback on this manual. What did you like about it? Where could it be improved? Please take a few minutes to give us feedback.

Email: manuals@grizzly.com

We are proud to provide a high-quality owner’s manual with your new machine!

instructions, specifications, drawings, and photographs in this manual. Sometimes we make mistakes, but our policy of continuous improvement also means that

you receive is

slightly different than shown in the manual

If you find this to be the case, and the difference between the manual and machine leaves you confused or unsure about something

check our

website for an updated version. W

current

manuals and

on our web-

site at

Alternatively, you can call our Technical Support for help. Before calling, make sure you write down the

from the machine ID label (see below). This information is required for us to provide proper tech support, and it helps us determine if updated documentation is available for your machine.

INTRODUCTION

Contact Info

and manufacture date from the

Grizzly Technical Support

1815 W. Battlefield Springfield, MO 65807 Phone: (570) 546-9663

Email: techsupport@grizzly.com

Grizzly Documentation Manager

P.O. Box 2069

Bellingham, WA 98227-2069

Manual Accuracy

made every effort to be exact with the

sometimes the machine

e post

manual updates for free

www.grizzly.com.

Manufacture Date and Serial Number

Manufacture Date

Serial Number

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Page 5

Model T27710 (Mfd. Since 04/16)

Identification

To reduce your risk of serious injury, read this entire manual BEFORE

Become familiar with the names and locations of the controls and features shown below to better understand the instructions in this manual.

A. 2" Tow Bar Coupler B. Coupler Lock Lever C. Hydraulic Tank Filter D. Beam Lock Pin E. Hydraulic Pump F. Control Lever G. Hydraulic Cylinder Assembly H. Splitting Wedge I. Dislodger J. Beam K. Foot Plate

L. Log Table M. Gas Cap N. Hydraulic Tank O. Vented Cap with Dipstick P. Tubeless Tire Q. Kohler Gasoline Engine R. Engine Controls (refer to Page 5 for details) S. Support Leg Lock Pin T. Support Leg U. Safety Chain

using machine.

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Model T27710 (Mfd. Since 04/16)

Controls &

To reduce your risk of serious injury, read this entire manual BEFORE

Components

E. Splitting Wedge: 7" high-carbon steel wedge

delivers 22 tons of ram force to split logs in half.

using machine.

Refer to Figures 1–4 and the following descriptions to become familiar with the basic controls and components of this machine. Understanding these items and how they work will help you understand the rest of the manual and stay safe when operating this machine.

Log Splitter Controls

F. Hydraulic Cylinder: 4" x 23" cylinder sup-

plies 3600 PSI of force using 23 operate splitting wedge.

G. Beam Lock Pin: Secures beam horizontally

for jobsite towing or horizontal operation.

H. Hydraulic Tank Filter: Removes contami-

nants from hydraulic fluid flowing back to hydraulic tank.

⁄8" stroke to

Figure 1. Log splitter controls.

A. Foot Plate: Supports log being split.

B. Beam: Stabilizes length of log being split.

C. Dislodger: Removes log from splitting wedge

after splitting operation is complete.

D. Control Lever: When placed in forward

position (toward foot plate), splitting wedge moves into log and splits it in half. When placed in full REVERSE, the splitting wedge retracts, the lever automatically moves to NEUTRAL, and wedge stops moving.

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Figure 2. Hydraulic tank components.

I. Log Table: Temporarily supports logs before

they are loaded onto beam for splitting.

J. Hydraulic Tank: Holds 3

ASLE H-150, universal hydraulic fluid, or ISO 32 equivalent hydraulic fluid for log splitter operations.

K. Vented Cap: Vents hot gases and fluid from

hydraulic tank. Features dipstick for checking tank fluid level.

L. Hydraulic Tank Drain Plug: Remove to

drain hydraulic tank fluid.

⁄2 gallons of AW-32,

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Model T27710 (Mfd. Since 04/16)

Components

Towing ControlsKohler Engine Controls &

Figure 3. Kohler engine controls and

components.

M. Choke Lever: Controls choke valve and

air-to-fuel ratio in engine. Move lever left to ON (I) position when starting engine when it is cold. Move lever right to OFF position (O) after engine starts. Use this position if starting engine when it is already warm.

N. Gas Cap: Remove to fill fuel tank.

O. Fuel Tank: Fill with clean, fresh gasoline.

Refer to Kohler engine manual to select required fuel type. Avoid overfilling.

P. ON/OFF Switch: Turn to ON position (I)

before starting engine. Turn to OFF position (O) to shut engine OFF.

Figure 4. Towing controls and components.

T. Coupler Lock Lever: Push down to lock

coupler onto vehicle tow ball; lift up to release coupler from vehicle tow ball. Features a hole for inserting a pin or padlock.

U. Support Leg Lock Pin: When engaged,

secures support leg in up or down position. When disengaged, allows support leg to pivot.

V. Support Leg: Supports weight of log splitter

and provides stability during splitting operations. Leg can be lowered for operation or raised for towing.

W. Safety Chains: Ensure log splitter remains

attached to towing vehicle if coupler accidentally separates from towing hitch ball while towing.

Q. Throttle Control Lever: Regulates amount

of air entering engine, thereby controlling its speed. Move halfway between SLOW (turtle) and FAST (rabbit) when starting engine. Adjust lever as needed for operation.

R. Starter Rope: Pull several times to start

engine and allow fuel to flow into engine. Slowly retract to engine once it starts.

S. Fuel Shutoff Lever: Controls flow of fuel

from tank to carburetor. Turn to ON position before engine startup. Turn to OFF position (O) when shutting down engine, or before towing to avoid flooding engine.

X. 2" Tow Bar Coupler: Connects log splitter to

2" trailer hitch ball for towing.

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Model T27710 (Mfd. Since 04/16)

22-TON LOG SPLITTER WITH KOHLER ENGINE

Product Dimensions:

...............................................................................................................................

Weight

(side-to-side) x Depth (front-to-back) x Height ..................................................................................

Width Footprint

Shipping Dimensions:

Type Content Weight Length Must

(Length x Width) ...............................................................................................................................

........................................................................................................................................................................ Wood Crate

...............................................................................................................................

x Width x Height ...............................................................................................................................

Ship Upright ...............................................................................................................................

Machine Data Sheet

MODEL T27710

............................................. 388

x 84 x 41 in.

42-1/2

..........85

........................................... Machine

............................................. 441

......45

x 34 x 22 in.

..................................Yes

lbs.

x 44 in.

lbs.

Engine Information:

Manufacturer Horsepower Bore

...............................................................................................................................

Stroke Displacement

Capacity ...............................................................................................................................

Oil

Hydraulic Information:

Hydraulic Automatic

Maximum Pump Pressure ............................................................................................................................................ 3600 PSI

Pump Hydraulic Hydraulic

Type ...............................................................................................................................

Filter Cycle

Main Specifications:

Operation Information

...............................................................................................................................

..................................... 68

...............................................................................................................................

................................................................................................................................................................. 196 CC

Cylinder Size (Diameter x Length) ...............................................................................................................4 x 23 in.

Cylinder Return ...............................................................................................................................

Rating ...............................................................................................................................

Tank Capacity ...............................................................................................................................

Oil Type ............................................................

Time ...............................................................................................................................................................13 Seconds

Ram

Force ...............................................................................................................................

Length of Log ...............................................................................................................................

Max.

Stroke Length ............................................................................................................................................23-1/8 in.

Max. Automatic Vertical

Cylinder Return ...............................................................................................................................

& Horizontal Operation ...............................................................................................................................

AW-32,

ASLE H-150, Universal Hydraulic Oil, or ISO 32 equivalent

..................................... Kohler

.......................................6.5

.................................. 54

......................................0.63

.....................Yes

....................11

................ Replaceable,

.............................22

GPM, 2-Stage

...............3-1/2

.............25-5/8

HP mm (2.7 in.) mm (2.1 in.)

qt.

gal.

Spin-Off

Tons

in.

...........Yes

....Yes

Construction Information

Splitter Wedge ..............................................................................................................................................Carbon Steel

Wedge Height ...............................................................................................................................

Splitter

...............................................................................................................................

Axle Hoses

...............................................................................................................................

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.................7

................................Carbon

................................Wire

in. Steel Braid

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Model T27710 (Mfd. Since 04/16)

Chassis:

Type

...............................................................................................................................

Tow

Ball Receiver ...............................................................................................................................

...............................................................................................................................

Wheels Tires

...............................................................................................................................

Tire

Max. Load ............................................................................................................................................................... 590 lbs.

Tire

Rating (Max. Speed) ...............................................................................................................................

Wheel

Bearing Type ...............................................................................................................................

Jackstand

Other Specifications:

Country of Origin ............................................................................................................................................................... China

Warranty Serial ISO Certified Assembly

Features:

Automatic 25-5/8 22-Ton 2"

Tow Ball Coupler

MPH Tow Rating Carbon Carbon

Included ...............................................................................................................................

...............................................................................................................................

Number Location ...............................................................................................................................

9001 Factory ..................................................................................................................................................................

by a Nationally Recognized Testing Laboratory ...................................................................................................... No

Time ......................................................................................................................................................... 30 Minutes

Cylinder Return

in. Log Capacity

Splitter Ram Force

Steel Splitter Wedge Steel Frame

........................................Carbon

............ 2

...........................Steel,

...................... Tubeless

............................................ 1

in. Ball Coupler

16 in. x 4.80-8

................45

............Tapered

................................Yes

................. ID

Steel

Integral Hub

MPH

Roller

Year

Label

Yes

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Model T27710 (Mfd. Since 04/16)

SECTION 1: SAFETY

For Your Own Safety, Read Instruction

Manual Before Operating This Machine

The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words intended to convey the level of importance of the safety messages. The progression of symbols is described below. Remember that safety messages by themselves do not eliminate danger and are not a substitute for proper accident prevention measures. Always use common sense and good judgment.

Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury. It may also be used to alert against unsafe practices.

This symbol is used to alert the user to useful information about

NOTICE

proper operation of the machine.

Safety Instructions for Machinery

OWNER’S MANUAL. Read and understand this

owner’s manual BEFORE using machine.

TRAINED OPERATORS ONLY. Untrained operators have a higher risk of being hurt or killed. Only allow trained/supervised people to use this machine. When machine is not being used, disconnect power, remove switch keys, or lock-out machine to prevent unauthorized use—especially around children. Make workshop kid proof!

DANGEROUS ENVIRONMENTS. Do not use machinery in areas that are wet, cluttered, or have poor lighting. Operating machinery in these areas greatly increases the risk of accidents and injury.

MENTAL ALERTNESS REQUIRED. Full mental alertness is required for safe operation of machinery. Never operate under the influence of drugs or alcohol, when tired, or when distracted.

ELECTRICAL EQUIPMENT INJURY RISKS. You can be shocked, burned, or killed by touching live electrical components or improperly grounded machinery. To reduce this risk, only allow qualified service personnel to do electrical installation or repair work, and always disconnect power before accessing or exposing electrical equipment.

DISCONNECT POWER FIRST. nect machine from power supply BEFORE making adjustments, changing tooling, or servicing machine. This prevents an injury risk from unintended startup or contact with live electrical components.

EYE PROTECTION. Always wear ANSI-approved safety glasses or a face shield when operating or observing machinery to reduce the risk of eye injury or blindness from flying particles. Everyday eyeglasses are NOT approved safety glasses.

Always discon-

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Page 11

Model T27710 (Mfd. Since 04/16)

WEARING PROPER APPAREL. Do not wear clothing, apparel or jewelry that can become entangled in moving parts. Always tie back or cover long hair. Wear non-slip footwear to reduce risk of slipping and losing control or accidentally contacting cutting tool or moving parts.

HAZARDOUS DUST. Dust created by machinery operations may cause cancer, birth defects, or long-term respiratory damage. Be aware of dust hazards associated with each workpiece material. Always wear a NIOSH-approved respirator to reduce your risk.

HEARING PROTECTION. Always wear hearing protection when operating or observing loud machinery. Extended exposure to this noise without hearing protection can cause permanent hearing loss.

REMOVE ADJUSTING TOOLS. Tools left on machinery can become dangerous projectiles upon startup. Never leave chuck keys, wrenches, or any other tools on machine. Always verify removal before starting!

USE CORRECT TOOL FOR THE JOB. Only use this tool for its intended purpose—do not force it or an attachment to do a job for which it was not designed. Never make unapproved modifications—modifying tool or using it differently than intended may result in malfunction or mechanical failure that can lead to personal injury or death!

AWKWARD POSITIONS. Keep proper footing and balance at all times when operating machine. Do not overreach! Avoid awkward hand positions that make workpiece control difficult or increase the risk of accidental injury.

CHILDREN & BYSTANDERS. Keep children and bystanders at a safe distance from the work area. Stop using machine if they become a distraction.

GUARDS & COVERS. Guards and covers reduce accidental contact with moving parts or flying debris. Make sure they are properly installed, undamaged, and working correctly BEFORE operating machine.

FORCING MACHINERY. Do not force machine. It will do the job safer and better at the rate for which it was designed.

NEVER STAND ON MACHINE. Serious injury may occur if machine is tipped or if the cutting tool is unintentionally contacted.

STABLE MACHINE. Unexpected movement during operation greatly increases risk of injury or loss of control. Before starting, verify machine is stable and mobile base (if used) is locked.

USE RECOMMENDED ACCESSORIES. Consult this owner’s manual or the manufacturer for recommended accessories. Using improper accessories will increase the risk of serious injury.

UNATTENDED OPERATION. To reduce the risk of accidental injury, turn machine OFF and ensure all moving parts completely stop before walking away. Never leave machine running while unattended.

MAINTAIN WITH CARE. Follow all maintenance instructions and lubrication schedules to keep machine in good working condition. A machine that is improperly maintained could malfunction, leading to serious personal injury or death.

DAMAGED PARTS. Regularly inspect machine for damaged, loose, or mis-adjusted parts—or any condition that could affect safe operation. Immediately repair/replace BEFORE operating machine. For your own safety, DO NOT operate machine with damaged parts!

MAINTAIN POWER CORDS. When disconnecting cord-connected machines from power, grab and pull the plug—NOT the cord. Pulling the cord may damage the wires inside. Do not handle cord/plug with wet hands. Avoid cord damage by keeping it away from heated surfaces, high traffic areas, harsh chemicals, and wet/damp locations.

EXPERIENCING DIFFICULTIES. If at any time you experience difficulties performing the intended operation, stop using the machine! Contact our Technical Support at (570) 546-9663.

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Page 12

Model T27710 (Mfd. Since 04/16)

Additional Safety for Log Splitters

HYDRAULIC PRESSURE RELIEF VALVE.

Serious injury or death can occur from getting hands or fingers crushed by logs or amputated by splitting wedge. Severe burns can be caused by touching hot parts during operation. Death can result from getting accidentally injected by hydraulic fluid or inhaling carbon monoxide. Workpieces can be ejected by splitter and strike operator or bystanders. To minimize risk of injury, anyone operating this machine MUST completely heed hazards and warnings below.

HOT ENGINE. Motor and other parts of machine

get hot during operation. Allow to cool before placing hands near motor, hydraulic cylinder, or hydraulic lines, adding fuel, or performing any service or maintenance.

SUPPORTING LOGS BY HAND. Never use any part of your body to guide or steady a log when ram is moving. Failure to follow this instruction can result in crushing or amputation injuries.

ADEQUATE VENTILATION. The log splitter engine produces carbon monoxide, which is a poisonous gas. Make sure work area is adequately ventilated. Never operate this machine indoors or in any type of enclosed area.

FLUID INJECTION. Fluid pressures developed from this machine are up to 3000 PSI, which are high enough to penetrate your skin and enter your bloodstream. Hydraulic fluid injected into your bloodstream is a medical emergency. If not treated immediately, this blood poisoning could result in an aggressive infection, amputation, or death. Keep body parts away from any high-pressure hydraulic leak.

CORRECT USAGE. Never split wood across grain or use log splitter to split concrete blocks, rocks, or to bend metal.

PROTECTING CHILDREN. Keep children away from log splitter at all times! It is not a toy. Never allow any child to climb or ride on log splitter.

FUEL SPILLS. Fuel exposed to hot engine components may ignite. Thoroughly clean all fuel spills before starting engine.

TROUBLESHOOTING. If you suspect a hydraulic leak, DO NOT use your hand or fingers to locate it. Instead, keep your skin at least 12" away from potential leaking areas and move a strip of cardboard to where leak may exist and watch to see if hydraulic oil is sprayed onto cardboard. Some high-pressure streams can be almost invisible to the naked eye.

Adjusting pressure limit screw may lead to hydraulic explosion and seriously injure operator and bystanders. The pressure relief valve is factory set and should not be adjusted unless by professional hydraulic technician.

TOWING. This log splitter is not designed to be towed on logging roads, forest service roads, public roads, or highways. This machine is designed for job site towing only where speed will not exceed maximum speed listed in Data Sheet.

WORKPIECE SELECTION. Logs with extensive knotting may be difficult or impossible to split. Making repeated attempts to split an unsuitable log will increase wear on the pressure relief valve, hydraulic lines, and increase risk of operator injury.

CORRECT USAGE. Never attempt to split more than one log at a time. Doing so may cause logs to fly off splitter with great force, resulting in serious injury or death.

MACHINE LOCATION. Never leave splitter running unattended, always block wheels to prevent rolling, and store unit in locked location.

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Page 13

Model T27710 (Mfd. Since 04/16)

SECTION 2: SETUP

This machine was carefully packaged for safe transport. When unpacking, separate all enclosed items from packaging materials and inspect them for shipping damage.

please

IMPORTANT:

you are completely satisfied with the machine and have resolved any issues between Grizzly or the shipping agent. You MUST have the original pack-

aging to file a freight claim. It is also extremely helpful if you need to return your machine later.

Keep children and pets away from plastic bags or packing materials shipped with this

get help from other people

The following items are needed, but not included, for the setup/assembly of this machine.

Needed for Setup

This machine presents serious injury hazards to untrained users. Read through this entire manual to become familiar with the controls and operations before starting the machine!

Wear safety glasses and gloves during entire setup process!

HEAVY LIF T! Straining or crushing injury may occur from improperly lifting machine or some of its parts. To reduce this risk,

and use a forklift (or other lifting equipment) rated for weight of this machine.

Description Qty

• Safety Glasses (for each person) ............... 1

• Gloves (for each person) ............................ 1

• Another Person .......................................... 1

• Adjustable Wrench ..................................... 1

• Flat Head Screwdriver ................................ 1

• Multi-Purpose Grease ................ As Needed

• Open-End Wrenches/Sockets 13mm ......... 2

• Open-End Wrenches/Sockets 17mm ......... 2

• Open-End Wrenches/Sockets 19mm ......... 2

• Phillips Head Screwdriver........................... 1

• Pliers........................................................... 1

• Rubber Hammer ......................................... 1

• Hydraulic Fluid AW-32/ISO 32 .. 3.5 Gallons

• Engine Oil .......... See Kohler Engine Manual

• Gasoline ..................................... As Needed

Unpacking

If items are damaged

call us immediately at (570) 546-9663.

Save all packaging materials until

SUFFOCATION HAZARD!

machine. Discard immediately.

