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Grizzly T27710 Owner's Manual

22-ton log splitter w/kohler engine
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MODEL T27710
22-TON LOG SPLITTER
w/KOHLER ENGINE
OWNER'S MANUAL
(For models manufactured since 04/16)
COPYRIGHT © JUNE, 2016 BY GRIZZLY INDUSTRIAL, INC.
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
V1.06.16
#BLWK18211 PRINTED IN CHINA

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  • Page 1 (For models manufactured since 04/16) COPYRIGHT © JUNE, 2016 BY GRIZZLY INDUSTRIAL, INC. WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC. V1.06.16 #BLWK18211 PRINTED IN CHINA...
  • 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.

  • Page 3: Table Of Contents

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

  • Page 4: Introduction

    ID label (see below). This information is required for us to provide proper tech support, and it helps us determine if updated documenta- tion is available for your machine. Manufacture Date Serial Number Model T27710 (Mfd. Since 04/16)

  • Page 5: Identification

    R. Engine Controls (refer to Page 5 for details) H. Splitting Wedge S. Support Leg Lock Pin Dislodger Support Leg Beam U. Safety Chain K. Foot Plate To reduce your risk of serious injury, read this entire manual BEFORE using machine. Model T27710 (Mfd. Since 04/16)

  • Page 6: Controls & Components

    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. Model T27710 (Mfd. Since 04/16)
  • Page 7 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. Model T27710 (Mfd. Since 04/16)

  • Page 8: Machine Data Sheet

    Max. Stroke Length ............................23-1/8 in. Automatic Cylinder Return ............................Yes Vertical & Horizontal Operation ...........................Yes Construction Information Splitter Wedge ..............................Carbon Steel Splitter Wedge Height ..............................7 in. Axle ................................Carbon Steel Hoses ................................Wire Braid Model T27710 (Mfd. Since 04/16) Model T27710 Page 1 of 2...
  • Page 9 Assembly Time ................................. 30 Minutes Features: Automatic Cylinder Return 25-5/8 in. Log Capacity 22-Ton Splitter Ram Force 2" Tow Ball Coupler 45 MPH Tow Rating Carbon Steel Splitter Wedge Carbon Steel Frame Page 2 of 2 Model T27710 Model T27710 (Mfd. Since 04/16)

  • Page 10: Section 1: Safety

    Everyday ery. Never operate under the influence of drugs or eyeglasses are NOT approved safety glasses. alcohol, when tired, or when distracted. Model T27710 (Mfd. Since 04/16)
  • Page 11 EXPERIENCING DIFFICULTIES. If at any time debris. Make sure they are properly installed, you experience difficulties performing the intend- undamaged, and working correctly BEFORE ed operation, stop using the machine! Contact our operating machine. Technical Support at (570) 546-9663. Model T27710 (Mfd. Since 04/16)

  • Page 12: Additional Safety For Log Splitters

    MACHINE LOCATION. Never leave splitter run- FUEL SPILLS. Fuel exposed to hot engine com- ning unattended, always block wheels to prevent ponents may ignite. Thoroughly clean all fuel rolling, and store unit in locked location. spills before starting engine. -10- Model T27710 (Mfd. Since 04/16)

  • Page 13: Section 2: Setup

    IMPORTANT: Save all packaging materials until 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.

  • Page 14: Inventory

    O. Lock Nuts M10-1.5 (Frame Tube) ....2 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 7. Hardware inventory. -12- Model T27710 (Mfd. Since 04/16)
  • Page 15 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. -13- Model T27710 (Mfd. Since 04/16)

  • Page 16: Site Considerations

    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. Figure 9. Working clearances. -14- Model T27710 (Mfd. Since 04/16)

  • Page 17: Assembly

    Flat Washer 12mm M12-1.75 x 35 Figure 10. Installing wheel onto axle. Frame Hydraulic Repeat Steps 1–3 to install the other wheel. Tube Tank Lock Nut M12-1.75 Figure 13. Installing frame tube onto tank. -15- Model T27710 (Mfd. Since 04/16)
  • Page 18 Lock Nut Cylinder M12-1.75 Hex Bolt Lock Washer Flat Washer M12-1.75 x 65 10mm 10mm Mounting Pad Figure 15. Hydraulic cylinder cover re-installed. Figure 17. Installing rubber spacers and flat washers onto motor mounting pad. -16- Model T27710 (Mfd. Since 04/16)
  • Page 19 Pressure (see Figure 20). Fitting Hose Hydraulic Figure 22. High pressure hose and control lever. Clamps Pump Suction Hose Hydraulic Tank Figure 20. Suction hose attached to hydraulic pump and hydraulic tank. -17- Model T27710 (Mfd. Since 04/16)
  • Page 20 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! -18- Model T27710 (Mfd. Since 04/16)

