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shop Manual
DW168F, DW177F, DW188F
Engines
INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA
DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO ANTES
DE USAR EL PRODUCTO.
English
Contents
SERVICE
bREAKDOWNS
Safety Information....................................................................................... 3
Air Filter.......................................................................................................... 23
Definitions: Safety Guidelines ................................................................ 3
Air CLEANER..................................................................................................... 24
Service Information..................................................................................... 3
MUFFLER....................................................................................................... 25-27
Serial Number................................................................................................. 3
Recoil Starter.............................................................................................. 28
Specifications.......................................................................................................... 4-6
ASSEMBLY................................................................................................... 29
Dimensional drawings......................................................................................... 7-9
INSPECTION................................................................................................ 30
P.T.O. Dimensional drawings................................................................................ 10
Wiring diagrams....................................................................................................... 11
Maintenance Standards..................................................................................12-13
Gas Tank........................................................................................................... 35
TORQUE TABLE............................................................................................................. 13
Governor LINKAGE........................................................................................ 36
MAINTENANCE
Governor........................................................................................................ 37
mAINTENANCE CHART..................................................................................... 14
Flywheel Ignition......................................................................................... 38
CLEANING AIR FLITER ELEMENT.................................................................... 14
Adjustment.............................................................................................. 39
OIL
INSPECTION................................................................................................ 39
............................................................................................................... 14
Carburetor............................................................................................... 31-33
Cleaning.................................................................................................... 34
SPARK PLUG...................................................................................................... 15
Starter Motor...................................................................................................... 40
SPARK ARRESTER............................................................................................ 15
VALVE CLEARANCE........................................................................................... 15
BRUSH LENGTH................................................................................................. 41
STARTER SOLENOID......................................................................................... 41
FUEL SYSTEM.................................................................................................... 16
BRUSHES - CONTINUITY CHECK..................................................................... 41
HIGH ALTITUDE OPERATION SERVICE........................................................... 16
ARMATURE......................................................................................................... 41
Troubleshooting
Engine............................................................................................................... 17
Cylinder Head Valves
Starter/Battery............................................................................................ 19
6.5 HORSEPOWER............................................................................................. 42
Compression.................................................................................................. 20
9 AND 13 HORSEPOWER.................................................................................. 43
OVERRUNNING CLUTCH................................................................................... 41
Perform Test Checks
SPEED/GOVERNOR ADJUSTMENT.................................................................. 21
Governor/Low Oil Shut-off............................................................................. 47
IGNITION TEST................................................................................................... 21
Compression RELIEF.................................................................................... 48
OIL ALERT TEST................................................................................................ 21
INSPECTION....................................................................................................... 48
START MECHANISM........................................................................................... 21
PISTON
COMPRESSION TEST........................................................................................ 22
2
Inspection........................................................................................... 44-46
............................................................................................................... 49
INSPECTION.................................................................................................. 50-52
Serial Number
SERVICE
Safety Information
The engine serial number is needed when ordering parts and making inquiries.
English
Definitions: Safety Guidelines
The definitions below describe the level of severity for each signal word. Please read
the manual and pay attention to these symbols.
DANGER: Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury.
NOTICE: Indicates a practice not related to personal injury which, if not avoided,
may result in property damage.
DANGER: If the service being performed requires the engine to be running operate it
only outside in clean, dry, well-ventilated areas. Exhaust from the gasoline engine contains
deadly carbon monoxide, which is odorless and toxic.
WARNING: Risk of explosion. Spilled gas­ol­ine and it’s vapors can be­come ignited
from sparks from smoking products, electrical arcing, exhaust, flame, gas­es and hot engine
components such as the muffler. Wipe any fuel spillage from engine.
WARNING: The engine exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive harm. Wash
hands after handling.
Warning: Risk of unsafe operation. Always wear gloves and certified safety equipment:
ANSI Z87.1 eye protection (CAN/CSA Z94.3) with side shields.
WARNING: Stop engine and remove the spark plug wire before servicing.
Warning: Hot surfaces. Risk of burn. Engine (especially the muffler) and surrounding
parts are very hot, do not touch. Allow engine to cool before servicing.
Warning: If protective covers must be removed during servicing keep away from moving
parts and wires.
Serial
Number
model
number
Service Information
• Always use identical replacement parts.
• Use tools designed for small engine repair, using incorrect tools could damage the
engine.
• Replace all gaskets, O-rings, etc. when reassembling.
• Clean all parts in non flammable solvent. Lubricate any sliding surfaces before reassembly.
month
year
3
engine number
English
Specifications
Application
Generator
Model
DW168F-2F
Type
DW177FD-F
DW188FD-F
Single Cylinder, 4 Stroke, OHV, Spark Ignition, Air Cooled
Max. Horsepower *
6.5 hp
9 hp
13 hp
Total Displacement
196 cc
270 cc
389 cc
Bore and Stroke
68 x 54 mm
77 x 58 mm
88 x 64 mm
Rated Speed
3600 rpm
3600rpm
3600 rpm
Max no load speed
3750 rpm.
3750 rpm.
3750 rpm.
Idle Speed
no idle control
2750 rpm.
2,750 rpm.
Dry weight
30.9 lbs. (14 kg)
57.6 lbs. (26.15 kg)
68.3 lbs. (31 kg)
Dimensions (L x W x H) in (mm)
15.2 x 13.1 x 10.4 (385 x 335 x 265)
17.3 x 16.5 x 12.2 (440 x 420 x 310)
16.1 x19.3 x 12.8 (410 x 490 x 325)
Mounting flange
Flange A per SAE J609a
Flange B per SAE J609a
Flange B per SAE J609a
Compression ratio
8.5 to 1
8.2 to 1
8.2 to 1
Ignition system
Transistorized Magneto Ignition
Transistorized Magneto Ignition
Transistorized Magneto Ignition
Spark plug
NGK (BP6ES, BPR6ES)
NGK (BP6ES, BPR6ES)
NGK (BP6ES, BPR6ES)
Carburetor
Float type, adjustable idle speed
Float type with a fuel-shutoff solenoid, Float type with a fuel-shutoff solenoid,
Adjustable idle speed
Adjustable idle speed
Air cleaner
Standard Semi-dry (foam), side mount
Standard Semi-dry (foam), side mount
Standard Semi-dry (foam), side mount
Lubricating system
Splash
Splash
Splash
Oil capacity
0.55 qt. (520 mL)
1.06 qt. (1000 mL)
1.11 qt. (1100 mL)
Starting system
Recoil, 2 o’clock position
18 V Electric motor and Recoil 2 o’clock
position
18 V Electric motor and Recoil 2 o’clock
position
Stopping system
Ignition primary circuit ground
Ignition primary circuit ground
Ignition primary circuit ground
Fuel used
Regular gasoline (86 octane)
Regular gasoline (86 octane)
Regular gasoline (86 octane)
P.T.O. shaft rotation
Counterclockwise (from P.T.O. side)
Counterclockwise (from P.T.O. side)
Counterclockwise (from P.T.O. side)
Crankshaft PTO
Ext. #5 per SAE J609a
(2.25" taper per foot)
Ext. #6 per SAE J609a (2.25" taper per foot)
Governor
Mechanical, centrifugal flyweight type, 60 Hz fixed speed
Fuel line
Low permeation, per SAE J1737 at 40º C or higher
FUEL FILTER
ON/OFF switch
Either in gas tank or in fuel line (earlier models)
Without
Without
Without
* Gross horsepower (HP). This horsepower rating represents the maximum output under laboratory conditions at 3600 RPM in accordance with SAE (Society of Automotive Engineers)
J1995 and should be used for comparison purposes only. Actual engine output will be lower and will vary depending on the application, speed and other variables including altitude
and temperature.
4
Application
PRESSURE WASHERS
Model
DW168F-2H
DW188F-H
Single Cylinder, 4 Stroke, OHV, Spark Ignition, Air Cooled
Max. Horsepower*
6.5 hp
9 hp
13 hp
Total Displacement
196 cc
270 cc
389 cc
Bore and Stroke
68 x 54 mm
77 x 58 mm
88 x 64 mm
Rated Speed
3400 rpm
3400 rpm
3600 rpm
Max no load speed
3700 rpm
3700 rpm
3800 rpm
Idle Speed
no idle control
2750 rpm
2750 rpm
Dry weight
37.5 lbs. (17 kg)
57.3 lbs. (26 kg)
70.5 lbs. (32 kg)
Dimensions (L x W x H) in (mm)
15.7 x 13.0 x 13.4 (400 x 330 x 340)
16.9 x 15.6 x 16.1 (430 x 395 x 410)
18.7 x 17.3 x 17.1 (475 x 440 x 435)
Mounting flange
Flange A per SAE J609a
Flange B per SAE J609a
Flange B per SAE J609a
Compression ratio
8.5 to 1
8.2 to 1
8.2 to 1
Ignition system
Transistorized Magneto Ignition
Transistorized Magneto Ignition
Transistorized Magneto Ignition
Spark plug
NGK (BP6ES, BPR6ES)
NGK (BP6ES, BPR6ES)
NGK (BP6ES, BPR6ES)
Carburetor
Float type, adjustable idle speed
Float type, adjustable idle speed
Float type, adjustable idle speed
Air cleaner
Standard Semi-dry (foam+paper), high Standard Semi-dry (foam+paper), high mount
mount
Standard Semi-dry (foam+paper), high mount
Lubricating system
Splash
Splash
Splash
Oil capacity
0.55 qt. (520 mL)
1.06 qt (1000 mL)
1.11 qt (1100 mL)
Starting system
Recoil, 10 o'clock position
Recoil, 10 o'clock position
Recoil, 10 o'clock position/Electric start
Stopping system
Ignition primary circuit ground
Ignition primary circuit ground
Ignition primary circuit ground
Fuel used
Regular gasoline (86 octane, up to 10% ethanol)
Fuel tank capacity
0.95 gal (3.6 L)
1.56 gal (5.9 L)
1.93 gal (7.3 L)
P.T.O. shaft rotation
Counterclockwise (from P.T.O. side)
Counterclockwise (from P.T.O. side)
Counterclockwise (from P.T.O. side)
Crankshaft PTO
Ext. #3 per SAE J609a (3/4" key way PTO) Ext. #4 per SAE J609a (1" key way PTO)
Ext. #4 per SAE J609a (1" key way PTO)
Governor
Mechanical, centrifugal flyweight type, variable speed
Fuel line
Low permeation, per SAE J1737 at 40º C or higher
FUEL FILTER
ON/OFF switch
In gas tank only
Equipped on recoil base
Equipped on recoil base
Equipped on recoil base
* Gross horsepower (HP). This horsepower rating represents the maximum output under laboratory conditions at 3600 RPM in accordance with SAE (Society of Automotive Engineers)
J1995 and should be used for comparison purposes only. Actual engine output will be lower and will vary depending on the application, speed and other variables including altitude
and temperature.