-11-

Page 14

Model T27710 (Mfd. Since 04/16)

Inventory

The following is a list of items shipped with your machine. Before beginning setup, lay these items out and inventory them.

If any non-proprietary parts are missing (e.g. a nut or a washer), we will gladly replace them; or for the sake of expediency, replacements can be obtained at your local hardware store.

NOTICE

If you cannot find an item on this list, carefully check around/inside the machine and packaging materials. Often, these items get lost in packaging materials while unpacking or they are pre-installed at the factory.

Box Inventory (Figures 5–6) Qty

A. Wheel Assemblies ...................................... 2

B. Support Leg and Coupler Assembly .......... 1

C. Rear Frame Tube ....................................... 1

D. Hydraulic Cylinder Assembly...................... 1

E. Log Splitter Assembly ................................ 1

F. Hydraulic Tank Assembly ........................... 1

G. Kohler Engine 3000, 6.5HP, 196CC ........... 1

H. Suction Hose .............................................. 1

Hardware Bag Contents (Figure 7) Qty

I. Axle Caps (Wheel) ..................................... 2

J. Flat Washers 20mm (Wheel)...................... 2

K. Cotter Pins 4 x 36 (Wheel) ......................... 2

L. Slotted Hex Nuts M20-2.5 (Wheel) ............ 2

M. Hex Bolts M10-1.5 x 70 (Frame Tube) ........ 2

N. Flat Washers 10mm (Frame Tube) ............. 2

O. Lock Nuts M10-1.5 (Frame Tube) ............... 2

P. Hex Bolts M12-1.75 x 35 (Frame/Tank) ...... 4

Q. Flat Washers 12mm (Frame/Tank) ............. 4

R. Lock Nuts M12-1.75 (Frame/Tank) .............. 4

Figure 5. Box inventory 1.

Figure 6. Box inventory 2.

J K

-12-

Figure 7. Hardware inventory.

Page 15

Model T27710 (Mfd. Since 04/16)

Addl. Hardware Bag Contents (Figure 8) Qty

S. Clevis Pin 21 x 126mm (Cylinder/Beam) .... 1

T. Hairpin Cotter Pin 1

⁄4" x 21⁄2 "

(Cylinder/Beam) .......................................... 1

U. Fender Washers 10mm (Engine) ................ 4

V. Rubber Spacers (Engine) ........................... 4

W. Hex Bolts M8-1.25 x 65 (Engine) ................ 4

X. Fender Washers 8mm (Engine) ................. 4

Y. Lock Washers 8mm (Engine) ..................... 4

Z. Lock Nuts M8-1.25 (Engine) ....................... 4

AA. Hose Clamps (Suction Hose) ..................... 2

AB. O-Ring 11. 2 x 2.4mm (High Press. Hose) . . 1

AC. O-Ring 17 x 2.5mm (Hydraulic Filter) ......... 1

Figure 8. Additional hardware inventory.

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Page 16

Model T27710 (Mfd. Since 04/16)

Site Considerations

Weight Load

for the weight

of your machine. Make sure that the surface upon

of the machine, additional equipment that may be

Physical Environment

The physical environment where the machine is operated is important for safe operation and longevity of components. For best results, operate this machine in a dry environment that is free from excessive moisture, hazardous chemicals, airborne abrasives, or extreme conditions. Extreme conditions for this type of machinery are generally those where the ambient temperature range is outside 41°–104°F; the relative humidity range is outside 20–95% (non-condensing); or the environment is subject to vibration, shocks, or bumps.

Shadows, glare, or strobe effects that may distract

Space Allocation

Consider the largest size of workpiece that will be processed through this machine and provide enough space around the machine for adequate operator material handling or the installation of auxiliary equipment. With permanent installations, leave enough space around the machine to open or remove doors/covers as required by the maintenance and service described in this manual.

See below for required space allocation.

Refer to the Machine Data Sheet

which the machine is placed will bear the weight

installed on the machine, and the heaviest workpiece that will be used. Additionally, consider the weight of the operator and any dynamic loading that may occur when operating the machine.

Lighting

Lighting around the machine must be adequate enough that operations can be performed safely.

or impede the operator must be eliminated.

Horizontal Operation

Important: Ensure log splitter is at least 7' from any dry leaves or combustibles, and at least 25' from any fresh air intake supplying working or living areas. Allow enough space on all sides to move logs to and from splitter.

-14-

84"

Figure 9. Working clearances.

Children or untrained people may be seriously injured by this machine. Only install in an access restricted location.

Vertical Operation

421/2"

87"

421/2"

Page 17

Model T27710 (Mfd. Since 04/16)

Assembly

The machine must be fully assembled before it can be operated. Before beginning the assembly process, refer to all cess goes smoothly, clean all

that have any heavy-duty rust preventative tory (if applicable).

5. Pull lock pin out and pivot support leg until pin locks leg in down position (see Figure 11).

Needed for Setup and gather

listed items. To make sure the assembly pro-

parts

applied by the fac-

To assemble log splitter:

1. Wipe dab of multi-purpose grease onto spin-

dle and wheel bearing (see Figure 10), and with valve stem facing outward, slide wheel onto axle until it stops.

2. Place 20mm flat washer with M20-2.5 slotted hex nut onto axle, then place 4 x 36mm cotter pin through hole in spindle end (see Figure 10).

3. Bend both cotter pin tangs so wheel is held onto axle, and tap axle cap (see Figure 10) onto wheel.

Lock Pin

Support Leg

Figure 11. Support leg locked in down position.

6. Attach front frame tube with support leg to

rear frame tube with (2) M10-1.5 x 70 hex bolts, (2) 10mm flat washers, and (2) M10-1.5 lock nuts (see Figure 12).

Rear Frame Tube

Lock Nut M10-1.5

Front

Frame

Tube

Flat Washer 10mm

Hex Bolt M10-1.5 x 70

Wheel

Bearing

Axle

Spindle

Figure 10. Installing wheel onto axle.

4. Repeat Steps 1–3 to install the other wheel.

Slotted Hex Nut

Valve Stem

Flat Washer 20mm

Cotter Pin 4 x 36

Axle Cap

Figure 12. Installing front frame tube onto rear

frame tube.

7. Place frame tube onto hydraulic tank and attach it with (4) M12-1.75 x 35 hex bolts, (4) 12mm flat washers, and (4) M12-1.75 lock nuts, as shown in Figure 13.

Hex Bolt

Flat Washer 12mm

Frame

Tube

Lock Nut

M12-1.75

Figure 13. Installing frame tube onto tank.

M12-1.75 x 35

Hydraulic Tank

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Page 18

Model T27710 (Mfd. Since 04/16)

8. Remove cylinder cover, then attach hydraulic cylinder to splitting wedge with pre-installed (1) M12-1.75 x 65 hex bolt and (1) M12-1.75 lock nut (see Figure 14).

10. With help of assistant, lift hydraulic cylinder and beam onto frame tube. Secure with (1)

21 x 126mm clevis pin and (1) 1

⁄4" x 21⁄2"

hairpin cotter pin (see Figure 16).

Hex Bolt

M12-1.75 x 65

Cylinder

Cover

Hydraulic Cylinder

Splitting

Wedge

Lock Nut

M12-1.75

Figure 14. Attaching hydraulic cylinder to

splitting wedge.

9. Re-install cylinder cover with (8) M10-1.5 x 20 hex bolts, (8) 10mm lock washers, and (8) 10mm flat washers that were removed in Step 8 (see Figure 15).

Cylinder Cover

Hairpin

Cotter Pin

Beam

Frame

Tube

Clevis Pin

Figure 16. Attaching hydraulic cylinder and

beam to frame tube.

11. Remove any paint chips or foreign material from engine mounting pad, then place (4) rubber spacers—each with a 10mm fender washer—over holes on engine mounting pad (see Figure 17).

Fender Washer 10mm

Hex Bolt

M10-1.5 x 20

Flat Washer

10mm

Lock Washer

10mm

Figure 15. Hydraulic cylinder cover re-installed.

Rubber Spacer

Mounting Pad

Figure 17. Installing rubber spacers and flat

washers onto motor mounting pad.

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Page 19

Model T27710 (Mfd. Since 04/16)

12. Attach engine to mounting pad with (4) M8-1.25 x 65 hex bolts, (4) 8mm fender washers, (4) 8mm lock washers, and (4) M8-1.25 lock nuts (see Figures 18–19). Tighten fasteners evenly, in alternating pattern, to reduce risk of cracking mounting flange. DO NOT overtighten!

Engine

Lock Nut M8-1.25

Lock Washer

8mm

14. Remove plastic cap from pump pressure port and add a couple of tablespoons of hydraulic fluid into pressure port (see Figure 21).

Location to Add

Hydraulic Fluid

Flat Washer 8mm

Hex Bolt M8-1.25 x 65

Figure 18. Installing rubber spacers and flat

washers onto engine mounting pad.

Fender Washer

10mm

Mounting Pad

Rubber Spacer

Figure 19. Engine fastener detail.

13. Attach suction hose to hydraulic pump suc-

tion port and hydraulic tank with hose clamps (see Figure 20).

Figure 21. Pump pressure port.

15. Unthread plastic plug from high pressure hose (see Figure 22).

16. Install high pressure hose onto pump pressure

fitting (see Figure 22) with (1) 11.2 x 2.4 O-ring.

High Pressure

Hose

Pump

Pressure

Fitting

Hose

Clamps

Hydraulic Tank

Figure 20. Suction hose attached to hydraulic

pump and hydraulic tank.

Hydraulic

Pump

Suction

Hose

Figure 22. High pressure hose and control lever.

-17-

Page 20

Model T27710 (Mfd. Since 04/16)

17. Remove plastic cap from hydraulic filter fitting (see Figure 23), and lubricate and install (1) 17 x 2.5mm O-ring on end of fitting.

21. Refer to Kohler engine manual to select required engine oil type, locate fill plug (see

Figure 24), and fill engine with required oil.

18. Unthread plastic plug from low pressure return hose (see Figure 23).

19. Install low pressure return hose onto tank

hydraulic filter fitting (see Figure 23), making sure O-ring stays in place.

Note: Tighten hydraulic hose connector to

18-20 inch/pounds.

Low Pressure

Return Hose

Hydraulic

Filter Fitting

22. Refer to Kohler engine manual to select required fuel type, locate gas cap (see Figure 24), and fill engine with required fuel.

Gas Cap

Oil Fill Plug

Figure 24. Engine gas cap and oil fill plug

locations.

Figure 23. Low pressure hose and oil filter

fitting.

20. Make sure log splitter is on level surface, and fill hydraulic tank with hydraulic fluid. Refer to

Checking/Adding Hydraulic Fluid on Page 29 for specific details.

IMPORTANT: Hydraulic tank is shipped from

factory without hydraulic fluid. It must be filled before operation!

Damage caused by running log splitter without hydraulic fluid or engine oil will not be covered under warranty.

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Page 21

Model T27710 (Mfd. Since 04/16)

Test Run/Break-In

This machine presents serious injury hazards to untrained users. Read through this entire manual and Kohler engine manual to become familiar with controls and operations before starting engine and using log splitter!

3. Move fuel shutoff lever to ON (I) position, as

shown in Figure 25.

Fuel Shutoff

Lever

Figure 25. Fuel shutoff lever in ON position.

HYDRAULIC INJECTION

HAZARD Hydraulic fluid leaks can be under sufficient pressure to penetrate your skin and enter your bloodstream. If fluid is injected into any part of your body, it is a medical emergency and may, if not treated immediately, result in severe infection, permanent disability, or even death.

IMPORTANT: Do not leave area during test run,

in case there is a problem or a leak.

To test run and break-in log splitter:

1. Read and understand Kohler engine manual

that accompanied this log splitter and follow all safety precautions. Read and understand entire Grizzly manual and follow all safety precautions.

2. Make sure hydraulic tank and engine have been filled to required fluid and fuel levels. Hydraulic tank and engine are not filled at factory for shipping purposes. DO NOT operate log splitter without filling hydraulic tank and engine!

4. Turn engine ON/OFF switch to ON (I) position, as shown in Figure 26.

Engine ON/OFF Switch

Figure 26. Engine ON/OFF switch in ON

position.

5. Move throttle control lever halfway between SLOW (turtle) and FAST (rabbit), and move choke lever to ON (I) position (see Figure 27).

Choke Lever

Throttle

Control Lever

Figure 27. Fuel shutoff lever and throttle lever

adjusted to starting positions.

-19 -

Page 22

Model T27710 (Mfd. Since 04/16)

6. Pull starter handle (see Figure 28) slowly until resistance is felt. Retract handle, then pull handle quickly with smooth, steady motion until engine starts.

Starter Handle

Engine ON/OFF Switch

Figure 31. ON/OFF switch in OFF position.

Figure 28. Starter handle location.

7. After several seconds, move choke lever

slowly to OFF (O) position.

8. Let engine run at 75% throttle for one hour.

9. Move control lever (see Figure 29) to cycle

log splitter ram back and forth periodically during break-in process to bleed hydraulic system and check for fluid leaks. Do not operate at full load until after engine break-in has been completed.

Control Lever

11. After first 5 to 10 hours of initial operation, change engine oil (refer to Kohler engine manual for details).

If any problem or leak is found, do the following before you troubleshoot or correct problem:

1. Shut engine down immediately and let it

cool for at least 15 minutes to prevent burn injuries.

2. DISCONNECT SPARK PLUG WIRE (see Figure 32) from spark plug to prevent

possibility of accidental start-up.

Spark Plug Wire

Figure 29. Control lever location.

10. To turn engine OFF, move throttle control

lever to SLOW (turtle), move ON/OFF switch to OFF (O), and move fuel shutoff switch to OFF (O), as shown in Figures 30–31.

Fuel Shutoff

Lever

Figure 30. Engine controls in OFF position.

-20-

Throttle

Control Lever

Figure 32. Location of spark plug.

IMPORTANT: If fluid leak is suspected or

seen, DO NOT touch area to find the leak. Move control lever completely to forward and backward positions to relieve any hydraulic pressure and prevent possibility of hydraulic fluid injection injury during repair.

3. Refer to Troubleshooting on Page 33 for solutions, or call Technical Support at

(570) 546-9663.

Page 23

Model T27710 (Mfd. Since 04/16)

SECTION 3: OPERATIONS

To reduce your risk of serious injury, read this entire manual BEFORE

The purpose of this overview is to provide the novice machine operator with a basic understanding of how the machine is used during operation, so the

discussed later

in this manual

Due to the generic nature of this overview, it is not intended to be an instructional guide. To learn more about specific operations, read this entire manual and rienced research outside of this manual by reading "howto" books, trade magazines, or websites.

Operation Overview

To complete a typical operation, the operator does the following:

1. Places log splitter on flat, stable work

surface, and blocks wheels.

machine controls/components

are easier to understand.

seek additional training from expe-

machine operators, and do additional

using machine.

Bodily injury could result from using this machine. Always wear safety glasses, hearing protection, leather work boots, and heavy-duty leather work gloves when operating this machine.

2. Makes sure support leg is secured in down

position.

3. Checks that engine and hydraulic tank are filled with proper amount of fluid.

4. Sets up log splitter for horizontal or vertical operation. If operating in horizontal position, ensures beam is secured with beam lock pin; if operating in vertical position, ensures foot plate sits on flat, stable ground.

5. Puts on safety glasses, hearing protection, leather work boots, and leather work gloves.

6. Turns engine ON.

7. Places log lengthwise on beam and flat

against foot plate.

8. Moves control lever to forward position to drive wedge through log, then moves lever to reverse position to retract wedge. After wedge retracts, lever automatically resets to neutral position.

9. Repeats Steps 4–8 as needed for remaining logs, then turns engine OFF.

NEVER run engine indoors such as in a garage, barn, carport, or storage shed, even if it is ventilated. Engine exhaust is poisonous and can kill animals and you without warning.

If you are not experienced with this type of machine, WE STRONGLY RECOMMEND that you seek additional training outside of this manual. Read books/magazines or get formal training before beginning any projects. Regardless of the content in this section, Grizzly Industrial will not be held liable for accidents caused by lack of training.

-21-

Page 24

Model T27710 (Mfd. Since 04/16)

Considerations

TransportingJob Site

Work Location

Only use this log splitter outdoors, and never leave the area while the engine is running. NEVER run the engine indoors such as in a garage, barn, carport, or storage shed, even if it is ventilated. Engine exhaust is poisonous and can kill people and animals without warning.

Always use the splitter on a flat, stable work surface, and block the log splitter wheels so it cannot roll forward or backward.

Position the log splitter in a well lit, flat area at least seven feet away from any dry leaves or combustibles, and at least 25 feet from any fresh air intake supplying working or living areas.

Working Clearances

Allow enough room on all sides to move logs to and from the splitter.

Keep your work zone clear of lumber to avoid tripping hazards while using the machine.

Log splitter is NOT designed to be towed on logging roads, forest service roads, public roads, or highways. It is designed for towing only where maximum speed will not exceed 45 MPH. Log splitter must be transported between job sites on trailer capable of carrying 1000 lbs.

To tow splitter:

1. Lower log splitter cylinder and beam to hori-

zontal position, and lock with beam lock pin (see Figure 33).

Beam Lock Pin

Figure 33. Beam lock pin location.

2. Raise and lock support leg in up position with support-leg lock pin (see Figure 34).

3. Raise coupler lock lever (see Figure 34) to

unlatch it, and place coupler onto tow ball.

Coupler

Lock Lever

Safety

Chains

Figure 34. Raising support leg to towing

position.

Support-Leg

Lock Pin

Support Leg

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Page 25

Model T27710 (Mfd. Since 04/16)

4. Make sure tow ball is fully seated inside coupler.

Control Lever

5. Push down on coupler lock lever until it pulls

the lock tongue up against underside of tow ball and locks tow ball and coupler together.

6. Secure safety chains (see Figure 34) to tow vehicle and double-check all your connections.

7. Close fuel shutoff valve (see Figure 35) on engine carburetor to prevent fuel leakage.

8. Make sure engine gas cap (see Figure 35) is secure and there are no tools or logs still on log splitter. Never allow any riders or cargo on log splitter while towing.

Gas Cap

When the engine is running and the control lever is in the neutral position (see Figure 36), the hydraulic pump delivers hydraulic fluid at 11 GPM through the control valve and back into the hydraulic tank.

Neutral

Forward

Figure 36. Control lever positions.

Reverse

Locked in

Retract

Mode

Fuel Shutoff

Valve

Figure 35. Fuel shutoff valve and gas cap

location.

9. Tow log splitter responsibly! Do not tow it while engine is operating, and take precautions to make sure machine will not tip over during towing, causing a fuel leak and possible fire.

When you move the control lever to the forward position, the control valve diverts hydraulic fluid up to 3600 PSI to one side of the splitter piston, moving the splitting wedge into the log and splitting the log in half. The maximum distance of the wedge stroke is 23

When you move the control lever to the full reverse position, the lever locks in retract mode, and the control valve diverts the hydraulic fluid to the other side of the splitter piston. As a result, both of your hands are free to load the next log for splitting.

When the ram fully retracts, the control lever automatically moves back to neutral, and the log splitter is ready to split another log.

⁄8".