  • Page 21: Test Run/Break-In

    Read and understand Kohler engine manual choke lever to ON (I) position (see Figure 27). that accompanied this log splitter and follow all safety precautions. Read and understand entire Grizzly manual and follow all safety Choke Lever Throttle precautions. Control Lever Make sure hydraulic tank and engine have been filled to required fluid and fuel levels.
  • Page 22 Control Lever pressure and prevent possibility of hydraulic fluid injection injury during repair. Refer to Troubleshooting on Page 33 for solutions, or call Technical Support at (570) 546-9663. Figure 30. Engine controls in OFF position. -20- Model T27710 (Mfd. Since 04/16)

  • Page 23: Section 3: Operations

    NEVER run engine indoors ects. Regardless of the content in this sec- such as in a garage, barn, tion, Grizzly Industrial will not be held liable carport, or storage shed, for accidents caused by lack of training. even if it is ventilated.

  • Page 24: Job Site Considerations

    Raise coupler lock lever (see Figure 34) to unlatch it, and place coupler onto tow ball. Support-Leg Coupler Lock Pin Lock Lever Support Leg Safety Chains Figure 34. Raising support leg to towing position. -22- Model T27710 (Mfd. Since 04/16)

  • Page 25: Control Lever

    When the ram fully retracts, the control lever tip over during towing, causing a fuel leak automatically moves back to neutral, and the log and possible fire. splitter is ready to split another log. -23- Model T27710 (Mfd. Since 04/16)

  • Page 26: Splitting Logs

    Horizontal Operation Vertical Operation Control Lever Beam Beam Splitting Assembly Wedge Beam Lock Work Zone is Approximately a 6-Foot Sphere Foot Plate Figure 37. Horizontal and vertical log splitter operating positions. -24- Model T27710 (Mfd. Since 04/16)

  • Page 27: Removing Stuck Logs

    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. -25- Model T27710 (Mfd. Since 04/16)

  • Page 28: Section 4: Accessories

    T21272—Golden Pigskin Gloves T20692—Deluxe Soft Goatskin Gloves Installing unapproved accessories may Grizzly offers a wide selection of synthetic and cause machine to malfunction, resulting in leather gloves for all-day comfort in a variety of serious personal injury or machine damage.
  • Page 29 (not included). Great for fast, on-site includes nutsand lock washer. 2" hitch ball, 1" x sharpening! ⁄ " shank. Figure 44. T10278 Chainsaw Filing Guide. Figure 46. H7824 2" Stainless Ball Hitch. www.grizzly.com 1-800-523-4777 order online at or call -27- Model T27710 (Mfd. Since 04/16)

  • Page 30: Section 5: Maintenance

    In reverse order, re-install wheel with compo- • Refer to the Kohler engine manual for gen- nents removed in Step 1. eral engine maintenance schedules. -28- Model T27710 (Mfd. Since 04/16)

  • Page 31: Checking/Adding Hydraulic Fluid

    3.5 gallons of hydraulic Figure 48. Vented cap location. fluid or amount needed to fill tank to middle of dipstick. Check hydraulic fluid level (follow steps from Checking Hydraulic Fluid Level) then re- install vented cap. -29- Model T27710 (Mfd. Since 04/16)

  • Page 32: Changing Hydraulic Fluid

    Block log splitter wheels to prevent them from rolling. 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. -30- Model T27710 (Mfd. Since 04/16)

  • Page 33: Changing Hydraulic Tank Filter

    #PT27710040 can be purchased by contacting for longer than fuel stabilizer manufacturer's the Grizzly Order Desk at (800) 523-4777. recommendation. To change the filter, DISCONNECT SPARK PLUG Perform Test Run/Break In procedure on...

  • Page 34: Sharpening Splitting Wedge

    The optimum point is somewhere between. Refer to Figure 52 for a general idea. Wedge Just Right Figure 52. Good and bad wedge points. -32- Model T27710 (Mfd. Since 04/16)

  • Page 35: Section 6: Service

    5. Bleed air out of hydraulic system. 1. Replace hydraulic fluid (Page 30). Hydraulic tank fluid 1. Hydraulic fluid old or contaminated with burnt or has tan water. discoloration. Note: Refer to the Kohler engine manual for engine-related troubleshooting. -33- Model T27710 (Mfd. Since 04/16)

  • Page 36: Section 7: Hydraulic System

    Hydraulic Fluid Reservoir This diagram is only provided as a refer- ence to help you identify hydraulic sys- tem components. Seek assistance from a professional hydraulic technician whenever servicing or repairing the hydraulic system. -34- Model T27710 (Mfd. Since 04/16)

  • Page 37: Section 8: Parts

    SECTION 8: PARTS 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. Main 61 75 57 37...