5
English
Type
DW177F-H
English
Application
Compressor
Model
DW168F-2E
Type
DW177FD-E
Single Cylinder, 4 Stroke, OHV, Spark Ignition, Air Cooled
Max. Horsepower*
6.5 hp
9 hp
Total Displacement
196 cc
270 cc
Bore and Stroke
68 x 54 mm
77 x 58 mm
Rated Speed
3400 rpm
3400 rpm
Max no load speed
3600 rpm
3600 rpm
Idle Speed
2400 rpm
2400 rpm
Dry weight
33  lbs. (15 kg)
57.3 lbs. (26 kg)
Dimensions (L x W x H) in (mm)
15.7 x 13.0 x 13.4 (400 x 330 x 340)
16.9 x 15.6 x 16.1 (430 x 395 x 410)
Mounting flange
Flange A per SAE J609a
Flange B per SAE J609a
Compression ratio
8.5 to 1
8.2 to 1
Ignition system
Transistorized Magneto Ignition
Transistorized Magneto Ignition
Spark plug
NGK (BP6ES, BPR6ES)
NGK (BP6ES, BPR6ES)
Carburetor
Float type, adjustable idle speed
Float type, adjustable idle speed
Air cleaner
Standard Semi-dry (foam+paper), high mount
Standard Semi-dry (foam+paper), high mount
Lubricating system
Splash
Splash
Oil capacity
.507 qt (480 mL)
1.06 qt (1000 mL)
Starting system
Recoil, 10 o'clock position
18 V Electric motor and
recoil starter 10 o'clock position
Stopping system
Ignition primary circuit ground
Fuel used
Ignition primary circuit ground
Regular gasoline (86 octane, up to 10% ethanol)
Fuel tank capacity
0.95 gal (3.6 L)
1.56 gal (5.9 L)
P.T.O. shaft rotation
Counterclockwise (from P.T.O. side)
Counterclockwise (from P.T.O. side)
Crankshaft PTO
Ext. #3 per SAE J609a (3/4" key way PTO)
Ext. #4 per SAE J609a (1" key way PTO)
Governor
Mechanical, centrifugal flyweight type, variable speed
Fuel line
Low permeation, per SAE J1737 at 40º C or higher
FUEL FILTER
ON/OFF switch
In gas tank only
Equipped on recoil base
Equipped on recoil base
* Gross horsepower (HP). This horsepower rating represents the maximum output under laboratory conditions at 3600 RPM in accordance with SAE
(Society of Automotive Engineers) J1995 and should be used for comparison purposes only. Actual engine output will be lower and will vary depending
on the application, speed and other variables including altitude and temperature.
6
Dimensional drawings
Pressure Washer DW168F
English
7
English
Dimensional drawings
Compessor and Pressure Washer DW177F
8
Dimensional drawings
Pressure Washer DW188F
English
9
Pressure Washers and Compressors
6.5 HP
Note: All dimensions in mm unless noted otherwise
.313-24
19.02
6.5 HP
9-13 HP
9-13 HP
25.4
.313-24
English
P.T.O. Dimensional drawings
Generator
10
Wiring diagrams
Electric start air compressor
Y/G
Bl
Y/G
Bl
E
IG
ENGINE SWITCH
IG
Bl
Bl
E
Y/G
Y/G
English
ENGINE SWITCH
Non electric start
Bl
Bl
Y
Y
Bl
Y
Yellow
Bl
Black
Bl
COMBINATION SWITCH
IG
E
Y
COMBINATION WIRE
ST BAT
OFF
Y/G Yellow /Green
Y
Yellow
Bl
Black
OIL LEVEL
SWITCH
IG
E
ST BAT
OFF
ON
IGNITION
COIL
SPARK
PLUG
OIL
ALE RT
Bl
COMBINATION SWITCH
Y/G Yellow /Green
ON
Y
OIL LEVEL
SWITCH
FUSE 5A
W
COMBINATION WIRE
Bl
W
White
Br
IG
Brown
Y/ G Yellow Green Bl/W Black White
E
ST BAT
R
Red
Y
Yellow
ON
G
Green
Bl
Black
START
W
M
BATTERY
White
Br
STARTER
OIL LEVEL
SWITCH
OIL
ALE RT
SPARK
PLUG
IGNITION
COIL
11
IG
Brown
E
ST BAT
BAT
W
Bl/W
Bl
Bl/W
Bl
M
OFF
R
Red
Y
Yellow
ON
G
Green
Bl
Black
START
Y
Bl
COMBINATION SWITCH
Y/ G Yellow Green Bl/W Black White
G
CHARGE
COIL
Y
R
COMBINATION WIRE
OFF
Bl
Br
Y
Bl
COMBINATION SWITCH
W
Y
Br
Y
Bl
Br
Y
R
FUSE 5A
W
Bl
Br
Y/G
Bl
Bl
Electric start
Y/G
E
IG
ST
DIODE
Bl/W
W
W
ENGINE SWITCH
Bl/W
Y/G
DIODE
Y/G
E
BAT
ENGINE SWITCH
IGNITION
COIL
SPARK
PLUG
OIL
ALE RT
IG
COMBINATION WIRE
Bl
Y
ST
Y
G
CHARGE
COIL
BATTERY
STARTER
OIL LEVEL
SWITCH
OIL
ALE RT
SPARK
PLUG
IGNITION
COIL
Maintenance Standards
English
DW168
Part
Item
Engine
Cylinder
Cylinder head
Piston
Piston rings
Connecting rod
Crankshaft
Valves
DW177
DW188
*Standard (mm)
*Service Limit
(mm)
*Standard (mm)
*Service Limit
(mm)
*Standard (mm)
*Service
Limit(mm)
Cylinder compression
Sleeve I.D.
Warpage
Skirt O.D.
50 – 90 psi
68.015~68.025
0
67.975~67.985
68.156
0.10
67.85
60 – 100 psi
77.02~77.03
0
76.970~76.980
77.179
0.10
76.85
60 – 100 psi
88.015~88.025
0
87.970~87.980
88.195
0.10
87.85
Piston-to-cylinder
clearance
0.030~0.050
0.12
0.040~0.060
0.1
0.045~0.065
0.1
Piston-to-piston pin
bore clearance
0.004~0.016
0.08
0.004~0.016
0.08
0.004~0.016
0.08
18.002~18.008
17.992~17.998
18.042
17.94
18.002~18.008
17.992~17.998
18.042
17.95
20.002~20.008
19.992~19.998
20.042
19.94
0.08~0.12
0.07~0.11
0.02~0.16
0.15~0.35
0.10
0.10
0.15
1.0
0.02~0.06
0.02~0.06
0.02~0.16
0.20~0.35
0.15
0.15
0.15
1.0
0.02~0.06
0.02~0.06
0.04~0.19
0.20~0.40
0.15
0.15
0.15
1.0
1.420~1.440
1.420~1.440
2.37~2.49
18.011~18.022
30.02~30.03
0.030~0.055
0.95~1.45
29.975~29.990
1.3
1.3
2.3
18.06
30.06
0.1
1.85
29.92
1.97~1.99
1.97~1.99
2.77~2.79
18.011~18.022
33.02~33.03
0.029~0.055
0.55~1.25
32.975~32.991
1.75
1.75
2.5
18.06
33.06
0.1
1.65
32.92
1.97~1.99
1.97~1.99
2.65~2.78
20.011~20.022
36.02~36.03
0.029~0.064
0.55~1.25
35.966~35.991
1.75
1.75
2.5
20.06
36.06
0.1
1.65
35.92
0.10~0.15
0.20~0.25
-
0.10~0.15
0.20~0.25
-
0.10~0.15
0.20~0.25
-
5.468~5.48
5.418~5.44
5.500~5.512
5.318
5.275
5.572
6.568~6.580
6.545~6.560
6.600~6.615
6.44
6.40
6.66
6.568~6.580
6.545~6.560
6.600~6.615
6.44
6.40
6.66
0.020~0.044
0.060~0.084
0.7~0.9
30~31
0.1
0.12
2.0
29.0
0.020~0.070
0.040~0.070
0.8~1.0
38.5~39.5
0.11
0.15
2.0
37.5
0.020~0.070
0.020~0.070
0.7~0.9
38.5~39.5
0.11
0.15
2.0
37.5
Piston Pin bore I.D.
Pin O.D.
Ring side clearance
Ring,Top
Ring, Compression
Ring Assy, Oil
Ring end gap
Ring width
Ring,Top
Ring, Compression
Ring Assy, Oil
Small end I.D.
Big end I.D.
Big end oil clearance
Big end side clearance
Crankshaft O.D.
Valve clearance
IN
EX
Stem O.D.
IN
EX
Guide I.D. IN/EX
Stem clearance
IN
EX
Seat width
Spring free length
* unless otherwise noted
12
DW168
Item
Camshaft
CAM height
IN
EX
Camshaft O.D.
Camshaft holder I.D.
Gap
Resistance
Resistance
Primary
Secondary
Air gap
Brush length
Crankcase cover
Spark plug
Spark plug boot
Ignition coil
Starter Motor
* unless otherwise noted
*Standard (mm)
*Service Limit
(mm)
*Standard (mm)
*Service Limit
(mm)
*Standard (mm)
*Service
Limit(mm)
27.700
27.747
13.966~13.984
14.000~14.018
0.7 ~ 0.8
10k
27.45
27.50
13.916
14.05
7.5 – 10.5 k
31.716
31.754
15.966~15.984
16.000~16.018
0.7 ~ 0.8
10k
31.35
31.35
15.92
16.05
7.5 – 10.5 k
32.585
32.068
15.966~15.984
16.000~16.018
0.7 ~ 0.8
10k
32.25
31.80
15.92
16.05
7.5 – 10.5 k
1.3Ω±0.2Ω
6.4kΩ±1kΩ
0.4±0.2
10
5.5
1.3Ω±0.2Ω
6.4kΩ±1kΩ
0.4±0.2
10
5.5
1.3Ω±0.2Ω
6.4kΩ±1kΩ
0.4±0.2
10
5.5
TORQUE TABLE
Item
Connecting rod bolt
Cylinder head bolt
Flywheel nut
Rocker arm pivot bolt
Crankcase cover bolt
Oil level switch joint nut
Fuel filter, join nut
Muffler mounting nut
Air cleaner wing nut
Oil drain bolt
Fuel tank bolt, nut
Air cleaner mounting nut
Unspecified torque values
  bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
gOVERNOR ARM RETAINER BOLT
DW188
Torque
168 (n– m)
12–14
32–35
80–90
28–32
27–30
6–8
6–8
27–30
8–12
20–25
8–10
1–2
177/188 (n– m)
14–16
50–55
90–115
28–32
27–30
6–8
6–8
27–30
8–12
25–30
8–10
1–2
168 (ft–lb)
10
26
66
24
22
6
6
22
9
18
7
1
177/188 (ft–lb)
12
41
85
24
22
6
6
22
9
18
7
1
5–7
8–12
24–28
50–55
7–9
5–7
8–12
24–28
50–55
7–9
5
9
21
41
5.2–6.6
5
9
21
41
5.2–6.6
13
English
Part
DW177
MAINTENANCE
English
Procedure
Daily
Clean engine exterior
50 hours
or weekly
(whichever
comes first)
100 hours
150 hours 500 Hours
or monthly
(whichever
comes first)
Cleaning Air Filter Element
X
Clean battery pack and
charger
Check oil level
Warning: Hot surfaces. Risk of burn. Engine and surrounding parts are very hot, do not
touch. Allow engine to cool prior to servicing.
A dirty air cleaner will restrict airflow to the carburetor. To prevent carburetor mal­func­tion,
service the air filter regularly. Service more frequently when operating the gen­erator in
extremely dusty areas.
Warning: Using gasoline or flam­mable solvent to clean the filter element can cause a
fire or explosion.
Warning: Risk of fire. Do not operate without air filter.
To Clean the elements
(DW168f-2e, dw177f-e, dw168f-2h, dw177f-h)
1.Remove the wing nut and the air filter cover.
2.Remove the second wing nut and remove the filter.
3.Remove the foam-type pre-filter from the filter.
4.Inspect foam and paper elements. Replace them if damaged.
To Clean the elements
Foam element: Wash element in warm, soapy
water. Then saturate it in clean engine oil.
Squeeze the element to remove excess oil.
Paper element: Clean element by tapping
gently to remove dust. Use compressed air to
blow off dust.
Warning: When using compressed air, user
always must wear eye protection that conforms to
ANSI Z87.1. (CAN/CSA Z94.3).
Never use oil. Always blow the element from the
inside. If using compressed air keep the air pressure less than 30 psi.
Place the foam pre-filter over the paper element and reinstall it onto the engine.
(DW168f-2F, DW177FD-F, dw188f)
1.Unsnap the air filter cover clips and remove
the air cleaner cover.
2.Remove the elements from air filter.
3.Wash elements in warm soapy water and
rinse thoroughly. Allow the elements to dry
thoroughly.
4.Soak the elements in clean engine oil and
squeeze out the excess oil. NOTE: The engine will smoke during initial start-up if too
much oil is left in the elements.
5.Reinstall the air filter elements and snap air filter cover in place.