-23-

Page 26

Model T27710 (Mfd. Since 04/16)

Splitting Logs

This log splitter is ONLY designed to split wood with the direction of the grain. DO NOT attempt to split or crush wood against the grain, or split brick, concrete blocks, or rock. If you do, you will damage the machine, void the warranty, and possibly severely injure or kill bystanders or yourself.

The log splitter can be operated in either the horizontal or vertical position, as shown in Figure 37. The horizontal position is generally for lighter, easy-to-lift logs; the vertical position is generally for splitting heavier logs that are difficult to lift onto the log splitter.

To operate log splitter:

1. Read and understand this entire manual and

Kohler engine manual.

Do NOT touch hydraulic cylinder or hydraulic tube during or immediately after operation. These components get extremely hot. Allow them to cool before repositioning ram and beam during following step.

4. Move beam and cylinder assembly to either

horizontal or vertical position (see Figure 37).

Horizontal Operation: Beam lock pin

automatically locks log splitter into position. Pull up on beam to ensure splitter is locked. Operator stands on side near control lever.

Vertical Operation: Pull beam lock pin out

and rotate beam and cylinder up until foot plate sits squarely on level ground. Operator stands in front of splitter on side by control lever.

2. Verify your job site location meets at least the minimum requirements for safety and use. Refer to Job Site Considerations on

Page 22 for details.

3. Lower support leg and secure it in place with

support leg lock pin.

Horizontal Operation Vertical Operation

Control Lever

Beam

Splitting

Wedge

5. Closely inspect all components and hydraulic lines for any evidence of damage, wear, or unsafe conditions. Correct before proceeding any further.

Beam

Assembly

Beam Lock

Work Zone is

Approximately a

6-Foot Sphere

Figure 37. Horizontal and vertical log splitter operating positions.

-24-

Foot Plate

Page 27

Model T27710 (Mfd. Since 04/16)

6. Put on safety glasses, hearing protection, and thick leather gloves.

Removing

7. Start engine and place log lengthwise on

beam and flat against foot plate, as shown in Figure 38.

Foot Plate

Log

Beam

Figure 38. Best placement of log against beam

and foot plate (horizontal operation shown).

8. Make sure bystanders are out of work zone and that zone is clear of split logs. The work zone is an approximate 6-foot sphere that extends around log splitter, as shown in

Figure 37.

Stuck Logs

Never use your hands to remove a log stuck on wedge, as it could crush hands and fingers during accidental startup. Always use log dislodger to remove log. If log is still stuck, turn log splitter OFF and use sledge hammer and crow bar to remove stuck log.

This log splitter features a dislodger for helping eject partially split logs or logs that get stuck on the wedge. To eject a stuck log, move the control lever to reverse until the split log contacts the dislodger brackets shown in Figure 39 and slips off the wedge.

Wedge

Dislodger

9. While keeping hands clear of splitting wedge, use control lever to split log, retract wedge, and remove split log from work zone.

Figure 39. Dislodger location.

If the log remains stuck on the wedge, turn the log splitter OFF and use a sledge hammer and crowbar to remove the log.

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Page 28

Model T27710 (Mfd. Since 04/16)

ACCESSORIES

Installing unapproved accessories may

order online at www.grizzly.com or call 1-800-523-4777

SECTION 4: ACCESSORIES

cause machine to malfunction, resulting in serious personal injury or machine damage. To reduce this risk, only install accessories recommended for this machine by Grizzly.

T21273—Golden Cowhide Gloves T21272—Golden Pigskin Gloves T20692—Deluxe Soft Goatskin Gloves

Grizzly offers a wide selection of synthetic and leather gloves for all-day comfort in a variety of working conditions.

T21273

NOTICE

Refer to our website or latest catalog for additional recommended accessories.

H4978—Deluxe Earmuffs - 27dB H4979—Twin Cup Hearing Protector - 29dB T20446—Classic Earplugs, 200-pair - 31dB

Protect yourself comfortably with a pair of cushioned earmuffs. Especially important if you or employees operate for hours at a time.

H4978

T20446

H4979

T21272

T20692

Figure 41. Assortment of gloves.

Basic Eye Protection

T20451—“Kirova” Clear Safety Glasses T20452—“Kirova” Anti-Reflective S. Glasses H7194—Bifocal Safety Glasses 1.5 H7195—Bifocal Safety Glasses 2.0 H7196—Bifocal Safety Glasses 2.5

Figure 40. Hearing protection.

H7194

Figure 42. Assortment of basic eye protection.

-26-

T20452

T20451

Page 29

Model T27710 (Mfd. Since 04/16)

order online at www.grizzly.com or call 1-800-523-4777

T10028—Pair of Wheel Chocks

Prevent accidental shifting of your vehicle with a pair of these stackable, high impact plastic Wheel Chocks. Just place each chock against the tires and you know your vehicle isn’t going anywhere. Great for campers and utility trailers as well as preventing vehicles from shifting during jacking.

Figure 43. T10028 Pair of Wheel Chocks.

T10278—Chainsaw Filing Guide

Get the most out of your chainsaw with a properly filed saw chain. This Chainsaw Filing Guide is easy to use—requires no chain removal from the saw. No guesswork involved—angle settings, depths and file heights are dial set. Designed to handle all saw chains. Accepts all chainsaw file sizes (not included). Great for fast, on-site sharpening!

T27709—17-Cubic-Foot Steel Dump Cart

This ruggedly constructed cart is perfect for hauling logs. Features tilting dump bed with removable rear panel for easy loading and unloading, and a maximum capacity of 500 lbs. Dimensions:

59"L x 30

⁄2 "W x 231⁄2 "H.

Figure 45. T27709 Dump Cart.

H7824—2" Stainless Ball Hitch

This ball hitch has a 5,000-pound capacity and includes nutsand lock washer. 2" hitch ball, 1" x

⁄4" shank.

Figure 44. T10278 Chainsaw Filing Guide.

Figure 46. H7824 2" Stainless Ball Hitch.

-27-

Page 30

Model T27710 (Mfd. Since 04/16)

SECTION 5: MAINTENANCE

Cleaning

To reduce risk of accidental start-up injury, disconnect spark plug wire before performing adjustments or maintenance.

For optimum performance from your log splitter, clean it with a brush after every use and wipe it down occasionally with a rag.

Schedule

For optimum performance from your machine, follow this maintenance schedule and refer to any specific instructions given in this section.

Daily Check:

• Hydraulic fluid and engine oil levels are full.

• Tires have recommended air pressure.

• Cracks, leaks, kinks, and abrasions do not exist in hydraulic hoses, fuel lines, or fittings.

• Engine air filter is clean.

• Loose fasteners, hose clamps, bent components.

• Safety features and guards are working and in place.

Every 25 Hours of Use:

• Clean hydraulic tank vented cap (see

Page 29) with solvent, let air dry, re-install.

Lubrication

Items Needed Qty

Flat Head Screwdriver #2 .................................. 1

Pliers .................................................................. 1

Rubber Mallet .................................................... 1

Multi-Purpose Bearing Grease .......... As Needed

The wheel bearings will require lubrication with multi-purpose bearing grease about every six months.

To lubricate wheel bearings:

1. Remove wheel axle cap, cotter pin, flat washer, and slotted hex nut shown in Figure 47.

2. Remove and clean inner and outer tapered

roller bearings (see Figure 47), re-pack these with multi-purpose grease, and re-install.

Every 100 Hours of Use:

• Change hydraulic tank fluid, clean inner filter.

Every 500 Hours of Use:

• Change hydraulic tank filter (see Page 30).

Every 6 Months

• Relubricate wheel bushings (on this page).

As Needed:

• Inspect for burnt-smelling or tan-colored, water-contaminated hydraulic fluid. If contaminated, replace tank vented cap, clean tank filter/strainer, flush system, and replace fluid.

• Refer to the Kohler engine manual for general engine maintenance schedules.

-28-

Tapered Roller

Bearing

Slotted

Hex Nut

Cotter Pin

Axle Cap

Flat Washer

Figure 47. Components removed from wheel to

access and grease outer wheel bearing.

3. In reverse order, re-install wheel with components removed in Step 1.

Page 31

Model T27710 (Mfd. Since 04/16)

Checking/Adding

4. Re-install vented cap, remove it, then check

oil level on dipstick.

Hydraulic Fluid

Do not remove hydraulic vented cap while engine is running or just after it is shut OFF. You could be severely burned by hot vented cap or hot hydraulic fluid escaping from tank. Allow log splitter to cool sufficiently before removing vented cap.

Items Needed Qty

Adjustable Wrench ............................................ 1

Clean Rag ......................................... As Needed

Drain Pan 5-Gallon ............................................ 1

Hydraulic Fluid AW-32, ASLE H-150, ISO 32 or

Universal Hydraulic Fluid ........... 3.5 Gallons

Flashlight ........................................................... 1

Checking Hydraulic Fluid Level

1. DISCONNECT SPARK PLUG WIRE!

2. Position log splitter on level ground, lower

support leg, and lock in place. Ensure engine is cold.

— If fluid level is near middle of dipstick (see

Figure 49), no fluid needs to be added.

Proper Hydraulic

Oil Level

Figure 49. Location of correct hydraulic fluid

level on dipstick.

— If fluid level is below middle of dipstick,

add hydraulic fluid as required to bring it to correct level. Refer to Adding Hydraulic Fluid below.

— If fluid level is above middle of dipstick,

place drain pan under drain plug (see Figure 48), and carefully remove plug from bottom of hydraulic tank. Allow fluid to drain to bring it to correct level. Re-install drain plug when finished.

3. Remove vented cap (see Figure 48) and wipe dipstick with clean rag.

Vented

cap

Drain Plug

Figure 48. Vented cap location.

5. Re-install vented cap.

6. Start engine. Use control lever to extend and

retract wedge several times to remove air from hydraulic lines.

7. Turn engine OFF and repeat Step 1.

8. Repeat Steps 3–4 and continue adding

hydraulic fluid until level is correct.

Adding Hydraulic Fluid

1. DISCONNECT SPARK PLUG WIRE!

2. Remove vented cap (see Figure 48) and fill

hydraulic tank with 3.5 gallons of hydraulic fluid or amount needed to fill tank to middle of dipstick.

3. Check hydraulic fluid level (follow steps from Checking Hydraulic Fluid Level) then re-

install vented cap.

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Page 32

Model T27710 (Mfd. Since 04/16)

Changing Hydraulic

Fluid

4. Loosen filter cover hex bolts and carefully

dislodge cover slightly so hydraulic fluid spills into drain pan (see Figure 50). Be careful to avoid dropping rubber gasket into drain pan.

The hydraulic fluid should be inspected and replaced on a regular basis. Replace the fluid after every 100 hours of operation, if it smells burnt, or if it is contaminated by water.

Water contamination can build up over time and can be identified as a tan discoloration in the fluid.

Wear safety goggles when servicing hydraulic system to avoid getting hydraulic fluid in your eyes.

Tools Needed Qty

Drain Pan 5-Gallon ............................................ 1

Disposable Shop Rags ...................... As Needed

Goggles ...................................1 Pair Per Person

Gloves ............................................ 1 Per Person

Hydraulic Fluid AW-32, ASLE H-150, ISO 32 or

Universal Hydraulic Fluid ........... 3.5 Gallons

Mineral Spirits ...................................... As Neeed

Open-End Wrench 10mm .................................. 1

5. When tank is empty, remove bolts all the way, then remove suction filter.

6. Remove tank vented cap.

7. Clean tank vent with mineral spirits and let air

dry.

8. Clean suction filter screen with mineral spirits and blow dry with compressed air.

9. Inspect suction filter screen and tank vent for any holes, and replace if any damage exists.

10. Reach into tank and wipe out as much residual fluid and contaminants as possible. We highly recommend tank be cleaned out with a pressure washer or steam cleaner and fully dried with compressed air for best results.

11. Re-install suction filter, rubber gasket, and hose.

12. Fill tank with 3.5 gallons of hydraulic fluid and re-install tank vented cap.

To change hydraulic fluid:

1. DISCONNECT SPARK PLUG WIRE!

2. Block log splitter wheels to prevent them from

rolling.

3. Place a 5-gallon drain pan under suction filter cover, as shown in Figure 50.

Suction

Filter

Suction

Filter

Cover

Figure 50. Example photo of draining hydraulic

fluid.

13. Check hydraulic fluid level (refer to Page 29).

IMPORTANT: Be sure to dispose of old

hydraulic fluid according to federal, state, and fluid manufacturer's requirements.

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Page 33

Model T27710 (Mfd. Since 04/16)

StorageChanging Hydraulic

Tank Filter

The hydraulic tank filter shown in Figure 51 needs to be replaced every 500 operating hours, but for convenience it should be done when you change the hydraulic fluid (follow Steps 1–13 from Changing Hydraulic Fluid on Page 30).

Hydraulic Tank

Filter

Figure 51. Location of hydraulic tank filter.

If the log splitter will not be used for longer than two months, we recommend storing it. Be sure to store the log splitter in a clean, dry, well-ventilated area that is away from ignition sources and inaccessible to children.

Preparing Log Splitter for Storage

1. Wait for engine to cool, and clean log splitter

thoroughly with a clean, dry cloth. Do not use water to clean log splitter, as it could damage bearings or the engine.

2. Use lightly oiled rag to wipe down all metal components to prevent rust.

3. Follow Kohler engine manual instructions for preparing engine for storage.

Bringing Log Splitter Out of Storage

1. Follow Kohler engine manual instructions for

storage in reverse.

The hydraulic tank filter can be purchased from most local hardware stores, or replacement part #PT27710040 can be purchased by contacting the Grizzly Order Desk at (800) 523-4777.

To change the filter, DISCONNECT SPARK PLUG WIRE!, drain the hydraulic tank, remove the old filter, and install the new one. Be sure to follow any additional instructions the replacement filter manufacturer provides.

IMPORTANT: Be sure to dispose of old hydraulic fluid according to federal, state, and fluid manufacturer's requirements.

2. Drain fuel from tank and use clean, fresh, unleaded gasoline that meets Kohler's specifications, especially if fuel has been sitting for longer than fuel stabilizer manufacturer's recommendation.

3. Perform Test Run/Break In procedure on Page 19 before putting log splitter back into

service.

-31-

Page 34

Model T27710 (Mfd. Since 04/16)

Sharpening Splitting

Wedge

To reduce risk of serious cuts, always wear leather gloves when sharpening splitting wedge.

During the life of your log splitter, you will need to sharpen the splitting wedge periodically. When sharpening the wedge, keep in mind that if you try to keep the wedge sharpened to a razor point (like an axe blade), you will greatly reduce the life of the wedge by always sharpening it. However, if you allow the point to become very dull or bullnosed, your log splitter will have to overwork to split logs, which will decrease the lifespan of the splitter. The optimum point is somewhere between. Refer to Figure 52 for a general idea.

Wedge Too Sharp

Wedge Too Dull

Wedge Just Right

Figure 52. Good and bad wedge points.

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Page 35

Model T27710 (Mfd. Since 04/16)

Review the troubleshooting and procedures in this section if a problem develops with your machine. If you need replacement parts or additional help with a procedure, call our Technical Support.

gather the serial number and manufacture date of your machine before calling.

SECTION 6: SERVICE

Troubleshooting

Operation

Symptom Possible Cause Possible Solution

Splitting wedge moves forward and backward too slowly, or does not move in either direction.

Splitting wedge moves forward too slowly or not at all, but retracts correctly.

Splitting wedge retracts too slowly or not at all, but moves forward correctly.

Splitter will not split wood or splits it too slowly.

Hydraulic tank fluid burnt or has tan discoloration.

1. Hydraulic tank empty or low.

2. Tank suction ﬁlter clogged.

3. Air in hydraulic system.

4. Control lever linkage at fault.

5. Pump or pump relief valve at fault.

6. Hydraulic control valve at fault.

7. Damaged ram piston seals.

1. Control lever linkage at fault.

2. Splitting wedge dull; log unsuitable for splitting.

3. Hydraulic ﬂuid too low or contaminated.

4. Hydraulic control valve at fault.

5. Damaged ram piston seals.

1. Control lever linkage at fault.

2. Hydraulic control valve at fault.

3. Damaged ram piston seals.

1. Splitting wedge dull.

2. Engine oil level too low or contaminated.

3. Hydraulic tank ﬁlter clogged.

4. Splitting wood against grain.

5. Air in hydraulic system.

1. Hydraulic ﬂuid old or contaminated with water.

1. Fill tank to required level (Page 29).

2. Clean suction ﬁlter (Page 30). Service hydraulic system.

3. Bleed air out of system by moving wedge back/forth several times until it moves smoothly.

4. Replace/repair bent or worn linkage to provide full range of travel.

5. Replace pump and ﬂush/service hydraulic system (Page 30).

6. Replace valve and ﬂush/service hydraulic system (Page 30).

7. Replace ram assembly and ﬂush/service hydraulic system (Page 30).

1. Replace/repair bent or worn linkage to provide full range of travel.

2. Sharpen wedge; avoid splitting logs with twisted grain, numerous knots, or high moisture content.

3. Replace/ﬁll tank to required ﬂuid level (Page 29).

4. Replace valve and ﬂush/service hydraulic system (Page 30).

5. Replace ram assembly and ﬂush/service hydraulic system (Page 30).

1. Replace/repair bent or worn linkage to provide full range of travel.

2. Replace control valve.

3. Replace ram assembly and ﬂush/service hydraulic system (Page 30).

1. Sharpen wedge (Page 32).

2. Add/replace engine oil.

3. Replace hydraulic tank ﬁlter (Page 31).

4. Split wood with grain instead of against grain.

5. Bleed air out of hydraulic system.

1. Replace hydraulic ﬂuid (Page 30).

Note: Please

Note: Refer to the Kohler engine manual for engine-related troubleshooting.

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Page 36

Model T27710 (Mfd. Since 04/16)

SECTION 7: HYDRAULIC SYSTEM

Fluid Tank

Control

Valve

Ram

Engine

Pump

Filter

Figure 53. Hydraulic system components.

Ram

Before servicing hydraulic parts, stop engine and depressurize entire hydraulic system by moving control lever back and forth a few times. Ignoring this warning may lead to hydraulic fluid poisoning, which is a serious and potentially fatal injury.

Control

Valve

Engine

Pump

DEW HYD-8.8/2.15

1H513109

Suction Filter

Hydraulic Fluid Reservoir

This diagram is only provided as a reference to help you identify hydraulic system components. Seek assistance from a professional hydraulic technician whenever servicing or repairing the hydraulic system.

Filter

20 GPM

200 PSI

1–12 UNF

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Page 37

Model T27710 (Mfd. Since 04/16)

We do our best to stock replacement parts when possible, but we cannot guarantee that all parts shown are available for purchase. Call (800) 523-4777 or visit www.grizzly.com/parts to check for availability.