  • Page 38: Main

    PT27710035 HEX BOLT M12-1.75 X 35 PT27710073 HEX BOLT M10-1.5 X 70 PT27710036 HEX BOLT M8-1.25 X 65 PT27710074 LOCK NUT M10-1.5 PT27710037 FLAT WASHER 8MM PT27710075 SET SCREW M6-1 X 10 PT27710038 LOCK NUT M8-1.25 -36- Model T27710 (Mfd. Since 04/16)

  • Page 39: Labels

    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. -37-...
  • Page 40 -38- Model T27710 (Mfd. Since 04/16)
  • Page 41 Would you recommend Grizzly Industrial to a friend? _____ Yes _____No 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.
  • Page 42 FOLD ALONG DOTTED LINE Place Stamp Here GRIZZLY INDUSTRIAL, INC. P.O. BOX 2069 BELLINGHAM, WA 98227-2069 FOLD ALONG DOTTED LINE Send a Grizzly Catalog to a friend: Name_______________________________ Street_______________________________ City______________State______Zip______ TAPE ALONG EDGES--PLEASE DO NOT STAPLE...

  • Page 43: Warranty & Returns

    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.
  • 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. Safety Maintenance Specifi cations Tools and Aids Troubleshooting Air Cleaner/Intake...
  • 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. CAUTION WARNING WARNING...
  • Page 65 Maintenance MAINTENANCE INSTRUCTIONS WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
  • Page 66 Maintenance OIL RECOMMENDATIONS STORAGE If engine will be out of service for 2 months or more We recommend use of Kohler oils for best performance. follow procedure below. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ 1.
  • Page 67 Specifi cations Engine Dimensions Dimensions in millimeters. 318.66 Inch equivalents shown in [ ]. [12.545] STRAIGHT PTO 181.60 [7.150] 369.40 [14.543] 113.44 [4.466] SPARK PLUG 273.97 [10.786] OIL FILL DRAIN PLUG 2X Ø 10.00 [0.394] 37.98 [1.495] 2X 10.00 X 15.50 37.50 [1.476] SLOT [0.394 X 0.610] 78.00...
  • 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...
  • Page 69 Specifi cations TORQUE SPECIFICATIONS 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.
  • 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. 14.000/14.018 mm (0.5512/0.5519 in.) Max. Wear Limit 14.048 mm (0.5531 in.) Connecting Rod Crankpin End I.D. @ 21°C (70°F) 30.021/30.026 mm (1.1819/1.1821 in.) Max.
  • Page 71 Specifi cations CLEARANCE SPECIFICATIONS SH265 Cylinder Bore Bore I.D. 70.027/70.035 mm (2.757/2.757 in.) Max. Wear Limit 70.200 mm (2.764 in.) Max. Out-of-Round 12.7 microns (0.0005 in.) Max. Taper 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.)
  • 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. 5.480 mm (0.2157 in.) Max. Wear Limit 5.32 mm (0.2094 in.) Exhaust Valve Stem O.D.
  • Page 73 Specifi cations 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 Into Aluminum Size Grade 2 Grade 5 Grade 8 Tightening Torque: N·m (in. lb.) ± 20% 8-32 2.3 (20) 2.8 (25)
  • 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.
  • Page 75 Tools and Aids TOOLS Description Source/Part No. Hose Removal Tool, Dual Size/End (also available in EFI Service Kit) Kohler 25 455 20-S Used to properly remove fuel hose from engine components. Hydraulic Valve Lifter Tool Kohler 25 761 38-S For removing and installing hydraulic lifters. Ignition System Tester Kohler 25 455 01-S For testing output on all systems, including CD.
  • 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 A spanner wrench to lift rocker arms or turn crankshaft fl ywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.
  • 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.
  • Page 78 Troubleshooting EXTERNAL ENGINE INSPECTION Engine Loses Power NOTE: It is good practice to drain oil at a location away ● Dirty air cleaner element. from workbench. Be sure to allow ample time for ● Engine overheated. complete drainage. ● Excessive engine load. ●...
  • Page 79 Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea, Rotating Parts can cause severe injury. fainting or death. Stay away while engine is in operation. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon Keep hands, feet, hair, and clothing away from all monoxide.
  • 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.
  • Page 81 Air Cleaner/Intake AIR CLEANER NOTE: Operating engine with loose or damaged air cleaner components could cause premature These systems are CARB/EPA certifi ed and components wear and failure. Replace all bent or damaged should not be altered or modifi ed in any way. components.