X
X
Change oil *
X(1)
Clean air filter
X(1)
Clean spark plugs
X
Check fuel line, hose clamps
and fuel tank
X
Oil leak inspection
X
X
Spark arrestor
Sediment cup
X
X
Clean inline fuel filter
Check for unusual
noise/vibration
Check and adjust valve
clearance (.15 mm intake,
.2 mm exhaust)
a.Make sure spark plug is correct type, see Spark Plug under Maintenance
Standards.
b.Ignition timing malfunction. Set ignition air coil gap, see the Flywheel Ignition
Adjustment section.
6.Excessive Wear – Plug worn to the point of having encrusted deposits and thin
rounded out electrodes. Replace plug.
X
X
Prepare unit for storage if it is to remain idle for more then 30
days
* The engine oil must be changed after the first 20 hours or operation. Thereafter change oil every
100 hours of operation or monthly, whichever comes first.
(1) Perform more frequently in dusty or humid conditions
Prepare unit for Storage
Spark Plug Condition Check
• Remove the spark plug for inspection
• Always use recommended plug see Specifications
• Set gap to specification, see Spark Plug under Maintenance Standards.
1.Normal Plug – Slightly rounded electrodes with light coat of ashy brown deposits indicate normal wear and a healthy engine.
2.Oil Fouling – Wet oily film will prevent the plug from sparking. This condition signals
worn valves or piston rings. This condition can be caused by running the engine in
the choke position. Check valves and piston rings, overhaul if needed. Replace spark
plug.
3.Carbon Fouling – Black dry soot covering the electrodes indicates incomplete combustion. This can be a result of weak ignition or a rich mixture.
a.Check carburetor adjustment, adjust speed if needed.
b. Check air filter, clean if needed.
4.Gap Bridging – A combustion particle lodged between the electrodes carries current
across the gap. This does not normally signal engine problems elsewhere.
5.Whitened Electrodes – This is evidence combustion is too hot and there is overheating. This can result from too lean fuel mixture.
Oil
Warning: Hot surfaces. Risk of burn. Engine and surrounding parts are very hot, do
not touch. Allow engine to cool prior to servicing.
To Check oil
1.Place unit on a flat level surface.
14
2.Remove oil fill/dipstick and wipe clean.
3.Reinsert oil fill/dipstick fully into oil fill port
Patterns
and tighten. Allow oil to collect on the
Patterns
dipstick for a few seconds.
4.Remove oil fill/dipstick to read oil level. If
oil falls below top of pattern on dipstick,
add oil.
NOTE: When filling the crankcase, allow
the oil to flow very slowly. If the oil is added too quickly, it will overflow and appear to be
full.
5.Replace dipstick and tighten securely.
Spark Plug Cross Reference
Part number
NGK
BP6ES, BPR6ES
AUTOLITE
63
AC DELCO
R41XL,R42XLS, R43FS,R43XL, R43XLS, R44XLS, R45XLS
CHAMPION
RJ14YC
1.Remove the spark plug boot.
2.Clean any dirt from around the spark plug base.
3.Use a spark plug wrench (not supplied) to remove the spark plug.
4.Visually inspect the spark plug. Replace it if the insulator is cracked or chipped. Clean
the spark plug with a wire brush if it is going to be reused.
5.Measure the plug gap with the feeler gauge. Correct as necessary by
carefully bending the side electrode. The gap should be: 0.70-0.80 mm
(0.028-0.031 in).
6.Make sure the spark plug washer is in good condition. Thread the spark
plug in by hand to prevent cross threading.
7.After the spark plug is seated, tighten with a spark plug wrench to compress
the washer. If installing a new spark plug, tighten the spark plug 1/2 turn
after it seats to compress the washer. If reinstalling a used spark plug,
tighten 1/8–1/4 turn after the spark plug seats to compress the washer. Do
not overtighten.
Note: The spark plug must be securely tightened. An improperly tightened spark plug
can become very hot and could damage the engine. Never use spark plugs which have an
improper heat range. Use only the recommended spark plugs or equivalent.
To change oil
NOTE: Engine oil contains substances that are regulated and must be disposed of in
accordance with local, state, provincial and federal laws and regulations.
1.Disconnect spark plug wire.
2.Locate a suitable container under oil drain plug (Q9).
3.Remove the oil fill/dipstick (J9) from crank­case. 4.Remove the oil drain plug.
J9
5.Allow ample time for all oil to drain out.
6.Install the oil drain plug and tighten securely.
7.Fill with recommended oil. Refer to the ViscosityAmbient Temperature Chart for recommended oil.
NOTE: Synthetic oil is NOT recommended.
Q9
Spark Arrester
Viscosity-Ambient Temperature Chart
WARNING: DO NOT operate engine without muffler cover or spark arrestor.
WARNING: If the engine has been running, the muffler will be very hot. To reduce the
risk of injury, allow engine to cool before proceeding.
WARNING: Always wear certified safety equipment: ANSI Z87.1 eye protection (CAN/CSA
Z94.3) with side shields when removing carbon deposits.
NOTE: The spark arrester must be serviced every 100 hours to maintain its efficiency.
30
10W-30
cc
5W-30
˚F -20
0
20
˚C -28.8 -17.7 -6.6
40 60
80 100
4.4 15.5 26.6 37.7
r12
8.Replace dipstick and tighten securely.
9. Reconnect spark plug wire.
10.Dispose of oil according to local, state, provincial and federal laws and regulations.
1.Remove the spark arrestor screws (R12) and remove the spark arrestor (CC).
2.Use brush to remove carbon deposits from the spark arrester screen. Inspect the spark
arrester screen for holes or tears. Replace the spark arrester if necessary.
Spark Plug
Use recommended spark plugs, see Spark Plug Cross Reference for correct spark plug.
To ensure proper engine operation, the spark plug must be properly gapped and free of
deposits.
WARNING: If the engine has been running, the muffler and spark plug will be very hot.
To reduce the risk of injury, allow cooling before proceeding.
WARNING: Always wear certified safety equipment: ANSI Z87.1 eye protection (CAN/CSA
Z94.3) with side shields.
Valve Clearance
Warning: Hot surfaces. Risk of burn. Engine and surrounding parts are very hot, do not
touch. Allow engine to cool prior to servicing.
NOTE: Engine must be cold to check the valve clearance.
1.Remove the cylinder head cover.
15
English
Brand
English
2.Set the piston in the top dead center position of its compression stroke.
NOTE: both rocker arms (p7, k8) will have the largest gap with each valve (u7, v7, p8, q8).
3.Insert a feeler gauge between the rocker arm and valve to measure valve clearance.
Warning: When using compressed air, user always must wear eye protection that
conforms to ANSI Z87.1. (CAN/CSA Z94.3).
Fuel Sediment Cup Cleaning (if equipped)
1.Place the fuel shut off valve (A, if equipped) in the closed (horizontal) position as
shown.
s7, n8
R10
r7, m8
A
A
p7, k8
B
u7, v7, p8, q8
Standard
(mm)
Valve
Clearance
IN
EX
0.10~0.15
0.20~0.25
c
d
Service
Limit
(mm)
2.Remove the sediment cup (D) from the fuel valve on the bottom of the tank.
3.Clean the sediment cup, screen (C) and O-ring (B) in nonflammable or high flash point
solvent.
4.Drain and remove gas tank, flush until clean.
5.Replace or clean fuel filter. Fuel filter may be inside gas tank where fuel exits or an
in line fuel filter may be on the fuel line. See Service Bulletin (SB06109)
-
4.Adjust rocker arm pivot (R7, M8) by loosening the rocker arm locknut (S7, N8) and
adjust the pivot lock nut (R10) until the clearance is correct. When clearance is correct
tighten the rocker arm locknut.
5.Check the clearance again with nuts tightened.
reassemble
1.Reinstall O-ring, sediment cup, carburetor bowl, carburetor bowl drain bolt, debris
screen and fuel cap
2.Replace inline filter (if equipped).
3.Turn the fuel shut-off valve (A, if equipped) to the open (vertical) position and check for
fuel leaks.
Fuel System
IMPORTANT: If the engine does not start, is hard to start or is performing poorly ensure
fuel system is clean and fuel tank contains fresh gasoline before troubleshooting.
WARNING: Risk of explosion. Spilled gas­o­line and it’s vapors can be­come ignited from
sparks from smoking products, electrical arcing, exhaust, flame, gas­es and hot engine components such as the muffler. Make sure there are no sources of ignition, such as smoking
products near servicing location. Wipe any fuel spillage from engine.
Warning: Hot surfaces. Risk of burn. Engine and surrounding parts are very hot, do
not touch. Allow engine to cool prior to servicing.
Drain Carburetor
1.Place the fuel shut off valve (A, if equipped)
A
in the closed (horizontal) position as
shown.
2.Place an OSHA-ap­proved con­tain­er
suitable for fuel under the carburetor
bowl. NOTE: Using a funnel will allow
the fuel to flow into the container with
less spillage.
3.Remove the carburetor bowl drain bolt (B2, K2, F3).
4.Fuel will drain from carburetor bowl.
5.Remove the carburetor bowl and clean it in nonflammable
or high flash point solvent.
A
High Altitude Operation Service
High Altitude Modification should only be made to engines operating at above
5,000 ft. (1524 m) for an extended period as manufactured engines are suitable for operation up to 5,000 ft. (1524 m) above sea level. NOTE: Reset to factory setting immediately
when engine is moved to operate below 5,000 ft. (1524 m). To reset, replace high altitude
main jet with low altitude main jet. If the engine is used at low altitudes after a carburetor
modification, the carburetor may cause the engine to overheat and result in serious engine
damage.
1.Set the fuel valve in the off position. Remove the carburetor drain bolt (b2, k2, f3) from
the carburetor bowl (E3, j2) and allow fuel to drain into a suitable container.
2.Remove the fuel cutoff solenoid (D3, if equipped) from the carburetor bowl using a
Phillips screwdriver.
B2, K2,
F3
E3, J2
Cleaning Debris Screen (if equipped)
1.Remove fuel cap.
2.Remove debris screen.
3.Clean debris screen. Use compressed air to blow off
debris.
b2,
k2, f3
x2
D3
V3, L2
I4
3.Remove the carburetor bowl (E3, j2) and retaining bolt (V3, L2) with a 14 mm socket.
16
Problem Possible cause
13.Gas tank/fuel
Engine will
filter does not
not start,
allow flow of gas
stay running
because it is dirty
or only runs
or blocked
when choked
(continued)
Solution
There are 2 types of gas tank/fuel filter designs
used:
One requires an in-line filter located in the fuel line
between the fuel valve and the carburetor. The other
has a tube shaped filter above the fuel valve inside
the gas tank. This second design does not require
an in-line filter.
To check the gas tank/fuel filter, place fuel valve
lever in the closed (horizontal) position, remove fuel
line from fuel valve and place fuel valve lever in the
on (vertical) position to check flow to a catch pan.
If there is flow and the engine has only the internal
tank filter, the filter is not the problem.
If there is no flow, , place fuel valve lever in the
closed (horizontal) position, remove fuel valve to
access tube filter, clean it and reassemble. To check
in line filter disconnect fuel line from carburetor and
place fuel valve lever in the on (vertical) position
to check for fuel flow. If no flow or weak, replace
fuel filter. See Service Bulletin SB06109 regarding
filters. NOTE: Air Compressors and Pressure
Washers have a fuel valve in the carburetor. On
these remove drain screw on carburetor bowl to
verify flow.
14.Sediment cup
Place the fuel valve lever in the closed (horizontal)
full of debris (fuel position, remove fuel line from fuel valve and
valve)
place fuel valve lever in the on (vertical) position to
check flow to a catch pan. If no flow or weak, clean
sediment cup, refer to Fuel System to clean the
sediment cup. With sediment cup removed from fuel
valve, place fuel valve lever in the ON position to
verify flow from cup area into a catch pan. This will
confirm fuel valve itself is not clogged.
15.Fuel valve
Remove valve from generator tank and with valve
clogged
in the OPEN position use compressed air to blow it
clean or soak it in solvent. Or replace valve.
Ensure no obstructions, kinks or blockages are in
16.Evaporative
evaporative system hose connected to bottom of
system not
venting fresh air gas tank and to charcoal canister on lower frame.
to tank to replace Disconnect hose from canister that goes to tank.