SECTION 8: PARTS

Main

-35-

Page 38

Model T27710 (Mfd. Since 04/16)

Main Parts List

REF PART # DESCRIPTION REF PART # DESCRIPTION

1 PT27710001 HYDRAULIC FLUID TANK 39 PT27710039 HYDRAULIC HOSE 602-1302 62"L 2 PT27710002 TONGUE SECTION (FRONT) 40 PT27710040 FILTER 20GPM 200PSI 5.4" 1-12UNF 10-30M 3 PT27710003 BEAM 41 PT27710041 CONNECTOR-MM M26-1.75, M26-1.75 4 PT27710004 WHEEL W/TIRE 8 X 3.75, 4.80-8 42 PT27710042 HYDRAULIC HOSE 602-1302 48"L 5 PT27710005 COTTER PIN 4 X 36 STANDARD 43 PT27710043 HYDRAULIC HOSE 1-3/8" X 18" (CLEAR) 6 PT27710006 FLAT WASHER 20MM 44 PT27710044 HOSE CLAMP 1-1/2" 7 PT27710007 AXLE CAP 45 PT27710045 HEX BOLT M12-1.75 X 90 8 PT27710008 HEX NUT THIN SLOTTED M20-2.5 46 PT27710046 HEX BOLT M12-1.75 X 80 9 PT27710009 CYLINDER COVER 47 PT27710047 FENDER WASHER 12MM 10 PT27710010 WEDGE SLIDE 48 PT27710048 SAFETY CHAIN W/HOOK 28-LINK 11 PT27710011 ENGINE KOHLER 3000 6.5HP 196CC 49 PT27710049 BALL RECEIVER 2" 12 PT27710012 RUBBER SHOCK ABSORBER 50 PT27710050 CLEVIS PIN 21 X 126 13 PT27710013 O-RING 16 X 2.5 51 PT27710051 CONTROL VALVE COVER 14 PT27710014 CONNECTOR-MF M22-1.75, M28-1.25 52 PT27710052 HYDRAULIC CYLINDER ASSEMBLY 15 PT27710015 CONTROL VALVE ASSEMBLY 53 PT27710053 DRAIN PLUG 3/8 NPT 16 PT27710016 ELBOW-MM 90DEG M22-1.75, M22-1.75 54 PT27710054 PHLP HD SCR M8-1.25 X 10 17 PT27710017 HYDRAULIC TUBE 16 OD X 560 L (SS) 55 PT27710055 SUPPORT LEG 18 PT27710018 SAFETY PIN 56 PT27710056 EXT RETAINING RING 62MM 19 PT27710019 COMPRESSION SPRING 1.5 X 18 X 60 57 PT27710057 LOCK WASHER 8MM 20 PT27710020 FLAT WASHER 12MM 58 PT27710058 FENDER WASHER 8MM 21 PT27710021 ELBOW-MM 90DEG M22-1.75, M26-1.75 59 PT27710059 PUMP DELI CBNA-8.8/2.1J 22 PT27710022 FLAT WASHER 10MM 60 PT27710060 HEX BOLT M8-1.25 X 30 23 PT27710023 HEX BOLT M10-1.5 X 20 61 PT27710061 EXT RETAINING RING 11MM 24 PT27710024 HEX BOLT M12-1.75 X 65 62 PT27710062 TONGUE SECTION (REAR) 25 PT27710025 LOCK NUT M12-1.75 63 PT27710063 PUMP COUPLER 26 PT27710026 FILTER MOUNT PLATE 64 PT27710064 ENGINE COUPLER 27 PT27710027 GASKET (RUBBER) 65 PT27710065 ENGINE COUPLER BUSHING 28 PT27710028 FLAT WASHER 6MM 66 PT27710066 PUMP MOUNTING BLOCK 29 PT27710029 LOCK WASHER 6MM 67 PT27710067 HEX BOLT M5-.8 X 10 30 PT27710030 HEX BOLT M6-1 X 20 68 PT27710068 COUPLER COVER 31 PT27710031 PUMP CONNECTOR M26-1.75 69 PT27710069 HEX BOLT M8-1.25 X 25 32 PT27710032 O-RING 11.2 X 2.4 70 PT27710070 INNER FILTER 33 PT27710033 O-RING 17 X 2.5 71 PT27710071 COTTER PIN 1-3/4–1-7/8 X 2-1/2 HAIRPIN 34 PT27710034 VENTED CAP 1-1/4 NPT 72 PT27710072 LOCK WASHER 10MM 35 PT27710035 HEX BOLT M12-1.75 X 35 73 PT27710073 HEX BOLT M10-1.5 X 70 36 PT27710036 HEX BOLT M8-1.25 X 65 74 PT27710074 LOCK NUT M10-1.5 37 PT27710037 FLAT WASHER 8MM 75 PT27710075 SET SCREW M6-1 X 10 38 PT27710038 LOCK NUT M8-1.25

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Page 39

Model T27710 (Mfd. Since 04/16)

101

111

WARNING!

To reduce risk of death or serious injury, read manual BEFORE using machine. To get a new manual, call (800) 523-4777 or go to www.grizzly.com.

WARNING!

AMPUTATION

HAZARD!

Keep hands and arms away from this splitting head when splitting logs.

102

EYE INJURY

HAZARD!

Always wear safety glasses when using this machine.

104

DO NOT touch hydraulic cylinder during operation. Cylinder gets extremely hot. Allow cylinder to cool before touching.

WARNING!

BURN HAZARD!

Labels

103

Specifications

Engine: Kohler 3000, 6.5 HP, 196 CC Splitting Force: 22 Tons Hydraulic Oil Capacity: 3.5 Gallons Hydraulic Pressure: 3600 PSI Max. Maximum Log Length: 25-5/8" Hydraulic Cyl. Bore/Stroke: 4" x 23-1/8" Tow Ball Diameter: 2" Weight: 388 lbs.

Date

S/N

Mfd. for Grizzly in China

WARNING!

BURN HAZARD!

DO NOT touch hydraulic

106

cylinder during operation. Cylinder gets extremely hot. Allow cylinder to cool before touching.

104

WARNING!

Support leg MUST be locked in horizontal position (with safety pin engaged) when towing/transporting log splitter. Failure to do this could cause serious injury from loss of vehicle control or severe property damage.

107

22-TON HYDRAULIC LOG SPLITTER

1. Read and understand manual and engine manual before using.

2. Always wear ANSI approved safety glasses and hearing protection.

3. Never place hands on log or splitter wedge during operation.

4. Make sure no fuel spills or leaks exist before starting engine.

5. Do not force log splitter beyond 22-ton capacity.

6. Never leave log splitter with a log under pressure.

7. Keep all combustibles away from engine exhaust port.

8. Never leave log splitter running unattended.

9. Always stop engine before refueling or clearing a jam.

MODEL T27710

WARNING!

:enihcam siht gnisu nehw yrujni lanosrep suoires fo ksir ecuder oT

10. Never operate log splitter engine in enclosed or non-ventilated areas. Carbon monoxide from engine exhaust is poisonous and odorless, and can kill without warning.

11. Do not tow log splitter on public roads or highway! It is only designed for backyard towing at speeds no greater than 45 MPH.

12. Tie back long hair and clothing, and remove all jewelry or other loose apparel to avoid entanglement.

13. Do not operate under influence of drugs or alcohol, or if tired.

14. Prevent unauthorized use by children or untrained users; restrict access or disable machine when unattended.

105

WARNING!

108

110

CHECK

HYDRAULIC FLUID/

ENGINE OIL LEVEL

BEFORE USING!

REFER TO

OWNER’S MANUAL

FOR FLUID/OIL TYPE

AND AMOUNT.

WARNING!

Beam MUST be locked in horizontal position (with safety pin engaged) when towing/transporting log splitter. Failure to do this could cause serious injury from loss of vehicle control or severe property damage.

109

TOWING HAZARD!

Do not tow this log splitter on highways or public roads. It is designed for repositioning at the jobsite only. Never exceed 45 MPH.

REF PART # DESCRIPTION REF PART # DESCRIPTION

101 PT27710101 AMPUTATION HAZARD LABEL 107 PT27710107 MACHINE ID LABEL 102 PT27710102 EYE INJURY HAZARD LABEL 108 PT27710108 TOWING HAZARD LABEL 103 PT27710103 TOUCH-UP PAINT, GRIZZLY GREEN 109 PT27710109 BEAM SAFETY PIN WARNING LABEL 104 PT27710104 BURN HAZARD LABEL 110 PT27710110 STOP CHECK FLUID/OIL TAG 105 PT27710105 TOUCH-UP PAINT, GLOSSY BLACK 111 PT27710111 READ MANUAL LABEL 106 PT27710106 SUPPORT LEG WARNING LABEL

Safety labels help reduce the risk of serious injury caused by machine hazards. If any label comes off or becomes unreadable, the owner of this machine MUST replace it in the original location before resuming operations. For replacements, contact (800) 523-4777 or www.grizzly.com.

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Model T27710 (Mfd. Since 04/16)

Page 41

WARRANTY CARD

Name _____________________________________________________________________________

Street _____________________________________________________________________________

City _______________________ State _________________________ Zip _____________________

Phone # ____________________ Email _________________________________________________

Model # ____________________ Order # _______________________ Serial # __________________

The following information is given on a voluntary basis. It will be used for marketing purposes to help us develop better products and services. Of course, all information is strictly confidential.

1. How did you learn about us? ____ Advertisement ____ Friend ____ Catalog ____ Card Deck ____ Website ____ Other:

2. Which of the following magazines do you subscribe to?

____ Cabinetmaker & FDM ____ Family Handyman ____ Hand Loader ____ Handy ____ Home Shop Machinist ____ Journal of Light Cont. ____ Live Steam ____ Model Airplane News ____ Old House Journal ____ Popular Mechanics

3. What is your annual household income? ____ $20,000-$29,000 ____ $30,000-$39,000 ____ $40,000-$49,000 ____ $50,000-$59,000 ____ $60,000-$69,000 ____ $70,000+

CUT ALONG DOTTED LINE

4. What is your age group? ____ 20-29 ____ 30-39 ____ 40-49 ____ 50-59 ____ 60-69 ____ 70+

5. How long have you been a woodworker/metalworker? ____ 0-2 Years ____ 2-8 Years ____ 8-20 Years ____20+ Years

6. How many of your machines or tools are Grizzly? ____ 0-2 ____ 3-5 ____ 6-9 ____10+

____ Popular Science ____ Popular Woodworking ____ Precision Shooter ____ Projects in Metal ____ RC Modeler ____ Rie ____ Shop Notes ____ Shotgun News ____ Today’s Homeowner ____ Wood

____ Wooden Boat ____ Woodshop News ____ Woodsmith ____ Woodwork ____ Woodworker West ____ Woodworker’s Journal ____ Other:

7. Do you think your machine represents a good value? _____ Yes _____No

8. Would you recommend Grizzly Industrial to a friend? _____Yes _____No

9. Would you allow us to use your name as a reference for Grizzly customers in your area? Note: We never use names more than 3 times. _____Yes _____No

10. Comments: _____________________________________________________________________

_________________________________________________________________________________

Page 42

FOLD ALONG DOTTED LINE

Place

Stamp

Here

GRIZZLY INDUSTRIAL, INC. P.O. BOX 2069 BELLINGHAM, WA 98227-2069

Send a Grizzly Catalog to a friend:

Name_______________________________

Street_______________________________

City______________State______Zip______

TAPE ALONG EDGES--PLEASE DO NOT STAPLE

Page 43

WARRANTY & RETURNS

Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly’s sole written warranty and any and all warranties that may be implied by law, including any merchantability or fitness, for any particular purpose, are hereby limited to the duration of this written warranty. We do not warrant or represent that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants. In no event shall Grizzly’s liability under this warranty exceed the purchase price paid for the product and any legal actions brought against Grizzly shall be tried in the State of Washington, County of Whatcom.

We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special, or consequential damages arising from the use of our products.

To take advantage of this warranty, contact us by mail or phone and give us all the details. We will then issue you a “Return Number,’’ which must be clearly posted on the outside as well as the inside of the carton. We will not accept any item back without this number. Proof of purchase must accompany the merchandise.

The manufacturers reserve the right to change specifications at any time because they constantly strive to achieve better quality equipment. We make every effort to ensure that our products meet high quality and durability standards and we hope you never need to use this warranty.

Please feel free to write or call us if you have any questions about the machine or the manual.

Thank you again for your business and continued support. We hope to serve you again soon.

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Page 63

SH265 Service Manual

IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating

instruction of equipment that this engine powers.

Ensure engine is stopped and level before performing any maintenance or service.

2 Safety 3 Maintenance

5 Speciﬁ cations 12 Tools and Aids 15 Troubleshooting 19 Air Cleaner/Intake 20 Fuel System 24 Governor System 25 Lubrication System 26 Electrical System 30 Starter System 33 Disassembly/Inspection and Service 43 Reassembly

18 690 01 Rev. C KohlerEngines.com

Page 64

Safety

SAFETY PRECAUTIONS

WARNING: A hazard that could result in death, serious injury, or substantial property damage.

CAUTION: A hazard that could result in minor personal injury or property damage.

NOTE: is used to notify people of important installation, operation, or maintenance information.

WARNING

Explosive Fuel can cause ﬁ res and severe burns.

Do not ﬁ ll fuel tank while engine is hot or running.

Gasoline is extremely ﬂ ammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or ﬂ ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent.

WARNING

Rotating Parts can cause severe injury.

Stay away while engine is in operation.

Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate engine with covers, shrouds, or guards removed.

WARNING

Carbon Monoxide can cause severe nausea, fainting or death.

Avoid inhaling exhaust fumes.

Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled.

Accidental Starts can cause severe injury or death.

Disconnect and ground spark plug lead(s) before servicing.

Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery.

Hot Parts can cause severe burns.

Do not touch engine while operating or just after stopping.

Never operate engine with heat shields or guards removed.

Cleaning Solvents can cause severe injury or death.

Use only in well ventilated areas away from ignition sources.

Carburetor cleaners and solvents are extremely ﬂ ammable. Follow cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent.

WARNING

Electrical Shock can cause injury.

Do not touch wires while engine is running.

Damaging Crankshaft and Flywheel can cause personal injury.

Using improper procedures can lead to broken fragments. Broken fragments could be thrown from engine. Always observe and use precautions and procedures when installing ﬂ ywheel.

Uncoiling Spring can cause severe injury.

Wear safety goggles or face protection when servicing retractable starter.

Retractable starters contain a powerful, recoil spring that is under tension. Always wear safety goggles when servicing retractable starters and carefully follow instructions in Retractable Starter for relieving spring tension.

CAUTION

WARNING

KohlerEngines.com 18 690 01 Rev. C

Page 65

Maintenance

MAINTENANCE INSTRUCTIONS

WARNING

Accidental Starts can cause severe injury or death.

Disconnect and ground spark plug lead(s) before servicing.

Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer.

MAINTENANCE SCHEDULE

After ﬁ rst 5 Hours

● Change oil. Lubrication System

Every 50 Hours or Annually

● Service/replace dual-element precleaner. Air Cleaner/Intake

Every 100 Hours or Annually¹

● Clean low-proﬁ le air cleaner element. Air Cleaner/Intake

● Replace dual-element air cleaner element. Air Cleaner/Intake

● Change oil. Lubrication System

● Clean cooling areas. Air Cleaner/Intake

● Clean spark arrestor (if equipped).

● Replace fuel ﬁ lter (if equipped).

Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery.

Every 100 Hours

● Check and adjust valve clearance when engine is cold. Reassembly

● Have combustion chamber decarbonized.

Every 125 Hours or Annually¹

● Replace spark plug and set gap. Electrical System

Every 200 Hours²

● Replace fuel line. Fuel System

Every 300 Hours

● Replace low-proﬁ le air cleaner element. Air Cleaner/Intake

Perform these procedures more frequently under severe, dusty, dirty conditions.

Have a Kohler authorized dealer perform this service.

REPAIRS/SERVICE PARTS

Kohler genuine service parts can be purchased from Kohler authorized dealers. To ﬁ nd a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

18 690 01 Rev. C KohlerEngines.com

Page 66

Maintenance

OIL RECOMMENDATIONS

We recommend use of Kohler oils for best performance. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ or higher are acceptable. Select viscosity based on air temperature at time of operation as shown in table below.

FUEL RECOMMENDATIONS

WARNING

Explosive Fuel can cause ﬁ res and severe burns.

Do not ﬁ ll fuel tank while engine is hot or running.

STORAGE

If engine will be out of service for 2 months or more follow procedure below.

1. Add Kohler PRO Series fuel treatment or equivalent to fuel tank. Run engine 2-3 minutes to get stabilized fuel into fuel system (failures due to untreated fuel are not warrantable).

2. Change oil while engine is still warm from operation. Remove spark plug(s) and pour about 1 oz. of engine oil into cylinder(s). Replace spark plug(s) and crank engine slowly to distribute oil.

3. Disconnect negative (-) battery cable.

4. Store engine in a clean, dry place.

NOTE: E15, E20 and E85 are NOT approved and

should NOT be used; effects of old, stale or contaminated fuel are not warrantable.

Fuel must meet these requirements:

● Clean, fresh, unleaded gasoline.

● Octane rating of 87 (R+M)/2 or higher.

● Research Octane Number (RON) 90 octane minimum.

● Gasoline up to 10% ethyl alcohol, 90% unleaded is

acceptable.

● Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blend (max 15% MTBE by volume) are approved.

● Do not add oil to gasoline.

● Do not overﬁ ll fuel tank.

● Do not use gasoline older than 30 days.

KohlerEngines.com 18 690 01 Rev. C

Page 67

Engine Dimensions

Dimensions in millimeters.

Inch equivalents shown in [ ].

273.97 [10.786]

369.40 [14.543]

Speciﬁ cations

318.66 [12.545] STRAIGHT PTO

181.60 [7.150]

113.44 [4.466]

SPARK PLUG

OIL FILL

DRAIN PLUG

342.20 [13.473]

65.05 [2.561]

32.53 [1.281]

66.00 [2.598]

65.05 [2.561]

88.00 [3.465]

162.00 [6.378]

110.00 [4.331] AIR CLEANER COVER REMOVAL

339.90 [13.382]

30.00 [1.181]

106.00 [4.173]

METRIC FLANGE: 4X M8 X 1.25-6H

SAE A FLANGE: 4X 5/16-24 UNF-2B THRU

METRIC FLANGE: 4X M8 X 1.25-6H

SAE A FLANGE: 4X

5/16-24 UNF-2B 15.00 [0.591]

37.98 [1.495]

37.50 [1.476]

THRU

15.00 [0.591]

78.00 [3.071]

2X Ø 10.00 [0.394]

2X 10.00 X 15.50 SLOT [0.394 X 0.610]

12.50 [0.492] GAS CAP REMOVAL

18 690 01 Rev. C KohlerEngines.com

Page 68

Speciﬁ cations

ENGINE IDENTIFICATION NUMBERS

Kohler engine identiﬁ cation numbers (model, speciﬁ cation and serial) should be referenced for efﬁ cient repair, ordering correct parts, and engine replacement.

Model . . . . . . . . . . . . . . . . . . . . . SH265

Courage Engine

Horizontal Shaft

Numerical Designation

Speciﬁ cation . . . . . . . . . . . . . . . SH265-0001

Serial . . . . . . . . . . . . . . . . . . . . . 4323500328

Year Manufactured Code Factory Code Code Year 43 2013 44 2014 45 2015

GENERAL SPECIFICATIONS

3,6

SH265

Bore 68 mm (2.7 in.) Stroke 54 mm (2.1 in.) Displacement 196 cc (12.0 cu. in.) Oil Capacity (reﬁ ll) 0.6 L (0.63 U.S. qt.) Maximum Angle of Operation (@ full oil level)

TORQUE SPECIFICATIONS

3,5

25°

SH265

Air Cleaner

Mounting Screw (into intake manifold) 8 N·m (70.8 in. lb.)

