If you have questions or comments, contact us. Pour toute question ou tout commentaire, nous contacter. Si tiene dudas o comentarios, contáctenos. 1-800-4-DeWALT • www.dewalt.com 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 bREAKDOWNS SERVICE Air Filter.......................................................................................................... 23 Safety Information....................................................................................... 3 Definitions: Safety Guidelines ................................................................ 3 Air CLEANER..................................................................................................... 24 Service Information.........
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.
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.
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.
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.
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.
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 Yel
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.
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.
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.
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.
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.
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.
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.
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) Breathe
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.
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.
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.
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.
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.
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.
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.
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.
English Recoil Starter XX. Recoil cover 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.
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.
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.
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).
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 N2. Float valve spring O2 Float 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.
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.
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.
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.
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).
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.