With gas gap removed, blow through hose. Air
gas as being
used. (California should flow freely. If not find obstruction and correct.
NOTE: On California versions of pressure washers,
Units)
evaporative system hose exits from top of gas tank.
Troubleshooting
NOTE: Make sure the engine has a good ground before troubleshooting.
Engine
Starting Problem
Problem
Engine will
not start,
stay running
or only runs
when choked
Possible cause
1. On/Off switch in
OFF position
2. Low or no fuel
3.Fuel valve in
OFF position
4. Low oil or no oil
5. Choke in wrong
position
Solution
Place On/Off switch in ON position.
Add fuel.
Place fuel valve in ON position.
Add oil.
For cold starts, choke must be in CLOSED position. On pull ring chokes, pull ring all the way out.
On lever chokes, move lever all the way in direction
of arrow.
If in doubt, remove air cleaner and visually verify
that choke plate is closed and completely blocking
entrance.
6. Check fuel
Ensure fuel is clean and fresh. If problem continues
condition
refer to Fuel System under Maintenance.
7. Spark plug wire Ensure that spark plug wire is tightly connected to
(is loose on plug spark plug
8. Low oil shutdown Make sure oil level is up to full mark, refer to Oil
(LOS)
under Maintenance. If problem continues refer to
Inspection/Oil Level Switch under Governor/Low
Oil Shutoff.
9. Check for spark Perform Ignition Test under Perform Test Checks.
10.Examine spark
plug condition
11.Improper valve
clearance
12.Cap not venting
Perform Spark Plug Condition Check under
Maintenance.
Reset valve clearances (see Maintenance
Standards)
After performing Fuel Check, if problem still continues:
Run engine with gas cap loose or removed to see
if engine still stalls. If it does not stall, gas cap is
not venting. NOTE: California models of generators
and pressure washers have non-venting gas caps
for emissions. Venting air is supplied from carbon
canister.
If gas cap is not venting properly the fuel filter
could be dirty or blocked, sediment cup full of
debris or fuel valve could be clogged.
17
English
4.Remove the main jet (i4) and e-tube (x2), with a flat head screwdriver.
5.Replace the main jet with the main jet specified for high altitude service. This high
altitude main jet comes in a high altitude carburetor adjustment package with new
carburetor bowl and fuel shut-off solenoid O-rings.
6.Reassemble carburetor in reverse order. Replace carburetor bowl O-ring and solenoid
O-ring if necessary.
7.Turn on fuel valve and inspect for fuel leak.
English
Problem Possible cause
17.Vacuum leak at
Engine will
carburetor
not start,
stay running
or only runs
when choked
(continued)
18.No or low
compression
19.Dirty air filter
Engine will
1.Battery is dead
not turn
(Electric start)
over, engine 2. Recoil pull
seized
starter rope
broken
3. Recoil pull start
not engaging
engine
4. Cylinder filled
with gas.
Solution
Ensure the evaporative system hose from the
charcoal canister is connected firmly to port
behind carburetor and other evaporative hoses
are connected firmly. Ensure carburetor is tightly
secured to engine by the two mounting nuts inside
air cleaner
Refer to Compression Test under Perform Test
Checks.
Ensure air cleaner is clean and not blocking air from
entering carburetor. Clean if necessary.
Try fully charged battery. Replace battery pack if
needed.
Replace pull start rope. Refer to Recoil Starter/
Assemble Recoil Starter under Breakdowns.
Problem Possible cause
2. Spark arrestor
Poor
dirty or clogged
performance,
low power,
running
too fast,
Backfiring
often
(continued)
Remove recoil assembly. Repair or replace as necessary. Refer to Recoil Starter/Assemble Recoil
Starter under Breakdowns.
Remove spark plug and tip engine momentarily. If
gas pours out hole, carburetor float bowl needle is
stuck open. Clean or replace carburetor. Refer to
Carburetor under Breakdowns for cleaning instructions.
NOTE: When transporting unit fuel valve must be in
OFF position, if not flooding will occur."
5. Electric starter
Refer to Start Mechanism under Perform Test
motor faulty
Checks and Starter Motor under Breakdowns for
checks.
Ensure choke mechanism operates
6. Excessive
correctly.
carbon buildup
in head. Engine With the choke in the fully open position and the
was possibly run engine running, the choke plate at entrance of the
with choke in
carburetor should be fully open.
closed or partially On lever chokes move the lever all the way to the
closed position
right
instead of open. Replace choke mechanism if choke does not
operate in this way or is damaged. Test and verify
compression is correct. Refer to Compression Test
under Perform Test Checks.
7. Internal part
With spark plug removed, rotate engine shaft by
failure
hand to see if it rotates smoothly. If still locked up,
remove crankcase cover and determine cause.
Refer to Engine will not start, stay running or
1. Fuel quality
Poor
only runs when choked steps 5,6,12 & 13 under
issue or
performance,
Starting Problem/Engine under Troubleshooting.
restriction
low power,
running
too fast,
Backfiring
often
3.Worn governor
arm rivet joint
Worn carburetor
throttle actuator,
Governor arm
slipping on shaft,
Throttle linkages
bent
High speed
screw has been
tampered with
4. Backfiring often
or air filter
melted, Ignition
coil could be
faulty
18
Solution
Clean spark arrestor, refer to Spark Arrestor under
Maintenance. Run engine briefly without spark
arrestor to verify that was the cause. Reassemble
spark arrestor to muffler. If screen is damaged
replace spark arrestor if screen is damaged.
Important: These products are equipped with
spark-arresting mufflers. It is legally required in
the state of California. It is a violation of California
statutes section 130050 and/or sec­tions 4442 and
4443 of the California Public Re­sourc­es Code,
unless the engine is equipped with a spark arrester,
as defined in section 4442, and maintained in ef­fec­
tive work­ing order. Spark arresters are also required
on some U.S. For­est Service land and may also be
legally required under other statutes and or­di­nanc­
es.
If engine is running over 4000 rpm (67Hz), first
ensure all linkages controlling the throttle position
actuate freely without binding over full travel. NOTE:
Comparing the old governor linkage to a new
replacement governor linkage may help to determine if the components in the system are worn or
damaged.
• The riveted joint in governor arm must pivot
freely but not be loose and sloppy.
• If the high speed adjusting screw has been tampered with it can be readjusted, refer to Speed/
Governor Adjustments under Perform Test
Checks. HOWEVER, if the root cause of the high
speed is due to the governor arm slipping on the
governor shaft, adjusting the speed will give a
false indication of being correct. The speed will
be ok until put under a load, the engine will droop
or bog down. After adjusting the speed, the
unit must be tested using a load bank tester by
gradually applying full rated load. If speed drops
more that 3 Hz, the governor arm has slipped on
the shaft and needs to be reset. To reset governor arm, refer to Speed/Governor Adjustments
under Perform Test Checks.
Replace ignition coil. Note: Coil resistance can
measure ok and still be faulty. It is best to replace
coil in this case.
Possible cause
Fuel level too low,
running out of gas
can cause speed
variation (hunting)
for a while before
engine quits
Fuel quality issue or
restriction
Spark arrestor dirty
or clogged
Gas leaks
Stretched or missing governor spring
(small)
Governor spring
(large) is connected
to wrong hole in
governor arm
Gas is leaking from
fuel valve
Problem
Gas leaks
(continued)
Possible cause
Gas leaks when
removing gas cap
and pressure can
be heard escaping
as cap is removed
(non-California
engines only)
Breather valve missHigh oil
consumption ing or damaged
and/or oil
dripping from
air cleaner
or spark plug
fouled with
carbon
PERFORMANCE Problem
Solution
Check fuel level, add fuel if needed.
Refer to Engine will not start, stay running or
only runs when choked steps 5,6,12 & 13 under
Starting Problem/Engine under Troubleshooting.
Clean spark arrestor, refer to Spark Arrestor under
Maintenance. Run engine briefly without spark
arrestor to verify that was the cause. Reassemble
spark arrestor to muffler. If screen is damaged
replace spark arrestor if screen is damaged.
Important: These products are equipped with
spark-arresting mufflers. It is legally required in
the state of California. It is a violation of California
statutes section 130050 and/or sec­tions 4442 and
4443 of the California Public Re­sourc­es Code,
unless the engine is equipped with a spark arrester,
as defined in section 4442, and maintained in ef­fec­
tive work­ing order. Spark arresters are also required
on some U.S. For­est Service land and may also be
legally required under other statutes and or­di­nanc­
es.
Replace spring, refer to Governor Linkage under
Breakdowns.
Solution
Gas cap is not venting properly. Replace gas cap.
English
Problem
Engine
surges,
hunts or runs
unevenly
Remove cylinder head cover and look for disc valve
just inside of breather hose. This disc must be free
to open or close off opening. If stuck in one position
or completely missing, replace cylinder head cover
assembly.
Problem
Check
Engine:
Lacks power
Overheats
Surges or runs
unevenly
Vibration or noise
level is excessive
Test spark plug firing No spark
Examine spark plug
condition
Compression
Try different connection holes in governor arm.
Refer to Governor Linkage under Breakdowns.
Check fuel condition
Fuel valve may be loose, tighten securing nut while
holding valve in proper orientation. If valve still
leaks, valve may be faulty, replace.
Gas is leaking from Ensure there are no splits or wear marks on gas
fuel line
line and ends are securely attached to fittings.
Gas is leaking from Remove float bowl and clean thoroughly. Remove
carburetor the float float needle and clean needle and bore where
it locates. Reassemble and check. If still leaks,
needle may be
replace carburetor. Refer to Carburetor under
stuck open
Breakdowns.
Carburetor floods
Fuel valve must always be placed into the OFF
while transporting
position when transporting.
Gas cap leaks when Gas should not be above shoulders of debris
transporting
screen, refer to engine instruction manual) NonCalifornia engines are equipped with vented caps,
a small amount of gas will leak if unit is tipped at a
steep angle and held there. If a large amount of gas
leaks, ensure the rubber gasket under cap is present and the mating surface of the tank is smooth
and flat. If >0.1 mm feeler gauge can fit under
straight edge at any point, replace tank.
Result
Solution
See Ignition Test.
Sparks inconsistently
See Speed/
Governor
Adjustment.
Spark plug is dry
See Carburetor/fuel
delivery troubleshooting.
Spark plug is wet:
Check compression
Poor compression
See Compression
Test.
Good Compression
Check fuel condition
Poor fuel
See Fuel System
under Maintenance.
Adequate Fuel
See Oil Alert Test.
Starter/Battery
recoil starter
Problem
Cause
Engine does not turn Starter cord cut
over correctly
19
Solution
Disassemble and replace
starter cord
Return spring broken
Replace or realign return
spring.
Ratchet assembly
malfunctioning
Replace ratchet
English
Problem
Cause
Solution
Debris is locking up flywheel
Disassemble and clear any
debris from recoil base
and recoil assembly. See
Flywheel Ignition under
Breakdown.
Performance Problem
Problem
Cause
Solution
Engine overheats
Cooling fins obstructed
Clear fins of debris
Excessive load
Clean combustion chamber
Carbon in combustion
chamber
Clean combustion chamber
Battery starter/battery failure
Problem
Cause
Solution
Low oil
Add oil
Battery does not
supply electricity to
starter
Battery leads faulty
Check for debris blocking
connections
If worn, replace battery
Set at wrong idle speed
See Speed/Governor
Adjustment under Perform
Test Checks.
Battery is dead
Charge and replace battery
pack.
Low power
Clogged spark arrestor
Remove, clean and replace.
Valves leaking
Perform valve job,
see Inspection under
Breakdowns: Cylinder Head
Valves.
Intake exhaust manifolds
clogged
Clean manifolds
Carbon build up
Clean combustion chamber
Carbon in combustion
chamber
Clean combustion chamber
Valves leaking/stuck
Check valves/seats.
Recondition if necessary.
Check valve to valve guide
fit up.
Blue exhaust smoke
Piston rings/cylinder bore
worn and passing oil
Replace rings and piston/
hone cylinder/check air filter.