Blower Housing and Sheet Metal

M6 Shoulder Screw 10 N·m (88.5 in. lb.) M6 Nut 8 N·m (70.8 in. lb.)

Carburetor

Stud 10 N·m (88.5 in. lb.) Primary Nut 8 N·m (70.8 in. lb.) Secondary Nut 10 N·m (88.5 in. lb.) Intake Cover Nut 4 N·m (35.4 in. lb.)

Connecting Rod

Cap Fastener (torque in increments) 12 N·m (106 in. lb.)

Crankcase

Oil Drain Plug 18 N·m (13 ft. lb.) Closure Plate Screw 24 N·m (212 in. lb.)

Cylinder Head

Fastener (torque in 2 increments) ﬁ rst to 12 N·m (106 in. lb.)

Values are in Metric units. Values in parentheses are English equivalents.

Exceeding maximum angle of operation may cause engine damage from insufﬁ cient lubrication.

Lubricate threads with engine oil prior to assembly.

Any and all horsepower (hp) references by Kohler are Certiﬁ ed Power Ratings and per SAE J1940 & J1995 hp

standards. Details on Certiﬁ ed Power Ratings can be found at KohlerEngines.com.

ﬁ nally to 24 N·m (212 in. lb.)

KohlerEngines.com 18 690 01 Rev. C

Page 69

Speciﬁ cations

TORQUE SPECIFICATIONS

3,5

SH265

Flywheel

Retaining Nut 74 N·m (655 in. lb.)

Fuel Tank

Mounting Nut 24 N·m (212 in. lb.) Mounting Screw 24 N·m (212 in. lb.) Inlet Fitting 1.5 N·m (13.3 in. lb.)

Governor

Arm Nut 10 N·m (88.5 in. lb.) Throttle Control Lever Nut 4.5-6 N·m (40-53 in. lb.)

Ignition

Spark Plug 27 N·m (20 ft. lb.) Module Fastener 8 N·m (70.8 in. lb.) Module Screw 10 N·m (88.5 in. lb.) Oil Sentry™ Module Screw 8 N·m (70.8 in. lb.)

Mufﬂ er

M8 Exhaust Screw 24 N·m (212 in. lb.) M6 Mufﬂ er Shield Screw 8 N·m (70.8 in. lb.) M4 Mufﬂ er Shield Screw 2 N·m (17.7 in. lb.) M5 Spark Arrestor Screw 3.5 N·m (31 in. lb.)

Retractable Starter

Cover Screw 5.4 N·m (47.8 in. lb.) Screw 10 N·m (88.5 in. lb.)

Rocker Arm

Stud 13.6 N·m (120 in. lb.) Pivot Jam Nut 10 N·m (88.5 in. lb.)

Valve Cover

Fastener 8 N·m (70.8 in. lb.)

Values are in Metric units. Values in parentheses are English equivalents.

Lubricate threads with engine oil prior to assembly.

18 690 01 Rev. C KohlerEngines.com

Page 70

Speciﬁ cations

CLEARANCE SPECIFICATIONS

SH265

Camshaft

End Play 0.025/0.602 mm (0.0010/0.0237 in.) Running Clearance 0.016/0.052 mm (0.0006/0.0020 in.) Bore I.D.

New Max. Wear Limit

14.000/14.018 mm (0.5512/0.5519 in.)

14.048 mm (0.5531 in.)

Connecting Rod

Crankpin End I.D. @ 21°C (70°F) New Max. Wear Limit

30.021/30.026 mm (1.1819/1.1821 in.)

30.08 mm (1.184 in.)

Connecting Rod-to-Crankpin Running Clearance New Max. Wear Limit

0.041/0.051 mm (0.002/0.002 in.)

0.12 mm (0.005 in.)

Connecting Rod-to-Crankpin Side Clearance New Max. Wear Limit

0.58/0.60 mm (0.023/0.024 in.)

1.10 mm (0.043 in.) Connecting Rod-to-Piston Pin Running Clearance 0.01/0.027 mm (0.0004/0.0011 in.) Piston Pin End I.D. @ 21°C (70°F)

New Max. Wear Limit

18.010/18.015 mm (0.709/0.709 in.)

18.08 mm (0.712 in.)

Crankcase

Governor Cross Shaft Bore I.D. New Max. Wear Limit

6.000/6.018 mm (0.2362/0.2369 in.)

6.037 mm (0.2377 in.)

Crankshaft

End Play (free) 0.025/0.703 mm (0.0010/0.028 in.) Ball Bearing 0.003/0.25 mm (0.0001/0.0010 in.) Bore (in crankcase)

New, without Main Bearing 51.961/51.991 mm (2.0457/2.0469 in.) Bore (in closure plate)

New, without Main Bearing 51.961/51.991 mm (2.0457/2.0469 in.) Flywheel End Main Bearing Journal O.D.

O.D.-New O.D.-Max. Wear Limit Max. Taper Max. Out-of-Round

24.975/24.989 mm (0.9833/0.9838 in.)

24.95 mm (0.9823 in.)

0.025 mm (0.0010 in.)

Closure Plate End Main Bearing Journal O.D. O.D.-New O.D.-Max. Wear Limit Max. Taper Max. Out-of-Round

24.975/24.989 mm (0.9833/0.9838 in.)

24.95 mm (0.9823 in.)

0.025 mm (0.0010 in.)

Connecting Rod Journal O.D. O.D.-New O.D.-Max. Wear Limit Max. Taper Max. Out-of-Round Width

29.975/29.985 mm (1.1801/1.1805 in.)

29.920 mm (1.1779 in.)

0.025 mm (0.0010 in.)

25.02/25.08 mm (0.9850/0.9874 in.) Runout (either end) 0.025 mm (0.0010 in.) Main Bearing I.D. (Crankcase/Closure Plate)

New (installed) 24.994/25.000 mm (0.9840/0.9842 in.)

Values are in Metric units. Values in parentheses are English equivalents.

Lubricate threads with engine oil prior to assembly.

KohlerEngines.com 18 690 01 Rev. C

Page 71

Speciﬁ cations

CLEARANCE SPECIFICATIONS

SH265

Cylinder Bore

Bore I.D. New Max. Wear Limit Max. Out-of-Round Max. Taper

70.027/70.035 mm (2.757/2.757 in.)

70.200 mm (2.764 in.)

12.7 microns (0.0005 in.)

Cylinder Head

Max. Out-of-Flatness 0.1 mm (0.0039 in.)

Governor

Governor Cross Shaft-to-Crankcase Running Clearance 0.013/0.075 mm (0.0005/0.0029 in.) Governor Cross Shaft O.D.

New Max. Wear Limit

5.95/5.98 mm (0.2342/0.2354 in.)

5.85 mm (0.2303 in.) Governor Gear Shaft-to-Governor Gear Running Clearance 0.09/0.19 mm (0.0035/0.0074 in.) Governor Gear Shaft O.D.

New Max. Wear Limit

6.028/6.043 mm (0.2373/0.2379 in.)

6.018 mm (0.2369 in.)

Ignition

Spark Plug Gap 0.76 mm (0.030 in.) Module Air Gap 0.254 mm (0.0100 in.)

Piston, Piston Rings, and Piston Pin

Piston-to-Piston Pin Running Clearance 0.009/0.016 mm (0.0003/0.0006 in.) Piston Pin Bore I.D.

New Max. Wear Limit

18.004/18.005 mm (0.7088/0.7089 in.)

18.05 mm (0.7106 in.)

Piston Pin O.D. New Max. Wear Limit

17.992/17.995 mm (0.7083/0.7084 in.)

17.95 mm (0.7067 in.)

Top and Center Compression Ring Side Clearance New Bore Used Bore (max.)

0.04 mm (0.002 in.)

0.15 mm (0.006 in.)

Top and Center Compression Ring End Gap New Bore Used Bore (max.)

0.325 mm/0.4 (0.013/0.016 in.)

1.00 mm (0.039 in.)

Top and Center Compression Ring Width New Bore Used Bore (max.)

1.5/1.51 mm (0.059/0.059 in.)

1.37 mm (0.054 in.) Oil Control Ring-to-Groove Side Clearance 0.06/0.18 mm (0.0023/0.0071 in.) Piston Thrust Face O.D.

New Max. Wear Limit

67.975/67.985 mm (2.6762/2.6766 in.)

67.85 mm (2.6712 in.)

Piston Thrust Face-to-Cylinder Bore Running Clearance New 0.057/0.075 mm (0.0022/0.0029 in.)

Values are in Metric units. Values in parentheses are English equivalents.

Measure 15 mm (0.5905 in.) above bottom of piston skirt at right angles to piston pin.

18 690 01 Rev. C KohlerEngines.com

Page 72

Speciﬁ cations

CLEARANCE SPECIFICATIONS

SH265

Valves and Valve Lifters

Intake Valve Stem-to-Valve Guide Running Clearance 0.020/0.044 mm (0.008/0.0017 in.) Exhaust Valve Stem-to-Valve Guide Running Clearance 0.030/0.054 mm (0.0011/0.0021 in.) Intake Valve Stem O.D.

New Max. Wear Limit

5.480 mm (0.2157 in.)

5.32 mm (0.2094 in.)

Exhaust Valve Stem O.D. New Max. Wear Limit

5.47 mm (0.2153 in.)

5.305 mm (0.2088 in.)

Intake Valve Stem to Guide New Max. Wear Limit

0.024/0.039 mm (0.001/0.002 in.)

0.10 mm (0.0004 in.)

Exhaust Valve Stem to Guide New Max. Wear Limit

0.098/0.112 mm (0.0038/0.0044 in.)

0.12 mm (0.0005 in.)

Valve Guide Reamer Size Standard Intake Standard Exhaust

5.506 mm (0.2168 in.)

5.506 mm (0.2168 in.) Valve Seat Width 0.800/2.00 mm (0.0315/0.787 in.) Nominal Valve Face Angle 30°, 45°, 60°

Values are in Metric units. Values in parentheses are English equivalents.

KohlerEngines.com 18 690 01 Rev. C

Page 73

GENERAL TORQUE VALUES

English Fastener Torque Recommendations for Standard Applications

Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel

Grade 2 or 5 Fasteners

Size Grade 2 Grade 5 Grade 8

Tightening Torque: N·m (in. lb.) ± 20%

8-32 2.3 (20) 2.8 (25) — 2.3 (20) 10-24 3.6 (32) 4.5 (40) — 3.6 (32) 10-32 3.6 (32) 4.5 (40) — —

1/4-20 7.9 (70) 13.0 (115) 18.7 (165) 7.9 (70)

1/4-28 9.6 (85) 15.8 (140) 22.6 (200) — 5/16-18 17.0 (150) 28.3 (250) 39.6 (350) 17.0 (150) 5/16-24 18.7 (165) 30.5 (270) — —

3/8-16 29.4 (260) — — —

3/8-24 33.9 (300) — — —

Tightening Torque: N·m (ft. lb.) ± 20%

5/16-24 — — 40.7 (30) —

3/8-16 — 47.5 (35) 67.8 (50) —

3/8-24 — 54.2 (40) 81.4 (60) — 7/16-14 47.5 (35) 74.6 (55) 108.5 (80) — 7/16-20 61.0 (45) 101.7 (75) 142.5 (105) —

1/2-13 67.8 (50) 108.5 (80) 155.9 (115) —

1/2-20 94.9 (70) 142.4 (105) 223.7 (165) — 9/16-12 101.7 (75) 169.5 (125) 237.3 (175) — 9/16-18 135.6 (100) 223.7 (165) 311.9 (230) —

5/8-11 149.5 (110) 244.1 (180) 352.6 (260) — 5/8-18 189.8 (140) 311.9 (230) 447.5 (330) — 3/4-10 199.3 (147) 332.2 (245) 474.6 (350) — 3/4-16 271.2 (200) 440.7 (325) 637.3 (470) —

Speciﬁ cations

Into Aluminum

Metric Fastener Torque Recommendations for Standard Applications

Size

4.8

Tightening Torque: N·m (in. lb.) ± 10%

M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18) M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35) M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60) M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150)

Tightening Torque: N·m (ft. lb.) ± 10%

M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25) M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45) M14 58.3 (43) 76.4 (56) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)

18 690 01 Rev. C KohlerEngines.com

Property Class

5.8

8.8

10.9 12.9

Torque Conversions

N·m = in. lb. x 0.113 in. lb. = N·m x 8.85

N·m = ft. lb. x 1.356 ft. lb. = N·m x 0.737

Noncritical

Fasteners

Into Aluminum

Page 74

Tools and Aids

Certain quality tools are designed to help you perform speciﬁ c disassembly, repair, and reassembly procedures. By using these tools, you can properly service engines easier, faster, and safer! In addition, you’ll increase your service capabilities and customer satisfaction by decreasing engine downtime.

Here is a list of tools and their source.

SEPARATE TOOL SUPPLIERS

Kohler Tools Contact your local Kohler source of supply.

TOOLS

Description Source/Part No.

Alcohol Content Tester

For testing alcohol content (%) in reformulated/oxygenated fuels.

Camshaft Endplay Plate

For checking camshaft endplay.

Camshaft Seal Protector (Aegis)

For protecting seal during camshaft installation.

Cylinder Leakdown Tester

For checking combustion retention and if cylinder, piston, rings, or valves are worn. Individual component available: Adapter 12 mm x 14 mm (Required for leakdown test on XT-6 engines)

Dealer Tool Kit (Domestic)

Complete kit of Kohler required tools. Components of 25 761 39-S Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Rectiﬁ er-Regulator Tester (120 V AC/60Hz)

Dealer Tool Kit (International)

Complete kit of Kohler required tools. Components of 25 761 42-S Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Rectiﬁ er-Regulator Tester (240 V AC/50Hz)

Digital Vacuum/Pressure Tester

For checking crankcase vacuum. Individual component available: Rubber Adapter Plug

Electronic Fuel Injection (EFI) Diagnostic Software

For Laptop or Desktop PC.

EFI Service Kit

For troubleshooting and setting up an EFI engine. Components of 24 761 01-S Fuel Pressure Tester Noid Light 90° Adapter Code Plug, Red Wire Code Plug, Blue Wire Shrader Valve Adapter Hose Wire Probe Set (2 pieces regular wire with clip; 1 piece fused wire) Hose Removal Tool, Dual Size/End (also sold as individual Kohler tool)

Flywheel Puller

For properly removing ﬂ ywheel from engine.

SE Tools 415 Howard St. Lapeer, MI 48446 Phone 810-664-2981 Toll Free 800-664-2981 Fax 810-664-8181

Design Technology Inc. 768 Burr Oak Drive Westmont, IL 60559 Phone 630-920-1300 Fax 630-920-0011

Kohler 25 455 11-S

SE Tools KLR-82405

SE Tools KLR-82417

Kohler 25 761 05-S

Design Technology Inc.

DTI-731-03

Kohler 25 761 39-S

Kohler 25 455 01-S Kohler 25 761 05-S Kohler 25 761 06-S Kohler 25 761 20-S

Kohler 25 761 42-S

Kohler 25 455 01-S Kohler 25 761 05-S Kohler 25 761 06-S Kohler 25 761 41-S

Design Technology Inc.

DTI-721-01

Design Technology Inc.

DTI-721-10

Kohler 25 761 23-S

Kohler 24 761 01-S

Design Technology Inc.

DTI-019 DTI-021 DTI-023 DTI-027 DTI-029 DTI-037 DTI-031 DTI-033

SE Tools KLR-82408

12 18 690 01 Rev. CKohlerEngines.com

Page 75

Tools and Aids

TOOLS

Description Source/Part No.

Hose Removal Tool, Dual Size/End (also available in EFI Service Kit)

Used to properly remove fuel hose from engine components.

Hydraulic Valve Lifter Tool

For removing and installing hydraulic lifters.

Ignition System Tester

For testing output on all systems, including CD.

Inductive Tachometer (Digital)

For checking operating speed (RPM) of an engine.

Offset Wrench (K and M Series)

For removing and reinstalling cylinder barrel retaining nuts.

Oil Pressure Test Kit

For testing/verifying oil pressure on pressure lubricated engines.

Rectiﬁ er-Regulator Tester (120 volt current) Rectiﬁ er-Regulator Tester (240 volt current)

For testing rectiﬁ er-regulators. Components of 25 761 20-S and 25 761 41-S CS-PRO Regulator Test Harness Special Regulator Test Harness with Diode

Spark Advance Module (SAM) Tester

For testing SAM (ASAM and DSAM) on engines with SMART-SPARK

™

Starter Servicing Kit (All Starters)

For removing and reinstalling drive retaining rings and brushes. Individual component available: Starter Brush Holding Tool (Solenoid Shift)

Triad/OHC Timing Tool Set

For holding cam gears and crankshaft in timed position while installing timing belt.

Valve Guide Reamer (K and M Series)

For properly sizing valve guides after installation.

Valve Guide Reamer O.S. (Command Series)

For reaming worn valve guides to accept replacement oversize valves. Can be used in low-speed drill press or with handle below for hand reaming.

Reamer Handle

For hand reaming using Kohler 25 455 12-S reamer.

Kohler 25 455 20-S

Kohler 25 761 38-S

Kohler 25 455 01-S

Design Technology Inc.

DTI-110

Kohler 52 455 04-S

Kohler 25 761 06-S

Kohler 25 761 20-S Kohler 25 761 41-S

Design Technology Inc.

DTI-031R DTI-033R

Kohler 25 761 40-S

SE Tools KLR-82411

SE Tools KLR-82416

Kohler 28 761 01-S

Design Technology Inc.

DTI-K828

Kohler 25 455 12-S

Design Technology Inc.

DTI-K830

AIDS Description Source/Part No.

Camshaft Lubricant (Valspar ZZ613) Kohler 25 357 14-S Dielectric Grease (GE/Novaguard G661) Kohler 25 357 11-S Dielectric Grease Loctite

51360

Kohler Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S Kohler Electric Starter Drive Lubricant (Solenoid Shift) Kohler 52 357 02-S RTV Silicone Sealant

Loctite Only oxime-based, oil resistant RTV sealants, such as those listed, are approved

5900® Heavy Body in 4 oz. aerosol dispenser.

for use. Permatex® the Right Stuff® 1 Minute Gasket™ or Loctite® Nos. 5900® or 5910® are recommended for best sealing characteristics.

Kohler 25 597 07-S

Loctite® 5910

Loctite® Ultra Black 598™

Loctite® Ultra Blue 587™ Loctite® Ultra Copper 5920™ Permatex® the Right Stuff® 1

Minute Gasket™

Spline Drive Lubricant Kohler 25 357 12-S

1318 690 01 Rev. C KohlerEngines.com

Page 76

Tools and Aids

FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL

A ﬂ ywheel holding tool can be made out of an old junk ﬂ ywheel ring gear and used in place of a strap wrench.

1. Using an abrasive cut-off wheel, cut out a six tooth segment of ring gear as shown.

2. Grind off any burrs or sharp edges.

3. Invert segment and place it between ignition bosses on crankcase so tool teeth engage ﬂ ywheel ring gear teeth. Bosses will lock tool and ﬂ ywheel in position for loosening, tightening, or removing with a puller.