  • Page 82: Fuel System

    Fuel System Typical carbureted fuel system and related components Fuel Shut-Off include: ● Fuel tank. WARNING ● Fuel lines. ● In-line fuel fi lter. Explosive Fuel can cause fi res and severe ● Fuel tank fi lter. burns. ● Carburetor. Do not fi...
  • Page 83 Fuel System CARBURETOR Gasoline is extremely fl ammable and its vapors can WARNING explode if ignited. Store gasoline only in approved Explosive Fuel can cause fi res and severe containers, in well ventilated, unoccupied buildings, away burns. from sparks or fl ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition.
  • Page 84 Fuel System Troubleshooting-Carburetor Related Causes Condition Possible Cause Conclusion Engine starts hard, runs rough, or Low idle fuel mixture (some models)/ Adjust idle speed screw or clean stalls at idle speed. speed improperly adjusted. carburetor. Engine runs rich (indicated by black, Clogged air cleaner.
  • Page 85 Fuel System • 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.
  • Page 86 Governor System GOVERNOR Governor Components Control Assembly Governor Spring Throttle Link Dampening Spring Throttle Control Lever Governor Lever Washer Governor Gear Governor Gear Shaft Governed speed setting is determined by position of ● When load is applied and engine speed and governor throttle control.
  • 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 Dipstick Oil Fill Plug Oil Drain Plug OIL RECOMMENDATIONS CHANGE OIL Refer to Maintenance. Change oil while engine is warm. CHECK OIL LEVEL 1.
  • Page 88 Electrical System SPARK PLUGS Inspection Inspect each spark plug as it is removed from cylinder CAUTION head. Deposits on tip are an indication of general Electrical Shock can cause injury. condition of piston rings, valves, and carburetor. Do not touch wires while engine is running. Normal and fouled plugs are shown in following photos: Normal Spark Plug Component and Details...
  • Page 89 Electrical System Carbon Fouled ELECTRONIC IGNITION SYSTEM Inductive Discharge Ignition System Components Soft, sooty, black deposits indicate incomplete combustion caused by a restricted air cleaner, over rich carburetion, weak ignition, or poor compression. Overheated Kill Switch/Off Position Air Gap 0.254 mm of Key Switch (0.010 in.) Flywheel...
  • Page 90 Electrical System Electronic Ignition Systems and Oil Sentry Tests ™ 1. Disconnect cap from spark plug and attach it to 4. Set an ohmmeter to Rx1 scale and zero meter. terminal end of spark tester. Attach tester spring clip Connect one ohmmeter lead to Oil Sentry fl...
  • Page 91 Electrical System 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.
  • 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.
  • Page 93 Starter System 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.
  • Page 94 Starter System RETRACTABLE STARTERS WARNING Retractable starters contain a powerful, recoil spring that is under tension. Always wear safety goggles when servicing Uncoiling Spring can cause severe injury. retractable starters and carefully follow instructions in Wear safety goggles or face protection when Retractable Starter for relieving spring tension.
  • Page 95 Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
  • Page 96 Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. 2. Remove muffl er assembly from exhaust outlet. Only clean parts can be accurately inspected 3. Remove exhaust gasket from exhaust outlet. and gauged for wear or damage. There are many commercially available cleaners that will quickly remove Remove Air Cleaner Assembly grease, oil, and grime from engine parts.
  • Page 97 Disassembly/Inspection and Service Remove air cleaner gasket and slide carburetor off Remove External Throttle, Governor and Choke mounting studs while disconnecting throttle linkage Linkage and dampening spring. Remove carburetor to insulator 1. Mark hole in which governor spring is attached and gasket, insulator, and insulator to cylinder head gasket.
  • Page 98 Disassembly/Inspection and Service Remove Valve Cover/Breather, Rocker Arms, Push Remove Valves Rods and Cylinder Head Assembly NOTE: Mark location of any part removed that will be NOTE: Mark location of push rods and any other part reused. removed that will be reused. 1.
  • Page 99 Disassembly/Inspection and Service Valve Details Item Dimension Intake Exhaust 25 mm + 0.1 mm 24 mm + 0.1 mm Head Diameter—Specifi cation (0.9842 in. + 0.0039 in.) (0.9449 in. + 0.0039 in.) 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.)