Can not handle load
Improper valve clearance
Check/adjust valve clearance
or perform valve job, see
Inspection under Cylinder
Head Valves Breakdowns.
Weak valve spring
Perform valve job, see
Inspection under Cylinder
Head Valves Breakdown.
Valve/valve seats worn or
damaged
Perform valve job, see
Inspection under Cylinder
Head Valves Breakdown.
Battery starter/starter motor failure
Problem
Cause
Solution
Starter motor fails
Pinion gear not engaged with
flywheel
Remove starter motor and
make sure the pinion gear
slides freely on helix
Solenoid faulty
Make sure gear teeth have
not been stripped
Starter motor damaged
Repair or replace starter
motor
Starter toggle switch faulty
Check for continuity on starter
toggle switch in the ON position. See Fan Cover breakdown section.
Electrical relay fails
Black exhaust
smoke
Compression
Starting Problem
Problem
Cause
Solution
Poor compression
Leaking/stuck valves
Valve job/replacement
Head gasket burned
Replace head gasket
Worn piston rings
Service/replace rings or piston
or crankcase
Worn cylinder bore
See Compression Test.
Warped/cracked cylinder head Replace cylinder head
20
Cause
Solution
Excessive vibration/
knocking
Loose/worn connecting rod
Repair connecting rod
Carbon in combustion
chamber
Clean carbon from chamber
Bent crankshaft
Disassemble crankcase and
repair
Engine mount damaged
Check engine mounting bolts
or replace rubber isolator
Timing out
Check flywheel key
8.Ensure the idle screw (with black spring under the head on the L-shaped lever on the
solenoid) is backed out far enough to just clear touching the governor arm with idle
control turned off.
9.Start the engine. Turn idle control on after engine has warmed up some. Solenoid
should push governor arm and throttle to the left toward carburetor and the black plastic
throttle should stop up against black plastic screw (L3, Q2). Adjust the idle speed to
2700–2800 RPM by adjusting this screw in to increase idle speed, back it out to reduce.
If solenoid does not push lever over far enough to touch black plastic screw (the screw
with the black spring on the L-shaped solenoid lever) can be turned in to make this
happen. Both of these screws can be adjusted in our out so one is not at the extreme
of it's adjustment length.
10.Cycle idle control switch on and off a few times and check both high speed and idle
speed to ensure they are still correct.
Perform Test Checks
Ignition Test
Speed/Governor Adjustment
If speeds are out of adjustment use this procedure to reset to factory settings.
1.Back off both idle adjustment screws far enough so they are out of the way.
NOTE: This is the black plastic screw (L3, Q2) at carburetor and the screw with the
black spring under the head on the solenoid L-shaped linkage (if equipped).
L3, Q2
C5
CHECK FOR SPARK
WARNING: Risk of explosion. Spilled gas­o­line and it’s vapors can be­come ignited from
sparks from smoking products, electrical arcing, exhaust, flame, gas­es and hot engine components such as the muffler. Make sure there are no sources of ignition, such as smoking
products near servicing location. Wipe any fuel spillage from engine.
WARNING:
• Never hold the spark plug wire with wet hands while performing test.
• Wipe any fuel spillage from engine.
• Make sure the spark plug is not wet with fuel.
• Do not allow sparks near the plug hole.
1.Remove the spark plug from the cylinder head.
2.Ground spark plug against air shroud as shown. 3.Place the on/off switch in the “ON” position and
crank the engine.
4.Check to see if the spark bridges the electrode
gap. If you can see the spark (this may be difficult
in bright daylight) the problem is most likely not the ignition system. If spark plug fails
to spark, see Flywheel Ignition Inspection.
N5, Z4
F2
E5, Q5
2.Loosen the governor arm (E5, Q5) from the shaft (F2) coming out of the top of engine.
On 9 and 13 HP engines:
Rotate the shaft counterclockwise with the governor arm held to the right at WOT
(wide open throttle). Make sure governor arm remains straight and does not pivot at
the joint in the middle (if equipped). Retighten governor arm to shaft in this extreme
position.
On 6.5 HP engines:
Rotate the shaft clockwise with the governor arm held to the right at WOT (wide open
throttle). Retighten governor arm to shaft in this extreme position.
3.Governor spring (large silver) should be in the hole on the governor arm closest to the
shaft.
4.Back out high speed adjustment screw (N5, Z4) on top of the engine at the small silver
lever. A few complete turns will do.
5.Start the engine. If it hunts (speed varies up and down.), move the governor spring to
the outer hole, if power is too low move it back in toward the shaft. NOTE: Hunting is
unpredictable and sometimes the opposite movement of the spring helps.
6.Engine will probably be running slow. Adjust high speed to 3600 rpm by turning high
speed screw (N5, Z4) on top, in to increase speed and out to slow down. If engine still
runs to fast, governor arm may still be out of adjustment on shaft or it has moved since
tightening. Or there could be an internal governor issue (this is rare).
NOTE: If governor arm was over tightened to shaft and has no gap at the end of the
arm next to the shaft, over tightening of the governor arm will not result in sufficient
holding force to shaft. The governor arm must be replaced.
7.With engine off, ensure idle linkages on solenoid are not binding and are free to move
the full travel. Also make sure throttle linkage from carburetor to governor arm moves
back and forth freely.
Oil Alert Test
Perform this check if the engine will not start and other troubleshooting attempts
have failed. Ensure oil is a proper level, see Oil under Maintenance.
Engine will not start:
Disconnect the lead from the oil alert
sensor and directly connect the
leads from the ignition switch and
the ignition bypassing the low oil
sensor. If the engine starts replace
the sensor.
Engine will not stop:
With the engine running disconnect
the oil alert sensor lead and ground
it against the engine. If the engine does not stop replace the sensor.
21
English
Problem
English
Start Mechanism
WARNING: Risk of explosion. Spilled gas­o­line and it’s vapors can be­come ignited
from sparks from smoking products, electrical arcing, exhaust, flame, gas­es and hot engine
components such as the muffler. Make sure there are no sources of ignition, such as
smoking products near servicing location. Wipe any fuel spillage from engine.
1.If the engine is equipped with a DeWALT battery
starter, push the start control to START and check
for crankshaft rotation. NOTE: Ensure a fully
charged 18V DeWALT battery is being used.
a.If the crankshaft does not rotate, pull the recoil
start cord. If the crankshaft rotates the electric
starter or connection to battery is faulty. Inspect
and repair.
b.If the battery start switch is engaged and the
electric motor can be heard running the problem
is with the drive pinion gear, service the starter
motor. If the electric motor can not be heard running the problem is electrical. See the Starter Motor Inspection section.
Compression Test
1.Remove the spark plug and thread in compression
gauge.
2.Use pull starter to simulate starting engine (pull
briskly) or use fully charge battery pack if electric
start. Compression gauge should read 40 psi min.,
if lower than 40 psi check valve clearance before
proceeding further.
3.If valve clearance is in spec and compression is
still low, check head gasket and then piston rings
and cylinder bore for wear.
HINT: Only use a peak compression gauge when
doing a compression test. Leak down testers can only
measure decay with the piston at TDC.
22
Breakdowns
Air Filter
NOTE: Hand tighten
wingnuts (E, G).
E
See
Cleaning
Air Filter
Element
under
Maintenance
to clean
F
G
H
I
J
K
M
L
NOTE: When removing
gasket (L) note the orientation
for reinstallation. Check gasket
(L) for damage, replace if
needed.
O P
NOTE: Insert breather
tube (N) into valve head cover
after installing onto air filter
housing
N
q
23
English
E.Wingnut
F.Air filter cover
G.Wingnut
H.Grommet
I.Air filter element (paper)
J.Air filter element (foam)
K Air filter element base
L.Gasket
M.O-ring
N.Breather tube
O.Sleeve (2)
P.Intake manifold nut (2)
Q.Air filter housing
English
Air Cleaner
R Air filter cover
S.Air filter element (one or two pieces of foam).
T. Snap Clip (2)
U. Flow control plate
V. Air cleaner nut (6)
W. Air cleaner gasket
X. Air cleaner base
Y. Intake manifold nut (2)
Z. Intake separator gasket
X
W
T
Y
V
S
See Cleaning Air
Filter Element under
Maintenance to clean
R
U
24
Z
Muffler
BB
Clean spark arrestor (CC),
see Spark Arrester under
Maintenance.
CC
GG
Muffler for
DW177F-H-E and
DW188F-H
AA
R14
HH
Muffler for
DW168F-2-h-2e
AA
FF
FF
EE
DD
EE
Do not reuse gasket (DD).
HH
DD
Important: These products are equipped with spark-arresting mufflers. It is legally
required in the state of California. It is a violation of California statutes section 130050 and/or
sec­tions 4442 and 4443 of the California Public Re­sourc­es Code, unless the engine is
equipped with a spark arrester, as defined in section 4442, and maintained in ef­fec­tive
work­ing order. Spark arresters are also required on some U.S. For­est Service land and
may also be legally required under other statutes and or­di­nanc­es.
25
English
NOTE: MODELS DW168F-2H-2E, DW177F-H-E,
DW188F‑H are equipped with a high mount
muffler
AA.Muffler
BB. Screws (4)
CC. Spark arrestor and screw
DD. Gasket
EE. Lockwashers (2)
FF. Nuts (2)
GG.Muffler cover
HH.Muffler Elbow
R14. Screws (3)
English
Muffler
NOTE: MODELS DW177FD-F, DW188F‑F are
equipped with a low mount muffler
II.Muffler
JJ. Bolts (9)
KK.Washer
CC. Spark arrestor and screws
LL.Muffler cover, front
MM.Exhuaust manifold
NN. Muffler Bracket
OO. Nuts (2)
PP. Muffler cover, back
QQ. Gasket (2)
R13.Manifold nuts (2)
NN
PP
JJ
II
JJ
LL
JJ
kk
JJ
OO
CC
JJ
QQ
R13
MM
QQ
JJ
JJ
JJ
Important: These products are equipped with spark-arresting mufflers. It is legally
required in the state of California. It is a violation of California statutes section 130050 and/or
sec­tions 4442 and 4443 of the California Public Re­sourc­es Code, unless the engine is
equipped with a spark arrester, as defined in section 4442, and maintained in ef­fec­tive
work­ing order. Spark arresters are also required on some U.S. For­est Service land and
may also be legally required under other statutes and or­di­nanc­es.
26
Muffler
NOTE: MODELS DW168F
English
equipped with Low mount muffler
KK.Washer
RR.Muffler
SS. Bolts (10)
CC. Spark arrestor and screws
UU.Muffler cover, front
VV. Muffler cover, back
WW.Gasket
SS
VV
RR
SS
kk
CC
WW
SS
Important: These products are equipped with spark-arresting mufflers. It is legally
required in the state of California. It is a violation of California statutes section 130050 and/or
sec­tions 4442 and 4443 of the California Public Re­sourc­es Code, unless the engine is
equipped with a spark arrester, as defined in section 4442, and maintained in ef­fec­tive
work­ing order. Spark arresters are also required on some U.S. For­est Service land and
may also be legally required under other statutes and or­di­nanc­es.
UU
SS
27
English
Recoil Starter
X.Recoil cover
X
YY.8 mm screws (5)
ZZ.Recoil starter spring
A1.Starter reel
B1.Studs (4)
C1.Friction spring
D1.Reel cover
E1.Ratchet
F1.Reel cover screw
G1.Starter rope
H1.Recoil Base
I1.On/Off Switch
(compressor and pressure washer)
J1.Nuts (4)
K1.Support bracket
L1.Weather stripping
M1.Snap ring
Warning: Risk of unsafe operation. Always wear
gloves and certified safety equipment: ANSI Z87.1 eye
protection (CAN/CSA Z94.3) with side shields when assembling
and disassembling.
L1
J1
K1
CAUTION: Risk of unsafe
operation. Carefully remove
starter reel (A1) from recoil
cover (XX). Spring will unwind
very quickly.
Before reassembling
starter rope check
for fraying and wear,
replace if needed.
YY
B1
NOTE: Unhook the On/Off switch (I1)
before removing the recoil base (H1).