A spanner wrench to lift rocker arms or turn crankshaft may be made out of an old junk connecting rod.

1. Find a used connecting rod from a 10 HP or larger engine. Remove and discard rod cap.

2. Remove studs of a Posi-Lock rod or grind off aligning steps of a Command rod, so joint surface is ﬂ at.

3. Find a 1 in. long capscrew with correct thread size to match threads in connecting rod.

4. Use a ﬂ at washer with correct I.D. to slip on capscrew and approximately 1 in. O.D. Assemble capscrew and washer to joint surface of rod.

14 18 690 01 Rev. CKohlerEngines.com

Page 77

Troubleshooting

TROUBLESHOOTING GUIDE

When troubles occur, be sure to check simple causes which, at ﬁ rst, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank.

Some general common causes of engine troubles are listed below and vary by engine speciﬁ cation. Use these to locate causing factors.

Engine Cranks But Will Not Start

● Battery connected backwards.

● Blown fuse.

● Carburetor solenoid malfunction.

● Choke not closing.

● Clogged fuel line or fuel ﬁ lter.

● Diode in wiring harness failed in open circuit mode.

● DSAI or DSAM malfunction.

● Empty fuel tank.

● Faulty electronic control unit.

● Faulty ignition coil(s).

● Faulty spark plug(s).

● Fuel pump malfunction-vacuum hose clogged or

leaking.

● Fuel shut-off valve closed.

● Ignition module(s) faulty or improperly gapped.

● Insufﬁ cient voltage to electronic control unit.

● Interlock switch is engaged or faulty.

● Key switch or kill switch in OFF position.

● Low oil level.

● Quality of fuel (dirt, water, stale, mixture).

● SMART-SPARKTM malfunction.

● Spark plug lead(s) disconnected.

Engine Starts But Does Not Keep Running

● Faulty carburetor.

● Faulty cylinder head gasket.

● Faulty or misadjusted choke or throttle controls.

● Fuel pump malfunction-vacuum hose clogged or

leaking.

● Intake system leak.

● Loose wires or connections that intermittently ground

ignition kill circuit.

● Quality of fuel (dirt, water, stale, mixture).

● Restricted fuel tank cap vent.

Engine Starts Hard

● Clogged fuel line or fuel ﬁ lter.

● Engine overheated.

● Faulty ACR mechanism.

● Faulty or misadjusted choke or throttle controls.

● Faulty spark plug(s).

● Flywheel key sheared.

● Fuel pump malfunction-vacuum hose clogged or

leaking.

● Interlock switch is engaged or faulty.

● Loose wires or connections that intermittently ground

ignition kill circuit.

● Low compression.

● Quality of fuel (dirt, water, stale, mixture).

● Weak spark.

Engine Will Not Crank

● Battery is discharged.

● Faulty electric starter or solenoid.

● Faulty key switch or ignition switch.

● Interlock switch is engaged or faulty.

● Loose wires or connections that intermittently ground

ignition kill circuit.

● Pawls not engaging in drive cup.

● Seized internal engine components.

Engine Runs But Misses

● Carburetor adjusted incorrectly.

● Engine overheated.

● Faulty spark plug(s).

● Ignition module(s) faulty or improperly gapped.

● Incorrect crankshaft position sensor air gap.

● Interlock switch is engaged or faulty.

● Loose wires or connections that intermittently ground

ignition kill circuit.

● Quality of fuel (dirt, water, stale, mixture).

● Spark plug lead(s) disconnected.

● Spark plug lead boot loose on plug.

● Spark plug lead loose.

Engine Will Not Idle

● Engine overheated.

● Faulty spark plug(s).

● Idle fuel adjusting needle(s) improperly set.

● Idle speed adjusting screw improperly set.

● Inadequate fuel supply.

● Low compression.

● Quality of fuel (dirt, water, stale, mixture).

● Restricted fuel tank cap vent.

Engine Overheats

● Cooling fan broken.

● Excessive engine load.

● Fan belt failed/off.

● Faulty carburetor.

● High crankcase oil level.

● Lean fuel mixture.

● Low cooling system ﬂ uid level.

● Low crankcase oil level.

● Radiator, and/or cooling system components clogged,

restricted, or leaking.

● Water pump belt failed/broken.

● Water pump malfunction.

Engine Knocks

● Excessive engine load.

● Hydraulic lifter malfunction.

● Incorrect oil viscosity/type.

● Internal wear or damage.

● Low crankcase oil level.

● Quality of fuel (dirt, water, stale, mixture).

1518 690 01 Rev. C KohlerEngines.com

Page 78

Troubleshooting

Engine Loses Power

● Dirty air cleaner element.

● Engine overheated.

● Excessive engine load.

● Restricted exhaust.

● Faulty spark plug(s).

● High crankcase oil level.

● Incorrect governor setting.

● Low battery.

● Low compression.

● Low crankcase oil level.

● Quality of fuel (dirt, water, stale, mixture).

Engine Uses Excessive Amount of Oil

● Loose or improperly torqued fasteners.

● Blown head gasket/overheated.

● Breather reed broken.

● Clogged, broken, or inoperative crankcase breather.

● Crankcase overﬁ lled.

● Incorrect oil viscosity/type.

● Worn cylinder bore.

● Worn or broken piston rings.

● Worn valve stems/valve guides.

Oil Leaks from Oil Seals, Gaskets

● Breather reed broken.

● Clogged, broken, or inoperative crankcase breather.

● Loose or improperly torqued fasteners.

● Piston blow by, or leaky valves.

● Restricted exhaust.

EXTERNAL ENGINE INSPECTION

NOTE: It is good practice to drain oil at a location away

from workbench. Be sure to allow ample time for complete drainage.

Before cleaning or disassembling engine, make a thorough inspection of its external appearance and condition. This inspection can give clues to what might be found inside engines (and cause) when it is disassembled.

● Check for buildup of dirt and debris on crankcase,

cooling ﬁ ns, grass screen, and other external surfaces. Dirt or debris on these areas can cause overheating.

● Check for obvious fuel and oil leaks, and damaged

components. Excessive oil leakage can indicate a clogged or inoperative breather, worn or damaged seals or gaskets, or loose fasteners.

● Check air cleaner cover and base for damage or

indications of improper ﬁ t and seal.

● Check air cleaner element. Look for holes, tears,

cracked or damaged sealing surfaces, or other damage that could allow unﬁ ltered air into engine. A dirty or clogged element could indicate insufﬁ cient or improper maintenance.

● Check carburetor throat for dirt. Dirt in throat is further

indication that air cleaner was not functioning properly.

● Check if oil level is within operating range on dipstick.

If it is above, sniff for gasoline odor.

● Check condition of oil. Drain oil into a container; it

should ﬂ ow freely. Check for metal chips and other foreign particles.

Sludge is a natural by-product of combustion; a small

accumulation is normal. Excessive sludge formation could indicate over rich fuel settings, weak ignition, overextended oil change interval or wrong weight or type of oil was used.

CLEANING ENGINE

WARNING

Cleaning Solvents can cause severe injury or death.

Use only in well ventilated areas away from ignition sources.

Carburetor cleaners and solvents are extremely ﬂ ammable. Follow cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent.

After inspecting external condition of engine, clean engine thoroughly before disassembly. Clean individual components as engine is disassembled. Only clean parts can be accurately inspected and gauged for wear or damage. There are many commercially available cleaners that will quickly remove grease, oil, and grime from engine parts. When such a cleaner is used, follow manufacturer’s instructions and safety precautions carefully.

Make sure all traces of cleaner are removed before engine is reassembled and placed into operation. Even small amounts of these cleaners can quickly break down lubricating properties of engine oil.

16 18 690 01 Rev. CKohlerEngines.com

Page 79

CRANKCASE VACUUM TEST

Troubleshooting

WARNING

Carbon Monoxide can cause severe nausea, fainting or death.

Avoid inhaling exhaust fumes.

Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled.

A partial vacuum should be present in crankcase when engine is operating. Pressure in crankcase (normally caused by a clogged or improperly assembled breather) can cause oil to be forced out at oil seals, gaskets, or other available spots.

Crankcase vacuum is best measured with either a water manometer or a vacuum gauge. Complete instructions are provided in kits.

To test crankcase vacuum with manometer:

1. Insert rubber stopper into oil ﬁ ll hole. Be sure pinch clamp is installed on hose and use tapered adapters to connect hose between stopper and one manometer tube. Leave other tube open to atmosphere. Check that water level in manometer is at 0 line. Make sure pinch clamp is closed.

2. Start engine and run no-load high speed.

3. Open clamp and note water level in tube.

Level in engine side should be a minimum of 10.2

cm (4 in.) above level in open side.

If level in engine side is less than speciﬁ ed (low/no

vacuum), or level in engine side is lower than level in open side (pressure), check for conditions in table below.

4. Close pinch clamp before stopping engine.

Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate engine with covers, shrouds, or guards removed.

To test crankcase vacuum with vacuum/pressure gauge:

1. Remove dipstick or oil ﬁ ll plug/cap.

2. Install adapter into oil ﬁ ll//dipstick tube opening,

3. Run engine and observe gauge reading. Analog tester–needle movement to left of 0 is a

Digital tester–depress test button on top of tester. Crankcase vacuum should be a minimum of 10.2 cm

Rotating Parts can cause severe injury. Stay away while engine is in operation.

upside down over end of a small diameter dipstick tube, or directly into engine if a tube is not used. Insert barbed gauge ﬁ tting into hole in stopper.

vacuum, and movement to right indicates a pressure.

(4 in.) of water. If reading is below speciﬁ cation, or if pressure is present, check table below for possible causes and conclusions.

WARNING

Condition Conclusion

Crankcase breather clogged or inoperative. NOTE: If breather is integral part of valve cover and

cannot be serviced separately, replace valve cover and recheck pressure.

Disassemble breather, clean parts thoroughly, check sealing surfaces for ﬂ atness, reassemble, and recheck pressure.

Seals and/or gaskets leaking. Loose or improperly torque fasteners.

Piston blow by or leaky valves (conﬁ rm by inspecting components).

Restricted exhaust. Check exhaust screen/spark arrestor (if equipped). Clean

Replace all worn or damaged seals and gaskets. Make sure all fasteners are tightened securely. Use appropriate torque valves and sequences when necessary.

Recondition piston, rings, cylinder bore, valves and valves guides.

or replace as needed. Repair or replace any other damaged/restricted mufﬂ er or exhaust system parts.

1718 690 01 Rev. C KohlerEngines.com

Page 80

Troubleshooting

COMPRESSION TEST

For Command Twins: A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s)

before removing them. Be sure choke is off, and throttle is wide open during test. Compression should be at least 160 psi and should not vary more than 15% between cylinders.

All other models: These engines are equipped with an automatic compression release (ACR) mechanism. It is difﬁ cult to obtain an

accurate compression reading because of ACR mechanism. As an alternative, use cylinder leakdown test described below.

CYLINDER LEAKDOWN TEST

A cylinder leakdown test can be a valuable alternative to a compression test. By pressurizing combustion chamber from an external air source you can determine if valves or rings are leaking, and how badly.

Cylinder leakdown tester is a relatively simple, inexpensive leakdown tester for small engines. This tester includes a quick-connect for attaching adapter hose and a holding tool.

1. Run engine for 3-5 minutes to warm it up.

2. Remove spark plug(s) and air ﬁ lter from engine.

3. Rotate crankshaft until piston (of cylinder being tested) is at top dead center (TDC) of compression stroke. Hold engine in this position while testing. Holding tool supplied with tester can be used if PTO end of crankshaft is accessible. Lock holding tool onto crankshaft. Install a 3/8 in. breaker bar into hole/slot of holding tool, so it is perpendicular to both holding tool and crankshaft PTO.

If ﬂ ywheel end is more accessible, use a breaker bar and socket on ﬂ ywheel nut/screw to hold it in position. An

assistant may be needed to hold breaker bar during testing. If engine is mounted in a piece of equipment, it may be possible to hold it by clamping or wedging a driven component. Just be certain that engine cannot rotate off of TDC in either direction.

4. Install adapter into spark plug hole, but do not attach it to tester at this time.

5. Turn regulator knob completely counterclockwise.

6. Connect an air source of at least 50 psi to tester.

7. Turn regulator knob clockwise (increase direction) until gauge needle is in yellow set area at low end of scale.

8. Connect tester quick-connect to adapter hose. While ﬁ rmly holding engine at TDC, gradually open tester valve. Note gauge reading and listen for escaping air at combustion air intake, exhaust outlet, and crankcase breather.

Condition Conclusion

Air escaping from crankcase breather. Ring or cylinder worn. Air escaping from exhaust system. Defective exhaust valve/improper seating. Air escaping from intake. Defective intake valve/improper seating. Gauge reading in low (green) zone. Piston rings and cylinder in good condition. Gauge reading in moderate (yellow) zone. Engine is still usable, but there is some wear present.

Customer should start planning for overhaul or replacement.

Gauge reading in high (red) zone. Rings and/or cylinder have considerable wear. Engine

should be reconditioned or replaced.

18 18 690 01 Rev. CKohlerEngines.com

Page 81

Air Cleaner/Intake

AIR CLEANER

These systems are CARB/EPA certiﬁ ed and components should not be altered or modiﬁ ed in any way.

Dual-Element Air Cleaner Components

A Wing Nut B Air Cleaner Cover

C Precleaner D Paper Element

E Air Cleaner Base

Low-Proﬁ le Air Cleaner Components

NOTE: Operating engine with loose or damaged air

cleaner components could cause premature wear and failure. Replace all bent or damaged components.

NOTE: Paper element cannot be blown out with

compressed air.

Dual-Element

Remove wing nut and air cleaner cover.

Precleaner

1. Remove precleaner from paper element.

2. Replace or wash precleaner in warm water with detergent. Rinse and allow to air dry.

3. Reinstall precleaner over paper element.

Paper Element

1. Remove wing nut (if equipped) and paper element with precleaner.

2. Separate precleaner from element; service precleaner and replace element.

3. Reinstall precleaner over paper element; secure with wing nut (if equipped).

Reinstall air cleaner cover and secure with wing nut.

Low-Proﬁ le

1. Remove screw and air cleaner cover.

2. Remove foam element from base.

3. Wash foam element in warm water with detergent. Rinse and allow to air dry.

4. Lightly oil foam element with new engine oil; squeeze out excess oil.

5. Reinstall foam element into base.

6. Reinstall cover and secure with screw.

BREATHER TUBE

Make sure both ends of breather tube are properly connected.

AIR COOLING

F Air Cleaner Base G Foam Element

H Air Cleaner Cover I Screw

18 690 01 Rev. C KohlerEngines.com

WARNING

Never operate engine with heat shields or guards removed.

Proper cooling is essential. To prevent over heating, clean screens, cooling ﬁ ns, and other external surfaces of engine. Avoid spraying water at wiring harness or any electrical components. Refer to Maintenance Schedule.

Hot Parts can cause severe burns. Do not touch engine while operating or just

after stopping.

Page 82

Fuel System

Typical carbureted fuel system and related components include:

● Fuel tank.

● Fuel lines.

● In-line fuel ﬁ lter.

● Fuel tank ﬁ lter.

● Carburetor.

● Fuel strainer screen in carburetor.

Fuel tank outlet is located above carburetor inlet, allowing gravity to feed fuel through in-line ﬁ lter and fuel line to carburetor.

Fuel then enters carburetor through a fuel shut-off valve and a ﬁ ne screen/sediment bowl, and then to carburetor ﬂ oat bowl. Fuel is drawn into carburetor body and is mixed with air. This fuel-air mixture is then burned in engine combustion chamber.

FUEL RECOMMENDATIONS

Refer to Maintenance.

FUEL LINE

Low permeation fuel line must be installed on carbureted Kohler Co. engines to maintain EPA and CARB regulatory compliance.

FUEL FILTER

Fuel Tank Filter

A serviceable fuel tank ﬁ lter is located under fuel tank cap, in ﬁ ller neck.

Daily or as required clean ﬁ lter of any accumulation as follows:

1. Remove fuel tank cap and ﬁ lter.

2. Clean ﬁ lter with solvent, replace if damaged.

3. Wipe ﬁ lter and insert it.

4. Tighten fuel tank cap securely.

FUEL SYSTEM TESTS

When engine starts hard or turns over but will not start, fuel system might be causing problems. Test fuel system by performing following test.

1. Check for fuel in combustion chamber. a. Disconnect and ground spark plug lead. b. Close choke on carburetor. c. Crank engine several times. d. Remove spark plug and check for fuel at tip.

2. Check for fuel ﬂ ow from tank to carburetor. a. Remove fuel line from inlet ﬁ tting of carburetor.

Condition Conclusion

Fuel at tip of spark plug. Fuel is reaching combustion chamber. No fuel at tip of spark plug. Check fuel ﬂ ow from fuel tank (step 2). Fuel ﬂ ows from fuel line. Check operation of fuel shut-off valve (step 3). No fuel ﬂ ow from fuel line. Check fuel tank vent, in-line ﬁ lter threaded into tank, and

Fuel ﬂ ows from valve. Check for dirt and water in sediment bowl and screen.

No fuel ﬂ ows from valve. Check for a restriction in fuel shut-off valve or inlet elbow.

Fuel Shut-Off

WARNING

Explosive Fuel can cause ﬁ res and severe burns.

Do not ﬁ ll fuel tank while engine is hot or running.

Engines are equipped with a fuel shut-off located at carburetor. It controls fuel ﬂ ow from tank to carburetor.

1. Stop engine.

2. Turn fuel shut-off lever to OFF position.

3. Remove fuel shut-off cup.

4. Clean fuel shut-off cup with solvent and wipe dry.

5. Inspect for worn or damaged O-ring; replace as necessary.

6. Place O-ring on fuel shut-off cup. Install fuel shut-off cup and O-ring; rotate until ﬁ nger tight. Turn with a wrench 1/2 to 3/4 full turn.

7. Turn fuel shut-off lever to ON position and check for leaks. If fuel shut-off cup leaks, repeat steps 5 and 6.

8. Tighten fuel tank cap securely.

b. Use an approved fuel container to catch fuel, and

hold line below bottom of tank to observe fuel ﬂ ow.

3. Check operation of fuel shut-off valve.

a. Remove fuel sediment bowl under inlet ﬁ tting of

carburetor.

b. Turn fuel shut-off valve ON and OFF and observe

operation.

fuel line. Correct any observed problem and reconnect line.

Clean bowl and screen as needed. Check for faulty carburetor, refer to Carburetor.

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Page 83

CARBURETOR

Fuel System

WARNING

Explosive Fuel can cause ﬁ res and severe burns.

Do not ﬁ ll fuel tank while engine is hot or running.

Typical One-Barrel Carburetor Components

These engines are equipped with a ﬁ xed main jet carburetor. Carburetor is designed to deliver correct fuelto-air mixture to engine under all operating conditions. Idle mixture is set at factory and cannot be adjusted.

Troubleshooting Checklist

When engine starts hard, runs rough, or stalls at low idle speed, check these areas before adjusting or disassembling carburetor.

1. Make sure fuel tank is ﬁ lled with clean, fresh

gasoline.