  • Page 100 Disassembly/Inspection and Service Inspection and Service Intake Valve Stem Seal After cleaning, check fl atness of cylinder head and Some engines use a valve stem seal on intake valve. corresponding top surface of crankcase, using a surface Always use a new seal when valves are removed plate or piece of glass and feeler gauge.
  • Page 101 Disassembly/Inspection and Service Crankcase Components Closure Plate Oil Seal Closure Plate Bearing Closure Plate Gasket Oil Sentry Float Camshaft Crankshaft End Cap ™ Switch Connecting Rod Piston Pin Retainer Piston Pin Piston Piston Ring Set Tappet Governor Cup Governor Washer Governor Shaft Governor Gear Governor Cross Shaft...
  • Page 102 Disassembly/Inspection and Service 1. Manual (retractable) starting is much easier. Without Remove Camshaft and Valve Tappets ACR, manual starting would be virtually impossible. 1. Remove camshaft by pulling it straight out of 2. Electric start models can use a smaller starter and crankcase.
  • Page 103 Disassembly/Inspection and Service Detonation damage occurs when a portion of fuel charge 1. Use a micrometer and measure diameter of piston ignites spontaneously from heat and pressure shortly 15 mm (0.5905 in.) above bottom of piston skirt and after ignition. This creates 2 fl ame fronts, which meet perpendicular to piston pin.
  • Page 104 Disassembly/Inspection and Service 1. Oil control ring assembly (bottom groove): Install Remove Crankcase and Closure Plate Seals and expander fi rst then bottom rail and top rail last. Make Bearings sure ends of expander are not overlapped. Adjust 1. Remove oil seal from crankcase. ring gaps.
  • Page 105 Reassembly Crankcase Components Oil Seal Closure Plate Bearing Closure Plate Gasket Oil Sentry Float Camshaft Crankshaft End Cap ™ Switch Connecting Rod Piston Pin Retainer Piston Pin Piston Piston Ring Set Tappet Governor Cup Governor Washer Governor Shaft Governor Gear Governor Cross Shaft Crankcase Bearing Dowel Pin...
  • Page 106 Reassembly 5. Apply a light coating of lithium grease to seal lips NOTE: Install oil control ring assembly fi rst, middle after installing. compression ring second, and top compression ring last. Oil control ring assembly is a three- Install Governor Assembly piece design, and consists of a top rail, 1.
  • Page 107 Reassembly Install Closure Plate Install Flywheel Torque Sequence CAUTION 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. NOTE: Before installing fl...
  • Page 108 Reassembly 8. Connect kill wire to ignition module bottom blade terminal and route wire lead across top of crankcase. Cylinder Head Components Valve Cover Adjusting Nut Rocker Arm Rocker Arm Stud Push Rod Guide Push Rod Valve Keeper Valve Spring Intake Valve Stem Cylinder Shroud Valve...
  • Page 109 Reassembly d. Hold adjuster from turning and tighten locknut. Valve Cover with RTV Torque locknut to 10 N·m (88.5 in. lb.). e. Recheck that clearance is correct. 5. Set gap of new spark plug to 0.76 mm (0.030 in.). 6. Install spark plug in cylinder head and torque to 27 N·m (20 ft.
  • Page 110 Reassembly Blower Housing/Control Panel Components Governor Lever Governor Spring Throttle Link Dampening Spring Control Assembly Carburetor Retractable Starter On/Off Wiring Oil Sentry Wiring ™ Harness Bullet Blower Housing Harness Bullet Oil Sentry Module ™ Connector Connector Oil Sentry Bracket ™ Install Throttle Plate Install Blower Housing Install throttle plate with screws.
  • Page 111 Reassembly Install Retractable Starter 1. Install retractable starter on blower housing using screws. Finger tighten screws only. 2. Pull rope handle to engage pawls and center starter to drive cup. Hold in this position and torque screws to 5.4 N·m (47.8 in. lb.). External Engine Components Oil Drain Plug Oil Fill Plug...
  • Page 112 Reassembly Install Throttle Lever, Governor Lever, Throttle Link, Dampening Spring, and Governor Spring 1. Install nylon washer and wave spring to throttle plate. 2. Connect spring to throttle lever and throttle plate. Install throttle lever to throttle plate. Install tabbed washer (with tab engaged in slot) and secure with nut.
  • Page 113 Reassembly 18 690 01 Rev. C KohlerEngines.com...
  • Page 114 Reassembly Install Oil Sentry Module Prepare Engine for Operation 1. Install Oil Sentry module and secure with screw. Engine is now reassembled. Before starting or operating ™ engine be sure to do following: 2. Connect electrical leads for Oil Sentry module.
  • Page 115 18 690 01 Rev. C KohlerEngines.com...
  • Page 116 KohlerEngines.com 18 690 01 Rev. C...
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