I1
XX
A1
H1
C1 E1
ZZ
G1
F1
M1
D1
C1
Before reassembling recoil cover
(XX) remove any dirt or debris.
Before reassembling lubricate moving parts
(C1, E1, F1) with bearing grease.
28
Before reassembling check ratchets
(E1) for wear, if needed replace.
Assemble Recoil Starter
English
5.Slide the starter rope end through
the recoil cover rope guide and pull
it outwards. Pass the starter rope
through the starter grip (Q1) and tie
a knot in the rope as shown. NOTE:
Rope will be under tension, clamp
rope with vise or similar devise to
hold rope while tying.
Warning: Risk of unsafe operation.
Do not separate the starter reel from the
recoil cover. If they are separated the
return spring inside the case will come off
and could cause serious injury.
Warning: Risk of unsafe operation. Always wear gloves and certified safety equipment:
ANSI Z87.1 eye protection (CAN/CSA Z94.3) with side shields when assembling and
disassembling.
1.Slide the starter rope (G1) through
G1
A1
the starter reel (A1) and tie a knot
(N1) in the rope as shown. Wind the
starter rope around the starter reel
in the direction of the arrow.
NOTE: Leave approximately 12"
(30 cm) of starter rope outside the
starter reel.
Q1
N1
2.Place the hook (P1) on the outer side
of the spring (ZZ) into the groove
(O1) inside the starter reel (A1).
6.Install the ratchets (E1) with the
friction springs (C1), snap ring (M1)
and reel cover (D1). Tighten reel
cover bolt (F1).
7.Pull the starter rope several times to
check the operation of the ratchet.
NOTE: Ratchet should extend
outward while pulling starter rope
and then retract.
o1
p1
zz
a1
3.Place the starter reel on the recoil
cover so the spring inner hook hooks
to the case tab.
4.While holding the recoil cover, rotate
the starter reel two revolutions in the
direction of the arrows for preliminary winding.
29
F1
D1
e1
m1
c1
English
Inspection
ON/OFF Switch
1.Remove switch from recoil base and detach leads from
terminals.
2.Using an ohm meter measure the resistance between
terminals 1 and 2 with the switch in the ON position(|). The
ohm meter should read approximately infinity.
3.Using an ohm meter measure the resistance between
terminals 1 and 2 with the switch in the OFF position (O). The ohm meter should read approximately zero.
4.If either of the tests described here yield a different result
replace the switch.
30
Carburetor
Disassembly
R1. Governor rod
S1. Governor spring
T1.Fuel line
U1. Spark plug wire
V1. Insulator plate (if equipped)
W1. Carburetor gaskets (3)
X1. Manifold gasket
Y1. Choke lever
Z1. Carburetor
A2. Throttle lever
B2. Carburetor bowl drain bolt
C2. Air cleaner gasket
BEFORE DISASSEMBLY:
• Drain gasoline from gas tank before removing. Loosen the
carburetor bowl drain bolt (B2, F3, K2) and drain the carburetor and gas tank completely.
• Disconnect the governor spring (S1).
WARNING: Risk of explosion. Spilled gas­o­line and it’s vapors
can be­come ignited from sparks from smoking products, electrical
arcing, exhaust, flame, gas­es and hot engine components such as
the muffler. Make sure there are no sources of ignition, such as
smoking products near servicing location. Wipe any fuel spillage
from engine.
WARNING: Risk of explosion or fire. Gasoline vapor is highly
flammable. Refuel outdoors only in well-ventilated areas. Do not refuel
or check gasoline level while the engine is running. Do not store, spill
or use gasoline near an open flame, a source of sparks (such as
welding), or near operating electrical equipment.
English
With the governor spring (S1)
unhooked, pull the carburetor out until
the groove in the throttle arm lines up
with the governor rod and then lift the rod
out. Assemble in reverse order.
S1
R1
A2
U1
T1
Y1
V1
W1
X1
C2
Z1
B2
31
English
Carburetor
Models DW168F-2H, DW168F-2E,
DW177F‑H, DW177F-E, DW188F-H
assembly
D2.O-Ring
E2.Fuel valve gasket
G2.Lever spring
H2.Fuel valve lever
I2.Choke lever
I4. Main jet
J2.Carburetor bowl
K2.Fuel drain bolt
L2.Set bolt
M2.Float pin
2.Float valve spring
N
O2Float valve
P2.Float
Q2.Throttle stop screw
R2.Pilot Jet
S2.Throttle stop screw seat
T2.Choke valve
U2.Carburetor Body
V2.Screw (2)
W2.Lever setting plate
X2.E-tube
I2
h2
V2
W2
g2
E2
Q2
Adjust throttle stop screw (Q2). See Speed/
Governor Adjustment under Maintenance.
S2
U2
R2
T2
Check for smooth movement after
installing the float. (P2).
X2
Clean carburetor body (U2).
OK
P2
M2
Replace
O2
N2
Before reassembling
float (P2), check float
valve for wear and replace
if needed.
i4
J2
After assembling set bolt
(L2) and carburetor check for
any signs of fuel leaking.
D2
L2
32
K2
Carburetor
Models DW177FD-F, DW188F1-F
Z2
DO NOT reuse carburetor gaskets
(B3) or manifold gasket (T3).
B3
Clean carburetor body (P3).
G4
Y3
U3
Z3
F4
E4
A4
E4
L3
B4
Adjust throttle
stop screw (L3). See
Throttle Adjustment
under Maintenance.
N3
D4
C4
Z3
R3
M3
H4
B3
P3
J3
O3
I3
X2
X3
I4
Q3
Check for smooth movement after
installing the float. (K3)
K3
H3
W3
E3
Z10
F3
Y2
V3
Y2
OK
Replace
S3
Before reassembling
float (K3), check float
valve spring (I3) and float
valve (J3) for wear and
replace if needed.
D3
33
English
assembly
Y2. O-ring, fuel shut off
Z2. Insulator Plate
B3 Carburetor gaskets (2)
D3. Valve assembly solenoid
E3. Carburetor bowl
F3.Fuel drain bolt
H3.Float pin
I3.Float valve spring
J3.Float valve
K3.Float
L3. Throttle stop screw
M3. Pilot Jet
N3. Throttle stop screw seat
03. Choke valve
P3. Carburetor Body
Q3. Choke ring
R3. Choke rod
S3. Screw (2)
T3. Gasket, manifold intake
U3. Long grommet
V3.Fuel shut off bolt
W3. O-ring, carburetor bowl
X3. Choke stopper
Y3. Choke bracket
Z3. E-ring (2)
A4. Choke linkage
B4. Choke guide
C4. Return spring
D4. Steel Washer
E4. Wear guard (2)
F4. Control post
G4. E-ring
H4. Choke Grommet
I4.Main jet
X2. E-tube
Z10 O-ring, drain bolt
T3
English
Cleaning
WARNING: Always wear certified safety equipment: ANSI Z87.1 eye protection (CAN/CSA
Z94.3) with side shields when using compressed air.
CAUTION: Commercially-available chemical cleaners are very caustic. These cleaners may
damage plastic parts such as O-rings, floats and float valve seats. Check the container for
instructions.
Do not use these products if in doubt.
CAUTION: Using high air pressure may cause damage to the carburetor, only use low air pressure settings when cleaning passages and ports.
Carburetor
1.Clean the carburetor body
with solvent.
2.Use low air pressure and
clean the following parts and
passages.
• Internal or external vent
port (J4)
• Pilot screw hole (K4)
• Pilot jet hole (L4)
• Pilot air jet (R2, M3)
• Main jet (I4)
• Transition ports (M4)
• Pilot outlet (N4)
M4
N4
J4
J4
eNGINE BLOCK SIDE
L4
K4
R2, M3
aIR cLEANER SIDE
I4
34
Gas Tank
BEFORE DISASSEMBLY:
• Drain gasoline from gas tank before removing. Loosen the carburetor fuel drain bolt (B2, K2, F3) and drain the carburetor completely.
• Remove recoil starter cover, recoil base and weather stripping
WARNING: Risk of explosion. Spilled gas­o­line and it’s vapors can
be­come ignited from sparks from smoking products, electrical arcing,
exhaust, flame, gas­es and hot engine components such as the muffler.
Make sure there are no sources of ignition, such as smoking products
near servicing location. Wipe any fuel spillage from engine.
WARNING: Risk of explosion or fire. Gasoline vapor is highly flammable.
Refuel outdoors only in well-ventilated areas. Do not refuel or check
gasoline level while the engine is running. Do not store, spill or use
gasoline near an open flame, a source of sparks (such as welding), or near
operating electrical equipment.
English
Models DW168F-2H, DW168F-2E,
DW177F‑H, DW177F-E, DW188F-H
P4. Gas tank
Q4. Fuel line
R4. Nuts (2)
S4. Screw
T4. Clamp (2)
U4. Gas cap
W4. Debris screen
U4
W4
P4
R4
S4
T4
Q4
35
English
Governor Linkage
Models DW168F-2F, DW177FD-F, DW188FD-F
X4.Control base cover
Y4.Shroud bolt (3)
Z4.Throttle stop screw
A5.Adjusting spring
B5.Governor spring
C5.Governor arm nut
D5.Governor arm bolt
E5.Governor arm
F5.Governor rod
G5.Governor spring
H5.Idle control solenoid
I5.Solenoid bolts (2)
The long end of the governor spring (B5)
goes toward the control lever and the short
end hooks into the governor arm (E5).
C5
D5
H5
B5
Y4
G5
X4
E5
The long end of the governor
spring (G5) goes toward the
governor arm (E5).
Y4
F5
After assembling throttle stop screw (Z4)
and adjusting spring (A5), see Speed/
Governor Adjustment under Maintenance.
Y4
A5
Z4
36
I5
Governor
BEFORE DISASSEMBLY:
• Drain gasoline from gas tank before removing. Loosen the carburetor fuel drain bolt
(B2, K2, F3) and drain the carburetor completely.
• Remove recoil starter cover, recoil base and weather stripping.
WARNING: Risk of explosion. Spilled gas­o­line and it’s vapors can be­come ignited
from sparks from smoking products, electrical arcing, exhaust, flame, gas­es and hot engine
components such as the muffler. Make sure there are no sources of ignition, such as
smoking products near servicing location. Wipe any fuel spillage from engine.
WARNING: Risk of explosion or fire. Gasoline vapor is highly flammable. Refuel outdoors only in well-ventilated areas. Do not refuel or check gasoline level while the engine
is running. Do not store, spill or use gasoline near an open flame, a source of sparks (such
as welding), or near operating electrical equipment.
P5
R5
K5
L5
Locknut (P5) adjusts the control
lever friction.
Adjust the governor. See
Throttle Adjustment under
Maintenance.
The long end of governor spring (R5) goes
toward the control lever (L5) and the short
end hooks into the outer hole of the governor
arm (Q5).
J5
S5
English
Models DW168F-2H, DW168F-2E,
DW177F‑H, DW177F-E, DW188F-H
J5.Control lever washer
K5.Control lever spring
L5.Control lever
M5.Control base
N5.Throttle lever limiting screw
U5.Governor rod
P5.Lock nut
Q5.Governor arm
R5.Governor spring
S5.Washer
T5.Washer
O4.Throttle pneumatic solenoid
(compressor only -E engines)
Q5
T5
N5
U5
O4
M5
The concave side of washer (S5)
should be against the control lever.
After assembling screw (N5),
start the engine and adjust the
maximum speed. See Throttle
Adjustment under Maintenance.
Align control lever washer (J5)
groove with tab on the control
base.
37
English
Flywheel Ignition
U5 Starter motor (electric start)
W5. Relay Assembly
Y5. Starter bolt (2)
Z5.Flange nut
A6. Starter pulley
B6.Fan
C6.Flywheel
D6. Ignition coil
E6. Spark plug wire
F6. Spark plug boot
G6. Spark plug
H6. Spacer
I6. Charge coil
J6. Bracket
K6.Bolt
L6. Bolt (2)
M6. Ignition wire
W5
U5
Clean
crankshaft
before reassembling
Y5
G6
H6
I6
NOTE: Place a screw
driver through slots in
starter pulley (A6) to hold
in place while loosening
nut (Z5).