2. Make sure fuel tank cap vent is not blocked and is

operating properly.

3. Make sure fuel is reaching carburetor. This includes

checking fuel shut-off valve, fuel tank ﬁ lter screen, in-line fuel ﬁ lter, fuel lines and fuel pump for restrictions or faulty components as necessary.

4. Make sure air cleaner base and carburetor are

securely fastened to engine using gaskets in good condition.

5. Make sure air cleaner element (including precleaner

if equipped) is clean and all air cleaner components are fastened securely.

6. Make sure ignition system, governor system,

exhaust system, and throttle and choke controls are operating properly.

A Fuel Shut-Off B Wave Washer

C Fuel Shut-Off Valve D

E Idle Jet F Fuel Shut-Off Gasket

G Main Nozzle Tube H Main Jet

I Bowl Gasket J Fuel Inlet Needle

K Spring L Hinge Pin

M Float N Fuel Bowl

Bowl Retaining Screw

18 690 01 Rev. C KohlerEngines.com

Gasket

P Bowl Retaining Screw

Low Idle Speed

Adjusting Screw

Page 84

Fuel System

Troubleshooting-Carburetor Related Causes

Condition Possible Cause Conclusion

Engine starts hard, runs rough, or stalls at idle speed.

Engine runs rich (indicated by black, sooty exhaust smoke, misﬁ ring, loss of speed and power, governor hunting, or excessive throttle opening).

Engine runs lean (indicated by misﬁ ring, loss of speed and power, governor hunting, or excessive throttle opening).

Fuel leaks from carburetor. Float damaged. Submerge ﬂ oat to check for leaks.

Low idle fuel mixture (some models)/ speed improperly adjusted.

Clogged air cleaner. Clean or replace air cleaner. Choke partially closed during

operation. Dirt under fuel inlet needle. Remove needle; clean needle and

Bowl vent or air bleeds plugged. Clean vent, ports, and air bleeds.

Leaky, cracked, or damaged ﬂ oat. Submerge ﬂ oat to check for leaks. Intake air leak. Check if carburetor is loose or one of

Idle holes plugged; dirt in fuel delivery channels.

Dirt under fuel inlet needle. Remove needle; clean needle and

Bowl vents plugged. Blow out with compressed air.

Adjust idle speed screw or clean carburetor.

Check choke lever/linkage to ensure choke is operating properly.

seat and blow with compressed air.

Blow out all passages with compressed air.

intake gaskets is leaking. Clean main fuel jet and all passages;

blow out with compressed air.

Replace ﬂ oat.

seat and blow with compressed air.

Carburetor bowl gasket leaks. Replace gasket.

Carburetor Circuits

Float

Fuel level in bowl is maintained by ﬂ oat and fuel inlet needle. Buoyant force of ﬂ oat stops fuel ﬂ ow when engine is at rest. When fuel is being consumed, ﬂ oat will drop and fuel pressure will push inlet needle away from seat, allowing more fuel to enter bowl. When demand ceases, buoyant force of ﬂ oat will again overcome fuel pressure, rising to predetermined setting and stop ﬂ ow.

Slow and Mid-Range

At low speeds engine operates only on slow circuit. As a metered amount of air is drawn through slow air bleed jets, fuel is drawn through main jet and further metered through slow jet. Air and fuel are mixed in body of slow jet and exit to idle progression (transfer port) chamber. From idle progression chamber, air fuel mixture is metered through idle port passage. At low idle air/fuel mixture is controlled by setting of idle fuel adjusting screws. This mixture is then mixed with main body of air and delivered to engine. As throttle plate opening increases, greater amounts of air/fuel mixture are drawn in through ﬁxed and metered idle progression holes. As throttle plate opens further, vacuum signal becomes great enough at venturi so main circuit begins to work.

Main (high-speed)

At high speeds/loads engine operates on main circuit. As a metered amount of air is drawn through air jet, fuel is drawn through main jet. Air and fuel are mixed in main nozzles then enters main body of airﬂow where further mixing of fuel and air occurs. This mixture is then delivered to combustion chamber. Carburetor has a ﬁxed main circuit; no adjustment is possible.

Carburetor Adjustments

NOTE: Carburetor adjustments should be made only

after engine has warmed up.

Carburetor is designed to deliver correct fuel-to-air mixture to engine under all operating conditions. Main fuel jet is calibrated at factory and is not adjustable. Idle fuel adjusting needles are also set at factory and are not adjustable.

Low Idle Speed (RPM) Adjustment

NOTE: Actual low idle speed depends on application.

Refer to equipment manufacturer’s recommendations. Low idle speed for basic engines is 1800 RPM.

1. Place throttle control into idle or slow position. Turn low idle speed adjusting screw in or out to obtain allow idle speed of 1800 RPM (± 75 RPM).

Carburetor Servicing

WARNING

Accidental Starts can cause severe injury or death.

Disconnect and ground spark plug lead(s) before servicing.

Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery.

NOTE: Main and slow jets are ﬁxed and size speciﬁc

and can be removed if required. Fixed jets for high altitudes are available.

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Page 85

• Inspect carburetor body for cracks, holes, and other wear or damage.

• Inspect ﬂoat for cracks, holes, and missing or damaged ﬂoat tabs. Check ﬂoat hinge and shaft for wear or damage.

• Inspect fuel inlet needle and seat for wear or damage.

1. Perform removal procedures for appropriate air

cleaner and carburetor outlined in Disassembly.

2. Clean exterior surfaces of dirt or foreign material

before disassembling carburetor. Remove bowl retaining screws, and carefully separate fuel bowl from carburetor. Do not damage fuel bowl O-rings. Transfer any remaining fuel into an approved container. Save all parts. Fuel can also be drained prior to bowl removal by loosening/removing bowl drain screw.

3. Remove ﬂoat pin and inlet needle. Seat for inlet

needle is not serviceable and should not be removed.

4. Clean carburetor bowl and inlet seat areas as

required.

5. Carefully remove main jet from carburetor. After

main jet is removed, main nozzles can be removed through bottom of main towers. Note orientation/ direction of nozzles. End with 2 raised shoulders should be out/down adjacent to main jets.

6. Save parts for cleaning and reuse unless a jet kit is

also being installed. Clean slow jets using compressed air or carburetor cleaner, do not use

wire. NOTE: There are 2 O-rings on body of idle jet. Carburetor is now disassembled for appropriate cleaning

and installation of parts in overhaul kit. See instructions provided with repair kits for more detailed information.

Fuel System

High Altitude Operation

Engines may require a high altitude carburetor kit to ensure correct engine operation at altitudes above 1219 meters (4000 ft.). To obtain high altitude kit information or to ﬁ nd a Kohler authorized dealer visit KohlerEngines.com or call1-800-544-2444 (U.S. and Canada).

This engine should be operated in its original conﬁ guration below 1219 meters (4000 ft.) as damage may occur if high altitude carburetor kit is installed and operated below 1219 meters (4000 ft.).

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Page 86

Governor System

GOVERNOR

Governor Components

A Control Assembly B Nut C Governor Spring D Throttle Link

E Dampening Spring F Throttle Control Lever G Governor Lever H Cup

I Washer J Governor Gear K Governor Gear Shaft

Governed speed setting is determined by position of throttle control. It can be variable or constant, depending on engine application.

Governor is designed to hold engine speed constant under changing load conditions. Most engines are equipped with a centrifugal ﬂ yweight mechanical governor. Governor gear/ﬂ yweight mechanism of mechanical governor is mounted inside crankcase and is driven off gear on crankshaft.

This governor design works as follows:

● Centrifugal force acting on rotating governor gear assembly causes ﬂ yweights to move outward as speed increases. Governor spring tension moves them inward as speed decreases.

● As ﬂ yweights move outward, they cause regulating pin to move outward.

● Regulating pin contacts tab on cross shaft causing shaft to rotate.

● One end of cross shaft protrudes through crankcase. Rotating action of cross shaft is transmitted to throttle lever of carburetor through external throttle linkage.

● When engine is at rest, and throttle is in fast position, tension of governor spring holds throttle plate open. When engine is operating, governor gear assembly is rotating. Force applied by regulating pin against cross shaft tends to close throttle plate. Governor spring tension and force applied by regulating pin balance each other during operation, to maintain engine speed.

● When load is applied and engine speed and governor gear speed decreases, governor spring tension moves governor arm to open throttle plate wider. This allows more fuel into engine, increasing engine speed. As speed reaches governed setting, governor spring tension and force applied by regulating pin will again offset each other to hold a steady engine speed.

Governor Adjustments

Initial Adjustment Procedure

NOTE: Make sure carburetor is mounted and secured in

place when adjustment is being made/checked.

Make this initial adjustment whenever governor lever is loosened or removed from cross shaft. To ensure proper setting, make sure throttle linkage is connected to governor lever and to carburetor throttle lever.

Adjust as follows:

1. Close fuel shut-off valve.

2. Remove air cleaner outer cover. Then either

reposition fuel tank to access governor shaft and lever joint, or disconnect fuel line and remove tank from engine.

3. Loosen governor lever mounting nut.

4. Move governor lever clockwise until it stops.

5. Rotate governor shaft clockwise until it stops.

6. Hold both in this position and torque governor lever

nut to 10 N·m (88.5 in. lb.).

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Page 87

Lubrication System

These engines use a splash lubrication system, supplying necessary lubrication to crankshaft, camshaft, connecting rod and valve train components.

Lubrication Components

A Dipstick B Oil Fill Plug C Oil Drain Plug

OIL RECOMMENDATIONS

Refer to Maintenance.

CHECK OIL LEVEL

NOTE: To prevent extensive engine wear or damage,

never run engine with oil level below or above operating range indicator on dipstick.

Ensure engine is cool. Clean oil ﬁ ll/dipstick areas of any debris.

1. Remove dipstick; wipe oil off.

2. Reinsert dipstick into tube; rest on oil ﬁ ll neck; turn counterclockwise until cap drops down to lowest point of thread leads; do not thread cap onto tube.

a. Remove dipstick; check oil level. Level should be

at top of indicator on dipstick.

b. Remove oil ﬁ ll plug. Level should be up to point of

overﬂ owing ﬁ ller neck.

3. If oil is low, add oil up to point of overﬂ owing ﬁ ller neck.

4. Reinstall dipstick or oil ﬁ ll plug and tighten securely.

CHANGE OIL

Change oil while engine is warm.

1. Clean area around oil ﬁ ll plug/dipstick and drain plug.

2. Remove drain plug and oil ﬁ ll plug/dipstick. Drain oil completely.

3. Reinstall drain plug. Torque 18 N·m (13 ft. lb.).

4. Fill crankcase with new oil, up to point of overﬂ owing ﬁ ller neck.

5. Reinstall oil ﬁ ll plug/dipstick and tighten securely.

6. Dispose of used oil in accordance with local ordinances.

OIL SENTRY™ (if equipped)

This switch is designed to prevent engine from starting in a low oil or no oil condition. Oil Sentry™ may not shut down a running engine before damage occurs. In some applications this switch may activate a warning signal. Read your equipment manuals for more information. For testing procedures refer to Electronic Ignition Systems and Oil Sentry™ Tests.

18 690 01 Rev. C KohlerEngines.com

Page 88

Electrical System

SPARK PLUGS

CAUTION

Electrical Shock can cause injury. Do not touch wires while engine is running.

Spark Plug Component and Details

Inspection

Inspect each spark plug as it is removed from cylinder head. Deposits on tip are an indication of general condition of piston rings, valves, and carburetor.

Normal and fouled plugs are shown in following photos:

Normal

Plug taken from an engine operating under normal conditions will have light tan or gray colored deposits. If center electrode is not worn, plug can be set to proper gap and reused.

Worn

A Wire Gauge B Spark Plug C Ground Electrode D Gap

NOTE: Do not clean spark plug in a machine using

abrasive grit. Some grit could remain in spark plug and enter engine causing extensive wear and damage.

Engine misﬁ re or starting problems are often caused by a spark plug that has improper gap or is in poor condition.

Engine is equipped with following spark plugs:

Gap 0.76 mm (0.03 in.) Thread Size 14 mm Reach 19.1 mm (3/4 in.) Hex Size 15.9 mm (5/8 in.)

Refer to Maintenance for Repairs/Service Parts.

Service

Clean out spark plug recess. Remove plug and replace.

1. Check gap using wire feeler gauge. Adjust gap to

0.76 mm (0.03 in.).

2. Install plug into cylinder head.

3. Torque plug to 27 N·m (20 ft. lb.).

On a worn plug, center electrode will be rounded and gap will be greater than speciﬁ ed gap. Replace a worn spark plug immediately.

Wet Fouled

A wet plug is caused by excess fuel or oil in combustion chamber. Excess fuel could be caused by a restricted air cleaner, a carburetor problem, or operating engine with too much choke. Oil in combustion chamber is usually caused by a restricted air cleaner, a breather problem, worn piston rings, or valve guides.

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Page 89

Electrical System

Carbon Fouled

Soft, sooty, black deposits indicate incomplete combustion caused by a restricted air cleaner, over rich carburetion, weak ignition, or poor compression.

Overheated

Chalky, white deposits indicate very high combustion temperatures. This condition is usually accompanied by excessive gap erosion. Lean carburetor settings, an intake air leak, or incorrect spark timing are normal causes for high combustion temperatures.

BATTERY

A 12 volt battery (not furnished) with a minimum current rating of 230 cold cranking amps/18 amp hours should be sufﬁ cient for cranking most electric start engine models. Actual cold cranking requirement depends on engine size, application and starting temperatures. Cranking requirements increase as temperatures decrease and battery capacity shrinks. Refer to equipment's operating instructions for speciﬁ c battery requirements.

If battery charge is insufﬁ cient to turn over engine, recharge battery.

Battery Maintenance

Regular maintenance is necessary to prolong battery life.

Battery Test

To test battery, follow manufacturer's instructions.

ELECTRONIC IGNITION SYSTEM Inductive Discharge Ignition System Components

Kill Switch/Off Position

C Flywheel D Magnet E Ignition Module F Spark Plug G Kill Terminal H Lamination

I Spark Plug Terminal J Spark Plug Boot

These engines are equipped with a dependable magneto breakerless ignition. In such a system, electrical energy is generated by cutting of magnetic ﬂ ux lines generated from ignition magnet on engine ﬂ ywheel via prescribed air gap as it passes ignition module. This energy is transferred through ignition module laminations and is then converted in module electronics and stored in module primary coil, as a current. Stored energy is transferred at correct moment by triggering a semiconductor switch inside module. Electrical break by switch initiates energy transfer by causing collapse of magnetic ﬁ eld at coil primary. This includes a voltage at coil primary that is ampliﬁ ed via transformer action at coil secondary. Amplitude of voltage at coil secondary is sufﬁ cient to jump gap at spark plug, igniting fuel air mixture in gap and initiating combustion. Note that by design, these modules only will provide proper function if mounted in correct orientation.

This ignition system is designed to be trouble free for life of engine. Other than periodically checking/replacing spark plugs, no maintenance or timing adjustments are necessary or possible. Mechanical systems do occasionally fail or break down. Refer to Troubleshooting to determine root of a reported problem.

Reported ignition problems are most often due to poor connections. Before beginning test procedure, check all external wiring. Be certain all ignition-related wires are connected, including spark plug leads. Be certain all terminal connections ﬁ t snugly. Make sure ignition switch is in run position.

of Key Switch

Air Gap 0.254 mm

(0.010 in.)

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Page 90

Electrical System

Electronic Ignition Systems and Oil Sentry™ Tests

1. Disconnect cap from spark plug and attach it to terminal end of spark tester. Attach tester spring clip to a good ground, not to spark plug. Turn ignition/key switch ON and crank engine while observing ﬁ ring tip of tester.

Condition Conclusion

Tester is ﬁ ring. Ignition system is good.

Install a new spark plug and try to start engine. If it still will not start, check other possible causes (fuel, compression, etc.).

Tester doesn't ﬁ re. Go to step 2.

2. Trace yellow lead wire from Oil Sentry™ control module to Oil Sentry connector where it joins lead from Oil Sentry switch (yellow lead wire). Repeat spark test.

ﬂ oat switch. Disconnect bullet

™

ﬂ oat

™

Condition Conclusion

Spark is now present. Control module or ﬂ oat

switch is faulty. Test control module (step 3) and ﬂ oat switch (step 4).

Still no spark. Test ignition module (step

5).

3. Connect a jumper lead from yellow lead terminal to a bare spot on crankcase (ground). Turn ignition switch ON, crank engine, and observe red LED indicator lamp.

Condition Conclusion

Indicator lamp was not ﬂ ashing.

Trace black lead from ignition switch. Separate bullet connector where switch lead joins double red harness lead. Crank engine, again observing red LED indicator lamp.

Indicator lamp ﬂ ashes during cranking.

Control module is functioning, proceed to step 5. If lamp was not

ﬂ ashing initially but did ﬂ ash in step 3, control

module is good, but ignition switch is probably faulty. Test ﬂ oat switch (step 4) and ignition switch (step 6).

4. Set an ohmmeter to Rx1 scale and zero meter. Connect one ohmmeter lead to Oil Sentry switch lead (yellow with green sleeve) and touch

ﬂ oat

™

other lead to a bare spot on crankcase (ground). Drain oil from crankcase and repeat test.

With oil at proper level, no continuity should have

been indicated. After oil was drained, continuity should have been indicated.

Condition Conclusion

No continuity indicated. Remove closure plate

from engine and remove ﬂ oat switch for further testing (steps 4a and 4b).

a. If continuity was indicated with and without oil

above, check if insulation has been scraped off ﬂ oat switch lead.

Condition Conclusion

Lead wire is bare. Allow it to short, repair

with electrical tape, or replace ﬂ oat switch.

b. With ﬂ oat switch removed, connect one

ohmmeter lead to ﬂ oat switch lead terminal and connect other lead to mounting bracket. Test resistance with switch in normal position and inverted. Repeat test 2 or 3 times in each direction.

Condition Conclusion

Switch continuity should

If not, replace it.

be as indicated.

5. Set an ohmmeter to Rx1K or Rx10K scale and zero. Connect one ohmmeter lead to kill lead (black/white) terminal and connect other lead into spark plug cap.

a. Remove cap from spark plug lead and test

resistance of cap alone.

b. If resistances are other than speciﬁ ed, remove

blower housing and remove ignition module. With kill lead and spark plug cap removed, test resistance from small spade terminal to core of spark plug lead wire. If resistance is not in this range, replace module.

Resistance Chart

Ignition Module 13.5-18.0 K ohms

Cap 4-6 K ohms

Spade Terminal to Spark

9.5-12.9 K ohms

Plug Lead Wire

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Page 91

6. Set an ohmmeter to Rx1 scale and zero meter. Test ignition/key switch as follows.

a. Trace two black leads from on/off switch and

separate them from any connections. Connect ohmmeter leads to switch leads, and check for continuity in both switch positions.

Condition Conclusion

Continuity should be indicated when and only when switch is in OFF position.

General Wiring Diagram

Replace switch for any other results.

Electrical System

A Ignition Module B Spark Plug

E Oil Alert Control Unit F

Optional Red

Ignition Switch

D Oil Sensor

Optional Micro

Shut Down Switch

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Page 92

Starter System

NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period between

starting attempts. Failure to follow these guidelines can burn out starter motor.