L6
M6
J6
K6
E6
Remove the ignition coil (D6)
before removing the flywheel.
C6
F6
D6
B6
A6
When removing fan be
careful not to damage the
fan blades.
Use a commercially available flywheel
puller to remove the flywheel. Avoid the
magnetic section of the flywheel when
attaching the puller. DO NOT hit the flywheel with a hammer.
When reassembling fan align
the four lugs on the rear side of
the fan with the small holes in the
flywheel.
38
Z5
Adjustment
Specified
clearance
0.3-0.5 mm
(0.012-0.020")
C6
Resistance
Standard
7.5k — 12.5k
I6
lAMP COIL (if equipped)
Measure the resistance between the wire
terminals.
thickness gauge
Resistance
Inspection
12 V — 15 W
Ignition Coil
Primary Side
Measure the resistance of the primary
coil:
1.Attach one ohmmeter lead to the
Ignition coil's primary (black) lead and
Touch the other test lead to the iron
core.
1.3 Ω ± 0.2 Ω
sECONDARY Side
Measure the resistance of the secondary
coil:
1.Remove the spark plug boot from
spark plug and touch one ohmmeter
lead to the spark plug lead wire and
the other test lead to the coil's iron
core.
Secondary
side
resistance
value
<7.5k or >12.5k
NOTE: Replace the spark plug boot if the
resistance is not within the range specified.
4.Remove the thickness gauge.
Primary side
resistance
value
Service limit
6.4 Ω ± 1k Ω
NOTE: A false reading will result if the spark plug boot is not removed.
39
0.75 ± 0.1 Ω
G6
English
Ignition coil air gap
Only required when ignition coil or flywheel
has been removed.
1.Loosen the ignition coil bolts.
2.Insert a long thickness gauge or
piece of paper of the proper thickness between the ignition coil (I6) and
the flywheel (C6). NOTE: Both gaps
should be adjusted simultaneously.
3.Push the ignition coil firmly toward the
flywheel and tighten the bolts.
Spark plug boot
Measure the resistance of the spark plug
boot.
1.Touch one ohmmeter lead to the wire
end of the cap and the other at the spark
plug (G6) end.
English
Starter Motor
N6
DW177FD-F, DW188FD-F
N6. Bolts (3)
O6. O-ring
P6. Commutator/Armature assembly
Q6.Brush plate
R6.Brush/terminal assembly
S6. Pinion gear
T6. Driver side housing
U6. Reduction gear
V6. Front bracket
W6. Overrunning clutch
X6. Starter solenoid
Y6. Terminal screw
Z6. Conductor wire
A7. Screw
B7. Washers (qty 3)
C7. Nuts (qty 3)
D7.Magnetic Can
To remove starter motor
fan, the cover and flywheel
must be removed.
Disconnect wires from power equipment.
O6
Check the commutator/armature
assembly (P6) for dust or other
damage. Wipe clean with lint-free
cloth
Q6
P6
Make sure magnets are clean
R6
C7
D7
B7
A7
Hold magnetic can (D7) tightly
when replacing, The magnetic field
will pull can onto armature (P6).
S6
Z6
Y6
X6
V6
Check flywheel ring gear teeth
if pinion gear teeth are damaged.
U6
W6
Make sure gears line up and commutator/
armature assembly (P6) turns freely.
40
T6
Brush Length
Measure the brush length:
Replace the brush if the brush length is less
than service limit.
Standard
(mm)
10
English
Brushes - continuity check
Remove the armature and check for
continuity between the brushes. There
should be no continuity between the
brushes.
Starter solenoid
Connect a 12V battery between the starter
terminal and the solenoid body and check
for continuity between terminals.
NOTE: Continuity should exist when the
battery is connected and not exist when the
battery is disconnected.
Overrunning clutch
1.Check the overrunning clutch for smooth
axial movement. Apply oil or replace
the overrunning clutch, if necessary.
Service limit (mm)
5.5
Armature
Continuity check: commutator segments
Check the continuity between the segments.
If an open circuit (no continuity) exists
between any two segments, replace the
armature.
2.Check the reduction gear movement by
holding the pinion gear (E7) and turning the reduction gear (U6). The reduction gear should turn counterclockwise
freely and should not turn clockwise.
3.Check the pinion gear for wear or damage and replace if necessary.
NOTE: If the pinion gear is worn or damaged the flywheel ring gear must be
inspected.
Continuity check: commutator to shaft
Check the continuity between commutator
and the armature shaft. If continuity exists
between any of the commutator segments
and the armature shaft, replace the armature shaft.
41
E7
U6
English
Cylinder Head Valves
6.5 H.P.
F7. Head Bolts (4)
G7. Cylinder head cover
G6. Spark plug
I7. Head gasket
J7. Gasket
K7. Valve cover bolts (4)
L7. Cylinder head
M7. Valve spring retainer (2)
N7. Valve rotator (2)
O7. Push rod guide
P7. Rocker arm (2)
Q7. Valve spring (2)
R7. Rocker arm pivot (2)
S7. Rocker arm pivot nut (2)
T7. Rocker arm pivot bolt (2)
U7. Exhaust valve
V7. Intake valve
W7. Oil seal
X7. Push rods (2)
Y7. Air shroud
Z7. Valve tappet (2)
A8. Shroud bolts (2)
Loosen and tighten
bolts in a crisscross
pattern, taking 2-3
steps.
Do not interchange
the exhaust (U7) and
intake (V7) valves.
J7
Clean spark plug. See Spark Plug
under Maintenance.
G6
U7
L7
F7
I7
V7
G7
Q7
Inspect valve
spring (Q7). K7
Before
installation,
remove any carbon deposits
from
the
combustion
chamber and inspect the
valve seats. After assembly
measure the cylinder
compression.
Z7
W7
M7
N7
P7
Y7
CAUTION: Do
not
remove the valve spring (Q7)
while the cylinder head is
installed or the valves (U7, V7)
will drop into the cylinder.
X7
O7
S7
R7
T7
Check for wear on rocker arm
and push rods, replace if needed.
42
A8
Cylinder Head Valves
G6
Clean spark plug. See Spark Plug
under Maintenance.
Loosen and tighten
bolts in a crisscross
pattern, taking 2-3
steps.
English
9 and 13 H.P.
B8. Head Bolts (4)
C8. Cylinder head cover
G6. Spark plug
D8. Head Gasket
E8. Gasket
F8. Dowel pins (2)
G8. Cylinder Head
H8. Valve spring retainer (2)
I8. Valve rotator (2)
J8. Push rod guide
K8. Rocker arm (2)
L8. Valve spring (2)
M8. Rocker arm pivot (2)
N8. Rocker arm pivot nut (2)
O8. Rocker arm pivot bolt (2)
P8. Exhaust valve
Q8. Intake valve
R8. Oil Seal
S8. Push rods (2)
T8. Plate
U8. Shroud bolt
D8
G8
B8
E8
F8
Before installation, remove any carbon deposits from
the combustion chamber and inspect the valve seats.
After assembly measure the cylinder compression.
T8
Do not interchange
the exhaust (P8) and
intake (Q8) valves.
p8
U8
C8
CAUTION: If the valve rotator (I8)
is not installed the exhaust valve (P8)
could drop into the cylinder when starting
the engine.
r8
L8
Remove carbon deposits
from exhaust valves (P8) and
inspect the valve.
h8
Inspect valve spring (L8). q8
i8
k8
CAUTION: Do not remove the
valve spring (L8) while the cylinder head
is installed or the valves (P8, Q8) will drop
into the cylinder.
S8
n8
m8
O8
J8
43
Check for wear on rocker arm
and push rods, replace if needed.
English
Inspection
Valve Stem O. D.
Inspect each valve for:
• surface irregularities
• bending
• stem wear
Replace valve if needed.
Measure and record each valve stem O. D.
Valve Spring Free Length
Measure the free length of the valve
springs.
MODEL
Standard
(mm)
Service
limit (mm)
DW168
30 ~ 31
29.0
DW177
38.5 ~ 39.5
37.5
DW188
38.5 ~ 39.5
37.5
CALIPER
DW168
NOTE: Replace the springs if they are
shorter than the service limit.
DW177
Valve Seat Width
Measure the valve seat width.
MODEL
Standard
(mm)
Service
limit (mm)
DW168
0.7 ~ 0.9
2.0
DW177
0.7 ~ 0.9
2.0
DW188
0.7 ~ 0.9
2.0
DW188
0
5.468~5.48
5.418~5.44
6.568~6.580
6.545~6.560
6.568~6.580
6.545~6.560
5.318
5.275
6.440
6.400
6.440
6.400
Valve guide I. D.
NOTE: ream the valve guides to remove any
carbon deposits before measuring.
Measure and record each valve guide I. D.
VALVE
SEAT
Cylinder Head
WARNING: Always wear certified safety equipment: ANSI Z87.1 eye protection (CAN/
CSA Z94.3) with side shields when removing carbon deposits.
WARNING: To reduce the possibility of fire or explosion, be careful when working around
gasoline. Use only a nonflammable solvent, not gasoline, to clean parts. Keep smoking
products, sparks and flames away from all fuel related parts.
• Remove carbon deposits from
combustion chamber using a wire Straight
Edge
brush.
• Remove any gasket material from
cylinder head surface.
• Check the spark plug hole and valve
areas for cracks.
• Check the cylinder head for warpage
with a straight edge and a feeler
Feeler
gauge.
Service limit
(mm)
IN
EX
IN
EX
IN
EX
Service
Limit
(mm)
NOTE: Replace the valves if the O. D. is smaller than the service limit.
NOTE: Recondition the valve seat if the
width is under the standard or over the
service limit.
Standard
(mm)
Standard
(mm)
model
mICROMETER
model
Standard
(mm)
DW168
DW177
DW188
5.500~5.512
6.600~6.615
6.600~6.615
Service
Limit
(mm)
5.572
6.660
6.660
rEAMING TOOL
vALVE
gUIDE
NOTE: Replace the valve guides if the I. D. Is
over the service limit.
Guide To Stem Clearance
Subtract each valve stem O. D. from the
corresponding guide I. D. to obtain the
stem to guide clearance.
Standard
(mm)
model
DW168
DW177
Gauge
DW188
0.10
44
IN
EX
IN
EX
IN
EX
0.020~0.044
0.060~0.084
0.020~0.070
0.040~0.070
0.020~0.070
0.040~0.070
Service
Limit
(mm)
0.10
0.12
0.11
0.15
0.11
0.15
dial indicator
bore gauge
Valve Seat Reconditioning
1.Clean the combustion chamber and valve
seats (V8) to remove carbon deposits.
2.Apply a light coat of Prussian Blue or erasable felt-tipped marker on valve face.
3.Insert the valve and snap it closed against
the seat several times. Ensure the valve does
not rotate on the seat. The transferred marking compound will show any area of the seat
this is not concentric.
NOTE: Follow the valve seat cutter manufacture
instructions.
Valve Guide Replacement
1.Drive the valve guides out of the head from
the combustion chamber side using a
valve guide driver.
2.Install the new valve guides from the
valve spring side of the cylinder head.
Exhaust side: Drive the exhaust valve
guide until the clip is fully seated as
shown.
Intake side: Drive the intake valve
guide to the specified height (measure
from the top of the valve guide to the
cylinder casting as shown)
IN valve guide
installation height
3.0 mm (0.12")
VALVE
guide
V8
English
If the stem to guide clearance exceeds the service limit:
Determine if the new guide with standard dimensions would bring the clearance within tolerance, if so replace any guide as necessary and ream to fit. If the stem to guide clearance
exceeds the service limit with new guides, replace the valves also.
NOTE: Recondition the valve seats when valve guides are replaced.
VALVE
SEAT
CUTTER
EX: CLIP
IN: 3.0 mm
.012 in
driver
3.After installation, inspect the valve guide
for damage, replace if necessary.
4.Use a 45° cutter to remove enough material
to produce a smooth and concentric seat.
Turn the cutter clockwise, never counterclockwise.
Continue to turn the cutter while lifting it from the valve
seat.
5.Use a 30° – 32° and 60° cutter to narrow and adjust the
valve seat so it contacts the middle of the valve face.
Use a 30° – 32° cutter to remove material from the
bottom edge (contact too low).
Use a 60° cutter to remove material from the top edge
(contact too high). Ensure the width of the finished
valve seat is within specifications.
Valve Guide Reaming
1.Coat the reamer and valve guide with
rEAMING TOOL
cutting oil.
2.Rotate the reamer clockwise through
the valve guide the full length of the
reamer.
3.Continue to rotate the reamer clockwise
while removing it from the valve guide.
4.Thoroughly clean the cylinder head
vALVE
gUIDE
to remove any cutting oil residue and
chips.
5.Check the valve guide bore: it should
be straight, round and centered in
the valve guide. Insert the valve and check operation. If the valve does not operate
smoothly, the guide may have been bent during installation. Replace the valve guide if
it is bent or damaged.
6.Check the Valve Guide to Stem Clearance.
correct
incorrect
45
English
Valve Seat Width
model
Standard
(mm)
DW168
DW177
DW188
0.7~0.9
0.7~0.9
0.7~0.9
Service
Limit
(mm)
2.0
2.0
2.0
6.Make a light pass with a 45° cutter to
remove any possible burrs at the edges of
the seat.
7.After resurfacing the seats, inspect for even
valve seating. Apply a light coat of Prussian Blue or erasable felt-tipped marker onto the
valve face. Insert the valve and snap it closed against the seat several times. Ensure
the valve does not rotate on the seat.
The transferred marking compound should show the seating surface has good contact
all the way around.
8.Lap the valves into their seats using a
hand valve lapper and lapping compound (commercially available).
Caution: Risk of property damage.
Ensure all lapping compound is removed
valve
from the engine before reassembly.
lapper
NOTE: Adjust the valve clearance after
reassembly.
46
Governor/Low Oil Shut-off
Oil seal (2)
Crankcase cover
Balancer bearing (2)
Crankcase cover gasket
Washer (2)
Governor weight holder
Governor weight pin (3)
Governor weight (3)
Governor holder
Governor slider
W8
See Reassembly for
Gear Installation.
Y8
X8
Z8
D9
A9
C9
B9
E9
A9
F9
U9
B10.Bolt, oil alert unit
IMPORTANT NOTES FOR DW168F
engines
• The governor gear assembly is
installed in a plain bearing in the
crankcase.
• The governor drive gear is installed
on the flywheel journal of the
crankshaft.
Make sure governor
weights (D9) move freely.
Spread the governor weights
(D9) to install governor slider
(F9). Make sure the governor
slider moves freely.
Clip
(Z9)
is
inser ted
into shaft
groove.
Install O-ring (K9)
firmly in the groove.
K9
G9
H9
J9
N9
A10
Y8
L9
I9
Before installing governor
weight holder (B9) check for
gear wear and damage. Install
governor weight before the
crankshaft.
Install the lock pin (H9)
after installing the governor
arm shaft (I9) and then move
the shaft up against the
governor slider (F9).
Push crankshaft (X9) until
it touches the bearing. Be
careful not to damage the oil
alert unit (O9).
Z9
M9
X9
W9
V9
B10
O9
Y9
T9
W9
W8
S9
R9
J9
Q9
47
P9
English
W8.
X8.
Y8.
Z8.
A9.
B9.
C9.
D9.
E9.
F9.
S9. Piston Assembly
T9. Valve lifters (2)
U9. Crankcase cover bolt (2)
V9. Dowel pin (2)
W9. Main bearing (2)
X9. Crankshaft
Y9.Camshaft
(see Compression Relief breakdown)
Z9. Crankshaft key
A10.Balancer gear
(DW168F engines not equipped with
balancer gear)
G9.Washer
H9. Lock pin
I9. Governor arm shaft
J9. Dipstick (2)
K9. O-Ring
L9.Flange nut
M9. Oil level switch assembly
N9. Bolts, Oil level switch assembly (2)
O9. Oil alert unit
P9. Drain plug washer (2)
Q9. Drain plug bolt (2)
R9. Connecting rod bolt (2)
English
Compression Relief
Y9.
C10.
E10.
D10.
F10.
Camshaft
Reducer pin
Flying block
Matching block
Flying block pin
Crankshaft Bearing
Use a hydraulic press and driver with a diameter
larger than crankcase cover (X8) opening to
press the new bearing (W9) onto the crankshaft.
Y9
Driver
F10
W9
C10
X8
Timing Mark Alignment
NOTE: Balancer gear equipped on DW188F engines only, for DW168F and DW177F
engines proceed to step 2.
1.With crankshaft (X9) installed in crankcase install balancer (A10). NOTE: Align marks
on balancer and balancer drive gear of crankshaft.
2.Install the camshaft aligning marks on camshaft (Y9) with those on timing gear of
crankshaft.
D10
E10
reassembly
Timing Gear
Use the old gear as reference and make a mark at the same position on the new gear.
Use a hydraulic press, driver and attachment I. D. (special tool) to press the new gear onto
the crankshaft.
Y9
X9
X10
Y9
X9
DW168
Driver 40 mm I.D.
07746 – 0030100
Attachment,
25 mm I.D.
07746 – 0030200
DW177 and DW188
Driver 40 mm I.D.
07746 – 0030100
Attachment,
30 mm I.D.
07746 – 0030300
align marks
DW168F, DW177F
Governor Drive Gear
Use a hydraulic press, driver and attachment I. D. (special tool) to press the new governor
drive gear onto the crankshaft.
07746 – 0030100
Attachment,
30 mm I.D.
07746 – 0030300
Oil level switch (DW177, DW188)
1.With the switch in the normal upright orientation test the continuity between the yellow
lead and the face of the brass ground connector as show. The ohm meter should read
approximately zero resistance.
2.Hold the switch upside down to simulate the float’s position in the crankcase when it is
filled with oil. Test the continuity in the same way between the face of the brass ground
connector and the yellow lead. The ohm meter should read approximately infinite
resistance.
3.If either test yields an incorrect reading replace the low oil shutdown unit.
DW177 and DW188
Driver 40 mm I.D.
07746 – 0030100
Attachment,
35 mm I.D.
07746 – 0030400
DW188F
Inspection
DW168
Driver 40 mm I.D.
align marks
48
Piston
Top ring
Second ring
Oil ring
Piston
Connecting rod
Piston pin
Piston pin clip (2)
Bushing rings (2)
Markings on rings must face upward.
J10
K10
DO NOT interchange the top (J10)
and second rings (K10).
L10
Q10
Make sure rings rotate smoothly
after installation.
The piston ring end gaps should be
120˚ apart. DO NOT align the gaps with
the piston pin bore.
O10
P10
Place one end of the piston pin clip
(P10) into the piston groove, hold the
other end with needle nose pliers and
rotate clip into piston groove. DO NOT
align clip end gap with cutout in the
piston pin bore.
M10
P10
Warning: Risk of unsafe operation. Always
wear gloves and certified safety equipment: ANSI Z87.1
eye protection (CAN/CSA Z94.3) with side shields when
assembling and disassembling.
N10
49
English
J10.
K10.
L10.
M10.
N10.
O10.
P10.
Q10.
English
INSPECTION
Piston Ring side Clearance
ring, Top
Cylinder i.d.
Measure and record the cylinder I. D. at three
levels in both the "X" axis (perpendicular to
the crankshaft) and the "Y" axis (parallel to
crankshaft).
Take the maximum reading to determine
cylinder wear and taper.
model
Standard
(mm)
DW168
DW177
DW188
68.015~68.025
77.02~77.03
88.015~88.025
dial indicator
bore gauge
Service
Limit
(mm)
68.156
77.179
88.195
Standard
(mm)
DW168
DW177
DW188
67.975~67.985
76.970~76.980
87.970~87.980
Service
Limit
(mm)
67.850
76.850
87.850
Standard
(mm)
DW168
DW177
DW188
0.08~0.12
0.02~0.06
0.02~0.06
Piston ring end gap
Piston Skirt O.D.
Measure and record the piston O. D. at a point
of 10 mm (0.4") from the bottom of the skirt
and 90° to the piston pin bore.
model
model
feeler
guage
Service
Limit
(mm)
0.10
0.15
0.15
model
Standard
(mm)
DW168
DW177
DW188
0.15~0.35
0.20~0.35
0.20~0.40
Service
Limit
(mm)
1.00
1.00
1.00
feeler
guage
NOTE: Use the top of the piston to position the
ring horizontally in the cylinder.
Piston Pin O. D.
mICROMETER
Standard (mm)
17.992~17.998
Service Limit (mm)
17.940
Piston to cylinder clearance
model
Standard
(mm)
DW168
DW177
DW188
0.030~0.050
0.040~0.060
0.045~0.065
Service
Limit
(mm)
0.120
0.100
0.100
mICROMETER
Piston Pin Bore I. D.
Piston Ring Width
model
Standard
(mm)
DW168
DW177
DW188
1.450
2.000
2.000
Service
Limit
(mm)
1.200
1.750
1.250
mICROMETER
50
model
Standard
(mm)
DW168
DW177
DW188
18.002~18.008
18.002~18.008
20.002~20.008
Service
Limit
(mm)
18.042
18.042
20.042
dial indicator
bore gauge
Piston Pin to Piston Pin Bore Clearance
Service Limit (mm)
0.08
Connecting Rod Small End I. d.
model
Standard
(mm)
DW168
DW177
DW188
18.011~18.022
18.011~18.022
20.011~20.022
Service
Limit
(mm)
18.06
18.06
20.06
dial indicator
bore gauge
Standard
(mm)
DW168
DW177
DW188
30.02~30.03
33.02~33.03
36.02~36.03
Service
Limit
(mm)
30.06
33.06
36.06
Standard
(mm)
DW168
DW177
DW188
0.95~1.45
0.55~1.25
0.55~1.25
Service
Limit
(mm)
1.85
1.65
1.65
Connecting Rod Big End Oil Clearance
1.Clean all oil from the crank pin and
connecting rod big end surfaces.
2.Place a piece of plastigauge on the
crank pin.
3.Install the connecting rod and cap.
4.Tighten the bolts and torque to 12 N•m
|(1.2 Kg-m, 9 ft.-lbs.).
NOTE: Do not rotate the crankshaft with the
plastigauge in place.
Connecting Rod Big End I. d.
model
model
English
Standard (mm)
0.004~0.016
Connecting Rod Big End Side Clearance
dial indicator
bore gauge
plastigauge
5.Remove the connecting rod and measure
the plastigauge.
Crankpin O. D.
model
Standard
(mm)
DW168
DW177
DW188
30.00
33.00
36.00
Service
Limit
(mm)
29.94
32.94
35.94
Standard
Service Limit
0.04~.066
0.12
6.If the clearance exceeds the service limit,
replace the connecting rod and recheck the
clearance.
mICROMETER
Camshaft Cam Height
Standard
(mm)
model
DW168
DW177
DW188
51
IN
EX
IN
EX
IN
EX
27.700
27.747
31.716
31.754
32.585
32.068
Service
Limit
(mm)
27.45
27.50
31.35
31.35
32.25
31.80
mICROMETER
English
Camshaft O. D.
Standard
Service Limit
13.966~13.984
13.916
mICROMETER
Crankshaft Bearing Free Play
1.Clean the bearing in solvent and dry.
2.Spin the bearing by hand and check for play.
Replace the bearing if it is noisy or has
excessive play.
Play
Play
Axial
Radial
Camshaft Holder I.D.
model
Standard
(mm)
DW168
DW177
DW188
14.000~14.018
16.000~16.018
16.000~16.018
Service
Limit
(mm)
14.050
16.050
16.050
caliper
52
DeWALT Industrial Tool Co., 701 Joppa Road, Baltimore, MD 21286
Copyright ©2010 DeWALT
(FEB10) Part No. RD001148-E DW168F, DW177F, DW188F
The following are trademarks for one or more DeWALT power tools: the yellow and black color scheme; the “D” shaped air intake grill; the array of pyramids on the handgrip;
the kit box configuration; and the array of lozenge-shaped humps on the surface of the tool.