NOTE: If engine develops sufﬁ cient speed to disengage starter but does not keep running (a false start), engine

rotation must be allowed to come to a complete stop before attempting to restart engine. If starter is engages while ﬂ ywheel is rotating, starter pinion and ﬂ ywheel ring gear may clash, resulting in damage of starter.

NOTE: If starter does not crank engine, shut off starter immediately. Check condition of inline fuse and do not make

further attempts to start engine until condition is corrected.

NOTE: Do not drop starter or strike starter housing. Doing so can damage starter. Engines in this series use inertia drive electric starters or retractable starters. Inertia drive electric starters are not

serviceable.

Troubleshooting-Starting Difﬁ culties

Condition Possible Cause Conclusion

Starter does not energize. Battery Check speciﬁ c gravity of battery. If low, recharge or replace

battery as necessary.

Wiring Check fuse condition.

Clean corroded connections and tighten loose connections. Replace wires in poor condition and with frayed or broken

insulation.

Starter energizes but turns slowly.

Starter Switch

or Solenoid

Battery Check speciﬁ c gravity of battery. If low, recharge or replace

Wiring Check for corroded connections, poor ground connection.

Transmission

Engine

Check switch or relay operation. If starter cranks normally, replace faulty components.

battery as necessary.

Make sure clutch or transmission is disengaged or placed in neutral. This is especially important on equipment with hydrostatic drive. Transmission must be exactly in neutral to prevent resistance which could keep engine from starting.

Check for seized engine components such as bearings, connecting rod, and piston.

Electric Starting System Tests

1. Test battery on unit. a. Connect a DC voltmeter across battery terminals

and read battery voltage (key switch OFF).

b. Turn key switch to start position and read battery

voltage again. Turn switch OFF.

Condition Conclusion

Voltage less than 12 volts. Charge battery.

Battery voltage should not fall below 9 volts during cranking.

If it does, battery may be faulty or there may be a short in starting circuit. Have battery load tested. If battery passes load test, check circuitry.

2. Remove electric starter cover panel and check fuse inside plastic holder. Fuse outside holder is a spare.

Condition Conclusion

Fuse is blown. Check for a wiring

problem (bare wire, short circuit). Correct problem and replace fuse. Try to start engine. If it still won’t start, go to step 3.

3. Disconnect blue relay lead. Be sure transmission is in neutral and PTO is OFF. Connect one end of a jumper lead to positive terminal of battery. Connect other end to terminal of relay.

Condition Conclusion

Relay engages and starter begins to crank.

Key switch is faulty, or there is a wiring problem to/from key switch. Check wiring and test key switch circuits with an ohmmeter.

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Page 93

4. Use a known, good, fully-charged battery and jumper cables to test starter motor. Be sure transmission is in neutral and PTO is OFF.

Remove heavy lead from post terminal on starter.

Connect one end of positive jumper cable to post terminal and connect other end to positive terminal of battery.

Connect one end of negative jumper cable to

negative terminal of battery. Touch other end of negative jumper cable to a bare surface on crankcase or to starter housing.

Condition Conclusion

Relay engages and starter begins to crank.

5. Disconnect leads from starter relay and remove it from starter for testing.

a. Set an ohmmeter on Rx1 scale and zero meter.

Connect one ohmmeter lead to terminal of blue lead from relay. Connect other ohmmeter lead to relay mounting bracket.

Key switch is faulty, or there is a wiring problem to/from key switch. Check wiring and test key switch circuits with an ohmmeter.

Starter System

Condition Conclusion

Meter reading less than

3.4 ohms, or an open circuit is indicated (inﬁ nity ohms).

b. With ohmmeter still on Rx1 scale, connect leads

to two large post terminals. Meter should indicate an open circuit (inﬁ nity ohms, no continuity).

c. Leave ohmmeter leads connected to large

terminals. Connect a jumper lead from positive terminal of battery to terminal of blue relay lead. Connect another jumper lead from negative terminal of battery to relay mounting bracket.

Condition Conclusion

When circuit is completed, applying 12 volts to energizing coil, an audible click should be heard as relay engages, and ohmmeter should then indicate continuity between large terminals.

Relay is faulty and must be replaced.

Results are other than indicated, replace relay.

18 690 01 Rev. C KohlerEngines.com

Page 94

Starter System

RETRACTABLE STARTERS

WARNING

Uncoiling Spring can cause severe injury. Wear safety goggles or face protection when

servicing retractable starter.

Retractable Starter Components

A Kit, Pawl Repair B Kit, Starter Rope with Handle

Remove Starter

1. Remove screws securing starter to blower housing.

2. Remove starter assembly.

Rope Replacement

NOTE: Do not allow pulley/spring to unwind. Enlist aid

of a helper if necessary.

Rope can be replaced without complete starter disassembly.

1. Remove starter assembly from engine.

2. Pull rope out approximately 12 in. and tie a temporary (slip) knot in it to keep it from retracting into starter.

3. Pull knot end out of handle, untie knot, and slide handle off.

4. Hold pulley ﬁ rmly and untie slipknot. Allow pulley to rotate slowly as spring tension is released.

5. When all spring tension on starter pulley is released, remove rope from pulley.

6. Tie a double left-hand knot in one end of new rope.

7. Rotate pulley counterclockwise to pre-tension spring (approximately 4 full turns of pulley).

8. Continue rotating pulley counterclockwise until rope hole in pulley is aligned with rope guide bushing of starter housing.

9. Insert unknotted end of new rope through rope hole in starter pulley and rope guide bushing of housing.

10. Tie a slipknot approximately 12 in. from free end of rope. Hold pulley ﬁ rmly and allow it to rotate slowly until slipknot reaches guide bushing of housing.

11. Insert starter rope through starter handle and tie a double, left-hand knot at end of starter rope. Insert knot into hole in handle.

12. Untie slip knot and pull on starter handle until starter rope is fully extended. Slowly retract starter rope into starter assembly. If recoil spring is properly tensioned, starter rope will retract fully and starter handle will stop against starter housing.

Pawls (dogs) Replacement

1. Install a clamp to hold pulley in starter housing and prevent it from rotating.

2. Unscrew center screw and lift off drive plate.

3. Note positions of pawls and pawl springs before removing. Remove parts from pulley.

4. Install pawl springs and pawls into pawl slots of pulley. All parts must by dry.

5. Position drive plate over pawls, aligning actuating slots in place with raised sections on each drive pawl. Torque center screw to 5-6 N·m (44-54 in. lb.).

6. Remove clamp and pull starter rope out part way to check operation of pawls.

Install Starter

1. Install retractable starter onto blower housing leaving screws slightly loose.

2. Pull starter handle out until pawls engage in drive cup. Hold handle in this position and tighten screws securely.

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Page 95

WARNING

Accidental Starts can cause severe injury or death.

Disconnect and ground spark plug lead(s) before servicing.

External Engine Components

Disassembly/Inspection and Service

Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery.

A Oil Drain Plug B Oil Fill Plug C Mufﬂ er Assembly D Breather Hose

E Air Cleaner Cover F Element/Precleaner G Air Cleaner Base H Carburetor Cover

I Fuel Tank J Fuel Tank Filter K

18 690 01 Rev. C KohlerEngines.com

Low-Proﬁ le Air

Cleaner

Page 96

Disassembly/Inspection and Service

Clean all parts thoroughly as engine is disassembled. Only clean parts can be accurately inspected and gauged for wear or damage. There are many commercially available cleaners that will quickly remove grease, oil, and grime from engine parts. When such a cleaner is used, follow manufacturer’s instructions and safety precautions carefully.

Make sure all traces of cleaner are removed before engine is reassembled and placed into operation. Even small amounts of these cleaners can quickly break down lubricating properties of engine oil.

Disconnect Spark Plug Lead

NOTE: Pull on boot only, to prevent damage to spark

plug lead.

1. Disconnect spark plug lead from spark plug.

2. Push fuel shut-off lever left to close fuel valve.

Drain Oil From Crankcase

1. Remove 1 oil drain plug and 1 oil ﬁ ll plug.

2. Allow ample time for oil to drain from crankcase.

Remove Mufﬂ er and Heat Shield Assembly

1. Remove nuts, lock washers, and ﬂ at washers.

Blower Housing/Control Panel Components

2. Remove mufﬂ er assembly from exhaust outlet.

3. Remove exhaust gasket from exhaust outlet.

Remove Air Cleaner Assembly

Remove air cleaner base from engine as follows:

1. Remove screws securing base of air cleaner assembly to engine.

2. Disconnect breather hose and remove base of air cleaner assembly.

3. Remove nuts and carburetor cover.

4. Loosely install nuts on studs (to temporarily hold carburetor on engine).

Remove Fuel Tank

1. Ensure fuel tank is empty.

2. Loosen clamp and disconnect fuel line from inlet of shut-off valve.

3. Remove nuts.

4. Remove screw and fuel tank while guiding fuel hose through engine bracket.

A Governor Lever B Nut C Governor Spring D Throttle Link

E Dampening Spring F Control Assembly G Carburetor H Retractable Starter

M Oil Sentry™ Bracket

On/Off Wiring

Harness Bullet

Connector

J Blower Housing K

Oil Sentry™ Wiring

Harness Bullet

Connector

L Oil Sentry™ Module

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Page 97

Disassembly/Inspection and Service

Remove External Throttle, Governor and Choke Linkage

1. Mark hole in which governor spring is attached and loosen nut securing governor lever arm to governor shaft. Lift off governor lever and remove carburetor throttle link, dampening spring, and governor spring from governor lever.

2. Remove nut securing throttle control lever. Unhook spring and remove throttle control lever.

3. Remove screws and throttle plate.

Remove Carburetor

WARNING

Explosive Fuel can cause ﬁ res and severe burns.

Do not ﬁ ll fuel tank while engine is hot or running.

Remove air cleaner gasket and slide carburetor off mounting studs while disconnecting throttle linkage and dampening spring. Remove carburetor to insulator gasket, insulator, and insulator to cylinder head gasket.

Remove Retractable Starter

Remove screws securing retractable starter assembly to blower housing.

Remove Electric Starter (if equipped)

Remove screws securing electric starter to blower housing.

Remove Blower Housing

1. Remove screws securing blower housing.

2. Release wiring harness bundle clamp and disconnect ON/OFF wiring harness bullet connectors.

3. Remove blower housing.

Remove Oil Sentry™ Module

Disconnect wiring harness bullet connector between Oil Sentry™ switch and module. Remove screw securing module to bracket.

Cylinder Head Components

A Valve Cover B Adjusting Nut C Rocker Arm D Rocker Arm Stud

E Push Rod Guide F Push Rod G Valve Keeper H Valve Spring

Intake Valve Stem

M Dowel Pins N Cylinder Head

Seal

J Cylinder Shroud K Valve L Spark Plug

18 690 01 Rev. C KohlerEngines.com

Page 98

Disassembly/Inspection and Service

Remove Valve Cover/Breather, Rocker Arms, Push Rods and Cylinder Head Assembly

NOTE: Mark location of push rods and any other part

removed that will be reused.

Valve Cover with Gasket

1. Remove screws and remove valve cover and gasket from engine. Breather assembly is inside valve cover.

2. Remove screws securing cylinder shroud and remove cylinder shroud.

3. Loosen and remove rocker arm lock nuts and adjuster nuts. Remove rocker arms and push rods.

4. Remove spark plug.

5. Remove screws securing cylinder head.

6. Remove cylinder head, dowel pins, and cylinder head gasket.

Valve Cover with RTV Sealant

NOTE: Valve cover is sealed to cylinder head using

RTV silicone sealant. When removing valve cover, use care not to damage gasket surfaces of cover and cylinder head. To break RTV seal, hold block of wood against 1 ﬂ at surface of valve cover. Strike wood ﬁ rnly with mallet. If seal doesn't break loose after 1 or 2 attempts, repeat procedure on other side.

1. Remove screws and remove valve cover from engine. Breather assembly is inside valve cover.

2. Using a brass wire brush and gasket remover or similar solvent, clean old RTV from surface of cylinder head and valve cover.

3. Remove screws securing cylinder shroud and remove cylinder shroud.

4. Loosen and remove rocker arm lock nuts and adjuster nuts. Remove rocker arms and push rods.

5. Remove spark plug.

6. Remove screws securing cylinder head.

7. Remove cylinder head, dowel pins, and cylinder head gasket.

Remove Valves

NOTE: Mark location of any part removed that will be

reused.

1. Supporting head of valve from below, depress valve keeper and valve spring until keeper can be released from valve stem. Remove valve spring and valve from head. Repeat this procedure for remaining valve.

2. Remove and replace intake valve stem seal whenever cylinder head is serviced or disassembled.

KohlerEngines.com 18 690 01 Rev. C

Page 99

Valve Details

Disassembly/Inspection and Service

Item Dimension Intake Exhaust

B Stem Diameter—Speciﬁ cation 5.5 mm (0.217 in.) 5.438 mm (0.214 in.)

D Face/Seat Width—Maximum 2.0 mm (0.079 in.) 2.0 mm (0.079 in.)

E Face/Seat Angle 90°-90.5°/89.5°-90° 90-90.5°/89.5°-90°

Stem to Guide Running Clearance—Speciﬁ cation 0.020 mm (0.0008 in.) 0.030 mm (0.0008 in.)

Stem to Guide Running Clearance—Maximum 0.044 mm (0.0017 in.) 0.054 mm (0.0021 in.)

Stem to Guide Running Clearance—Service Limit 0.10 mm (0.0039 in.) 0.12 mm (0.0047 in.)

Head Diameter—Speciﬁ cation

Head Diameter—Maximum 25.1 mm (0.9881 in.) 24.1 mm (0.9488 in.)

Head Diameter—Service Limit 24.9 mm (0.9803 in.) 23.9 mm (0.9409 in.)

Stem Diameter—Maximum 5.491 mm (0.216 in.) 5.430 mm (0.214 in.)

Stem Diameter—Service Limit 5.340 mm (0.210 in.) 5.280 mm (0.208 in.)

Valve Length—Speciﬁ cation

Valve Length—Maximum 64.15 mm (2.5256 in.) 62.15 mm (2.4468 in.)

Valve Length—Service Limit 64.15 mm (2.5256 in.) 62.15 mm (2.4468 in.)

Stem to Guide—Speciﬁ cation 0.024 mm (0.0009 in.) 0.098 mm (0.0038 in.)

Stem to Guide—Maximum 0.039 mm (0.0015 in.) 0.112 mm (0.0044 in.)

Stem to Guide—Service Limit 0.10 mm (0.0039 in.) 0.12 mm (0.0047 in.)

Valve Guide – Speciﬁ cation 5.5 mm (0.2165 in.) 5.5 mm (0.2165 in.)

Valve Guide – Maximum 5.512 mm (0.2170 in.) 5.512 mm (0.2170 in.)

25 mm + 0.1 mm

(0.9842 in. + 0.0039 in.)

64 mm + 0.15 mm

(2.5197in. + 0.0059 in.)

24 mm + 0.1 mm

(0.9449 in. + 0.0039 in.)

62 mm + 0.15 mm

(2.4409 in. + 0.0059 in.)

18 690 01 Rev. C KohlerEngines.com

Page 100

Disassembly/Inspection and Service

Inspection and Service

After cleaning, check ﬂ atness of cylinder head and corresponding top surface of crankcase, using a surface plate or piece of glass and feeler gauge. Maximum allowable out of ﬂ atness is 0.1 mm (0.0039 in.).

Carefully inspect valve mechanism parts. Inspect valve springs and related hardware for excessive wear or distortion. Check valves and valve seats for evidence of deep pitting, cracks, or distortion. Check running clearance between valve stems and guides.

Hard starting, or loss of power accompanied by high fuel consumption may be symptoms of faulty valves. Although these symptoms could also be attributed to worn rings, remove and check valves ﬁ rst. After removal, clean valve heads, faces, and stems with a power wire brush.

Then, carefully inspect each valve for defects such as warped head, excessive corrosion, or worn stem end. Replace valves found to be in bad condition.

Valve Guides

If a valve guide is worn beyond speciﬁ cations, it will not guide valve in a straight line. This may result in burned valve faces or seats, loss of compression, and excessive oil consumption.

To check valve guide-to-valve stem clearance, thoroughly clean valve guide and, using a split-ball gauge, measure inside diameter of guide. Then, using an outside micrometer, measure diameter of valve stem at several points on stem where it moves in valve guide. Use largest stem diameter to calculate clearance by subtracting stem diameter from guide diameter. If intake or exhaust clearance exceeds speciﬁ cations in Valve Speciﬁ cation table, determine whether valve stem or guide is responsible for excessive clearance.

If guides are within limits but valve stems are worn beyond limits, install new valves.

Valve Seat Inserts

Hardened steel alloy intake and exhaust valve seat inserts are press-ﬁ tted into cylinder head. Inserts are not replaceable but can be reconditioned if not too badly pitted or distorted. If cracked or badly warped, cylinder head should be replaced.

Recondition valve seat inserts following instructions provided with valve seat cutter being used. Cutting proper valve face angle, as speciﬁ ed in Clearance Speciﬁ cations table and proper valve seat angle (89.5°- 90°) will achieve desired 0° (1° full cut) interference angle where maximum pressure occurs on outside diameters of valve face and seat.

Lapping Valves

Reground or new valves must be lapped in, to provide proper ﬁ t. Use a hand valve grinder with a suction cup for ﬁ nal lapping. Lightly coat valve face with a ﬁ ne grade of grinding compound, then rotate valve on seat with grinder. Continue grinding until a smooth surface is obtained on seat and on valve face. Thoroughly clean cylinder head in hot, soapy water to remove all traces of grinding compound. After drying cylinder head, apply a light coating of SAE 10 oil to prevent rusting.

Intake Valve Stem Seal

Some engines use a valve stem seal on intake valve. Always use a new seal when valves are removed

from cylinder head. Seals should also be replaced if deteriorated or damaged in any way. Never reuse an old seal.

Flywheel/Ignition Components

Flywheel Retaining

C Flywheel Fan D Flywheel

E Flywheel Shield F Ignition Module

Remove Ignition Module

Remove screws securing ignition module to crankcase. Remove module.

Remove Flywheel

NOTE: Whenever possible, an impact wrench should be

used to loosen ﬂ ywheel retaining nut. A ﬂ ywheel strap wrench may be used to hold ﬂ ywheel when loosening or tightening ﬂ ywheel retaining nut.

NOTE: Always use a puller to remove ﬂ ywheel from

crankshaft. Do not strike ﬂ ywheel or crankshaft as these parts could become cracked or damaged.

1. Remove ﬂ ywheel retaining nut.

2. Remove drive cup and fan from ﬂ ywheel.

3. Remove screw and shield on right side of ﬂ ywheel (required for use of puller in next step).

4. Remove ﬂ ywheel from crankshaft using a suitable puller.

5. Remove ﬂ ywheel key from crankshaft keyway.

Inspection

Inspect ﬂ ywheel for cracks and ﬂ ywheel keyway for damage. Replace ﬂ ywheel if it is cracked. Replace ﬂ ywheel, crankshaft, and key if ﬂ ywheel key is sheared or keyway is damaged.

Nut

B Drive Cup

KohlerEngines.com 18 690 01 Rev. C